US3676967A - Forms for concrete wall construction - Google Patents

Forms for concrete wall construction Download PDF

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US3676967A
US3676967A US3676967DA US3676967A US 3676967 A US3676967 A US 3676967A US 3676967D A US3676967D A US 3676967DA US 3676967 A US3676967 A US 3676967A
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pans
courses
pan
course
concrete
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Augustus Frati
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Augustus Frati
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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84Walls made by casting, pouring, or tamping in situ
    • E04B2/86Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2/8635Walls made by casting, pouring, or tamping in situ made in permanent forms with ties attached to the inner faces of the forms

Abstract

Rectangular sheets of galvanized metal pans are assembled to construct wall forms at the construction site. Each pan includes inwardly bent flanges along its peripheral edges. A course of several pans is erected by joining a horizontal row of pans along abutting vertical side flanges. Several courses are stacked in a vertical plane to construct one face of a wall form. The other face of the form is constructed of similar pans in spaced parallel relationship to the first face. The abutting edges of the pans are either welded or joined by connector plates. A plurality of spaced vertical ribs project outwardly from the face of each pan. The ribs provide contiguous coplanar surfaces against which sheet wall covering may be mounted. Spaced between the ribs are columns of louvers which serve as a lath if the wall is plastered. A further option is the use of an insulation panel, nestably received on the inside face of each pan between the peripheral edges thereof. Concrete is poured into the assembled form and the forms remain permanently affixed to the sides of the concrete core.

Description

United States Patent Frati [451 July 18, 1972 [5 1 FORMS FOR CONCRETE WALL 2,017,973 10/1935 Jenkins ..52/383 CONSTRUCTION [72] inventor: Augustus Frat], 95 Greenlawn Road, Greenlawn, NY. 11743 [22] Filed: July 1, 1970 [21] Appl. No.: 51,523
[52] US. Cl ..52/220, 52/404, 52/422, 52/426, 52/444, 52/715 [51] Int. Cl. ..E04b 2/68, E04f 17/08 [58] Field of Search ..52/422, 352, 428, 675, 426, 52/425, 424, 427, 429, 431, 440, 444, 353, 367, 373, 378, 383, 404, 220, 249, 269, 34, 563, 712, 715, 204, 213
[56] References Cited UNITED STATES PATENTS 2,919,572 1/1960 Salzil ..52/444 X 2,248,348 7/1941 Hall ..52/426 1,852,002 4/1932 Clark. ....52/352 X 2,116,886 5/1938 Goetz ....52/440 X 3,255,563 6/1966 Sauer ....52/221 X 1,616,977 2/1927 Koivu ..52/426 Primary Examiner-Price C. F aw, Jr. Attorney-Jeffrey A. Schwab ABSTRACT Rectangular sheets of galvanized metal pans are assembled to construct wall forms at the construction site. Each pan includes inwardly bent flanges along its peripheral edges. A course of several pans is erected by joining a horizontal row of pans along abutting vertical side flanges. Several courses are stacked in a vertical plane to construct one face of a wall form. The other face of the form is constructed of similar pans in spaced parallel relationship to the first face. The abutting edges of the pans are either welded or joined by connector plates. A plurality of spaced vertical ribs project outwardly from the face of each pan. The ribs provide contiguous coplanar surfaces against which sheet wall covering may be mounted. Spaced between the ribs are columns of louvers which serve as a lath if the wall is plastered. A further option is.
the use of an insulation panel, nestably received on the inside face of each pan between the peripheral edges thereof. Concrete is poured into the assembled form and the forms remain permanently affixed to the sides of the concrete core.
16 Claim, 12 Drawing Figures PATENTED JUL 1 8 I972 SHEET 1 OF 2 INVENTOR AUGUSTUS F ATI C% km ATTORNEY O O O 240 W 0 4a 72 O o o o o 40 O PATENT! JUL 1 8 I972 Fl G. 6
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FORMS FOR CONCRETE WALL CONSTRUCTION BACKGROUND OF THE INVENTION 1. Field of the Invention Concrete wall construction employing modular metal pans for forms.
2. Description of the Prior Art Because concrete is initially in a plastic state, it is necessary to use forms to confine and support the poured concrete until it is rigid and self-supporting. As a result, the cost of concrete for most structures is relatively high because it not only includes the actual cost of the concrete, but additionally includes the cost of forms that are required to temporarily support the concrete.
Most concrete wall forms in present employment include spaced parallel opposed surfaces formed of wood sheathing. The sheathing is in turn supported by a plurality of spaced vertical studs joined by a series of horizontal wales. The wales are usually reinforced with shoring. This method of constructing concrete walls is expensive due to the fact that the labor costs of constructing the wall forms are quite high. Furthermore, expense is involved due to the fact that the materials used in the construction of the wall forms are costly and are only reusable for a limited number of applications. Additionally, reuse of the conventional wall forms entails further labor costs of reassembly. Even if the forms are not reused, the cost of stripping the wall forms after the concrete wall has gained sufficient strength cannot be obviated.
