US20120155960A1 - Curb forming system - Google Patents
Curb forming system Download PDFInfo
- Publication number
- US20120155960A1 US20120155960A1 US13/327,350 US201113327350A US2012155960A1 US 20120155960 A1 US20120155960 A1 US 20120155960A1 US 201113327350 A US201113327350 A US 201113327350A US 2012155960 A1 US2012155960 A1 US 2012155960A1
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- Prior art keywords
- curb
- forms
- trowel
- shaping
- structured
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- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
- E01C19/00—Machines, tools or auxiliary devices for preparing or distributing paving materials, for working the placed materials, or for forming, consolidating, or finishing the paving
- E01C19/50—Removable forms or shutterings for road-building purposes; Devices or arrangements for forming individual paving elements, e.g. kerbs, in situ
- E01C19/502—Removable forms or shutterings, e.g. side forms; Removable supporting or anchoring means therefor, e.g. stakes
- E01C19/506—Removable forms or shutterings, e.g. side forms; Removable supporting or anchoring means therefor, e.g. stakes for kerbs, gutters or similar structures, e.g. raised portions, median barriers
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- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
- E01C19/00—Machines, tools or auxiliary devices for preparing or distributing paving materials, for working the placed materials, or for forming, consolidating, or finishing the paving
- E01C19/50—Removable forms or shutterings for road-building purposes; Devices or arrangements for forming individual paving elements, e.g. kerbs, in situ
- E01C19/502—Removable forms or shutterings, e.g. side forms; Removable supporting or anchoring means therefor, e.g. stakes
Definitions
- This disclosure relates generally to a curb forming system, and more particularly to a system of components that can be used to construct a substantially uniform concrete curb.
- Curbs are constructed in a variety of manners for use with roads, pathways, landscaping, and structures. Typically, curbs are formed where a raised portion of land or material meets an unraised portion of land or material. However, some curbs can be constructed as raised sections between two unraised portions of land or material. Curbs may be formed to provide draining options, provide borders for roads or paths, provide decorative edges, provide support for portions of raised materials, or provide safety or directional means for pedestrians and a variety of transporting vehicles. Curbs generally are constructed of sturdy materials such as concrete, asphalt, stone, or similar materials. Concrete curbs are especially popular because of the flexibility in shaping them, their relatively reasonable cost, and durability.
- the basic method of constructing concrete curbs includes building and setting up forms and pouring malleable concrete in the built forms.
- These forms are typically made of building materials, such as 2 ⁇ 4 planks, metal strips, or other sturdy building materials.
- building and setting up these traditional forms takes considerable skill to achieve a consistent curb shape. Additionally, building the forms can be time consuming and expensive. Further, the shapes that curbs can take are limited by the shapes that can be created with these building materials.
- slip form casting machine can be used to create a seamless concrete curb in a variety of shapes.
- slip form casting machines are very expensive and make little sense for smaller projects.
- slip form casting machines and techniques are of little use for a “do-it-yourself” homeowner or contractors that only need a relatively small section of curb on a project.
- a curb forming system includes a first elongated form and a second elongated form for setting a width of a curb.
- the curb forming system also includes a shaped trowel that has a handle, a shaping surface, a hook guide to position the trowel on the first elongated form, and a level guide structured to position the trowel on the second elongated form.
- the hook guide may be structured to slide along the first elongated form while keeping the shaping surface of the trowel at a fixed distance relative to the first elongated form.
- the level guide may be structured to maintain a vertical position of the trowel relative to the second elongated form.
- spacers may be used to ensure that the first and second elongated forms are positioned at substantially consistent distances from each other.
- form stakes may be used to fix the first and second elongated forms in the ground and form splices may be used to attach other forms to the first and second elongated forms.
- the method includes setting a first elongated form, positioning a second elongated form relative to the first elongated form, and placing spacers between the first and second elongated forms to set the second elongated form at a consistent distance from the first elongated form.
- the spacers can be removed and concrete is poured between the first and second elongated forms.
- a shaping trowel is then attached to one end of the first elongated form with a hook guide and positioned on the second elongated form with a level guide. The trowel is then slid along the elongated forms from the first of the forms to a second end of the forms to create a consistently shaped curb.
- FIG. 1 is a detail diagram of a curb forming system according to embodiments of the invention.
- FIG. 2 is a side view of a curb forming system according to embodiments of the invention.
- FIG. 3 is a top view of a curb forming system according to embodiments of the invention.
- FIG. 4A is a top view of an example layout for a curb forming system that splices forms together to create a curved curb shape according to embodiments of the invention.
- FIG. 4B is a top view of another example layout for a curb forming system that splices forms together to create a circular curb shape according to embodiments of the invention.
- FIG. 5 is a flow diagram of a method of constructing a curb according to embodiments of the invention.
- FIG. 6 is a detail diagram of an example curb forming system for a high curb according to embodiments of the invention.
- FIG. 7 is a detail diagram of an example curb forming system for a sloped curb according to embodiments of the invention.
- FIG. 8 is a detail diagram of an example curb forming system for a contour curb according to embodiments of the invention.
- FIG. 9 is an end view of a plastic trowel for a high curb forming system according to embodiments of the invention.
- FIG. 10 is a top view of a plastic trowel for a high curb forming system according to embodiments of the invention.
- FIG. 11 is an end view of a plastic trowel for a sloped curb forming system according to embodiments of the invention.
- FIG. 12 is a top view of a plastic trowel for a sloped curb forming system according to embodiments of the invention.
- FIG. 13 is an end view of a plastic trowel for a contour curb forming system according to embodiments of the invention.
- FIG. 14 is a top view of a plastic trowel for a contour curb forming system according to embodiments of the invention.
- FIG. 15 is an end view of a steel trowel for a high curb forming system according to embodiments of the invention.
- FIG. 16 is a top view of a steel trowel for a high curb forming system according to embodiments of the invention.
