US2455455A - Prefabricated concrete form - Google Patents

Description

Dec. 7, 1948. 5, WEST 2,455,455

PREFABRICATED CONCRETE FORM Filed Dec. 12, 1946 2 Sheets-Sheet l INVEN TOR.

Adan gay Patented Dec. 7, 1948 UNITED STATES PATENT OFFICE PREFABRICATED CONCRETE FORM Paul'B. West, Newark, N. J.

Application December 12, 1946, Serial No. 715,839

12 Claims.

This invention relates to' improvements in form structures adapted for use in the production of concrete walls, roofs, floors and other parts of concrete building erections; and the invention has reference, more particularly, to a novel construction of prefabricated form structure ready to be transported to and set up at a building site.

This invention has for its primary object to provide novel form unit structures of such design that the same may be prefabricated in a shop, whereby to provide complete unitary form units ready to be transported to a building site, and there set up preparatory to application thereto of concrete or like moldable mixture for the production of a desired building wall, floor, roof or other part of a building construction, each form unit including form walls for shaping the applied concrete into monolithic wall and stud or like formations, together with properly positioned and related elements adapted to reenforce the concrete formations, as well as lathing for supporting plaster facings at interior sides of the finished wall or other concrete formation.

The invention has for another object to provide a novel prefabricated form structure of the kind stated wherein the form walls comprise relatively inexpensive sheet material, such, e. g., as corrugated paperboard or the like, which may be left in the finished concrete formation; said sheet material being so folded upon itself as to provide a strong and substantially rigid self-trussed form wall assembly, well able to withstand and support the stresses and pressure of the concrete applied thereto, especially when the application is made by a gunning method, while at the same time, providing for suitably shaped stud or like molding cavities, whereby the finished concrete formation is provided with stud or like portions which are unitary therewith; the sheet material being also arranged so as to provide insulating air cells within the wall or other finished concrete formation.

The invention has for a further object to provide a prefabricated form structure, the form wall portions of which comprise folded sections of sheet material, such as corrugated paperboard or the like, which are completed by joining marginal portions thereof by novel interlocking joint formations; said joint formations being, in turn, secured against separation or disruption by easily applied wire stapling.

The invention has for a still further object to provide novel means for both tying its form wall sections together in aligned relation, while, at the same time, providing means for supporting con- 2 crete reenforcing elements in fixed spaced relation to the outer face wall of the form to which the concrete is to be applied.

The invention has for another object to provide a novel prefabricated form structure as above characterized which is especially well adapted to receive gunned application of concrete thereto.

Other objects of this invention, not at this time more particularly enumerated, will be understood from the following detailed description of the same.

An illustrative embodiment of the invention is shown in the accompanying drawings, in which Fig. 1 is a perspective view of the novel, prefabricated form structure according to this invention, with parts broken away and in part section; and Fig. 2 is a vertical cross sectional View of the form structure, taken on line 2-2 in Fig. 1.

Fig. 3 is a fragmentary skeletal perspective view of an assembly of parts of the form structure omitting the form wall sections.

Fig. 4 is a fragmentary perspective view of a joint formation of the form wall sections.

Fig. 5 is a fragmentary perspective view showing a base or ground nailing block at the foot of a form wall section.

Fig. 6 is a fragmentary perspective view of corrugated paper board which constitutes the preferred sheet material from which the form wall sections are produced.

Similar characters of reference are employed in the hereinabove described views, to indicate corresponding parts.

The novel form structure according to this invention comprises a plurality of preformed form wall sections made by folding and assembling sheet material, preferably corrugated paperboard of the kind shown in Fig. 6, whereby to produce substantially right triangular units A and inverted U-shaped units B.

