US3559944A

US3559944A - Means for constructing a hollowed wall concrete structure

Info

Publication number: US3559944A
Application number: US652842A
Authority: US
Inventors: Victor J Clough
Original assignee: Individual
Current assignee: Individual
Priority date: 1967-07-12
Filing date: 1967-07-12
Publication date: 1971-02-02
Anticipated expiration: 1988-02-02

Abstract

This disclosure relates to a method and means for the construction of a prestressed hollow concrete wall used for the rapid and economical construction of an entire house or the like. More particularly, this disclosure relates to the use of collapsible form means to construct by the method of this disclosure a hollow wall structure with inner support columns insulated from adjacent parallel outer walls to prevent temperature transfer therebetween. Still, more specifically, this disclosure relates to a means and method of constructing an entire section of a hollow cored wall requiring little time and expanse to produce a structure that is fireproof, insect and rodent proof, and can be readily produced with a variety of decorative wall designs. Additionally, this disclosure relates to the use of collapsible form means operable to present an upright structure that can be sprayed with a fluid construction material to form a wall structure thereon whereby, upon solidification of the material, the form means can be readily removed.

Description

United States Patent [72] lnventor Victor J. Clough 1647 S. Madison, Wichita, Kans. 67211 [21] Appl. No. 652,842 [22] Filed July 12, 1967 [45] Patented Feb. 2, 1971 [54] MEANS FOR CONSTRUCTING A HOLLOWED WALL CONCRETE STRUCTURE 9 Claims, 14 Drawing Figs.

[52] US. Cl 249/36, 249/ l 52 [51] lnt.Cl E04g11/18 [50] Field of Search 249/36, 37, 35,27,47, 178, 180,146,144, 152, 192, 219; 25/131CM, 13111, 131CP, 131W, (Reinforcement digest) [56] References Cited UNITED STATES PATENTS 1,375,328 4/1921 Sheeley 249/180 Primary Examiner-J. Spencer Overholser Assistant Examiner Michael 0. Sutton Attorney-John H. Widdowson ABSTRACT: This disclosure relates to a method and means for the construction of a prestressed hollow concrete wall used for the rapid and economical construction of an entire house or the like. More particularly, this disclosure relates to the use of collapsible form means to construct by the method of this disclosure a hollow wall structure with inner support columns insulated from adjacent parallel outer walls to prevent temperature transfer therebetween. Still, more specifically, this disclosure relates to a means and method of constructing an entire section of a hollow cored wall requiring little time and expanse to produce a structure that is fireproof, insect and rodent proof, and can be readily produced with a variety of decorative wall designs. Additionally, this disclosure relates to the use of collapsible form means operable to present an upright structure that can be sprayed with a fluid construction material to form a wall structure thereon whereby, upon solidification of the material, the form means can be readily removed.

PATENTEU FEB 2197:

SHEET 1 [IF 4 INVENTOR.

VICTOR J. CLOUGH ATTORNEYS PATENTEUFEB 21971 3.559.944

. sum 2 UF 4 4%?" A. IL g) 29 6 ATTORNE S PATENTED FEB 2 M SHEET 5 0F 4 F ll til r INVENTOR.

VICTOR J. CLOUGH ATTORNEYS MEANS FOR CONSTRUCTING A HOLLOWED WALL CONCRETE STRUCTURE Numerous types of collapsible form members are known to the prior art usable to construct a hollow wall structure. However. these prior art structures are not operable in a way to be self-supporting on connection to exterior form means to simplify and economize construction of a continuous hollow cored wall. Additionally, the prior art devices are not usable to construct an integral, structurally strong hollow wall having opposite wall sections entirely insulated from each other to prevent a heat transfer therebetween. The prior art solid concrete walls have always been undesirable because of the heat transfer and the resultant sweating thereof. Also, the prior art method and means of constructing a hollow wall requires considerable effort to assemble and disassemble the necessary forms thereby making the same time consuming and costly defeating the purpose of an integral concrete wall construction.

