US20190264455A1

US20190264455A1 - Corner form/flatwall form release system

Info

Publication number: US20190264455A1
Application number: US15/906,554
Authority: US
Inventors: Joseph Scalamandre; Nicole Scalamandre
Original assignee: Individual
Current assignee: Individual
Priority date: 2018-02-27
Filing date: 2018-02-27
Publication date: 2019-08-29

Abstract

Systems and methods are provided for separating one or more forms from a hardened material is provided. The system includes a support structure, a securing mechanism, coupled to the support structure, wherein the securing mechanism is configured to secure the system to the one or more forms, and a threaded rod, threaded through an opening in the support structure, wherein the threaded rod is configured to apply pressure to the hardened material.

Description

CLAIM OF PRIORITY

This application is a United States non-provisional application and claims no priority to any previous patent or patent application.

FIELD OF THE EMBODIMENTS

This invention relates to building construction tools and, in particular, to tools for removing forms from cement and concrete.

BACKGROUND OF THE EMBODIMENTS

Cement and concrete are widely used in the construction of buildings. Oftentimes, wet concrete is poured into forms such that, when it hardens, it takes the internal shape of the forms. Once the concrete hardens, the forms are removed.
Removal of the forms can be a difficult process, since it can be a very arduous process to separate the form from the hardened concrete. A great deal of force is thus often necessary to cause the separation. This force is often applied with crowbars. The presently used methods of causing this separation can cause damage to the forms and/or the newly built concrete structures, can be time consuming, and can be unsafe. Labor must stand on top of the newly formed structure to try to pry the form from the structure which, depending on the height of the structure, can be illegal. This practice is banned if caught companies may be fined for this behavior, and people may be hurt during the form removal process. Using present methods, companies must therefore invest in expensive safety equipment in order to be compliant with relevant safety laws.
For at least these reasons, a simple and safe system and method of removing forms from hardened concrete structures is thus needed.

Examples of related art are described below:

U.S. Pat. No. 6,817,590 generally describes a method and tool for removing modular concrete forms from underlying rigid concrete. The tool includes a lever end, a fulcrum, and a claw end having a notch particularly adapted to engage a knob that protrudes from a surface of the modular concrete form. The method includes engaging the claw end of the tool with the knob, abutting the fulcrum against rigid concrete adjacent the modular form, and exerting a force on the lever end in the direction of the adjacent rigid concrete.
U.S. Pat. No. 7,086,640 generally describes a mechanical assembly for pulling the form work away from a concrete structure after the concrete structure has cured. The form work is typically wood or steel and requires a large mechanically force to free it from the concrete structure. The form puller assembly includes a lever assembly, a fulcrum assembly, and a form pulling assembly. The user pulls down on the opposite end of the lever assembly generating a mechanical force sufficient to free the form work from the concrete structure. Also, the mechanical assembly may include at least one embedded element extracting assembly for removing vertically oriented elements embedded in the soil and/or concrete.
U.S. Pat. No. 4,102,527 generally describes a handtool particularly adapted to engage concrete forms for prying the same loose from the concrete after setting. The tool includes a gripping mechanism carried on a tool frame, the gripper mechanism enabling the lip portion of the concrete form to be gripped or clamped during the prying operations to maintain the engagement of the tool with the concrete form. The tool frame includes a support member for the gripper mechanism extending transversely to the tool handle which provides leverage for prying the form while it is engaged with the gripper mechanism. The gripper mechanism consists of a self-engaging cam clamp element pivotally supported and spring-biased to the engaging position with a release handle provided for releasing the grip from the form.
U.S. Pat. No. 3,690,613 generally describes securing means for a concrete wall form including a flat tie rod having means at its end sections for attachment to the form sides so that the medial section of the tie rod spans the form and becomes embedded in the concrete which is poured between the form sides, thus leaving outwardly projecting tie rod end sections. Elongated sleeve cones surround such tie rod end sections and have their inner ends drivingly connected to the same at regions in the immediate vicinity of the tie rod breakbacks, and also have torque-application facilities at their exposed outer ends to that the manual application of torque to the sleeve cones will impart a radial tear or shear effect at the breakbacks to thus free the projecting tie rod end sections.
U.S. Pat. No. 4,284,014 generally describes a safe rigidly and permanently mounted in an opening in a concrete wall or floor. Two interfitting sleeves co-operating in a pre-oriented, rigid relationship with each other and the surface bordering the opening to preclude unauthorized removal. A container element is assembled to one of the sleeves. To retard “sweating” or the accumulation of moisture in the container and to obviate corrosion development, a rigid plastic, such as polyvinyl chloride, is used for container fabrication. A cover is provided which is releasably secured in close fitting relationship to one of the sleeves, capturing a cover plate therebetween in pre-selected orientation adjacent the safe mouth. The co-operation between the cover, the cover plate and the interfitting sleeves maximizes safe security and precludes extraction from or pushing through the opening in the wall or floor.
U.S. Pat. No. 5,031,879 generally describes a stake extraction implement for primary utilization with respect to stakes used for concrete forms. The stake extraction implement is composed of an elongate member, incorporating a handle portion and a curved portion, and a pivotally connected gripper tool, incorporating a pair of jaws. When a stake is to be extracted, the curved portion of the elongate member is placed upon the adjacent concrete form and the jaws of the gripper tool are aligned to rest upon the sides of the subject stake. According to the method of use disclosed, as a lever movement of the handle portion is effected, effortless extraction of the stake from the ground is made possible by automatic clamping of the jaws of the gripper tool onto the stake, the stake having been nailed to the concrete form notwithstanding. The stake pulling implement is structured to permit user selection of either a first class or second class lever mode of operation, and two types of jaw members for the gripper tool are disclosed.
U.S. Pat. No. 7,581,709 generally describes a system of interconnecting structural components for supporting and forming suspended concrete slabs that allow removal of form panels without disturbing the slab support posts (shores). Additional features of the system accommodate changes in suspended slab thickness, horizontal slab dimensions that are not multiples of the basic component dimensions, slab edge cantilevered form panels, attachment to walls and remote manipulation of form panels from the floor below using an erection staff. The primary system components are panels, support posts, telescopic beams, adjustable hanger connections, wall hangers, wall beams, raking shore assemblies and erection/stripping staffs. Form panels are directly supported by the shores without the use of an intermediate member (usually a beam) that is common practice in the concrete forming industry. The system reduces the number of required components that in turn reduces the capital cost to the user and improves his labor efficiency and quality of the concrete surface.
U.S. Pat. No. 9,309,688 generally describes a post anchoring support device comprising a ground anchor having a shaft with a threaded upper portion terminating in an upper end that may be engaged and rotated by a drive tool for rotating the shaft about a vertical axis, and a lower portion for insertion into the ground, and a post receiving bracket having base with a vertically oriented internally threaded portion adapted to receive the externally threaded portion of the shaft, a support portion defining a support surface for abutting the end of the post, vertical planar walls extending above the support surface, each planar wall having an inside surface for abutting a side of the post, and each planar wall defining a plurality of vertically oriented elongate holes and having a raised portion on the outside surface adjacent each elongate hole adapted to abut a lower surface of a head of a fastener passing through the elongate hole and into the post to allow the fastener to travel within the elongate hole upon the application of a vertically force to the post anchoring support device sufficient to overcome a coefficient of friction between the head of the fastener and the raised portion.