The right triangular units A each comprise a face or front panel I0 and end panel H extending right angularly from one perpendicular side of said front panel, and an angular rear panel I2 which extends from the rear perpendicular side of said end panel to converge upon theopposite perpendicular side of said front panel. Said end panel and rear panel are preferably unitary, and their adjoining portions are scored to provide perpendicular fold lines, whereby, when relatively folded into ultimate angular relation, to provide at the juncture thereof a comparatively narrow rear face portion l3 disposed to lie in a plane 3 parallel to that of the front panel l0. Mounted on the inner surface of said rear face portion l3, to extend perpendicularly therealong from bottom to top thereof, is a sheet metal strip I4, from which is outwardly struck a series of longitudinally spaced prongs l5. Said prongs [5 project through the body of said rear face portion l3 so as to project from the outer surface thereof, whereby tozserve' as-means for attaching lathing-v or plasterboard to the rearfaoe of theformstructure, as will subsequently appear. Formed by folded portions of the perpendicular meeting; sides of the front panel I0 and .endipanell ls a joint structure by which said panels are'united'. Said joint structure comprises an inturned:ma1e.-- joint member it which extends from the front panel l0, and an inverted, outwardly opem U-'- shaped female joint member I! which extends from the end panel II. Said joint structure is assembled by inserting. the male joint member [5 into; and 'within the embrace v of .,the. female joint member l1," and thereupon securing these parts. together.by engaging wire staples, Wtherethrough at. suitably spaced Lintervals. along the length thereof Theadjoining onvergent. perpendicua lar sidespf the front. panel .I 0 and rear panel 1 l 2" are respectively provided with an inturnedmale joint. member l9 .and an out-turnedmaleyjoint member. Ztljwhich are disposed :in lapped contiguous; relation, andjwhichform parts of a V joint structure whereby a right'triangular form wall" unitAis joined to anadjacent inverted ;U'-'shaped r wa unit "Bias.w llisub qu st pe r-- The outwardly open, inverted U-shaped' units B each. comprise a rear panel 2| of suitable width, .from. the respective perpendicular sides of which.extend outwardly projecting side panels 22; Sa djsid panels 22, are .unitarLWith the rear panel ..2l intermediate fold defining; scores. be, ing provided whereby the .former ,may'befolded' relative to the latter into. thedescribedj outward extension therefrom... Mountedpn the inner surface of. saidnr'ear, p.anel' .2l,1 to.. extend .perpendicularlytherealong intermediate its sides. and fromtop. to. bottom, thereon is. another. sheet metalfstrip... ltithfeLprong I51,0f "Which project, through andexteriorly of the body of .saidlurear panel 2],. whereby to likewise serve for attaching lath'ingor plasterboarwtothe. rear. face of the. form :stn1.cture. Formed .by folded. parts..- of .the. respective forward marginal pprtionsof jth'eside panels 22 ar e outward1y open, U.-sha.p edj female jointjmembersgzij To arrange the form wall units ,AgandwBjin" operative assembled relation, pairs of the units A are. adjoinedwith theirend' panels. I I opposed and'gabutted, whereupon units are interposed. betweenthus relatedfpairs of .units A;.and joined thereto; such. assemblin relation; being. con, tinued until a desired. length of .1 formstructure is obtained." The meetin sides.of.the unitsAfl. and B,are. join ed together.byinsertingJhe contiguousmale, joint'mem'bers lllrfindjzflfof a unit... A .into and within the embrace.,of.jthe..female. joint member 2.3.iat the side .of an. adj oining unit B, and thereupon securing these, parts together by. wire, staples, similar. to the. above mentioned wire. staples 1 l 8, and similarly. applied along. the. thus. formed jointstructure at. desirably. spaced; intervals. f

The form. wall units are proyided with...suit=. ably located.coupler.loops. 24 arranged,,.toypro ject exteriorly from the. forwardface or front. of the. assembly thereof- These .coupler loops,.in one satisfactory form thereof, comprise wire formations made of doubling a length of wire upon itself into a loop, the legs of which terminate in angularly and oppositely extending foot pieces 25. The foot piece ends of said coupler are inserted within the female joint members I! and 23, and then the coupler loops are secured to the joint formations by certain of the staples [8 which are disposed to bridge the coupler loop legs :(see Fig 4-);2 The coupler :loopszl l are positinned: in connection with ,..the. respective form wall units A and B so as to be laterally aligned in,a plurality of horizontally spaced rows extendingacross theiront of the assembly of said units, said---rows-beingarranged in suitably vertically spacedqapart relation.