ln one preferred embodiment of the means of this invention, a form support base is provided adapted to be supported upon a ground surface or footing structure and receive a plurality of longitudinally extended upright collapsible form means therein. A plurality of spacer or block members are laid within the form support base to support and elevate the collapsible form means thereon so that electrical conduit and the like can be placed within the wall structure. The support base and contacting collapsible form means are adapted to be positioned between and contacting end support means abutting opposite outer ends and extended laterally of both sides of the collapsible form means. The collapsible form means are of the retractable and expandable type so as to be removable from the interior of the finished hollow wall structure when the material used for construction thereof, such as concrete, granite, plastic, etc., solidifies. A plurality of exterior form means are positionable on opposite sides of the collapsible form means and connected to the end support means providing a parallel upright form structure of a size substantially identical to the collapsible form means. A plurality of support tie members are extended transversely of the collapsible form means adjacent abutting ends and secured to the exterior form means to provide lateral stability thereto. Additionally, an insulation stripping is placed against the spacing between the adjacent collapsible form means and the end support means, respectively, to prevent the fluid construction material from entering into the interior of the collapsible form means which would make the same inoperable Elongated sheets of reinforcing mesh are positionable on opposite sides of the collapsible form means with respective opposite ends extended through the end support means. Clamps or turnbuckle members are connected to the opposite ends of the reinforcing mesh to apply tension thereto which results in a prestressed final hollow concrete wall structure. After removing the collapsible form means, upright ridges in the outer faces of the subject form means leaves indentations in the solidified material adapted to receive elongated form or insulation strips therein from top to bottom to cooperate with with the insulation stripping to receive construction material therein to form upright column members therein. This results in the fonnation of upright column members which are insulated to prevent the transfer of heat from one wall side of the hollow wall structure to the other and adapted to serve as roof supports. After the hollow wall structure has solidified, it is obvious that the end support means and exterior form means can be removed providing an upright rigid structure having opposite wall sections insulated from each other with the outer surface of the wall structure being formed with a brick design, wood design, etc. as desired.

In one embodiment of the method of constructing a hollow wall structure of this invention, the elongated support base of U-shape in transverse cross section is first placed upon a foundation extended at least the length of the wall section to be formed. The support base is open upwardly having opposite ends abutting upright end support means. A plurality of collapsible form means are placed, when in an expanded condition, within the support base so as to be in sealing engagement therewith and also abutting the end support means. The collapsible form means are placed upon elongated block members to elevate the same and allow electrical conduits and plumbing to be placed therein. The collapsible form means have outer parallel form plates interconnected by linkage means allowing retraction thereof from the expanded condition when desired. The outer form plates are formed with upright elongated parallel ribs extended through cutouts in the support base. The upper ends of the collapsible form means are interconnected by lock rod members for lateral stability. Next, a reinforcing mesh is extended the length and width on both sides of the collapsible form means having opposite ends extending through the end support means, respectively, and connected to turnbuckle or clamp members operable to add tension thereto. A plurality of exterior form means are placed on opposite sides of the collapsible form means and interconnected to each other by clamp members whereas to provide a cavity on both sides of the collapsible form means with opposite ends of the external form means adjacent and secured to the end support means. An insulating strip material is placed between the abutting ends of the collapsible form means on both sides thereof and additionally on the outer ends of the collapsible form means and the adjacent upright end support means to seal the same. Although the opposite ends of the external form means are connected to the upright end support means, a plurality of tie members are extended through the adjacent abutting ends of the collapsible form means and the insulating strips so as to hold the upright external form means in a given spaced and lateral position. The facing sides of the external form means and the collapsible form means are covered with a form releasing material such as a teflon powder, grease, or the like so that the same may be readily removed therefrom in the final product. Next, a fluid construction material such as concrete is poured between the openings on opposite sides of the collapsible form means and agitated sufficiently to completely fill the cavity. It is obvious that the overall method of this invention is operable to construct an entire wall section of perhaps the height of 8 to 10 feet of almost unlimited length.

The upper surface of the form plates extend upwardly of the top surface of the wall being formed to prevent the construction material from reaching the interior of the collapsible form means. After the construction material such as concrete has solidified, the lock rods are removed from adjacent collapsible form means whereupon the rods are used as gripping means for lifting or pulling upwardly on the collapsible form means whereupon the linkage means pulls the outer form plates inwardly into the retracted position allowing the collapsible form means to be lifted therefrom. Because of the shape of the ribs of the collapsible form means, a plurality of upright parallel grooves are formed within the concrete material. These grooves are adapted to receive elongated form strip members therein which, in conjunction with the insulation strips previously placed upon the outer surface of the collapsible form means, forms a substantially square, elongated area adapted to receive additional material such as concrete therein to form upright support columns for the hollow wall structure of this invention. It is seen that the combination of the insulation strips and the upright form strips after solidification of the concrete therein forms upright support columns used to support roof trestles or the like thereon. This method results in a hollow wall structure having two external wall sections each of which can be of a greatly different temperature but insulated preventing the formation of water by sweating on the interior wall during certain climatic conditions. It is obvious that on removal of the exterior form means and the upright end support means, the overall structure now presents a rigid wall section having, if desired, unique and unusual designed patterns which cannot be achieved by other construction means. Additionally, the use of the elongated pretension wire mesh adds great strength and stability to the hollow wall structure.