Metal pan form structures have been employed in concrete construction. The previous employment of metal pans has generally been restricted to use of the pans in the construction of concrete floors. This type of floor construction has become popular because the amount of concrete required to support a given floor loading is less than is required for the beam-andslab floor. Furthermore, the use of the metal pan forms reduced the cost of floor construction. The metal pan forms used in floor construction were, however, stripped after the concrete had gained sufficient strength to be self-supporting.
The use of metal pan forms in wall construction has not become popular due to several factors. Among the disadvantages is the fact that heretofore, the metal pans could not be easily and simply joined together to erect a contiguous form for a wall. Furthermore, the use of some metal pans rendered the resulting wall of a shape which did not easily permit the application of plaster without the cumbersome task of applying a lath.
Another disadvantage encountered with the use of metal pans for wall forms was the fact that the shape of the metal pans did not permit the easy application of sheet wall covering to interior wall surfaces.
SUMMARY OF THE INVENTION It is an object of the present invention to provide a form for concrete wall construction of the general character described which is so constructed that it is not subject to any of the foregoing disadvantages.
More specifically it is an object of the present invention to provide a modular form for concrete wall construction which includes metal pans which may be joined to like pans with great facility yet is lightweight, strong and well adapted for rapid on site assembly.
A further object of the present invention is to provide a form for concrete wall construction of the general character described which includes a plurality of peripherally flanged metal pan sheets arranged in a course with abutting flanges of each pan joined.
A still further object of the present invention is to provide a form for concrete wall construction which includes a plurality of substantially rectangular modular pans, each of which includes a face and with a plurality of elongate outwardly projecting ribs against which sheet covering may be secured.
Yet another object of the present invention is to provide a form for concrete wall construction of the general character described which optionally provides a plaster adhering base surface or a planar surface against which sheet wall material may be positioned.
A still further object of the present invention is to proVide a concrete wall which includes a plurality of rectangular metal pans arranged in vertically stacked horizontal courses and an opposed plurality of like pans arranged in parallel courses with various utility and service conduits extending within the wall and between the opposed parallel courses.
A still further object of the present invention is to provide a wall structure including a poured concrete core andopposite faces clad with metal pans and wherein water feed pipes are positioned adjacent the pans and with the pipes and pans subsequently covered with a layer of plaster.
Yet another object of the present invention is to provide a wall structure including a poured concrete core with metal clad faces, the faces being formed of galvanized metal pans and with the peripheral edges of each pan having a flange and with the flanges of adjacent pans being joined and forming a V-notch to tightly engage an anchoring nail used to secure sheet wall covering.
Other objects of the invention in part will be obvious and in part will be pointed out hereinafter.
The invention accordingly consists in the features of construction, combinations of elements and arrangements of parts which will be exemplified in the form for concrete wall construction hereinafter described, and of which the scope of application will be indicated in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS In the accompanying drawings in which are shown some of the various possible embodiments of the invention,
FIG. 1 is a perspective view of a wall form constructed in accordance with and embodying the invention, and with portions thereof broken away for clarity, and showing opposed parallel courses of galvanized metal pans;
FIG. 2 is a fragmentary enlarged exploded perspective view of an I-I-shaped connector plate which joins adjacent pans along abutting vertical side flanges of each pan;
FIG. 3 is an enlarged fragmentary sectional view taken substantially along the line 3-3 of FIG. 1 and illustrating a portion of a tie rod joining parallel pans and further illustrating the contour of the face of a pan including a plurality of vertical ribs and a plurality of shrouded louvers spaced between the ribs;
FIG. 4 is a fragmentary perspective view of a portion of a pan forming the end of a wall and showing the specific configuration of an H-shaped connector plate which serves to space the parallel opposed panS;
FIG. 5 is a fragmentary transverse sectional view through a poured concrete wall constructed in accordance with the invention wherein the face of the wall is plastered;
FIG. 6 is a reduced scale sectional view taken substantially along the line 6-6 of FIG. 1 and showing, in substantially plan configuration, the interior surface of a pan wherein an insula tion pad is nestably received between the inturned peripheral flanges of a pan;
FIG. 7 is a transverse sectional view through a wall constructed with the insulated pad illustrated in FIG. 6;
FIG. 8 is a longitudinal sectional view through a wall showing the application of a sheet wall covering over the metal clad face of the wall and With an anchoring nail being received in a V-notch formed between adjacent flanges;
FIG. 9 is a longitudinal sectional view through a wall and showing a utility conduit within the concrete core along with water feed pipes positioned adjacent the face of a pan and between the vertical ribs, with the wall face being subsequently plastered to conceal the water feed pipes;
FIG. 10 is a fragmentary elevational view of a wall constructed in accordance with this invention including a window frame;
FIG. 1 l is a sectional view taken substantially along the line 11-11 of FIG. 10, and through a jamb of the frame, and showing the manner in which the frame is anchored to the wall; and
FIG. 12 is a plan view of an l-l-shaped connector plate constructed in accordance with an alternate embodiment of the invention wherein the plate includes a plurality of perforations to reduce heat transfer between opposed faces of a wall.