U.S. Pat. No. 9,458,591 generally describes piling apparatus and methods for installing a reinforced concrete piling apparatus into the ground without the use of a pile driver or an auger. A helical screw anchor and coupling device are used to pull pipe sections into the ground. A preassembled reinforcing rod cage is placed into the pipe sections in the ground. Wet concrete is poured into the pipe sections to encase the reinforcing rod cage. The pipe sections are then removed. Removal of the pipe sections from the helical screw anchor is accomplished using the coupling device.
U.S. Pat. No. 9,631,392 generally describes a post anchoring support device comprising a ground anchor having a shaft with a threaded upper portion terminating in an upper end that may be engaged and rotated by a drive tool for rotating the shaft about a vertical axis, and a lower portion for insertion into the ground, and a post receiving bracket having a base with an elongate aperture adapted to receive the externally threaded portion of the shaft, a support portion defining a support surface for abutting the end of the post, vertical planar walls extending above the support surface, each planar wall having an inside surface for abutting a side of the post, and each planar wall defining a plurality of vertically oriented elongate holes and having a raised portion on the outside surface adjacent each elongate hole adapted to abut a lower surface of a head of a fastener passing through the elongate hole and into the post to allow the fastener to travel within the elongate hole upon the application of a vertically force to the post anchoring support device sufficient to overcome a coefficient of friction between the head of the fastener and the raised portion.
U.S. Pat. No. 9,746,019 generally describes a securement device that includes a pair of plungers movable within a housing. The plungers act as quick lock mechanism to engage and secure a threaded rod (or other object) that passes into a hole that runs through the housing. The plungers are spring-biased to position themselves toward so as to provide a radially inward force, for example to engage a threaded rod or device in the through hole in the housing. A spring within the housing presses the plunger pieces toward a portion of the housing where the outer surfaces engage other surfaces to push the plungers inward. The device includes a disengagement feature or mechanism that is used to push the plunger pieces out of engagement with the threaded rod. The disengagement feature may include a disengagement tool, and may include wings, such as on the plungers or on carriers for the plungers, that protrude out of the housing.
U.S. Patent Publication No. 2016/0312460 generally describes a device and method in which, in a load-bearing concrete vertical building part, particularly a support, with an upper support area for a load-transferring connection to a concrete horizontal building part thereabove, in which the vertical building part includes reinforcements with reinforcement rods extending essentially vertically beyond the upper support area, an upper section of the vertical building part abutting the upper support area is embodied as a thermal insulation element for the thermal decoupling of the vertical building part from the horizontal building. The upper section forming the thermal insulation element is made at least partially from a compressive load transferring and thermally insulating material, particularly light-weight concrete, and reinforcement rods extending beyond the upper support area are made from a fiber composite material, and extend through the upper section of the vertical building part forming the thermal insulation element essentially vertically to the lower section of the vertical building part located underneath thereof.
International Patent Publication No. WO2004065722A1 generally describes a system of interconnecting structural components for supporting and forming suspended concrete slabs that allow removal of form panels without disturbing the slab support posts. Additional features of the system accommodate changes in suspended slab thickness, horizontal slab dimensions that are not multiples of the basis component dimensions, slab edge cantilevered form panels, attachment to walls and remote manipulation of form panels from the floor below using an erection staff. The primary system components are panels, support posts, telescopic beams, adjustable hanger connections, wall hangers, wall beams, raking shore assemblies and erection/stripping staffs. Form panels are directly supported by the shores without the use of an intermediate member (usually a beam) that is common practice in the concrete forming industry. The system reduces the number of required components that in turn reduces the capital cost to the user and improves his labor efficiency and quality of the concrete surface.
International Patent Publication No. WO2006124079A1 generally describes a wheeled slab removal device, for concrete or other materials, grabs and lifts a slab from a lower level to a higher lever, without dropping the wheels into the hole/space left by removing the slab. The device may include a pivotal jaw system that tightens its grasp on the slab as the weight of the slab pivots the jaw. An elongated central support/handle provides leverage, whereby a single operator may lift, pivot, and wheel the slab away, without the need to hoist the slab removal device and slab out of the hole left by the slab. Preferred versions of the device have a carry plate, and a pivotal jaw for grasping the slab between them, wherein the distance between the carry plate and the jaw may be adjusted, for example, by extending the longitudinal axis of the central support. In use, the preferred device is placed over the slab, the distance between the jaw and carry plate is shortened to grasp the slab, and the device handle is lifted to pivot the slab, at which time the jaw system tightens even more due to the weight of the slab pivoting the jaw and lengthening the central support. At generally the same time, the wheel system pivots to move the fulcrum for the device to a position on top of the adjacent concrete or other structure higher than the original position of the slab being removed.
International Patent Publication No. WO2016041015A1 generally describes a device for clamping a piece of formwork. The device comprises a bar having an end for attachment to a body. The device comprises a jaw mounted on the bar and for receiving the piece of formwork, the jaw being movable along the bar.
None of the art described above addresses all of the issues that the present invention does.