When a desired member of form wall units A and--B-liave been-assembled in the mutual relatiomabovedescribed, a rigid steel lock bar or strip 26 of suitable width, thickness and length is. threadedthrough each horizontal row. of coupll'iloops zdi lock .bars or strips .not.

only tie.the.;assembled form wall units .togethen' beddedin the,concretawhen the latteris. applied'..

to thelform structure andjthussoas to .provide.

a strong reenforcingmeans. .for.. the... wallimass,

which is. formed.by,.t11e applied .concrete.

One illustrativeform ofthe-reenforcing means...

lastrefe1.'r,ed...to,v as. .showrmcomprises.suitably. sized panels. or grids zfl.formedgby suitably interconnectedipeltpendicular and, horizontal metallic. bars, thei perpendicular bars. being affixed to..the.. outenedges ,of .thedock ,bars.,.or.. strips, 26.. in any suitable ,manner, as..by..tack welding ,the .same to,

the latter. Adjoining, ends. .of the thusapplieds reenforcing panels. or. .grids-,2], .may; be. tied to.- gether. bynwiret ties; B..-if so desired,

It. will.-.-be.--observed .that the, U. .-.shaped. form wall units 13-, which .arespaoed at selected intervals .along;.the..,form' wall..struc.ture..by ..the.- inter: vening units .asbeirie; outw rdly opemform mold. .cavitiessinnwhich the. concrete,v when appl ed t th'eform structure: mayt wh y .t i.

produce suitablyspaced .stud oralike formations S. which ,are, unitary. with the. wall formed, by, appliedzconcrete, and. which,.are., disposed to .extench rearwardlyt-f rom .the. wall .mass.. Meansis'.

"provided 1 for, suDPOrt A I reenforcingv elements.

within. said..mold. cauitiesi,provided 3 by the. form.

wall..-units.-B; so. that. said. elements. will .be imv bedded. in .the... applied; concrete. To this end each; form. wall...unit..B,., is rovided...with t a ..rod..

hanger;.,means. adapted. to support. and... position. a metallic reenforcing rod 29 for perpendicular. extension! through. the. interior... of the. .wall form unit .3. In an illustrative. form thereof as shown. said .mdhangier means. comprises --.-a bridge. piece, stvharing,,susnension..hook portions- 3 l... upstancb.

ing from .its...respectiye. ends;..said.1bridgepie e having at ..least1'. one fopening through which the. reenforcing,rod l29,'.inayibeeng= .edl he $115.:- pension .hooksportions .31. are....respectiv.el engaged over the top marginal portionspflthehside S0,, 30. spans.,the.-,int.erior,;oiJsaid unit..-

Additional ;,means; is provided-Zion holdingithe, reenforcing.l'ods.. 2am .desired.perpendicular ,ex-,. tension and position within the interior of the form wall units B. Said means comprise forwardly extending tie-members 3.2 for interconnection between the reenforcing rods 29 andthe lock bars or strips 26. Said tie-members 32 preferably comprise wire formations each provided with a rear hook portion 33 to engage around a reenforcing rod 29 and a forward hook portion 3a to engage around a lock bar or strip 26. Said tie-members 32 serve to retain the reenforcing rods 29 against lateral and rearward displacement. The rod holding means further includes rearwardly extending tie-members 35 for interconnection between the reenforcing rods 29 and an adjacent metallic strip it with which each form wall unit B is provided. Preferably, said tie-members 35 also comprise wire formations each provided with a forward hook portion 36 to engage around a reenforcing rod 29 and a rearward lateral arm 31 to engage in a retaining knuckle or bearing 38 with which the adjacent metallic strip I4 is provided. Said tiemembers 35 serve to retain the reenforcing rods 29 against lateral and forward displacement.