In another preferred embodiment of the method of constructing a hollow wall structure of this invention. the steps involve the use of the previously described collapsible form means set upon a given foundation or footing in the support base. The collapsible form means extend upwardly with the adjacent ends thereof spaced and connected by specially designed irregularly shaped coupling members which are adapted to interconnect and prevent the construction material being used from entering the interior of the collapsible form means. A special design protective box structure is connected to the upper portion of each collapsible form means having elongated bar members extended adjacent and downwardly on opposite sides thereof which acts to protect the upper open end of the collapsible form means from obtaining construction material, namely concrete, therein. Additionally, a plurality of spaced upright column form means may be attached to the upright protective box structure and downwardly depending therefrom operable to receive reinforcing bar therein for the construction of an upright column. A reinforcing mesh is used on opposite sides of the collapsible form means and tensioned by turnbuckle members as is in the first embodiment, This embodiment is not provided with a plurality of external form means as a process known as "Gunite may be used whereupon a fluidic mixture of concrete material can be sprayed under air pressure up against the wire mesh and the collapsible form means so as to build up gradually to build a wall structure thereon. Additionally, the upright column form means are sprayed and filled with the Gunite" or concrete material to form roof support columns. On solidification of the concrete material, it is obvious that the protective box structures may be removed and the collapsible form means moved to the retracted condition allowing the upward removal thereof Additionally, the upright column form means can be removed to form columns having the upper surfaces thereof extended below the upper surface of the hollow wall section therefore adapted to receive steel beam members thereon or the like for the construction of a roof assembly. Additionally, the upper open surface of the hollow wall structure may be covered by conventional edging material to provide an attractive. weatherproof, hollow wall structure.

Accordingly, it is an object of this invention to provide a new and novel method and means of constructing a hollow wall structure overcoming the above mentioned disadvantages of the prior art means and methods.

Another object of this invention is to provide a means for constructing a hollow wall structure operable to insulate the inner and outer wall sections to prevent heat transfer therethrough.

One other object of this invention is to provide a collapsible form means usable to construct a hollow wall structure that is movable from an expanded to a retracted position so as to be removed from a given concrete wall structure after the same is formed.

Still, another object of this invention is to provide a means for producing a prestressed hollow wall concrete structure having insulated upright roof support columns therein adapted to prevent heat transfer therethrough.

A still further object of this invention is to provide a method of constructing a hollow wall structure using a plurality of central collapsible form members, parallel exterior form members on the outer sides of the collapsible form members, andprestressed wire mesh therebetween operable whereby a fluid construction material is poured between the collapsible and exterior form members for solidification and forming of the hollow wall structure.

A further object of this invention is to provide a means for construction of a hollow wall structure having a plurality of collapsible form means extended longitudinally with opposite ends abutting end support means; reinforcing mesh placed on both sides of the collapsible form means and connected to the end support means; turnbuckle means secured to and applying tension to the reinforcing mesh, and a plurality of exterior form means placed on opposite sides of the collapsible form means and interconnected to each other and to the end sup port means whereby the construction material is placed on opposite sides of the collapsible form means between the same and the exterior form means to form a hollow cored wall structure.

Still, one other object of this invention is to provide a method of constructing a hollow wall structure having a plu rality of upright collapsible form means having adjacent ends thereof interconnected by special connector members; protective box structures connected to the upper ends of the collapsible form means; downwardly depending column form means secured to the box structures; reinforcing mesh material under tension placed against opposite side of the collapsible form means; and means for spraying as by Gunite process a concrete material on both sides of the collapsible form means to form a hollow wall and upright column structure.

Various other objects, advantages, and features of the invention will become apparent to those skilled in the art from the following discussion, taken in conjunction with the accompanying drawings, in which:

FIG. I is a fragmentary perspective view of a hollow wall structure constructed by the method and means of this invention having portions broken away for clarity;

FIG. 2 is an enlarged top plan view of a comer section of a hollow wall structure constructed by the method and means of this invention;

FIG. 3 is a fragmentary enlarged foreshortened view taken along line 3-3 in FIG. 1;

FIG. 4 is a top plan view of a collapsible form means of the means of this invention;

FIG. 5 is an enlarged foreshortened side elevational view of the collapsible form means of this invention;

FIG. 6 is a view similar to FIG. 5 showing the collapsible form means in a retracted condition;

FIG. 7 is a fragmentary perspective view illustrating the first step in one method of construction of a hollow wall structure of this invention;

FIG. 8 is a view similar to FIG. 7 having the collapsible form means, inner wall tie supports, and reinforcing mesh material applied thereto in practice of the method of this invention;

FIG. 9 is a view similar to FIG. 8 having exterior form means connected thereto;

FIG. 10 is a fragmentary perspective view of the hollow wall structure in the latter stages of the method of this invention;

FIG. 11 is a fragmentary perspective view of the upper portion of the hollow wall structure of this invention having portions broken away for clarity;

FIG. 12 is an enlarged fragmentary perspectiveview of a second embodiment of the method of constructing a hollow wall structure of this invention by the use of a Gunite process;

FIG. 13 is a fragmentary sectional view taken along line 13-13 in FIG. 12; and

FIG. 14 is a fragmentary perspective view of the completed hollow wall structure constructed by the second method of this invention having a finishing cap member and roof support beam connected thereto.