DESCRIPTION OF THE PREFERRED EMBODIMENT The form of the present invention is used to erect a permanently metal clad concrete wall structure wherein both faces of a concrete core are encased between spaced parallel courses of galvanized metal pans. The face of each pan includes a plurality of parallel spaced vertical ribs which serve as surfaces against which sheet wall covering, e.g. plaster board, wall board, plywood paneling, tongue and groove paneling, etc., may rest to insure a smooth flat backing for the wall covering. Furthermore, the peripheral edges of each pan include a tapered flange so that a narrow V-notch peripherally surrounds each interior pan, i.e. not at the periphery of the wall form. The V-notches may easily receive nails, screws or other anchoring implements which are forced into the wall. Thus, the concrete wall will easily accomodate sheet wall covering as well as provide convenient anchoring surfaces for picture hooks, etc. The faces of the pans further include a plurality of upturned shrouded louvers which readily catch plaster if the wall face is to be subsequently plastered. This obviates the necessity for a separate lath.
Window and door frames are pre-fabricated and installed in a space provided between the pans to complete an apertured wall form before the concrete is poured.
In order to insure against heat losses, the invention includes the optional employment of insulating pads which are nestably received on the inner faces of the pans and between the peripheral flanges thereof. Furthermore, the connector members which join opposed parallel pans and link adjacent pans in a course may be perforated to reduce heat loss through conduction.
Referring now in detail to the drawings, the reference numeral denotes a metal wall form constructed in accordance with and embodying the invention. The wall form 10 is constructed of stacked horizontal courses of aligned galvanized modular metal pans 12. The stacked courses provide one face of a wall form and the opposite face is provided by similar pans 12 aligned in courses in parallel spaced relationship to the opposed side.
It will be appreciated that although the metal pans forming the wall form are joined together and rigidified through various securing devices, the application of the present wall form securing devices alone are indicated wherein the stacked courses do not reach extensive heights, e.g. more than two courses, because the increased pressure of the plastic concrete necessitates further external rigidifying structures, e.g. wales, shores, etc., to prevent the pans in opposed courses from bulgmg or separating.
It should also be noted that a concrete wall constructed in accordance with the present invention will be permanently clad on each face thereof with the galvanized metal pans 12. The metal pans l2 render a wall essentially vermin proof as this structure is impenetrable. Further, the galvanized cladding reduces seepage of air and/or moisture through the concrete core.
Each of the pans 12 is generally rectangular in configuration and includes an inwardly bent horizontal flange 14 adjacent the top and bottom edges thereof. The flanges 14 are not perpendicular to a plane of the face of the pan 12, however, and are bent to an acute angle of approximately 80. The purpose of the angular orientation of the flanges 14 will be subsequently described. Each of the side edges of the pan 12 includes a vertical flange 16 which is also bent to the same acute angle to the plane of the pan l2.
It will be noted that a substantially rectangular vertical notch 18 is formed at the base of the flanges 16 adjacent the top and bottom edges of the pan 12 and with a longitudinal edge of each notch coinciding with the side edges of the pan 12. The notches 18 are used to join side edges of adjacent pans 12 and are engaged by a connector in a manner hereinafter described.
Referring now to FIG. 2 wherein a connector device used to join adjacent side flanges 16 of the pans 12 is illustrated, it will be seen that an l-l-shaped connector plate 20 is employed. The plate 20 is shaped with two spaced parallel horizontal reaches 21 joined by a short vertical reach 23. The overall configuration of the connector is in the shape of the letter .H lying on one side.
Adjacent each of the ends of the horizontal reaches 21, the reaches are bifurcated to form two spaced tabs 22 which are bent to lie in a plane perpendicular to that of the horizontal reaches 21. A tab portion 24 of the horizontal reach intermediate the two tabs 22 is bent in an opposite direction to lie in the same plane as the tabs 22.
It will be observed that to join (lock) adjacent flanges 16, the tab portion 24 is forced through registered notches 18 of adjacent pans 12 and is subsequently bent to lie in a plane substantially parallel to the reach 21 and overlies the interior surface of a flange 16. In this locked position, the horizontal reaches 21 will lie in juxtaposition with the adjacent flange l6 sandwiched between the reach 21 and the bent tab portion 24. In the locked position, the tabs 22 lie flush against the interior of the face of a pan 12.