To complete the prefabricated form structure, lathing, plasterboard or like inner wall face means or component, is secured to and in covering relation to the rear side of the assembled form wall units A and B, the same being secured in place by the penetration therethrough of the prongs l5 of the sheet metal strips I4 with which said units are provided, the free ends of said prongs being thereupon clinched over and in holding relation to the applied lathing, plasterboard or the like (see Fig, 2). For example, as shown, panels 39 of wire mesh, expanded metal lath or the like, are thus secured to the rear face of the form structure, whereby, after a concrete wall or the like is produced by aid of the form structure, the same serves to receive and hold an interior finishing coating or plaster or the like (not shown).

In making up the wall form units A and B from the preferred corrugated paperboard, said paperboard is so disposed that the corrugations thereof extend horizontally or transverse to the perpendicular height of the form units. As thus disposed,

the corrugations are best arranged to stiffen the units so that they efficiently resist the stresses and pressures of the applied concrete, both during application and thereafter, while at the same time enhancing the self trussing efficiency of said units due to the shape thereof.

The corrugated paperboard or other similar sheet material from which the form wall units A and B are produced, should generally be impregnated or coated inside and outside with a suitable waterproofing material, whereby said units provide, with respect to the finished wall or the like, a very efficient barrier between outer and inner sides of the latter, against penetration of the wall or the like by moisture.

The described form wall structure may be made up in advance of use in a shop or erection plant as complete fabricated sections of suitable length and of one storey height, ready to be transported to the site of the building in connection with which use thereof is to be made. When delivered at the building site, the prefabricated form structure sections can be quickly stood up and assembled on the foundation or other footing therefor ready to receive application of concrete thereto. If desired, the lower ends of the form wall units may be provided with nailing blocks 40 for footing the same on the foundation or other support or ground, the units being fastened to said blocks 40 by passing nails 4| through the unit material and contiguous sheet metal stri s I4 and driving said nails into the blocks.

A plate 42 is superposed upon the top of the erected form wall structure, and is provided with stud bolts 43 and fastening nuts 44. Said stud bolts are provided with suitably enlarged lower end portions 45 which are positioned to depend into interiors of mold cavities provided by the form wall units B, so that the same will be imbedded and anchored in the concrete, when the latter is filled into said cavities.

The upper margins of the mesh panels 39 are preferably dimensioned to extend somewhat beyond the top of the form structure, so that the upper marginal portions of said panels may lap theplate 42, and then be secured thereto by suitable fastening means, such as by staples 46 (see Fig.2).

It will be noted that by reason of the provision of the coupler loops '24, which receive the lock bar or strip 26, at the joint structures of the form wall units A and B, in addition to the firmly secured connection of the lathing 39 to the rear portions of said units A and B, and the inter-tying of the lathing 39 and lock bar or strips 25 by the tiemembers 32 and 35, a form structure of great strength and rigidity is assured, wherein all said parts mutually cooperate to sustain the stresses and pressures of the applied concrete.

After the form structure is in place, the concrete C may be applied to the front side thereof so as to be shaped thereby, while at the same time imbedding the reenforcing material 21 and 29 in the applied concrete mass. Due to the character and qualities of the form wall structure, the same is especially well adapted to receive application of the concrete by a gunning method; although by use of a retaining wall erected in front of the form structure, the concrete may, if desired, be applied by a casting or pouring method. Since the form structure remains in the wall or other concrete formation it will be seen that the hollow form wall units A will provide insulating air cells within the finished Wall or other formation.

Owing to the character of the form wall units A and B, it will be obvious that form structure sections may be relatively spaced and arranged, or-parts thereof easily cut away and shaped at desired points for provision of window, door, or other desired building openings.