The following is a discussion and description of preferred specific embodiments of the new means and method of constructing a hollow wall structure of this invention, such being made with reference to the drawings whereupon the same reference numerals are used to indicate the same or similar parts and/0r structure. It is to be understood that such discussion and description is not to unduly limit the scope of the invention.

Referring to the drawings in detail and in particular to FIG. I, a plurality of hollow wall section 18 usable to construct an entire house are illustrated constructed on a conventional foundation 19 by the method and meansof this invention. A pair of spaced

openings

21 and 22 have been provided between the wall sections 18 for use as a window space and a door opening, respectively. The wall sections 18 are illustrated as constructed of concrete material on the foundation l9;

however, it is obvious, that the same can be erected on any given solid supporting surface and with any suitable construction material that can be poured into restricted areas for hardening similar to concrete.

The structural means of this invention, indicated generally at 23 in FIG. 9, includes a form support base 24 having elevator block members 26 therein; at least a pair of cooperating, spaced end support means 28; a plurality of collapsible form means 29; mountable in the support base 24'. reinforcing mesh material 31 on both sides of the collapsible form means 29 and turnbuckle means 32 to apply tension to the mesh 31; and a plurality of exterior form means 34 mounted on opposite sides of the collapsible form means 29 as will be seen for reasons to become obvious.

More specifically, as shown in FIGS. 4 to 6, inclusive, each collapsible form means 29 includes a pair of elongated

upright form plates

36 and 37 interconnected by a linkage means 39 for movement from expanded to retracted positions and vice versa. The

form plates

26 and 27 are of a rectangular shape having outer smooth surfaces with upright parallel laterally extended ribs 41 connected thereto adjacent the outer vertical edges. It is obvious that the collapsible form means 29 could be of any overall size and may be 8 feet by 4 feet wide for construction of a conventional wall section for a one story house but the same may be of any desired dimension with the main consideration being that of weight and maneuverability for practical usage.

The linkage means 39 includes three connector means 43, 44, and 45 all releasably interconnected by an elongated lock rod or bar 47 as will be explained. As the connector means are identical, only connector means 43 need be described in detail. The connector means 43 includes a pair of spaced

angle iron members

49 and 51 secured to the facing sides of each

fonn plate

26 and 27, respectively, as by rivet members or the like and cooperating with opposite pairs of the

angle iron members

49 and 51. Intermediate the opposed pairs of the

angle iron members

49 and 51, a pair of upright connector bars 53 and 54 are pivotally connected at three vertically spaced positions as by toggle links 56 to the adjacent

angle iron members

49 and 51. Elongated bolts 58 are used to interconnect the connector bars 53 and 54 to the toggle links 56. The

angle iron members

49 and 51 are formed with slots 59 adapted to receive the lower pair of bolts 58 when the collapsible form means 29 is moved to the retracted position (FIG. 6).

Additionally, the collapsible form means 29 are movable into expanded positions, as shown in FIG. 5, and held in this relative position by lock assemblies 61 on each connector means 43, 44 and 45 to prevent inward movement of the

form plates

26 and 27 resulting from external pressure from poured concrete as will be explained. More specifically, each lock assembly 61 consists of a pair of spaced parallel link members 63 pivotally connected as by bolts 64 to the upper end of the respective

parallel connector bar

53 and 54 and having central plates 66 and lock hooks 67 connected thereto. The lock hooks 67 are mountable through holes in the central plates 66 having downwardly depending hook portions 68 mounted through holes 70 in the

angle iron members

49 and 51. The lock hooks 67 have threaded upper portions 71 on which are mounted lock or wing nut 73 to secure the link members 63 between the central plates 66 and the

angle iron members

49 and 51 to prevent axial movement of the connector bars 53 and 54 and provide rigidity to the collapsible form means 29. It is noted that the upper ends of all the connector bars 53 and 54 are parallel with aligned openings 75 to receive the lock rod 47 for reasons to be explained.

As shown in FIG. 7, the collapsible form means 29 are adapted to fit within the elongated form support base 24 constructed of a channel shape having a base 77 and upright sidewalls 78 and 79. The sidewalls 78 and 79 are provided with cutout openings 81 adapted to receive the ribs 41 on the collapsible form means 29 when the same is placed therein in the expanded condition. When in this expanded condition, the

upright sidewalls 78 and 79 and lower surfaces of the collapsible. form means 29 form a seal together to prevent the construction material, such as concrete, from reaching the interior of the collapsible form means 29. It is obvious that a plurality of collapsible form means 29 can be set within the support base 24 in abutting relationship and the length is such that the upright edges of the outer collapsible form means 29 are aligned with the respective ends of the elongated support base 24.