SUMMARY OF THE EMBODIMENTS

According to an aspect of the present invention, a system for separating one or more forms from a hardened material is provided. The system includes a support structure, a securing mechanism, coupled to the support structure, wherein the securing mechanism is configured to secure the system to the one or more forms, and a threaded rod, threaded through an opening in the support structure, wherein the threaded rod is configured to apply pressure to the hardened material.
It is an object of the present invention to provide the system for separating one or more forms from the hardened material, wherein the hardened material is selected from the group consisting of: cement; and concrete.
It is an object of the present invention to provide the system for separating one or more forms from the hardened material, wherein the securing mechanism is further configured to secure the system to the one or more forms using a nut and bolt.
It is an object of the present invention to provide the system for separating one or more forms from the hardened material, wherein the threaded rod further includes a foot portion.
It is an object of the present invention to provide the system for separating one or more forms from the hardened material, wherein the foot portion is configured to rest against the hardened material.
It is an object of the present invention to provide the system for separating one or more forms from the hardened material, wherein the threaded rod further includes a knob section, the knob section being configured to assist in threading the threaded rod through the opening in the support structure.
It is an object of the present invention to provide the system for separating one or more forms from the hardened material, wherein the securing mechanism has an adjustable length.
According to another aspect of the present invention, a method for separating one or more forms from a hardened material is provided. The method includes securing one or more release systems to the one or more forms, each of the one or more release systems including: a support structure; a securing mechanism, coupled to the support structure, wherein the securing mechanism is configured to secure the system to the one or more forms; and a threaded rod, threaded through an opening in the support structure, wherein the threaded rod is configured to apply pressure to the hardened material. The method further includes threading the threaded rod through the opening in the support structure until the one or more forms separates from the hardened material.
It is an object of the present invention to provide the method for separating one or more forms from the hardened material, wherein the hardened material is selected from the group consisting of: cement; and concrete.
It is an object of the present invention to provide the method for separating one or more forms from the hardened material, wherein the securing further includes securing the system to the one or more forms using a nut and bolt.
It is an object of the present invention to provide the method for separating one or more forms from the hardened material, wherein the threaded rod further includes a foot portion.
It is an object of the present invention to provide the method for separating one or more forms from the hardened material, wherein the foot portion is configured to rest against the hardened material.
It is an object of the present invention to provide the method for separating one or more forms from the hardened material, wherein the threaded rod further includes a knob section, the knob section being configured to assist in threading the threaded rod through the opening in the support structure.
It is an object of the present invention to provide the method for separating one or more forms from the hardened material, wherein the threading further includes rotating the knob.
It is an object of the present invention to provide the method for separating one or more forms from the hardened material, wherein the securing mechanism has an adjustable length and can freely rotate to align/be compatible with existing modular forms.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a device for separating forms from hardened concrete structures, according to an embodiment of the present invention.

FIG. 2 shows the device of FIG. 1 in use with a form and a hardened concrete structure, according to an embodiment of the present invention.

FIG. 3 shows a device for separating forms from hardened concrete structures, according to an embodiment of the present invention.

FIG. 4 shows the device of FIG. 3 in use with a form and a hardened concrete structure, according to an embodiment of the present invention.

FIG. 5 shows a flowchart of a method for separating forms from hardened concrete structures, according to an embodiment of the present invention.

FIG. 6 shows a form having multiple devices for separating forms from hardened concrete structures, according to an embodiment of the present invention.