I am aware that changes could be made in the above described prefabricated form wall structure without departing from the scope of this invention as defined in the herefollowing claims. It is therefore intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

I claim:

1. A prefabricated form structure for the purposes described comprising an assembly of hollow form wall units made of folded sheet material, certain of said units being of substantially claimzd uvherein.:.the sheet material fromwwhich .1 I

thesform-cwall. units;altermaddlcomprisesewatera prooltedecorrugated; paperboard, ,said ipaperboardsl being'zsozdisposed; that. ;the corrugations :.theree[:.-. extend;;transversely across the panels comprising; saidiunitsr 511A prefabricated form StIllCtuI'evfOD;thEJUP-lr poses: described;.comprisinggan .assembly; of .-hol-;=- lowzaform wallunits made of: folded rsheet: ma.-. terial, certain of; said-.unitsbeing .;of substantia1ly rightctrian lllar: cross sectionand-other ofiesaid 3O unitsgrbeing; ;of;; substantially; U..-shape d-., cross: seer-.- tiorr; said-fri htitrian ular units being: arranged in pairse-witlrptlreirsroblique:Dane1srearwardly -,-pre.-.- sellllfiduandcgtheil; end panels abuttedwherebyq to. fonwardmpresent-their ,remaininglprefront panelsin .a-, ,commona--plane,l a .U..-shaped;unit. being. dise posed; intermediate-1 adjacent. pairs.I of athus-v ar-.-- ranged right ptriangulareunits-v with its: open: faee1- disposedinrtheplaneqof said front; panels- 0t the latterrunits, marginal .-portions.,-of-.:-said'= thus ad-;--

joinett;:un-its being folded -and-interen a ed 1307- provide -uniting jointestructures; l wire1--stapleS-eX'- tending; through said -.j oint. structu-resa-tmsecureez together the; components athereofi; locls EbarSkdiS? posed across the front of the thus assembled unitscoupler: loops rooted: in said-v unit: joint structures and :securedvthereto: bycertain ,of. said :wireesta... ples; saidcouplerlloops projecting from .the errant... face tOfriSflid assembled units: so as to .receiveitheo. lock bars and thus secure=the-units thereto,,-mee!-- 5Q tallic mesh for concreteireenforcement.secured'to. thelouterredges of said lockloars to extend across theriront, of the. assembled units 1 in; outwardly spaced. relation .thereto; an.-inner;;wal1- -;medium disposed lacross thenrearrof: theassembled units;-

and said-:units having means-fonsecurmg said-iner- 1161": Wall medium thereto.-

6 A prei abricatedaform structure for;-.the ;1: ir.-., poses described comprising; an; assembly; of; hole low form wall units made of folded sheetuma- 3 teria-l, certain of saidunits-being of substantially right tria-ngularcross sections and; other said: units being; ofsubstantiallyu-shapedecross'sec-a tion; said vright triangular units being; arranged}. inzpairswithztheir oblique panels. rearwardly pre-esentechand their end panels abutted:wherebmto.- forwardly; present their remaining or'front panels; in:.a;common'pl,ane,' a U-shaped unitibeing'disposedintermediate r adjacent pairs. ofi thus. are

ranged right triangular units with: its open-face 7 0 disposed in the plane-of-said front panels of the: latter units-marginal portionswofi said -thus;:ad--

joinedn units: being. foldedand interengaged'. to. provide uniting. .j oint structures. .wire staplesoelb.

tendinglthroueh said'rjointstructurextozsecurertoa Tponerrts 8; I gether; the.-.-c0mponents i thereof; lock': barsdise posed.nacross.--.thei front-.ofathe thus.- assembled units, coupleriloopserootedin said unit joint structures andsecured thereto bycertain of saidwire staples, said ,7 coupler. loops-1 projecting. from r the front ,face-..of:saideassembled'units so astorecei-ve-theelocle bars aandrthuslsecure the units thereto metallic. mesh forconcrete. reenforcemerit seeureddto .theouter edges-.ofsaid lock bars :to; extend across lthetfront. of. the-assembled runits.