- FIG. 17 is an end view of a steel trowel for a sloped curb forming system according to embodiments of the invention.
- FIG. 18 is a top view of a steel trowel for a sloped curb forming system according to embodiments of the invention.
- FIG. 19 is an end view of a steel trowel for a contour curb forming system according to embodiments of the invention.
- FIG. 20 is a top view of a steel trowel for a contour curb forming system according to embodiments of the invention.
- FIG. 21 is a side and end view of a handle for a steel trowel according to embodiments of the invention.
- FIG. 22 is a side and end view of bracket for the handle shown in FIG. 16 according to embodiments of the invention.
- FIG. 23 is a detail diagram of a handle to trowel adaptor and metal handle for a trowel according to embodiments of the invention.
- FIG. 24 is a detail diagram of elongated form ends and form stiffeners according to embodiments of the invention.
- FIG. 25 is top and end views of the form stiffeners shown in FIG. 19 according to embodiments of the invention.
- FIG. 26 is a front view of a plastic spacer for a high curb forming system according to embodiments of the invention.
- FIG. 27 is a front view of a plastic spacer for sloped and contour curb forming systems according to embodiments of the invention.
- FIG. 28 is a top view of a plastic spacer for a curb forming system according to embodiments of the invention.
- FIG. 29 is a front view of a steel spacer for a high curb forming system according to embodiments of the invention.
- FIG. 30 is a front view of a metal spacer for sloped and contour curb forming systems according to embodiments of the invention.
- FIG. 31 is a back view of a metal spacer for sloped and contour curb forming systems according to embodiments of the invention.
- FIG. 32 is a top view of a steel spacer for a curb forming system according to embodiments of the invention.
- FIG. 33 is a detail diagram of form stakes, stack brackets, and bracket rivets according to embodiments of the invention.
- FIG. 1 is a detail diagram of a curb forming system 100 according to embodiments of the invention.
- the curb forming system 100 includes a first elongated form 110 , a second elongated form 120 , and a shaping trowel 150 .
- the first elongated form 110 has a first end 112 and a second end 114 on opposite longitudinal sides of the form.
- the second elongated form 120 has a first end 122 and a second end 124 on opposite longitudinal sides of the form.
- the forms 110 , 120 can be made of a variety of materials including polyethylene, polyvinyl chloride (PVC) plastic, other plastic materials, sheet metal, or other flexible or semi-flexible materials.
- PVC polyvinyl chloride
- the forms 110 , 120 are made of materials that allow the form to be at least partially flexible.
- the flexibility of the form material allows for the creation of curved and/or decorative curb orientations.
- polyethylene forms 110 , 120 can be positioned in a variety of shapes without breaking or overly stressing the forms.
- the ends 112 , 114 , 122 , 124 of the forms 110 , 120 may include splicing devices 170 that allow the multiple forms to be attached together at their ends or the ends of the same form to be attached to one another.
- the splicing devices 170 may include holes to allow the form ends 112 , 114 , 122 , 124 to be bolted together, or may include dove tail grooves or other apparatuses that allow the ends to be connected. Additional stiffeners (see e.g., FIG. 24 ) or others mechanisms may also be used to facilitate the splicing of the form ends 112 , 114 , 122 , 124 .
- the shaping trowel 150 includes a handle 152 , a shaping surface 155 , a hook guide 160 , and a level guide 165 .
- the shaping trowel 150 may be constructed of plastic, metal, wood, or other materials, or a combination of materials.
- the trowel 150 may be entirely formed of a rigid plastic material, or may have a steel shaping surface 155 and a wooden handle 152 .
- the shaping surface 155 is used to form at least the top surface of a curb.
- the shaping surface 155 can be formed in a variety of shapes to form different style curbs. Additionally the forms 110 , 120 may be constructed to provide for different shaped or styled curbs.
- the hook guide 160 is structured to fit over a top surface of the first form 110 . Additionally, the hook guide 160 allows the trowel 150 to be slid or dragged along the forms 110 , 120 while keeping the shaping surface 155 at a substantially consistent distance from the first form 110 .
- the level guide 165 is structured to fit over a top surface of the second form 120 . The level guide 165 allows the trowel 150 to be maintained at a consistent vertical position relative to the second form 120 . Additionally, because the level guide is not restricted horizontally on the second form 120 , small differences in distances between the first and second forms 110 , 120 will not prevent the trowel 150 from being slid over the top surfaces of the forms.
- a shaping trowel 150 may have hook guides 160 on each side of the trowel, or level guides 165 on each side of the trowel.
- the curb forming system 100 may also include spacers 180 that fit over or otherwise attach to the forms 110 , 120 so that the forms can be kept at substantially consistent distances from one another. Since the distance between the forms 110 , 120 determines the width of the finished curb, having a substantially consistent space between the forms helps the curb have a substantially uniform width.
- the spacers 180 may be made of plastic, metal, or other rigid materials. Multiple spacers may allow the forms 110 , 120 to be spaced at a predefined distance over the length of the forms. This may be especially helpful when forming curbs with curves or bends.
- a curb forming system 100 may include multiple different sized spacers to allow for a variety of different width curbs to be formed with the system.
- the curb forming system 100 may also include stake brackets 190 that can be attached to the forms 110 , 120 .
- the stake brackets 190 may be fixed to the forms 110 , 120 with rivets or other substantially permanent attachment means, or may be removable so they can be moved to desired locations on the forms.
- the stake brackets 190 allow stakes 195 to be used to fix the forms 110 , 120 to a work surface, such as the ground.
- FIG. 2 is a side view of a curb forming system according to embodiments of the invention.
- a curb material 205 such as concrete, is disposed between the first form 210 and second form 220 after they have been set on a work surface.
- a shaping trowel 250 is then used to shape the curb material 205 .
- the shaping trowel includes a handle 252 , a shaping surface 255 , a hook guide 260 , and a level guide 265 .
- the shape of the hook guide 260 may correspond to a top surface of a first and/or second form 210 , 220 .