FIG. 7 shows a fully constructed form having one or more channels for securing one or more devices for separating forms from hardened concrete structures, according to an embodiment of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The preferred embodiments of the present invention will now be described with reference to the drawings. Identical elements in the various figures are identified with the same reference numerals.
Reference will now be made in detail to each embodiment of the present invention. Such embodiments are provided by way of explanation of the present invention, which is not intended to be limited thereto. In fact, those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made thereto.
Referring now to FIGS. 1-2, a device 100 for separating one or more forms 116 from hardened concrete structures 102 is illustratively depicted, in accordance with an embodiment of the present invention. It is noted, however, that any suitable hardenable material such as, e.g., cement, may be used in addition to, or instead of, concrete in the formation of the hardened structures 102.
According to an embodiment, the device 100 includes a support structure 104, a threaded rod 106 coupled to the support structure 104, and a securing mechanism 108 coupled to the support structure 104.
According to an embodiment, the securing mechanism 108 includes an opening 114, enabling the securing mechanism 108 to secure the support structure 104 to a form 116. According to an embodiment, the securing mechanism 108 is secured to the form 116 via a nut and bolt 118. It is noted, however, that the securing mechanism 108 may secure the support structure 104 to the form using any suitable means, while maintaining the spirit of the present invention.
According to an embodiment, the threaded rod 106 is threaded through a threaded opening 120 in the support structure 104. According to an embodiment, the threaded rod 106 includes a knob portion 110 and a foot portion 112. According to an embodiment, the foot portion 112 rests against the hardened concrete structure 102. The threaded rod 106 is threaded through the support structure 104, causing the foot portion 112 to apply force against the concrete structure 102, causing a separating force between the hardened concrete structure 102 and the form 116. According to an embodiment, once a sufficient force has been applied to the hardened concrete structure 102, the form 116 separates from the hardened concrete structure 102. According to an embodiment, the threaded rod 106 is threaded through the opening 120 by rotating the knob portion 110. It is noted, however, that any suitable means may be used to thread the threaded rod, while maintaining the spirit of the present invention.
Referring now to FIGS. 3-4, a device 300 for separating one or more forms 116 from hardened concrete structures 102 is illustratively depicted, in accordance with an embodiment of the present invention.
According to the embodiment as shown in FIG. 4, the form 116 and the hardened concrete structure 102 is not linear. In the embodiment shown in FIG. 4, the structure 102 and form 116 are bent at a right angle. It is noted, however, that the structure 102 and form 116 may be at any suitable shape, while still maintaining the spirit of the present invention.
According to an embodiment, depending on the shape of the structure 102 and the forms 116, two or more devices 300 may need to be used to separate the forms 116 from the structure 102. According to an embodiment, the two or more devices 300 are positioned against the forms 116 in such a way that, when the threaded rod 106 is threaded through the opening 120 by rotating the knob portion 110, a separating force is produced between the hardened concrete structure 102 and the form 116 causing the form 116 to separate from the hardened concrete structure 102.
According to an embodiment, the securing mechanism 108 may have an adjustable length. The adjustable length may be due to the use of a threaded bolt 122 and/or any other suitable means. According to an embodiment, the securing mechanism 108 can freely rotate to align/be compatible with existing modular forms 116
It is noted that, in any of the embodiments of the present invention, the device 100, 300 may be placed in any suitable location to cause an appropriate separating force between the form 116 and the structure 102.
Referring now to FIG. 5, a flowchart of a method 500 for separating forms from hardened concrete structures is illustratively depicted, in accordance with an embodiment of the present invention.
At step 505, one or more forms 116 are set in place, wherein the one or more forms 116 are configured such that a liquid hardening material may be poured into the forms 116. At step 510, the liquid hardening material is poured into one or more gaps formed by the placement of the forms 116. According to an embodiment, the liquid hardening material is liquid concrete. It is noted, however, that any suitable hardening material may be used, while still maintaining the spirit of the present invention. At step 515, the liquid hardening material hardens, forming the hardened structure 102 in the shape of the cavity of the one or more forms 116 into which the liquid hardening material was poured. According to an embodiment, the shape is a wall. However, it is noted that the shape may be any suitable shape, while maintaining the spirit of the present invention.
At step 520, after the liquid hardening material hardens, the release system 100, 300 is attached to the form 116 using a threaded rod and bolt 118. According to an embodiment, the foot 112 of the release system 100, 300 rests flat on the hardened structure 102. According to an embodiment, the release system 100, 300 is positioned and configured to apply a force perpendicular to the hardened structure 102, thus pushing the form 116 away from the hardened structure 102. According to an embodiment, the release system 100, 300 is attached to the form 116 prior to the curing and/or hardening. According to an embodiment, the release system 100, 300 is secured to channels 604 (shown in FIGS. 6-7) in the form 116. According to an embodiment, the release system 100 is secured to the form 116 using one or more securing mechanisms such as, e.g., one or more pins 606 (shown in FIG. 6).
At step 525, the threaded rod 106 of the release system 100, 300 is further threaded through an opening 120 of a support structure 104 of the release system 100, 300, increasing the force of the foot 112 on the newly constructed hardened structure 102 to push the form 116 away from the hardened structure 102. At step 530, the pushing force applied by the foot 112 causes the form to separate from the hardened structure. According to an embodiment, prior to applying the pushing force, one or more shear bolts 602 (shown in FIG. 7) are removed. According to an embodiment, concrete ties 608 (shown in FIG. 6) are positioned after the removal of the shear bolts 602.
The present release system improves upon the existing systems and methods in several ways. The present release system decreases the amount of time needed to separate forms from hardened structures. Since many workers are paid by the hour, decreasing the amount of time can significantly reduce construction costs. The present release system further reduces wear on expensive modular forms for use in construction. By decreasing wear, the forms can be used more often, decreasing repair costs and decreasing costs to build new forms. Furthermore, the present release system provides a system and method for removing forms from hardened structures that is safer than previous systems and methods. This can help decrease injuries, which can be expensive to both the workers and the employers.
When introducing elements of the present disclosure or the embodiment(s) thereof, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. Similarly, the adjective “another,” when used to introduce an element, is intended to mean one or more elements. The terms “including” and “having” are intended to be inclusive such that there may be additional elements other than the listed elements.
Although this invention has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made only by way of illustration and that numerous changes in the details of construction and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention.