In FIG. 4 a fragmentary view of an end of a wall form is illustrated. It will be observed that the l-I-shaped connector 20 does not join a pan 12 to an adjacent pan but that the tab portion 24 merely overlies the outer surface of the flange 16 while the tabs 22 abut the interior surface of the face of the pan 12. When the concrete is poured into a completed wall fonn, the open ends of the wall forms are blocked off by any suitable strippable sheathing. During such pouring, the sheathing is secured against the end of the wall form and abuts the end flanges 16 along with the end connector 20.
In order to provide strength not only for the form, but also to reinforce the concrete wall itself, a reinforcing rod 26 is received within aligned notches 28 formed in the horizontal reaches 21 of each l l-shaped connector 20. The reinforcing rod 26 is circular in transverse cross section, and bridges between the l-I-shaped connectors within the notches 28.
It will be noted that each of the horizontal reaches 21 of each l-l-shaped connector are correspondingly notched ad jacent each end thereof. This is to reduce the time required to set up the wall form by eliminating the necessity of finding out which side of each connector 20 is up. Thus, when the pans are assembled to erect two parallel courses, the notches 28 will automatically be aligned and thereby nestably receive a reinforcing rod 26.
As was previously mentioned, the rod 26 serves to strengthen the wall form. It reinforces the form by providing a stiff pan connector thereby reducing lateral deflection as well as serving to reinforce the poured concrete.
The function of the I-l-shaped connector in securing adjacent pans 12 forming a course has been previously described. The l-l-shaped connectors 20 serve a second purpose, however, to wit, they maintain the spaced relationship between opposed pans against the deflecting forces of the weight of the poured concrete, thereby reducing the tendency of the opposed pans to separate.
A further device is provided to support the pans l2 and prevent outward deflection, i.e. buckling, when the concrete is plastic. A tensile reinforcing member which is provided is a tie rod 30 of circular transverse cross section. The tie rod 30 includes a generally straight central portion and a pair of parallel depending legs 32 with one leg at each end of the central portion.
The leg portions 32 engage an inwardly struck protuberance 34 which extends from the approximate center of the face of each pan 12. The protuberances 34 include upper and lower open edges and the legs 32 extend between said edges and are captively retained therebetween. The weight of the tie rod 30 maintains the legs 32 in engagement with the 'protuberances 34. It will be appreciated that when the concrete is poured, the tie rod 30 is put under tensile stress and maintains the faces of the pans 12 in substantially coplanar relationship for each course.
A complete wall form is erected by aligning and stacking successive courses of pans 12. Each of the courses are placed with the horizontal flanges 14 in abutting contact. It should be noted that the exterior surface of each flange 14 is roughened to prevent slipping of abutting flanges 14 during initial assembly. After the pans are stacked atop one another, the adjacent flanges 14 are spot welded as at 36 (see FIG. 1).
The face of each pan 12 includes a series of vertical parallel ribs 38 which are stamped. The ribs 38 include ridges which provide a continuous co-planar surface against which sheet wall covering such as wallboard or paneling may rest. This is more fully illustrated in FIG. 8. It will also be appreciated from an observation of FIG. 8 that an anchoring nail 40 for sheet wall covering 41 is secured to the wall through the wall covering and extends between the angular flanges 16 which form a hollow tapered V-channel. The edges of the flanges l6 bear against the nail 40 to securely anchor the nail.
Referring now to FIGS. 1 and 3, it will be observed that a plurality of upwardly struck louvers 42 are positioned in vertical rows and spaced between the ribs 38. The louvers 42 serve as anchoring surfaces for a wall covering such as stucco or plaster. This is more readily observed in FIG. 5 wherein the surface of a wall having a core 46 of poured concrete is covered by a layer of plaster 44. It will be seen that portions of the plaster 44 seep into the open mouth at the top of each louver 42 between the upper edge of the louver and the face of the pan 12.
Referring again to FIG. 3 it will be seen that the louvers 42 project from the plane of the face of the pan 12 a distance less than the distance that the ribs 38 project. Thus, the option of either using sheet wall covering which rests against the ribs 38 or plastering, stuccoing, etc. is left open to meet the needs of the individual application.
It will be seen that the wall board or wall paneling may be applied without any impediment being presented by the louvers. Furthermore, the upper edge of each louver 42 is at an elevation approximately equal to that of the edge of the face of the pan 12 from which the louver was struck. Thus, the tendency for the plastic concrete to seep or ooze from the louvers is reduced.
It should be noted at this time that the wall form is well adapted for use in constructing walls in submerged or semisubmerged areas. When the concrete is poured between the courses, ny water between the courses will be forced out through the louvers by the concrete.
If it is desired to have additional insulation material within the wall, the present invention provides for the placement of insulating pads 48 adjacent the interior surface of each pan and nested within the confines of the flanges l4, 16. Because the pads 46 are of a thickness less than the width of the flanges, the insulating pads will not have a tendencyto catch or snag the concrete as it is being poured. The pad 48 may be formed of any suitable insulating material, e.g. Fiberglas, polyurethane, etc.
