US3383817A - Concrete form structure for walls - Google Patents

Description

May 21, 1968 w. K. H. GREGORI CONCRETE FORM STRUCTURE FOR WALLS 2 Sheets-Sheet Filed Aug. i966 I N VEN 1 OR. WERNER K. H. GREGORI FIGZ ATTORNEYS May 21, 1968 w. K. H. GREGORI CONCRETE FORM STRUCTURE FOR WALLS 2 Sheets-Sheet :5

Filed Aug.

INVENTOR.

WERNER K. H. GREGORI ATTORNEYS United States Patent 0 3,383,817 CONCRETE FORM STRUCTURE FOR WALLS Werner K. H. Grcgori, Oakville, Ontario, Canada, assignor, by direct and mesne assignments, to Roberliohni Limited, Nassau, Bahamas Filed Au". 3, 1966, Ser. No. 570,072 Claims priority, application Canada, June 2, 1966,

961,888 7 Claims. (Cl. 52309) This invention relates to building construction and is particularly concerned with a form for pouring concrete walls characterized in that the form is left in place following pouring of the concrete and provides finished wall surfaces on both sides of the wall.

In the construction of concrete walls, both outer walls and partition walls, it is common practice to build a temporary form with plywood or the like sheets which are braced to resist the Weight of the concrete until the latter has hardened. Following setting of the concrete the forms are removed and the wall finished in any one of a number of different ways, depending upon the type of wall concerned and the desired finish. Internal walls which form permanent partitions are normally covered with lathing or other material capable of holding plaster and the plasvide a concrete form structure for walls which may be left in place following setting of the concrete and which further provides finished surfaces to the wall.

It is a further object of the invention to provide a structure of the above type which is equally adaptable to the construction of interior walls and exterior walls.

It is a further object of the invention to provide a structure of the above type which can be made inexpensively and which provides internal insulation against heat and cold and which is adapted to provide concrete reinforcing rod material within the space which receives the poured concrete.

It is a further object of the invention to manufacture a concrete form structure of the above type which is light in weight as to be easily transportable to the building side and easily handled when being arranged for reception of concrete.

The above and further objects of the invention will be better understood from the following description of a preferred embodiment thereof as read in conjunction with the accompanying drawings.

In the drawings which illustrate this embodiment of the invention FIG. 1 is an exploded perspective view of a concrete form structure in accordance with the invention showing the various components making up the structure as spaced apart from one another for better illustration;

FIG. 2 is an enlarged cross-sectional view taken approximately along the line 22 of FIG. 1 but showing a portion of the structure of FIG. 1 in the assembled form of the structure; and

FIG. 3 is a perspective view of the structure of FIG. 1 in its assembled form and illustrating the manner in which the structure is oriented when used.

Referring to FIG. 1, the concrete form structure of the invention essentially consists of a pair of parallel spaced panel members 10 and 12 which are held together by a 3,383,817 Patented May 21, 1968 plurality of tension members 14. The panel members are characterized by composite construction including an outer panel element which is capable of forming a finished outcr wall surface. Thus, for example, the outer panel elements 16 may be formed of a gypsum board such as the sheet material sold under the trade name Gyproc by Gypsum, Lime & Alabastine Canada Ltd. In this case, the structure would be used to form an interior partition wall. Of course, as other materials apart from gypsum are used as facings on interior Walls, it is within the scope of the invention that similar alternatives might be used as the outer panel element in the panel members 10 and 12. Where the structure is used to form and to eventually constitute part of an exterior wall for a building, the panel member which is exposed to the weather will naturally be made of a weather resistant sheet material.

The second component used in the panel members 10 and 12 is preferably formed of a rigid plastic foam having good thermal insulation properties. This inner panel element 1-8 is adhesively attached to the outer panel element 16. As various different foam materials as well as different materials for the outer panel element 16 are possible wi.hin the scope of the invention, the adhesive selected will vary with the different materials. A preferred combination of these materials is gypsum board and a rigid expanded polystyrene foam such as the rigid foam sold under the trade name Styrospan by Dow Chemical of Canada Limited. An excellent adhesive for gluing these two particular materials together is a rubber based adhesive sold under the trade name Bondmaster K 727 by the Adhesive Products Division of the Pittsburgh Plate Glass Co.