- the level guide 265 may extend horizontally from the shaping surface 255 of the trowel and allow the trowel to sit on top of the first and/or second form 210 , 220 .
- FIG. 3 is a top view of a curb forming system according to embodiments of the invention.
- a shaping trowel 350 is positioned on top of a first and second form 310 , 320 .
- the shaping trowel 350 includes a handle 352 , a hook guide 360 , and a level guide 365 .
- the shaping trowel 350 can be slid along (horizontal in FIG. 3 ) the forms 310 , 320 to shape curb material disposed between the forms into a desired shape.
- a spacer 380 is also shown in FIG. 3 .
- the spacer 380 is positioned over the first and second forms 310 , 320 to keep the forms at a predefined distance from one another.
- the forms 310 , 320 may also include attached stake brackets 390 that hold stakes 395 used to fix the forms to a work surface.
- FIG. 4A is a top view of an example layout for a curb forming system that splices forms together to create a curved curb shape according to embodiments of the invention.
- a first form 410 is spliced to a third form 411 with a splicing device 485
- a second form 420 is attached to a fourth form 421 with a splicing device 485 .
- a curb start location 401 and a curb finish location 402 are mapped out and two sets of forms are needed to complete the desired curved curb.
- Spacers 480 and stakes 495 in stake brackets 490 attached to the forms 410 , 411 , 420 , 421 are used to set the forms at in the desired position and maintain a substantially consistent curb width.
- FIG. 4B is a top view of another example layout for a curb forming system that splices forms together to create a circular curb shape according to embodiments of the invention.
- the first form 410 is spliced from end to end in a circle using a splicing device 485
- the second form 420 is spliced from end to end in another circle using a splicing device 485 .
- This layout allows for circular curbs to be formed, such as for curbs formed around trees. Since the circle for the second form 420 is shorter than the circle for the first form 410 , one or both of the forms may have to be cut or otherwise modified to fit the desired length of the curb.
- Spacers 480 and stakes 495 in stake brackets 490 attached to the forms 410 , 411 , 420 , 421 are used to set the forms at in the desired position and maintain a substantially consistent curb width.
- FIG. 5 is a flow diagram of a method of constructing a curb according to embodiments of the invention. Although the processes illustrated in FIG. 5 are shown in a particular order, they may be performed in a different order. Furthermore, additional processes may be performed as part of the curb construction method.
- a flow 500 includes a process 525 where a first elongated form is set on a work surface.
- the work surface may be dirt ground, or may include other building materials previously placed on the ground, such as asphalt.
- the first elongated form may be set in the work surface by fixing the first form to the work surface with anchoring devices.
- this fixing process includes inserting stakes into stack brackets attached to the first form and hammering the stakes into the work surface.
- this fixing process may include bolting the first form to the work surface.
- a second elongated form is then set on a work surface in process 530 .
- the second form is set at a predefined distance from the first form, where the predefined distance corresponds to a desired width of the curb.
- the second form may be set on the work surface in a similar manner to setting the first form on the work surface.
- Spacers may optionally be used in process 530 to set the second form at a consistent distance from the first form. After the first and second form are set, such as by being staked or bolted down to the work surface, the spacers may be removed.
- a curb material is disposed between the first and second forms on the work surface.
- process 540 includes pouring mixed concrete between the first and second forms.
- Process 540 may also include removing excess wet concrete that above the top surfaces of the forms.
- the hook guide of a shaping trowel is aligned with the top surface of the first form.
- the hook guide of the shaping trowel may be structured to correspond to the top surface of the first form so that when the shaping trowel is moved along the first form, it is maintained in a substantially consistent position relative to the first form.
- a level guide of the shaping trowel is positioned on the top surface of the second form. The level guide of the shaping trowel may maintain the shaping trowel at a consistent vertical position relative to the second form while allowing the shaping trowel to slide over the first and second forms even when there are small inconsistencies in the distance between the first and second forms.
- the shaping trowel is then slid along the top surfaces of the first and second forms to shape a top surface of the curb by patterning the curb material between the first and second forms in process 555 .
- the method may further include preparing the work surface for the curb.
- Process 510 may include, for example, compacting dirt on the ground or laying a base surface of concrete or asphalt that the curb will be formed on.
- the method may also include optional process 515 , where the desired location for the curb is laid out.
- the desired positions of the curb edges may be set drawn out or otherwise designed. Measurements may be taken to ensure the curb is located in an optimal position. Additionally, stakes, string, markers, paint, or other devices may be used to mark the work surface with a desired location of the curb.
- the first and second elongated forms may be prepared prior to being set in optional process 520 .
- the forms may be modified as needed to complete a desired curb. For example, if a circular curb (such as the one shown in FIG. 4B ) is desired, a portion of the one or both of the elongated forms may have to be cut.
- additional elongated forms may be spliced together (shown in FIG. 4A ) prior to being set.
- the forms are removed after the curb is shaped.
- the same forms may be used again to extend the curb. That is, the curb may be formed in incremental processes using the same first and second forms. Once a portion of the curb is made, the forms are moved and the above processes are repeated.
- FIGS. 6-8 show curb forming systems for three example curb shapes: a high curb shape, a sloped curb shape, and a contour curb shape. Although these figures show embodiments with three different curb shapes, various other embodiments may include other curb shapes. As shown in these figures, two forms are set apart at a substantially consistent distance in a desired orientation. Form stakes are used to set the forms in the ground. Brackets are attached to the form with rivets or other attachment means to provide a connection point for the form stakes. Form splices are used to connect the end of one elongated form to the end of another elongated form. This allows longer curbs to be formed in one formation cycle rather than forming sections of the curb in a repeated process of setting the forms, pouring the concrete, and shaping the curbs.
- FIGS. 9-14 show various embodiments of a plastic trowel with an integrated plastic handle.
- Plastic trowels may be advantageous in that they can be inexpensively formed and disposed of after use.