FIG. 6 illustrates a pad 48 placed in the pan 12 positioned to the right of the forwardmost pan 12 in FIG. 1. The pad 48 includes a crossed slot 49 at the center thereof, through which the tie rod 30 is fed. The pad 48 is placed within the confines of the peripheral flanges during the assembly of the wall form.
Referring now to FIG. 7 showing a poured concrete wall having a core 46, an insulating pad 48 and a plaster outer facing, it will be seen that the concrete core 46 is in abutting contact with one face of the pad 48, while the inner face of the pan 12 is in abutting contact with the other face of the pad 48. Additionally it will be observed that the plaster coating 44 has seeped deeply into each louver 42 because the concrete core 46 did not reach the interior surfaces of the louvers.
Turning again to the wall form 10 illustrated in FIG. 1, prior to pouring the concrete, it is highly advantageous to place service conduits between the courses of the form. A typical installation would include a plastic conduit 50 within which electrical cable may be threaded. The plastic conduit 50 is of circular transverse cross section to allow the concrete to easily flow and set up. Any commercially available plastic having sufficient compressive strength is suitable for such application. Typical examples of suitable plastics are polyethylene, polystyrene, acrylonitile-butadiene-styrene, etc.
Various sewage pipes and venting pipes 52 are also expeditiously positioned between the conFines of the wall form prior to pouring the concrete.
The conduit 50 through which electrical cables may be threaded extends along the longitudinal axis of a course while the sewage pipes 52 are positioned between the courses and extend in a vertical direction. The sewage pipes 52 are illustrated in FIG. 1 and, additionally, in the sectional view of FIG. 9.
In FIG. 9 a wall having an outer covering of stucco 54, a poured concrete core 46 and a vertically extending sewage pipe 52 is shown. It should be additionally noted that the inner face of the wall includes a layer of plaster 44. Two water feed pipes 56 are positioned adjacent the pans l2 and between the 7 vertical ribs 38. It will be observed that the layer of plaster covers the pipes 56 to thus conceal the pipes.
Normal utility connections, e.g. between the sewage pipes 52 and a drain or sump; between circuit breakers, switches, and the electrical cables, etc. will be constructed in the usual manner as will be the connections between the sinks, tubs, etc. to the water feed and sewage pipes. In order to provide suitable inlets to the sewage pipes 52, a T-fitting is provided in a sewage pipe 52 with a trunk of the fitting extending out of the wall through an opening in a pan 12. After the concrete core 46 is poured, the facilities, e.g. sinks, tubs, wash basins, lavato ries, are connected into the T-fittings in the conventional manner and final electrical connections are completed.
It should also be understood that although the use of plastic conduits and pipes have been described, the use of metal pipes within the wall core 46 is equally feasible.
The present invention also provides for the installation of window and door frames within the wall forms prior to pouring of the concrete. Referring now to FIG. 10 wherein a window frame 58 is illustrated, the pans 12 adjacent the frame 58 have been cut on the site to accomodate the positioning of the frame 58. Such on site modification of the pan 12 is easily accomplished with the use of conventional sheet metal snips or shears.
The frame 58 includes a top beam 60, a sill 62 and a pair of upright jambs 64 interconnecting the ends of the beams. From an observation of FIG. 11 it will be seen that the beam 60, sill 62 and jambs 64 are preferably constructed of angle iron, although other suitable metals may be used, e.g. aluminum or galvanized metal of L-shaped transverse cross section. The frame 58 includes a peripheral flange 66 which extends along the inner surface of the wall form 10 and overlies a portion of the pans. After the concrete core 46 has been poured, the wall form 10 is covered with either plaster or sheet wall covering. When the form covering is applied, it may be applied over the peripheral flange 66 to conceal the same or, optionally, it may terminate at the edge of the flange 66 so that the flange 66 serves as decorative trim.
A door frame is constructed in a similar manner and may include, in lieu of a sill, an open floor engaging bottom. The door frame is, of course, proportioned differently than a window frame and the jambs thereof are considerably longer.
In order to assure that the frame 58 is securely joined and anchored to the concrete core 46, a plurality of metal anchoring straps 68 (see FIG. 11) are affixed to the surfaces of the frame 58 which abut the concrete core. The straps 68 are of U-shaped longitudinal cross-section and include planar feet 70 at the tips of the free ends thereof. The feet 70 are conventionally joined to the frame 58 as by spot welding, rivets, etc.
When the concrete is poured into the wall form 10, the concrete will flow around the U-shaped strap 68 and into the space between the mid length of the strap and the frame and thereby the straps will tightly anchor the frame 58 to the core 46. On the exterior (outside) wall surface of a wall having a window frame 58, a suitable bead is provided along with trim and flashing, all in the conventional manner.