In order to hold the concrete material within the longitudinal limits of the collapsible form means 29 and the support base 24, the end support means 28 are placed against opposite ends of the collapsible form means 29. As shown in FIG. 10, each end support means 28 includes a pair of parallel upright end plates 83 interconnected by an actuator linkage 84. The upright end plates 83 are of a rectangular shape and of a width substantially greater than the collapsible form means 29 movable in parallel relationship to each other. The actuator linkage 84 includes upper and

lower connector arms

86 and 87, respectively, having midportions thereof pivotally interconnected and outer ends connected by hinge members 89 to respective ones of the end plates 83. The

connector arms

86 and 87 are provided with aligned openings therein adapted to receive an actuator shaft 92 having an upper T-section for grasping purposes and a lower end connected to the lower connector arm 87. Then, with the end support means 28 in the collapsed position as shown in FIG. 10, it is obvious that the actuator linkage 84 can be moved downwardly and cause outward movement of the end plates 83 so as to be abutting opposed ends of spaced collapsible form means 29. It is obvious that a positive lock could be added to the end support means 28 to maintain the same rigid in the expanded condition against external forces. In addition, it is obvious that the end support means 28 may be readily constructed of various widths, heights and sizes so as to be usable as a form to create an open area such as for windows, doorways, etc. and walls of various thickness as will become obvious. The outer edges of each upright end plate 83 is formed with a plurality of equally spaced and upwardly aligned openings 94 adapted to receive the reinforcing mesh 31 therein as will be explained.

As best shown in FIG. 8, the reinforcing mesh 31 is used for placement adjacent opposite sides of the collapsible form means 29 extended substantially the identical width and length thereof and having opposite ends of the mesh extended transversely of the end plates 83 of the end support means 28 through the plurality of openings 94 therein. The subject outer extended ends of the reinforcing mesh 31 are thereupon tied to common upright shaft or rod members 95 in a conventional manner such as tying or the like. In order to flatten out or straighten out the reinforcing mesh 31 plus applying a predetermined tension thereto, a plurality of turnbuckle means 32 are connected to the upright support shafts 95 as by wire segments 96 or the like. Each turnbuckle means 32 is provided with a central main body 98 having an outer eyelet member 99 threaded therein whereupon the main body 98 is rotatable to either extend or retract the eyelet members 99 as in a conventional manner. Therefore, it is seen that the tumbuckle means 32 are operable on rotation to increase or decrease the pressure on the upright support shafts 95 connected to the reinforcing mesh 31 to add a tension thereto which is very desirable in the construction of most concrete structures.

In order to seal the cracks or spacing between the abutting collapsible form means 29 and also between the ends of the outermost collapsible form means 29 and the end support means 28, a plurality of strips 101, preferably of insulation material, is placed on these areas. As shown in FIG. 9, the central strips 101 substantially fill up the area between the projecting ribs 41 of the adjacent collapsible fonn means 29. A mold release compound or grease is placed on the contacting areas of the strips 101 and the collapsible form means 29 for reasons to become obvious.

ln order to provide a cavity on both sides of the collapsible form means 29 having the reinforcing mesh 31 therein. a plurality of the exterior form means 34 are positioned on opposite sides of the collapsible form means 29 and extended between the supporting foundation 19 and the outermost end support means 28 so as to leave only an open area at the upper edge between the same and the collapsible form means 29. More specifically, each exterior form means 34 is of a rectangular shape having a size substantially equal to that of a collapsible form means 29. lt is seen that each exterior form means 34 is provided with a main body 102 having supporting outer flanges 104 about its periphery to add rigidity thereto. The exterior form means 34 can be readily connected to the end support means 28 as by bolts or the like and also attached to the lower foundation 19 to achieve added rigidity. In order to provide additional lateral stability. a plurality of inner wall tie supports 105 are extended through the openings between the adjacent ones of the collapsible form means 29 and having outer ends thereof extended between adjacent ones of the exterior form means 34 whereupon the same can be held thereto'as by clamps 106 as desired. The inner or form facing surface of the exterior form means 34 may be formed with an unusual design such as a floral, wood shingle, or with a pattern of a brick construction whereupon the finished wall may be painted as desired to assume a brick appearing structure at extremely low cost.

The structural means of this invention is clearly indicated in FIG. 9 in the assembled condition whereupon concrete material or the like may be poured through the upper spacing on both sides thereof between the collapsible form means 29 and the exterior form means 34. This results in a very substantial hollow wall structure whereby additional vertical stability may be given to the wall section as by reinforcing rod 108 which may be extended upwardly from the foundation 19 when the same is poured. It is obvious that the structure of this invention may be readily assembled and disassembled thereby providing for a speedy and economical method of producing a hollow wall section 18 which may be part of an overall building to be constructed.