Before the foam 18 is fixed by adhesion to the outer panel element 16, the foam is provided with a number of cut-outs 2.0 shaped and sized to snugly receive the tension members 14. These cut-outs extend completely through the foam sheet so that when the foam is glued to the Gyproc the latter is exposed at the inner ends of the cut-outs. This exposure of the gypsum board permits gluing the tension members 14 directly to the gypsum board. In this regard, it should be understood that it is the function of the tension members to prevent the panel members 10 and 12 from spreading apart when the space between them is filled with cement or concrete. It will also be understood that for this same reason, the tension members must themselves be strong in tension. Thus, while tension members made of the same rigid foam as is used in the inner panel elements 18 would be excellent from the point of view of light weight and good insulation quality, such foam material is not strong in tension. Thus, the tension members are formed of a laminate of a centre core of fibreboard or like material sandwiched between two pieces of foam. The tensionmembers 14 may be made of foamed glass which, because it is a foam, has good insulation qualities and is light in weight and also is quite strong in tension. In either case, the tension members are glued to the surface of the gypsum board which is exposed at the inner ends of the cut-outs in the inner panel elements 18. The same type of adhesive mentioned above is adequate for this purpose. It should also be understood that while in the illustrated embodiment of the invention a total of forty tension members 14 are used, more or less tension members can be used depending upon the dimension of the particular structure involved.

In its simplest construcdon, the form structure of the invention consists of the above described spaced panel members 16 and 1.; and the interconnecting tension members 14. For certain applications a simple form structure of this type without providing steel reinforcing rods with in the poured concrete is sufficient. However, in the majority of cases it will be necessary to include steel reinforcing and the illustrated embodiment of the invention employs two grids 26 and 28 of reinforcing rod. It will be appreciated that while two such grids are shown in the drawings, there will be certain applications where only one grid need be used and other applications where more than two grids will be required.

To provide means for holding the grids spaced from one another and spaced from the panel members, the top and bottom rows of the tension members 14 are drilled to receive holding rods 30. These are used in the following manner. Following installation of all the tension members 14 in one panel member, a first pair of rods are slipped through the apertures 32 in the upper and lower rows of tension members, the two grids 26 and 28 are lowered down over the tension members and then the final two holding rods are slipped through the apertures 34. The grid 26 is then tied to the first installed holding rods by a few pieces of tie wire and then the second grid 28 is lifted up and tied to the last installed pair of holding rods. Finally, the second panel member is dropped onto the free ends of the tension members and adhesively fixed thereto. It will be appreciated that where only one reinforcing rod grid is employed or where more than two grids are employed, a similar type of holding arrangement can be used. It is to be noted that the ends of the rods making up the grids are extended on one side as to project outwardly from the side of the form structure. This provides overlap with the next adjacent form structure as required by building regulations.

The manner in which the form structure of the invention is used in building a wall is shown in FIG. 3. One or more of the form structures are positioned as in FIG. 3. The number and/or size of the structures employed is, of course, dictated by the thickness and length of the wall being constructed. In any case, the concrete or cement is poured into the centre of the structure as to fill same and allowed to set. This done, the wall is finished. This wall has a centre core of concrete or cement which has been reinforced with reinforcing red as required. it has two insulation sheets on either side of the poured concrete, and it has two outer surfaces which require no other finishing.

It is to be noted that the side edges of the form structure are provided with tongues and grooves as to smoothly mate with adjacent structures. The tongued sides are simply formed by extending the two inner panel elements 18 outwardly beyond the associated side edges of the outer panel elements 16 while the grooved side edge is formed in the reverse manner by extending the outer panel elements 16 beyond the associated side edges of the inner panel elements 18. In FIG. 2 the right-hand end of the illustrated structure is a grooved side edge.

Throughout the foregoing specification, reference is made to the building of concrete walls, but it should be understood that the term concrete is used in a broad sense and that the structure of the invention is adapted to form and constitute part of walls of any cementitious material.