In FIG. 12 an alternate form of the l-l-shaped connector is illustrated. This modified connector a is of the same general configuration as the previous l-l-shaped connector 20 and includes parallel top and bottom reaches 21a, each of which includes notches 2812 a and with tabs formed at the ends of the horizontal reaches 21a. A tab 240 extends in a direction perpendicular to the plane of the connectors and this tab engages slots in the vertical flanges of the pans to secure adjacent pans together as well as to provide parallel spacing between opposed pans. The tabs 240 are bent to overlie a flange 16 as previously discussed with respect to the first described embodiment.
The H-shaped connector 20a differs in construction from the l-l-shaped connector 20 previously described because it includes a plurality of perforations 72 which are presently illustrated as circular. The perforations 72 are distributed uniformly throughout the structure of the l-l-shaped connector 20a and serve the primary function of reducing the quantity of metal in a connector 20a. The reduction in the quantity of metal results in a lowering of the heat transfer characteristics of the connector 20a as compared to the connector 20. With a reduced heat transfer capability, heat loss through a concrete wall by virtue of heat conductivity of a connector is thereby lowered.
A wall constructed with the modular metal pans described in the present invention will be economically and rapidly fabricated on site at reduced cost compared to previous construction techniques. Furthermore, the wall will be highly resistant to wind, water and vermin penetration. Additionally, the pan surfaces will readily accomodate any conventional wall covering and the pans themselves are highly adaptable for use with various framed openings, so that an entire wall including window and door openings may be poured uniformly at sequential steps building up the height of the wall as by two stacked courses at a time.
It will be appreciated that poured concrete walls constructed in accordance with this invention are well suited for use in areas where wood lumber construction is undesirable or impractical, e.g. humid areas, or where wood is unavailable or so costly that it is impractical even for use as wall forms. Furthermore, because the modular pans can be arrayed in stacked courses, the concrete core poured, and then subsequent stacked courses arrayed above the previously poured section, this construction technique is highly desirable where concrete delivery is restricted. lf delivery is restricted for a period of time, wall forms for further walls may be erected during this time. If the concrete deliveries are in limited quantities, the assembly of the wall forms may be readily geared to accomodate such deliveries.
A further feature of the present wall forms is the fact that if the forms are to be used as interior non-load bearing walls, e.g. curtain walls, etc., it is not necessary to pour a concrete core. This wall may optionally be a hollow wall of stacked courses of pans with plaster or wallboard directly applied over the faces of the pans.
it will also be appreciated thAt the thickness of any wall form may be varied by altering the length of both the reaches of the H-shaped connectors and the tie rods.
If it is desirable to erect a wall of plane curved configuration, e.g. in a silo, etc., the pans used on the concave side of the wall will be of a shorter length than those on the convex side.
Furthermore, if a spherically curved wall is to be erected, e.g. in a stadium, amphitheater, planetarium, etc., the pans on the concave side of the wall will be smaller than the pans on the convex side in both length and height.
Thus it will be seen that there has been described a modular form for concrete wall construction which achieves the various objects of the invention and which is well adapted to meet the conditions of practical use.
As various possible embodiments might be made of the present invention, and as various changes might be made in the embodiment above set forth, it is to be understood that all matter herein described or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.
Having thus described the invention, there is claimed as new and desired to be secured by Letters Patent:
1. A wall form for concrete wall construction, said form comprising a plurality of modular pans, each pan being formed of sheet metal and having a substantially planar rectangular face, an inturned marginal flange adjacent each peripheral edge of the face, means forming parallel columns of shrouded louvers extending outwardly from the plane of the face, each pan further including a plurality of vertical ribs projecting outwardly from the plane of the face, the faces of several pans being substantially vertical and aligned along a substantially horizontal course, the flanges of adjacent pans of the course abutting one another, a second course of like pans, the second course being spaced from the first course, means securing adjacent flanges together and maintaining a spaced parallel relationship between the courses, the means securing adjacent flanges and maintaining the spaced parallel relationship including a planar connector, said connector having a pair of horizontal reaches, and means forming a bendable tab at each end of each reach, said reaches being continuous from said first course to said second course, meanS forming registered apertures in adjacent portions of abutting pans, the bendable tabs extending through the registered apertures and being bent to lie in a plane substantially parallel to the plane of the reach.
2. A wall form constructed in accordance with claim 1 further including wall tie means, said wall tie means comprising a rod having parallel depending legs at the opposite ends thereof, each pan being of one piece construction and having an inwardly projecting depressed looped protuberance on its face, each leg engaging the protuberance of an opposite pan, the wall form further including a poured concrete core between the courses, the wall tie means preventing the buckling of the pans when the concrete is poured into the form.
3. A wall form constructed in accordance with claim 1 wherein insulating pads are provided, said pads being nestably received between the flanges of each pan.