in.outwardly spacedrelationthereto, plaster supporting lathingl disposed across the rear ofthe assembledtunits, each said unithavinga perpene dicular', sheet metahstriprcontiguous; to an inner surf-ace. .oia reap-face.portiomthereof, and said. strip havinehprongs struck out therefrom .to proiect ithroughandlexteriorly of the unit material, said .prongsbeing clinched overrintovholding relae tion..to saidulathing claim tfi-vwhereinwthesheet materialfrom which theuformewall".unitsd-are. made comprises waterproofed corrugatedepaperboard, said paperboard being soddisp osed that. the. corrugations thereof extendrtransversely across. the; panels comprising saidrlunitsr SQApIefabriQated form structure as defined in:

c1aim 1'.wher ein.at least'one reenforcing' rod. is disposed'to extend perpendicularlywithin the in terionnfleachl .U-"shaped unit, and means to support .lsa-idj'rodih. such position;

QTLInap efabIicated form structure as defined in claim 5'wh'ereinzatfleast one reenforcing rod is disposed lto extend perpendicularly.withinthe interior oiifeachu shaped unit; and means to sup? port .saidrod in .such position:

10.? Inna. prefabricated form structure-as defined in;.claim.5 'wherein.at .least 'ones-reenforcing' rod,-iis, di'Sposed .to extend pe pfindicularly within- U.-shapectfunit"having h'anger means to. support the. containederod; and tie-members interconnestedrespeetivelmbetween said rod and the lock barsandb'etween.saidrod and arear sideportion ofethe ,U.='sl1'ap,ed unit.

11. Iii-l arprefahricatedi form structure as definedinrlaim B'Avh'erein at .least one reenforcing rodiis'udisposed Ito -extend1perpendicularly within the. interiorof leach. Ueshaped .unit; each said i uesh'apedlunit liaving, hanger meansv .to support the contained rod, and tie-members intercone nectedlrespectively between said rod and the lock bars .-and between said rod .and theqsh'eet metal. strip..0.tlieuesh'apfi 12...A,pi;eabricated form structure for the purposes. describedrcomprising an assembly-of hollow. formvwa-ll unitsrmadeoi-folded waterproofedcorrugatedpaperboard .with .thecorrugations thereof disposed tr.ansverse.,toltheuverticallaxes of said ;-units, certain of said units..being. ofsubstantially right..triangularicrosssection and'othersaid units beings of r substantially U-sh'a-ped cross. section,

saidrisht'triangular, .unit'sbeing. arraneedin. pairs withatheirr oblique 1 panels ,rearwardly, presented andrtthelrt end-panels. abutted wherebyto. forwardly;presentztheirr-remaining pr-front panels in alcommomplana. atueshaped unit being. disposed intermediate adjacent: pairs .01? thus arrangedz right trianguiartunitsewith its open face-disposed imthelplaneiof the frontpanelsof the latter units, marginaL-por-tions ;'-Of'I'1Sai'd" thus. adj oined units being folded:zandeinterengaged to' provide uniting J'oint-':strnctures,a.Wire estaples extending. through saidzrjoint istructuresstolsecure together. the com- 75 ,Aiprefabricated.formstructure asdefined in the interior ,.of .each" ueshapedunit; each said.

othereofirglockl i bars disposed. across the;

front of said thus assembled units, coupler loops rooted in said joint structures and secured thereto by certain of said wire staples, said coupler loops projecting from the front face of said assembled units so as to receive the lock bars and thus secure the units thereto, metallic mesh for concrete reenforcement secured to the outer edges of said lock cars to extend across the front of the assembled units in outwardly spaced relation thereto, plaster supporting lathing disposed across the rear of the assembled units, each said unit having a perpendicular sheet metal strip contiguous to an inner surface of a rear face portion thereof, said strip having prongs struck out therefrom to project through and exteriorly of the unit material, said prongs being clinched over into holding relation to said lathing, at least one reenforcing rod disposed to extend perpendicularly within the interior of each U-shaped unit, each said U-shaped unit having hanger means to support 10 the contained rod, and tie-members interconnected respectively between said rod and the lock bars and between said rod and the sheet metal strip of the U-shaped unit.

- PAUL B. WEST.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS

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