- FIGS. 15-20 show various embodiments of a steel trowel with a replaceable plastic handle. These steel trowels may be more sturdy than the plastic trowel embodiments, and may be preferred by contractors that wish to reuse them in multiple projects.
- the handle may be replaced if damaged, or switched out with a handle adapter that can be used with a longer handle, such as a broom handle or a hollow metal handle.
- the trowels include a hook guide and a level guide to interface with the elongated forms.
- the hook guide fits over a top edge of one of the elongated forms and allows a shaping surface of the trowel to be maintained at a fixed distance from the forms. That is, the hook guide constrains the vertical and horizontal movement of the trowel relative to the forms. Additionally, the hook guide allows the trowel to be slid along the form to construct a uniform curb.
- the level guide of the trowel contacts the other form and maintains a vertical position of the trowel relative to the second elongated form. The level guide allows the trowel to be slid along the forms even when small changes in distance between the forms exist.
- other trowel embodiments may include two hook guides or two level guides.
- FIGS. 21-23 show detail diagrams of handles and accessories that can be used with some of the trowel embodiments.
- FIGS. 24 and 25 show form stiffeners used as splices to connect two forms together end to end. As FIG. 24 shows, the ends of each form may include dove tails or other features that allow the forms ends to connect to one another.
- FIGS. 26-32 show various embodiments of spacers that may be used to position one elongated form from another. These spacers may ensure that the width of the curbs remains consistent over the length of the curb.
- FIG. 33 shows various form brackets, stakes, and a connection rivet used to help set the elongated forms on the ground in a desired orientation.
- the brackets may be connected to the forms with the rivets (or other attachments means) and include an opening that allows one of the form stakes to pass through the bracket and hold the elongated forms in a particular orientation.
- the curb forms can be used to construct all types of curbs, and is especially suited for making decorative or distinctive concrete curbs.
- the curb forms may be made of polyethylene, polyvinyl chloride (PVC) plastic, other plastic materials, sheet metal, or other flexible or semi-flexible materials.
- PVC polyvinyl chloride
- the flexibility of the form material allows for the creation of curved and/or decorative curb orientations.
- the curb forms may be available in five foot, ten foot, or other lengths.
- the splicing devices discussed above may allow a user to construct continuous curbs that are longer than the length of individual forms.
- the forms may be set with the form stakes, which may be available in multiple sizes to fit different form heights, or different terrain. For example, sandy terrain may require longer stakes than clay to secure the forms in place.
- the stakes may be made of steel or other rigid materials to allow them to be hammered into the ground. Additionally, a top portion of the stakes may be bent or have a horizontal portion to allow a wide area for hammering.
- the spacers discussed above may be provided in multiple different widths to allow construction of curbs with differing specified widths.
- the concrete for the curbs can be made of a standard concrete mix of gravel, sand and cement; a premixed bagged concrete; or a premixed Type-S mortar with fiber mesh mixed in.
- the Type-S mortar works best for a stiffer mix and smoother finish and is extra strong with the addition of fiber mesh. Using a concrete with a very stiff mix may provide better results in some circumstances as it will better hold its shape when troweled.
- the forms When setting the forms, establishing a lay out for the curb by marking out portions of the ground can be helpful. For straight curbs, using separate stakes and a string line will help ensure the straightness of the curb. Once the layout is established, then the forms can be set using the provided stakes and spacers. Preparation work may be required on the dirt, such as leveling and/or compacting the land.
- the mix is shoveled into the forms (square point shovel works best). Excess mix can then be raked off of the forms prior to using the trowel or shovel. The spacers are removed as the concrete is worked into the forms. The shaped trowel may then be used to begin troweling.
- the hook guide of the trowel is set on one end of the forms and trowel is moved back and forth along the forms to create a desired curb shape.
- the forms can be removed.
- a cut for expansion can be made at intervals in the curb, such as at every four feet. Once the cuts are made, a brush can be used to create a “brush finish” on all surfaces.
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Abstract
Embodiments of the present invention are directed to a curb forming system used to construct a curb made out of concrete or similar material that has a consistent finished shape and width. The curb forming system can be used to make decorative curbs for landscaping or other building projects. The curb forming system includes a first elongated form and a second elongated form for setting a width of a curb. The curb forming system also includes a shaped trowel that has a handle, a shaping surface, a hook guide to position the trowel on the first elongated form, and a level guide structured to position the trowel on the second elongated form. The hook guide and level guides may be structured to slide along the first and second elongated forms, respectively, so that the shaping surface is used to form the building material into a consistent shape.
Description
- This application claims priority to U.S. Provisional Application No. 61/424,490 filed Dec. 17, 2010, entitled CURB FORMING SYSTEM, the contents of which are hereby incorporated by reference.
- This disclosure relates generally to a curb forming system, and more particularly to a system of components that can be used to construct a substantially uniform concrete curb.
- Curbs are constructed in a variety of manners for use with roads, pathways, landscaping, and structures. Typically, curbs are formed where a raised portion of land or material meets an unraised portion of land or material. However, some curbs can be constructed as raised sections between two unraised portions of land or material. Curbs may be formed to provide draining options, provide borders for roads or paths, provide decorative edges, provide support for portions of raised materials, or provide safety or directional means for pedestrians and a variety of transporting vehicles. Curbs generally are constructed of sturdy materials such as concrete, asphalt, stone, or similar materials. Concrete curbs are especially popular because of the flexibility in shaping them, their relatively reasonable cost, and durability.
- The basic method of constructing concrete curbs includes building and setting up forms and pouring malleable concrete in the built forms. These forms are typically made of building materials, such as 2×4 planks, metal strips, or other sturdy building materials. However, building and setting up these traditional forms takes considerable skill to achieve a consistent curb shape. Additionally, building the forms can be time consuming and expensive. Further, the shapes that curbs can take are limited by the shapes that can be created with these building materials.