In the practicing of one preferred embodiment of a method of this invention, the form support base 24 is first laid upon the foundation 19 or supporting surface and extended between upright end support means 28 as shown in FIG. 7. The form support base 24 is centered between the width of the end plates 83 of the end support means 28 and is provided with a plurality of the elongated block members 26 laid within the U- shaped support base 24. Next, the plurality of, in this example three, collapsible form means 29 are placed within the support base 24 and mounted upon the elongated block members 26. This results in an elevation of the collapsible form means 29 whereupon electrical conduit and piping can be laid within the support base 24 without having the pressure of the collapsible form means 29 thereon whereby the entire electrical and/or plumbing system in a house may be formed during the wall construction thereby simplifying on finishing the same. It is seen that reinforcing rods 108 are embedded and extend upwardly from the foundation 19 somewhat adjacent the support base 24 and provides a means of centering the same. The elongated insulation strips 101 are placed between the ribs 41 of the outer collapsible form means 29 and adjacent the end support means 28 and also between abutting ends of the collapsi ble form means 29 to provide an insulating and sealing means. The exterior surfaces of the collapsible form means 29 are coated with a mold release compound or a heavy grease so that the collapsible form means 29 will not adhere to the concrete wall section 18 being formed. It is obvious that the collapsible form means 29 are placed within the support base 24 in the fully expanded condition with the upper lock assemblies 61 latched to prevent retraction whereupon the lower portion of the collapsible form means 29 forms a seal with the support base 24 to prevent concrete material from moving therein. The reinforcing mesh 31 is then placed on opposite sides of the collapsible form means 29 and extended through the openings 94 in the end support means 28 and secured to the upright support shafts 95. The turnbuckle means 32 are connected to the adjacent upright support shafts 95 whereupon the main body 98 of the turnbuckle means 32 is rotated in order to apply a predetermined tension on the reinforcing wire mesh 31 to produce a prestressed concrete wall of substantial strength.

The exterior form means 34 are thereupon placed on opposite sides of the collapsible form means 29 and interconnected to each other as by the inner wall tie supports and the clamps 106 and to the end support means 28 as required. It is obvious that the various widths of end plates 83 of the end support means 28 will allow variation of the distance between the exterior form means 34 and the closest facing portion of the collapsible form means 29 whereby a wall section of any desired thickness may be created. The area between the collapsible form means 29 and the exterior form means 34 are thereupon filled with the construction material, such as concrete, which may be poured in the upper open ends and agitated by conventional means so as to fill all the space therein.

After sufficient curing of the construction material, namely concrete, the lock assemblies 61 on the collapsible form means 29 are removed whereupon the elongated lock rods 47 may be removed axially so as to be mounted within the three connector means 43, 44 and 45 on a single collapsible form means 29. With the lock assemblies 61 removed, the lock rod 47 may be grasped and. pulled upwardly whereupon the toggle links 56 tend to move the

form plates

36 and 37 inwardly towards the position as shown in FIG. 6. This allows the bolts 58 to move within the downwardly open slots 59 whereupon the opposing

angle iron members

49 and 51 are movable into abutting engagement and the collapsible form means 29 has moved out of contact with the hardened concrete material allowing the same to be moved upwardly and removed therefrom.

Next, a plurality of rectangular shaped insulation form strips 111 are thereupon placed within upright grooves 112 formed therefrom by the laterally extended ribs 41 of the col lapsible form means 29. In other words, the insulation form strips 111 are of a width substantially the same as the distance between opposed pairs of grooves 112 so that the same may be readily placed therein. The lower edges of the insulation form strips 111 may be provided with semicircular cutouts 114 in order to fit over any conduit that has been positioned within the support base 24. Additionally, means may be provided such as attachment by ropes or strings to the block members 26 within the support base 24 so as to be movable after extraction of the collapsible form means 29 for additional usage.

The upright vacant areas between the insulation form strips 101 and 111 are adapted to receive reinforcing rod 115 and thereupon filled .with the construction material, namely concrete, and allowed to set. After sufficient curing the end support means 28 and also the outer exterior form means 34 are disconnected and removed therefrom whereby an upright rigid structure is formed having an interior support column 117 insulated from the parallel walls by the insulation strips 101 and 1 11. In this example, the outer surface of the wall section 18 is formed with a brick design for appearance. Additionally, it is noted thatthe upper surface of the upright columns 117 are formed below the upper surface of the wall section 18 so that two by four lumber may be placed thereupon for ready attachment of roof support structure or the like thereto. The outer ends of the hollow wall section 18 are adapted to receive four by four column members therein for securing a window or door structure. The grooves 112 at these ends can receive a backing plate therein to properly'position the column members.