I claim:

1. A preassembled concrete form structure for use in pouring a concrete wall, said structure being intended to be left in place following pouring of the concrete and to provide finished wall surfaces, said structure comprising two side-by-side composite panel members, each of said panel members consisting of an outer finished wall surface providing panel element and an inner insulation panel element formed of a thermal insulating, fire resistant rigid plastic foam, said inner panel element being adhesively fixed to the inside surface of said outer panel element and having a plurality of cut-outs extending therethrough for the reception of tension members for interconnecting said panel members; a plurality of tension members received in opposed pairs of cut-outs in said inner panel elements and adhesively fixed to the surface areas of said outer panel elements exposed by said cut-outs in said foam plastic panel elements, said tension members serving to interconnect said panel members and to prevent spreading apart of said panel members from the weight of poured concrete received between said panel members in the construction of a permanent concrete wall.

2. A preassembled concrete form structure as claimed in claim 1 further including at least one grid of reinforcing rod material positioned between said panel members and spaced therefrom.

3. A preassembled concrete form structure as claimed in claim 2 having two grids of reinforcing rod material and further including means for holding said grids spaced from one another and spaced from said panel members, said holding means comprising holding rods passed through apertures in certain of said tension members and tie wire connecting said grids to said holding rods.

4. A preassembled concrete form structure as claimed in claim 3 in which said outer panel elements are formed of gypsum board and in which said insulation panel elements are formed of expanded polystyrene.

5. A preassembled concrete form structure as claimed in claim 4 in which one side of said structure is provided with a tongue and in which the other side is provided with a groove, said tongued and grooved side edges providing means for mating said structure with like structures to form an elongated wall, said grooved side edge having the two outer panel elements extended beyond the two associated insulation panel elements, said tongued side edge having the two insulation panel elements extended beyond the two associated outer panel elements, said two grids of reinforcing rod having rod elements extending outwardly from one side edge of the structure whereby to provide overlap with reinforcing rod material in adjacent concrete form structures.

6. A preassembled concrete form structure as claimed in claim 5 in which said tension members consist of laminated blocks having a central core of fibreboard and two outer layers of the same plastic foam material used in said insulation panel elements.

7. A preassembled concrete form structure as claimed in claim 5 in which said tension members consist of blocks of foamed glass.

References Cited UNITED STATES PATENTS 3,255,562 6/1966 Altschuler 52-309 3,292,331 12/1966 Sams 52-405 3,353,315 11/1967 Barker 52-309 X JOHN E. MURTAGH, Primary Examiner.

Claims (1)

1. A PREASSEMBLED CONCRETE FORM STRUCTURE FOR USE IN POURING A CONCRETE WALL, SAID STRUCTURE BEING INTENDED TO BE LEFT IN PLACE FOLLOWING POURING OF THE CONCRETE AND TO PROVIDE FINISHED WALL SURFACES, SAID STRUCTURE COMPRISING TWO SIDE-BY-SIDE COMPOSITE PANEL MEMBERS, EACH OF SAID PANEL MEMBERS CONSISTING OF AN OUTER FINISHED WALL SURFACE PROVIDING PANEL ELEMENT AND AN INNER INSULATION PANEL ELEMENT FORMED OF A THERMAL INSULATING, FIRE RESISTANT RIGID PLASTIC FOAM, SAID INNER PANEL ELEMENT BEING ADHESIVELY FIXED TO THE INSIDE SURFACE OF SAID OUTER PANEL ELEMENT AND HAVING A PLURALITY OF CUT-OUTS EXTENDING THERETHROUGH FOR THE RECEPTION OF TENSION MEMBERS FOR INTERCONNECTING SAID PANEL MEMBERS; A PLURALITY OF TENSION MEMBERS RECEIVED IN OPPOSED PAIRS OF CUT-OUTS IN SAID INNER PANEL ELEMENTS AND ADHESIVELY FIXED TO THE SURFACE AREAS OF SAID OUTER PANEL ELEMENTS EXPOSED BY SAID CUT-OUTS IN SAID FOAM PLASTIC PANEL ELEMENTS, SAID TENSION MEMBERS SERVING TO INTERCONNECT SAID PANEL MEMBERS AND TO PREVENT SPREADING APART OF SAID PANEL MEMBERS FROM THE WEIGHT OF POURED CONCRETE RECEIVED BETWEEN SAID PANEL MEMBERS IN THE CONSTRUCTION OF A PERMANENT CONCRETE WALL.

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