4. A wall form constructed in accordance with claim 1 the wall form further including a poured concrete core between the courses, a water feed pipe, said water feed pipe being positioned adjacent the louvers, a course including the louvered pan further including an exterior plaster coating, the plaster coating extending into selected shrouded louvers of the pan, the plaster coating covering the water feed pipe, thereby concealing said pipe.
5. A wall constructed in accordance with claim 4 wherein the louvered pan further includes a plurality of vertical ribs, said ribs projecting outwardly from the plane of the face thereof, the ribs being positioned between the columns of shrouded louvers, the water feed pipe being positioned between two adjacent ribs.
6. A wall constructed in accordance with claim 4 wherein conduit means is positioned between the courses, the conduit means including electrical and sewage conduits.
7. A wall form constructed in accordance with claim 1 wherein one of the horizontal reaches extends between a first pair of apertures of pans in opposed courses, said first pair of apertures being positioned in proximate relatiOn to the lower edge of the respective pans, a second of the horizontal reaches extending between a second pair of apertures of pans in opposed courses, said second pair of apertures being positioned in proximate relation to the upper edge of the respective pans, whereby a wall form for the pouring of concrete walls and withstanding the static pressures of the poured concrete without substantial deflection is provided.
8. A wall form constructed in accordance with claim 7 wherein each of the horizontal reaches includes at least one other tab at each end thereof, each of the other tabs lying in a plane substantially perpendicular to the plane of the reach and parallel to the plane of the face of the respective pan, and in abutting contact with the pan, whereby displacement of the pans from their aligned course is restricted.
9. A wall form constructed in accordance with claim 1 wherein the connector includes means forming a notched portion on the upper edge of a horizontal reach, means aligning the notched portions of each connector joining successive pans of a course, the wall form further including an elongate horizontal reinforcing rod, said rod having an effective length greater than the combined length of at least two successive pans in a course, said rod being nestably received in the aligned notches of the reaches, thereby preventing deflections of the courses during pouring of the core and reinforcing the concrete structure of a finished wall.
10. A wall form for concrete wall construction, said form comprising a plurality of metal pans, each of said pans having a substantially planar rectangular face, an inturned marginal flange adjacent each peripheral edge of the face, the flanges being inclined from the plane of the face at an acute angle, a group of pans being aligned along a horizontal course, a second group of pans being aligned along an opposed horizon tal course and in parallel spaced relationship to the first mentioned course, means for pouring a concrete core into the wall form directly between the courses, the flanges of adjacent pans in each course abutting one another, means securing the adjacent pans together, and means for lockingly engaging a wall anchoring device driven toward the wall core, the adjacent flanges forming an inwardly tapered open faced hollow V-channel, said last named means including said hollow V channel; the pans having a juncture line at the intersection of the abutting flanges, the V-channel being positioned at the juncture line, the hollow V-channel being adapted to receive anchoring devices which are subsequently driven into the wall with the abutting portion of the flanges spreading apart to receive and lockingly engage the anchoring device to affix an object to the wall.
11. A wall form constructed in accordance with claim 10 further including conduit means positioned between the courses.
12. A wall form constructed in accordance with claim 11 wherein the conduit means includes at least one electrical conduit and at least one sewage conduit.
13. A wall form constructed in accordance with claim 10 wherein the pans are arranged in several courses with the courses being stacked and means securing the abutting flanges of pans in adjacent courses, the securing means including a fused weld.
14. A wall form constructed in accordance with claim 10 wherein insulating pads are provided, said pads being nestably received within the flanges of each pan.
15. A wall form constructed in accordance with claim 10 further including wall tie means, said wall tie means comprising a rod having parallel depending legs at the opposite ends thereof, each pan having an inwardly projecting protuberance formed in its face, the legs of each wall tie means engaging the protuberances of opposite pans in opposed courses, the wall form further including a poured concrete core between the courses, whereby the wall tie means prevents buckling when the concrete is poured into the form.
16. A wall form for concrete wall construction, said form comprising a plurality of edge abutting modular pans, each pan being formed of sheet metal and having a substantially planar rectangular face, the faces of several pans being substantially vertical and aligned along a substantially horizontal course, a second course of like pans, the second course being spaced from the first course, means securing ad acent pans 0 each course together, means maintaining a spaced parallel relationship between courses, means forming an opening through the wall form, said opening means including a frame member, said frame member including a first portion, said first portion being of a width at least equal to the distance between the courses, the width of said first portion bridging pans in 0pposed courses in a plane perpendicular to the planes of the courses, a second portion, said second portion including a flange extending perpendicularly to the first portion and overlying an area of the face of a pan in one of the courses and means for anchoring the frame member to a concrete core to be poured into the form.