In anotherembodiment of the method of this invention as illustrated in FIGS. 1214, inclusive, the same collapsible form means 29 are used and placed with the form support base 24 as previously described; however, the adjacent ends of the collapsible form means 29 are interconnected by specially designed connector means 118. More specifically, the connec tor means 118 are formed with two outwardly opcn U-shaped end sections 121 interconnected by a main body plate 123. The end sections 121 are of a size adapted to fit snugly about the ends of the collapsible form means 29 to prevent the entry of concrete material or the like therein. Additionally. the upright main body plate 123 is formed with a plurality of openings whereupon reinforcing rods 124 may be extended therethrough for additional strength. The upper portions of -the collapsible form means 29 are protected by specially designed coverage means 126 to prevent the entry of the concrete material or the like within the open upper endv More specifically, the coverage means 126 is provided with a pair of elongated bar members 128 interconnected by U- shaped handle members 129 The outer parallel bar members 128 are of a contour adapted to fit snugly against opposite sides of the interconnected collapsible form means 29 and supported thereon by contact of an undersurface of the handle members 129 with the upright edges of the collapsible form means 29. Additionally, the bar members 128 may be constructed of wood whereupon special column form means 131 may be readily secured thereto. The column form means 131 is a hollow boxlike structure having upright sides 133 secured in an upper member 135 as by T-shape clamps or the like. The upper member 135 is provided with two angle straps 136 each having one end connected thereto and the other end releasably connected to the bar members 128 as by nails or the like. Upright reinforcing rod 138 may be placed within the column form means 131 and extended through the upper member 135 for reasons to become obvious. A protective box assembly 139 is provided of U-shape having an upper top and connected to the coverage means 126 as by straps 141 and nails or the like.

In the method of this embodiment, the special means for interconnecting the collapsible form means 29 and the provision of the column fon'n means 131 makes the same readily adaptable for fast and efficient construction by the Gunite process, namely, the spraying of a special concrete mixture against the collapsible form means 29 through the reinforcing mesh 31 which has been connected thereto. It is seen that the protective box assemblies 139 act to prevent movement of the sprayed concrete material onto the turnbuckle means 32 and, also, the upper protective coverage means 126 serves as a border to prevent movement of material into the open upper ends of the collapsible form means 29. Additionally, the column form means 131 is sprayed by the Gunite process as shown in FIG. 12 to form a laterally extended column when finished integral with overall wall section being formed.

After the concrete material has hardened, it is obvious that the column form means 131, the protective box assemblies 139, and the upper coverage means 126 may be readily removed leaving a substantially rigid hollow wall structure as shown in FIG. 14. The upper ends of the connector means 118 may be severed in a conventional manner to leave a flat surface. The connector means 118 can be made of an insulation type material thereby providing a hollow wall section 143 without interconnected concrete portions to prevent the transfer of heat therethrough. The upper ends of the columns in the finished wall section 143 are adapted to receive elongated roof support beams 145 for extreme rigidity and simplification of construction. Additionally, the upper surfaces of the hollow wall section 143 is covered with a cap member 147 to prevent the entry of water and the like therein.

in summary, it is seen that the new and novel structure of this invention is usable by the method taught herein to produce a new and novel hollow wall section having extreme rigidity and while maintaining isolation of exterior and interior walls to restrict the transfer of heat therethrough and prevent the conventional sweating that is found in solid concrete wall structures. Additionally, it is seen that the collapsible form means of this invention presents a rigid structure in the expanded position which can be readily moved to the retracted position so as to be usable over and over. it is seen that the method of this invention is unique and produces all the desirable qualities of a hollow wall section while requiring a minimum amount of man hours, low capital investment, and inexpensive material costs to produce a final product that is extremely durable.

As will be apparent from the foregoing description of the applicant's means and method for construction of a hollow wall structure, relative simple and inexpensive means have been provided which are readily usable on conventional foundations or other supporting surfaces to erect a high strength, low cost, hollow wall section with a minimum of labor and time. Applicants method and means is readily adaptable to construction to a plurality of sizes and shapes of buildings and especially for the production of modern houses with upright floor-to-ceiling window openings that can be finished by decorative wood paneling to present an overall attractive appearance.

While the invention has been described in connection with preferred specific embodiments thereof, it will be understood that this description is intended to illustrate and not to limit the scope of the invention defined by the following claims.

lclaim:

1. Means for construction of an integral hollow wall section, comprising:

a. a plurality of upright, longitudinally aligned collapsible form means,

b. connector means interconnecting said form means,

c. end portion support means positioned at opposite end portions of the outer ones of said collapsible form means extended laterally therefrom,

d. a plurality of exterior form means positioned on opposite sides of said form means extended parallel thereto and spaced therefrom,

e. clamp means interconnecting adjacent ones of said exterior form means, and

sealing means connected to abutting end portions of said collapsible form means and next to said end portion support means whereby construction material may be inserted between said exterior form means and said collapsible form means to form the hollow wall on removal of said collapsible form means.

2. Means as described in claim 1 to construct a hollow wall section, including:

a. a form support base of U-shape in transverse cross section extended the length of the wall section having said collapsible form means mounted therein for alignment and sealing purposes.

3. Means as described in claim 1 to construct a hollow wall section, including:

a. reinforcing mesh positioned between said exterior form means and both sides of said collapsible fonn means extended parallel thereto through said end support means, and

b. means connected to opposite ends of said reinforcing mesh to apply tension thereto whereby usage of construction material on both sides of said collapsible form means between same and said exterior form means forms a prestressed hollow wall section.