- In large projects, a slip form casting machine can be used to create a seamless concrete curb in a variety of shapes. However, slip form casting machines are very expensive and make little sense for smaller projects. In addition, it is difficult to use slip form casting techniques for curbs that are created in certain locations. For example, a landscape curb positioned away from an accessible road or drivable path often must be constructed using forms. Hence, slip form casting machines and techniques are of little use for a “do-it-yourself” homeowner or contractors that only need a relatively small section of curb on a project.
- Embodiments of the present concept provide a curb forming system that addresses the above discussed issues and other problems. In one embodiment, a curb forming system includes a first elongated form and a second elongated form for setting a width of a curb. The curb forming system also includes a shaped trowel that has a handle, a shaping surface, a hook guide to position the trowel on the first elongated form, and a level guide structured to position the trowel on the second elongated form. The hook guide may be structured to slide along the first elongated form while keeping the shaping surface of the trowel at a fixed distance relative to the first elongated form. The level guide may be structured to maintain a vertical position of the trowel relative to the second elongated form. In some embodiments, spacers may be used to ensure that the first and second elongated forms are positioned at substantially consistent distances from each other. Further, form stakes may be used to fix the first and second elongated forms in the ground and form splices may be used to attach other forms to the first and second elongated forms.
- Other embodiments of the present concept provide a method of forming a concrete curb. In one embodiment, the method includes setting a first elongated form, positioning a second elongated form relative to the first elongated form, and placing spacers between the first and second elongated forms to set the second elongated form at a consistent distance from the first elongated form. After the first and second elongated forms are set, such as by being staked down, the spacers can be removed and concrete is poured between the first and second elongated forms. A shaping trowel is then attached to one end of the first elongated form with a hook guide and positioned on the second elongated form with a level guide. The trowel is then slid along the elongated forms from the first of the forms to a second end of the forms to create a consistently shaped curb.
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FIG. 1 is a detail diagram of a curb forming system according to embodiments of the invention. -
FIG. 2 is a side view of a curb forming system according to embodiments of the invention. -
FIG. 3 is a top view of a curb forming system according to embodiments of the invention. -
FIG. 4A is a top view of an example layout for a curb forming system that splices forms together to create a curved curb shape according to embodiments of the invention. -
FIG. 4B is a top view of another example layout for a curb forming system that splices forms together to create a circular curb shape according to embodiments of the invention. -
FIG. 5 is a flow diagram of a method of constructing a curb according to embodiments of the invention. -
FIG. 6 is a detail diagram of an example curb forming system for a high curb according to embodiments of the invention. -
FIG. 7 is a detail diagram of an example curb forming system for a sloped curb according to embodiments of the invention. -
FIG. 8 is a detail diagram of an example curb forming system for a contour curb according to embodiments of the invention. -
FIG. 9 is an end view of a plastic trowel for a high curb forming system according to embodiments of the invention. -
FIG. 10 is a top view of a plastic trowel for a high curb forming system according to embodiments of the invention. -
FIG. 11 is an end view of a plastic trowel for a sloped curb forming system according to embodiments of the invention. -
FIG. 12 is a top view of a plastic trowel for a sloped curb forming system according to embodiments of the invention. -
FIG. 13 is an end view of a plastic trowel for a contour curb forming system according to embodiments of the invention. -
FIG. 14 is a top view of a plastic trowel for a contour curb forming system according to embodiments of the invention. -
FIG. 15 is an end view of a steel trowel for a high curb forming system according to embodiments of the invention. -
FIG. 16 is a top view of a steel trowel for a high curb forming system according to embodiments of the invention. -
FIG. 17 is an end view of a steel trowel for a sloped curb forming system according to embodiments of the invention. -
FIG. 18 is a top view of a steel trowel for a sloped curb forming system according to embodiments of the invention. -
FIG. 19 is an end view of a steel trowel for a contour curb forming system according to embodiments of the invention. -
FIG. 20 is a top view of a steel trowel for a contour curb forming system according to embodiments of the invention. -
FIG. 21 is a side and end view of a handle for a steel trowel according to embodiments of the invention. -
FIG. 22 is a side and end view of bracket for the handle shown inFIG. 16 according to embodiments of the invention. -
FIG. 23 is a detail diagram of a handle to trowel adaptor and metal handle for a trowel according to embodiments of the invention. -
FIG. 24 is a detail diagram of elongated form ends and form stiffeners according to embodiments of the invention. -
FIG. 25 is top and end views of the form stiffeners shown inFIG. 19 according to embodiments of the invention. -
FIG. 26 is a front view of a plastic spacer for a high curb forming system according to embodiments of the invention. -
FIG. 27 is a front view of a plastic spacer for sloped and contour curb forming systems according to embodiments of the invention. -
FIG. 28 is a top view of a plastic spacer for a curb forming system according to embodiments of the invention. -
FIG. 29 is a front view of a steel spacer for a high curb forming system according to embodiments of the invention. -
FIG. 30 is a front view of a metal spacer for sloped and contour curb forming systems according to embodiments of the invention. -
FIG. 31 is a back view of a metal spacer for sloped and contour curb forming systems according to embodiments of the invention. -
FIG. 32 is a top view of a steel spacer for a curb forming system according to embodiments of the invention. -
FIG. 33 is a detail diagram of form stakes, stack brackets, and bracket rivets according to embodiments of the invention. -
FIG. 1 is a detail diagram of acurb forming system 100 according to embodiments of the invention. Referring toFIG. 1 , thecurb forming system 100 includes a firstelongated form 110, a secondelongated form 120, and a shapingtrowel 150. The firstelongated form 110 has afirst end 112 and asecond end 114 on opposite longitudinal sides of the form. Similarly, the secondelongated form 120 has afirst end 122 and asecond end 124 on opposite longitudinal sides of the form. Theforms forms - The ends 112, 114, 122, 124 of the
forms devices 170 that allow the multiple forms to be attached together at their ends or the ends of the same form to be attached to one another. Thesplicing devices 170 may include holes to allow the form ends 112, 114, 122, 124 to be bolted together, or may include dove tail grooves or other apparatuses that allow the ends to be connected. Additional stiffeners (see e.g.,FIG. 24 ) or others mechanisms may also be used to facilitate the splicing of the form ends 112, 114, 122, 124. - The shaping