Claims

What is claimed is:

1. A system for separating one or more forms from a hardened material, comprising:

a support structure;

a securing mechanism, coupled to the support structure,

wherein the securing mechanism is configured to secure the system to the one or more forms; and

a threaded rod, threaded through an opening in the support structure,

wherein the threaded rod is configured to apply pressure to the hardened material.

2. The system as recited in claim 1, wherein the hardened material is selected from the group consisting of: cement; and concrete.

3. The system as recited in claim 1, wherein the securing mechanism is further configured to secure the system to the one or more forms using a nut and bolt.

4. The system as recited in claim 1, wherein the threaded rod further includes a foot portion.

5. The system as recited in claim 4, wherein the foot portion is configured to rest against the hardened material.

6. The system as recited in claim 1, wherein the threaded rod further includes a knob section, the knob section being configured to assist in threading the threaded rod through the opening in the support structure.

7. The system as recited in claim 1, wherein the securing mechanism has an adjustable length.

8. A method for separating one or more forms from a hardened material, comprising:

securing one or more release systems to the one or more forms, each of the one or more release systems including:

a support structure;

a securing mechanism, coupled to the support structure,

a threaded rod, threaded through an opening in the support structure,

wherein the threaded rod is configured to apply pressure to the hardened material; and

threading the threaded rod through the opening in the support structure until the one or more forms separates from the hardened material.

9. The method as recited in claim 8, wherein the hardened material is selected from the group consisting of: cement; and concrete.

10. The method as recited in claim 8, wherein the securing further includes securing the system to the one or more forms using a nut and bolt.

11. The method as recited in claim 8, wherein the threaded rod further includes a foot portion.

12. The method as recited in claim 11, wherein the foot portion is configured to rest against the hardened material.

13. The method as recited in claim 1, wherein the threaded rod further includes a knob section, the knob section being configured to assist in threading the threaded rod through the opening in the support structure.

14. The method as recited in claim 13, wherein the threading further includes rotating the knob.

15. The method as recited in claim 8, wherein the securing mechanism has an adjustable length.