4. Means as described in claim 1 to construct a hollow wall section, wherein:

a. said collapsible form means having spaced, upright parallel face plates interconnected by a linkage means, and

b. said linkage means having spaced upright support bars and toggle links connected to said bars and said face plates whereby said bars are movable vertically to expand and retract said face plates allowing said collapsible form means to be retracted after placement and solidification of construction material between same and said exterior form means.

5. Means as described in claim 4 to construct a hollow wall section, wherein:

a. said connector means having elongated rod members positioned in aligned openings of said support bars in adjacent ones of said collapsible form means to align and give lateral stability thereto.

6. Means as described in claim 4 to construct a hollow wall.

wherein:

a. said linkage means having cross bars pivotally connected to an upper portion of said support bars and a plurality of lock assemblies connected to said cross bars and said face plates when said collapsible form means are in the expanded positions to lock same for forming of the hollow wall section.

7. Means as described in claim 1 to construct a hollow wall.

wherein.

a. said exterior form means each of size equal to said collapsible form means. respectively. having a designed form face positioned toward said collapsible form means operable to create a hollow wall section having an outer designed surface 8. Means for construction of an integral hollow wall section using a spray application of fluid construction material, comprising:

a a plurality of upright. longitudinally aligned collapsible form means,

b. connector means secured to adjoining end portions of said collapsible form means to prevent the construction material from reaching the exterior of said collapsible form means, and

c. coverage means connected to the upper end portions of said collapsible form means having elongated bar members operable to restrict movement of the material into the open upper end portions of said collapsible form means.

9. Means as described in claim 8 for construction of a hollow wall section, including:

a. column box means secured to said coverage means extended downwardly and laterally of said collapsible form means, and said column box means adapted to receive construction material therein to form columns to support a roof structure thereon.

Claims

1. Means for construction of an integral hollow wall section, comprising: a. a plurality of upright, longitudinally aligned collapsible form means, b. connector means interconnecting said form means, c. end portion support means positioned at opposite end portions of the outer ones of said collapsible form means extended laterally therefrom, d. a plurality of exterior form means positioned on opposite sides of said form means extended parallel thereto and spaced therefrom, e. clamp means interconnecting adjacent ones of said exterior form means, and f. sealing means connected to abutting end portions of said collapsible form means and next to said end portion support means whereby construction material may be inserted between said exterior form means and said collapsible form means to form the hollow wall on removal of said collapsible form means.

2. Means as described in claim 1 to construct a hollow wall section, including: a. a form support base of U-shape in transverse cross section extended the length of the wall section having said collapsible form means mounted therein for alignment and sealing purposes.

3. Means as described in claim 1 to construct a hollow wall section, including: a. reinforcing mesh positioned between said exterior form means and both sides of said collapsible form means extended parallel thereto through said end support means, and b. means connected to opposite ends of said reinforcing mesh to apply tension thereto whereby usage of construction material on both sides of said collapsible form means between same and said exterior form means forms a prestressed hollow wall section.

4. Means as described in claim 1 to construct a hollow wall section, wherein: a. said collapsible form means having spaced, upright parallel face plates interconnected by a linkage means, and b. said linkage means having spaced upright support bars and toggle links connected to said bars and said face plates whereby said bars are movable vertically to expand and retract said face plates allowing said collapsible form means to be retracted after placement and solidification of construction material between same and said exterior form means.

5. Means as described in claim 4 to construct a hollow wall section, wherein: a. said connector means having elongated rod members positioned in aligned openings of said support bars in adjacent ones of said collapsible form means to align and give lateral stability thereto.

6. Means as described in claim 4 to construct a hollow wall, wherein: a. said linkage means having cross bars pivotally connected to an upper portion of said support bars and a plurality of lock assemblies connected to said cross bars and said face plates when said collapsible form means are in the expanded positions to lock same for forming of the hollow wall section.

7. Means as described in claim 1 to construct a hollow wall, wherein: a. said exterior form means each of size equal to said collapsible form means, respectively, having a designed form face positioned toward said collapsible form means operable to create a hollow wall section having an outer designed surface.

8. Means for construction of an integral hollow wall section using a spray application of fluid construction mAterial, comprising: a. a plurality of upright, longitudinally aligned collapsible form means, b. connector means secured to adjoining end portions of said collapsible form means to prevent the construction material from reaching the exterior of said collapsible form means, and c. coverage means connected to the upper end portions of said collapsible form means having elongated bar members operable to restrict movement of the material into the open upper end portions of said collapsible form means.

9. Means as described in claim 8 for construction of a hollow wall section, including: a. column box means secured to said coverage means extended downwardly and laterally of said collapsible form means, and said column box means adapted to receive construction material therein to form columns to support a roof structure thereon.