trowel 150 includes ahandle 152, a shapingsurface 155, ahook guide 160, and alevel guide 165. The shapingtrowel 150 may be constructed of plastic, metal, wood, or other materials, or a combination of materials. For example, thetrowel 150 may be entirely formed of a rigid plastic material, or may have asteel shaping surface 155 and awooden handle 152. The shapingsurface 155 is used to form at least the top surface of a curb. The shapingsurface 155 can be formed in a variety of shapes to form different style curbs. Additionally theforms - The
hook guide 160 is structured to fit over a top surface of thefirst form 110. Additionally, thehook guide 160 allows thetrowel 150 to be slid or dragged along theforms surface 155 at a substantially consistent distance from thefirst form 110. Thelevel guide 165 is structured to fit over a top surface of thesecond form 120. Thelevel guide 165 allows thetrowel 150 to be maintained at a consistent vertical position relative to thesecond form 120. Additionally, because the level guide is not restricted horizontally on thesecond form 120, small differences in distances between the first andsecond forms trowel 150 from being slid over the top surfaces of the forms. That is, thelevel guide 165 allows for at least some horizontal movement of thetrowel 150 relative to thesecond form 120 and prevents the too much friction from occurring when the trowel is slid along the forms where the distances between the first and second forms vary slightly. In other embodiments, a shapingtrowel 150 may have hook guides 160 on each side of the trowel, or level guides 165 on each side of the trowel. - The
curb forming system 100 may also include spacers 180 that fit over or otherwise attach to theforms forms forms curb forming system 100 may include multiple different sized spacers to allow for a variety of different width curbs to be formed with the system. - The
curb forming system 100 may also includestake brackets 190 that can be attached to theforms stake brackets 190 may be fixed to theforms stake brackets 190 allowstakes 195 to be used to fix theforms -
FIG. 2 is a side view of a curb forming system according to embodiments of the invention. Referring toFIG. 2 , acurb material 205, such as concrete, is disposed between thefirst form 210 andsecond form 220 after they have been set on a work surface. A shapingtrowel 250 is then used to shape thecurb material 205. The shaping trowel includes ahandle 252, a shapingsurface 255, ahook guide 260, and alevel guide 265. As shown inFIG. 2 , the shape of thehook guide 260 may correspond to a top surface of a first and/orsecond form level guide 265 may extend horizontally from the shapingsurface 255 of the trowel and allow the trowel to sit on top of the first and/orsecond form -
FIG. 3 is a top view of a curb forming system according to embodiments of the invention. Referring toFIG. 3 , a shapingtrowel 350 is positioned on top of a first andsecond form trowel 350 includes ahandle 352, ahook guide 360, and alevel guide 365. The shapingtrowel 350 can be slid along (horizontal inFIG. 3 ) theforms spacer 380 is also shown inFIG. 3 . Thespacer 380 is positioned over the first andsecond forms forms stake brackets 390 that holdstakes 395 used to fix the forms to a work surface. -
FIG. 4A is a top view of an example layout for a curb forming system that splices forms together to create a curved curb shape according to embodiments of the invention. Referring toFIG. 4A , afirst form 410 is spliced to athird form 411 with asplicing device 485, and asecond form 420 is attached to afourth form 421 with asplicing device 485. In the embodiment shown inFIG. 4A , acurb start location 401 and acurb finish location 402 are mapped out and two sets of forms are needed to complete the desired curved curb.Spacers 480 andstakes 495 instake brackets 490 attached to theforms -
FIG. 4B is a top view of another example layout for a curb forming system that splices forms together to create a circular curb shape according to embodiments of the invention. Referring toFIG. 4B , thefirst form 410 is spliced from end to end in a circle using asplicing device 485, and thesecond form 420 is spliced from end to end in another circle using asplicing device 485. This layout allows for circular curbs to be formed, such as for curbs formed around trees. Since the circle for thesecond form 420 is shorter than the circle for thefirst form 410, one or both of the forms may have to be cut or otherwise modified to fit the desired length of the curb.Spacers 480 andstakes 495 instake brackets 490 attached to theforms -
FIG. 5 is a flow diagram of a method of constructing a curb according to embodiments of the invention. Although the processes illustrated inFIG. 5 are shown in a particular order, they may be performed in a different order. Furthermore, additional processes may be performed as part of the curb construction method. - Referring to
FIG. 5 , aflow 500 includes aprocess 525 where a first elongated form is set on a work surface. The work surface may be dirt ground, or may include other building materials previously placed on the ground, such as asphalt. The first elongated form may be set in the work surface by fixing the first form to the work surface with anchoring devices. In some embodiments, this fixing process includes inserting stakes into stack brackets attached to the first form and hammering the stakes into the work surface. In other embodiments, this fixing process may include bolting the first form to the work surface. - A second elongated form is then set on a work surface in
process 530. The second form is set at a predefined distance from the first form, where the predefined distance corresponds to a desired width of the curb. The second form may be set on the work surface in a similar manner to setting the first form on the work surface. Spacers may optionally be used inprocess 530 to set the second form at a consistent distance from the first form. After the first and second form are set, such as by being staked or bolted down to the work surface, the spacers may be removed. - In
process 540, a curb material is disposed between the first and second forms on the work surface. In embodiments where the curb is a concrete curb,process 540 includes pouring mixed concrete between the first and second forms.Process 540 may also include removing excess wet concrete that above the top surfaces of the forms. - In
process 545, the hook guide of a shaping trowel is aligned with the top surface of the first form. The hook guide of the shaping trowel may be structured to correspond to the top surface of the first form so that when the shaping trowel is moved along the first form, it is maintained in a substantially consistent position relative to the first form. Inprocess 550, a level guide of the shaping trowel is positioned on the top surface of the second form. The level guide of the shaping trowel may maintain the shaping trowel at a consistent vertical position relative to the second form while allowing the shaping trowel to slide over the first and second forms even when there are small inconsistencies in the distance between the first and second forms. - The shaping trowel is then slid along the top surfaces of the first and second forms to shape a top surface of the curb by patterning the curb material between the first and second forms in process 555.
- In
optional process 510, the method may further include preparing the work surface for the curb.Process 510 may include, for example, compacting dirt on the ground or laying a base surface of concrete or asphalt that the curb will be formed on. The method may also includeoptional process 515, where the desired location for the curb is laid out. Here, the desired positions of the curb edges may be set drawn out or otherwise designed. Measurements may be taken to ensure the curb is located in an optimal position. Additionally, stakes, string, markers, paint, or other devices may be used to mark the work surface with a desired location of the curb. - The first and second elongated forms may be prepared prior to being set in
optional process 520. Here, the forms may be modified as needed to complete a desired curb. For example, if a circular curb (such as the one shown inFIG. 4B ) is desired, a portion of the one or both of the elongated forms may have to be cut. On the other hand, for longer curb projects, additional elongated forms may be spliced together (shown inFIG. 4A ) prior to being set. Inoptional process 560, the forms are removed after the curb is shaped. In some projects, the same forms may be used again to extend the curb. That is, the curb may be formed in incremental processes using the same first and second forms. Once a portion of the curb is made, the forms are moved and the above processes are repeated. -
FIGS. 6-8 show curb forming systems for three example curb shapes: a high curb shape, a sloped curb shape, and a contour curb shape. Although these figures show embodiments with three different curb shapes, various other embodiments may include other curb shapes. As shown in these figures, two forms are set apart at a substantially consistent distance in a desired orientation. Form stakes are used to set the forms in the ground. Brackets are attached to the form with rivets or other attachment means to provide a connection point for the form stakes. Form splices are used to connect the end of one elongated form to the end of another elongated form. This allows longer curbs to be formed in one formation cycle rather than forming sections of the curb in a repeated process of setting the forms, pouring the concrete, and shaping the curbs. -
FIGS. 9-14 show various embodiments of a plastic trowel with an integrated plastic handle. Plastic trowels may be advantageous in that they can be inexpensively formed and disposed of after use.FIGS. 15-20 show various embodiments of a steel trowel with a replaceable plastic handle. These steel trowels may be more sturdy than the plastic trowel embodiments, and may be preferred by contractors that wish to reuse them in multiple projects. The handle may be replaced if damaged, or switched out with a handle adapter that can be used with a longer handle, such as a broom handle or a hollow metal handle. - Although plastic and steel are shown as materials used in the trowels shown in
FIGS. 9-20 , trowels in other embodiments may be constructed of other materials. As shown in these embodiments, the trowels include a hook guide and a level guide to interface with the elongated forms. The hook guide fits over a top edge of one of the elongated forms and allows a shaping surface of the trowel to be maintained at a fixed distance from the forms. That is, the hook guide constrains the vertical and horizontal movement of the trowel relative to the forms. Additionally, the hook guide allows the trowel to be slid along the form to construct a uniform curb. The level guide of the trowel contacts the other form and maintains a vertical position of the trowel relative to the second elongated form. The level guide allows the trowel to be slid along the forms even when small changes in distance between the forms exist. However, other trowel embodiments may include two hook guides or two level guides. -
FIGS. 21-23 show detail diagrams of handles and accessories that can be used with some of the trowel embodiments.FIGS. 24 and 25 show form stiffeners used as splices to connect two forms together end to end. AsFIG. 24 shows, the ends of each form may include dove tails or other features that allow the forms ends to connect to one another.FIGS. 26-32 show various embodiments of spacers that may be used to position one elongated form from another. These spacers may ensure that the width of the curbs remains consistent over the length of the curb.FIG. 33 shows various form brackets, stakes, and a connection rivet used to help set the elongated forms on the ground in a desired orientation. Here, the brackets may be connected to the forms with the rivets (or other attachments means) and include an opening that allows one of the form stakes to pass through the bracket and hold the elongated forms in a particular orientation. - These and other embodiments of the curb forming system can be used to construct all types of curbs, and is especially suited for making decorative or distinctive concrete curbs. The curb forms may be made of polyethylene, polyvinyl chloride (PVC) plastic, other plastic materials, sheet metal, or other flexible or semi-flexible materials. The flexibility of the form material allows for the creation of curved and/or decorative curb orientations. The curb forms may be available in five foot, ten foot, or other lengths. The splicing devices discussed above may allow a user to construct continuous curbs that are longer than the length of individual forms.
- The forms may be set with the form stakes, which may be available in multiple sizes to fit different form heights, or different terrain. For example, sandy terrain may require longer stakes than clay to secure the forms in place. The stakes may be made of steel or other rigid materials to allow them to be hammered into the ground. Additionally, a top portion of the stakes may be bent or have a horizontal portion to allow a wide area for hammering. The spacers discussed above may be provided in multiple different widths to allow construction of curbs with differing specified widths.
- The concrete for the curbs can be made of a standard concrete mix of gravel, sand and cement; a premixed bagged concrete; or a premixed Type-S mortar with fiber mesh mixed in. The Type-S mortar works best for a stiffer mix and smoother finish and is extra strong with the addition of fiber mesh. Using a concrete with a very stiff mix may provide better results in some circumstances as it will better hold its shape when troweled.
- When setting the forms, establishing a lay out for the curb by marking out portions of the ground can be helpful. For straight curbs, using separate stakes and a string line will help ensure the straightness of the curb. Once the layout is established, then the forms can be set using the provided stakes and spacers. Preparation work may be required on the dirt, such as leveling and/or compacting the land.
- In one formation method, after the forms are set and the mix is ready, the mix is shoveled into the forms (square point shovel works best). Excess mix can then be raked off of the forms prior to using the trowel or shovel. The spacers are removed as the concrete is worked into the forms. The shaped trowel may then be used to begin troweling. Here, as discussed above, the hook guide of the trowel is set on one end of the forms and trowel is moved back and forth along the forms to create a desired curb shape. Once the pour is smooth and the concrete has started setting but is still wet, the forms can be removed. After the forms are removed, a cut for expansion can be made at intervals in the curb, such as at every four feet. Once the cuts are made, a brush can be used to create a “brush finish” on all surfaces.
- Some embodiments of the invention have been described above, and in addition, some specific details are shown for purposes of illustrating the inventive principles. However, numerous other arrangements may be devised in accordance with the inventive principles of this patent disclosure. Further, well known processes have not been described in detail in order not to obscure the invention. Thus, while the invention is described in conjunction with the specific embodiments illustrated in the drawings, it is not limited to these embodiments or drawings. Rather, the invention is intended to cover alternatives, modifications, and equivalents that come within the scope and spirit of the inventive principles set out in the appended claims.
Claims (20)
1. A concrete curb forming system comprising:
a first elongated form, the first form substantially composed of a polyethylene material so as to be at least partially flexible;
a second elongated form, the first form substantially composed of a polyethylene material so as to be at least partially flexible;
a plurality of first stake brackets structured to be attached to the first form;
a plurality of second stake brackets structured to be attached to the second form;
a plurality of stakes structured to be inserted into the first and second stake brackets to fix the first and second forms to a work surface;
at least one spacer structured to fit over a portion of the first form and a portion of the second form to maintain a predefined distance between the first form and the second form; and
a shaping trowel including a handle, a shaping surface, a hook guide, and a level guide, where the hook guide is structured to slide along a top surface of the first form and maintain the shaping surface at a substantially consistent distance from the first form, and where the level guide is structured to maintain a vertical position of the trowel relative to a top surface of the second form.
2. The system of claim 1 , wherein:
the first form includes a first end having a splicing attachment device; and
the second form includes a first end having a splicing attachment device.
3. The system of claim 2 , wherein:
the splicing attachment device at the first end of the first form is structured to attach the first end of the first form to the second end of the first form; and
the splicing attachment device at the first end of the second for in is structured to attach the first end of the second form to the second end of the second form.
4. The system of claim 2 , wherein:
the splicing attachment device at the first end of the first form is structured to attach the first end of the first form to a third elongated form; and
the splicing attachment device at the first end of the second form is structured to attach the first end of the second form to a fourth elongated form.
5. The system of claim 2 , wherein splicing attachment devices for the first end of the first form and the first end of the second form respectively include elongated stiffening devices structured to be bolted to the respective first ends of the first and second forms.
6. The system of claim 1 , wherein the first and second stake brackets are removable from the first and second forms, respectively.
7. The system of claim 1 , wherein the shaping surface of the shaping trowel is substantially composed of a plastic.
8. The system of claim 1 , wherein the shaping surface of the shaping trowel is substantially composed of metal.
9. The system of claim 1 , wherein the handle of the shaping trowel is removable.
10. A method of constructing a curb on a work surface, the method comprising:
setting a first elongated form on the work surface;
setting a second elongated form on the work surface; the second form set at a predefined distance from the first form where the predefined distance corresponds to a desired width of the curb;
disposing a curb material between the first and second forms on the work surface;
aligning a hook guide of a shaping trowel with a top surface of the first form;
positioning a level guide of the shaping trowel on a top surface of the second form; and
sliding the shaping trowel along the top surfaces of the first and second forms to shape a top surface of the curb.
11. The method of claim 10 , further comprising preparing the work surface to support the curb prior to setting the first and second forms.
12. The method of claim 10 , further comprising laying out a desired position for the curb, where the first and second forms are set to correspond with the desired position layout.
13. The method of claim 10 , wherein setting a first elongated form on the work surface includes fixing the first form to the work surface using stakes positioned in stake brackets attached to the first form, and wherein setting a second elongated form on the work surface includes fixing the second form to the work surface using stakes positioned in stake brackets attached to the second form.
14. The method of claim 13 , wherein setting a second elongated form on the work surface further includes setting spacers on the first and second forms to set the second form at the predefined distance from the first form.
15. The method of claim 10 , further comprising preparing the material disposed between the first and second forms.
16. The method of claim 15 , wherein preparing the material includes mixing concrete.
17. The method of claim 10 , further comprising removing the first and second forms from the work surface.
18. A system for forming a substantially uniform curb, the system comprising:
a first elongated form;
a second elongated form;
a shaping trowel including:
a shaping surface corresponding to a desired shape of the curb,
a handle attached to the shaping surface,
a hook guide structured to fit over and slide along a top surface of the first form, and
a level guide structured to slide along a top surface of the second form.
19. The system of claim 18 , wherein the hook guide maintains the shaping surface at a substantially consistent distance from the first form when the shaping trowel is moved from a first position on the first and second forms to a second position on the first and second forms.
20. The system of claim 18 , further comprising anchoring devices structured to fix the first form and the second form to a work surface.
Priority Applications (1)
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US13/327,350 US20120155960A1 (en) | 2010-12-17 | 2011-12-15 | Curb forming system |
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US201061424490P | 2010-12-17 | 2010-12-17 | |
US13/327,350 US20120155960A1 (en) | 2010-12-17 | 2011-12-15 | Curb forming system |
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US20120155960A1 true US20120155960A1 (en) | 2012-06-21 |
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US13/327,350 Abandoned US20120155960A1 (en) | 2010-12-17 | 2011-12-15 | Curb forming system |
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US9982432B1 (en) * | 2015-10-14 | 2018-05-29 | Illinois Tool Works Inc. | Curb wall forming apparatus and method of forming a curb wall |
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