Claims (16)

1. A wall form for concrete wall construction, said form comprising a plurality of modular pans, each pan being formed of sheet metal and having a substantially planar rectangular face, an inturned marginal flange adjacent each peripheral edge of the face, means forming parallel columns of shrouded louvers extending outwardly from the plane of the face, each pan further including a plurality of vertical ribs projecting outwardly from the plane of the face, the faces of several pans being substantially vertical and aligned along a substantially horizontal course, the flangEs of adjacent pans of the course abutting one another, a second course of like pans, the second course being spaced from the first course, means securing adjacent flanges together and maintaining a spaced parallel relationship between the courses, the means securing adjacent flanges and maintaining the spaced parallel relationship including a planar connector, said connector having a pair of horizontal reaches, and means forming a bendable tab at each end of each reach, said reaches being continuous from said first course to said second course, meanS forming registered apertures in adjacent portions of abutting pans, the bendable tabs extending through the registered apertures and being bent to lie in a plane substantially parallel to the plane of the reach.
2. A wall form constructed in accordance with claim 1 further including wall tie means, said wall tie means comprising a rod having parallel depending legs at the opposite ends thereof, each pan being of one piece construction and having an inwardly projecting depressed looped protuberance on its face, each leg engaging the protuberance of an opposite pan, the wall form further including a poured concrete core between the courses, the wall tie means preventing the buckling of the pans when the concrete is poured into the form.
3. A wall form constructed in accordance with claim 1 wherein insulating pads are provided, said pads being nestably received between the flanges of each pan.
4. A wall form constructed in accordance with claim 1 the wall form further including a poured concrete core between the courses, a water feed pipe, said water feed pipe being positioned adjacent the louvers, a course including the louvered pan further including an exterior plaster coating, the plaster coating extending into selected shrouded louvers of the pan, the plaster coating covering the water feed pipe, thereby concealing said pipe.
5. A wall constructed in accordance with claim 4 wherein the louvered pan further includes a plurality of vertical ribs, said ribs prOjecting outwardly from the plane of the face thereof, the ribs being positioned between the columns of shrouded louvers, the water feed pipe being positioned between two adjacent ribs.
6. A wall constructed in accordance with claim 4 wherein conduit means is positioned between the courses, the conduit means including electrical and sewage conduits.
7. A wall form constructed in accordance with claim 1 wherein one of the horizontal reaches extends between a first pair of apertures of pans in opposed courses, said first pair of apertures being positioned in proximate relatiOn to the lower edge of the respective pans, a second of the horizontal reaches extending between a second pair of apertures of pans in opposed courses, said second pair of apertures being positioned in proximate relation to the upper edge of the respective pans, whereby a wall form for the pouring of concrete walls and withstanding the static pressures of the poured concrete without substantial deflection is provided.
8. A wall form constructed in accordance with claim 7 wherein each of the horizontal reaches includes at least one other tab at each end thereof, each of the other tabs lying in a plane substantially perpendicular to the plane of the reach and parallel to the plane of the face of the respective pan, and in abutting contact with the pan, whereby displacement of the pans from their aligned course is restricted.
9. A wall form constructed in accordance with claim 1 wherein the connector includes means forming a notched portion on the upper edge of a horizontal reach, means aligning the notched portions of each connector joining successive pans of a course, the wall form further including an elongate horizontal reinforcing rod, said rod having an effective length greater than the combined length of at least two successive pans in a course, said rod being nestably received in the aligned notches of the reaches, thereby preventing deflections of the courses during pouring of The core and reinforcing the concrete structure of a finished wall.
10. A wall form for concrete wall construction, said form comprising a plurality of metal pans, each of said pans having a substantially planar rectangular face, an inturned marginal flange adjacent each peripheral edge of the face, the flanges being inclined from the plane of the face at an acute angle, a group of pans being aligned along a horizontal course, a second group of pans being aligned along an opposed horizontal course and in parallel spaced relationship to the first mentioned course, means for pouring a concrete core into the wall form directly between the courses, the flanges of adjacent pans in each course abutting one another, means securing the adjacent pans together, and means for lockingly engaging a wall anchoring device driven toward the wall core, the adjacent flanges forming an inwardly tapered open faced hollow V-channel, said last named means including said hollow V-channel, the pans having a juncture line at the intersection of the abutting flanges, the V-channel being positioned at the juncture line, the hollow V-channel being adapted to receive anchoring devices which are subsequently driven into the wall with the abutting portion of the flanges spreading apart to receive and lockingly engage the anchoring device to affix an object to the wall.
11. A wall form constructed in accordance with claim 10 further including conduit means positioned between the courses.
12. A wall form constructed in accordance with claim 11 wherein the conduit means includes at least one electrical conduit and at least one sewage conduit.
13. A wall form constructed in accordance with claim 10 wherein the pans are arranged in several courses with the courses being stacked and means securing the abutting flanges of pans in adjacent courses, the securing means including a fused weld.
14. A wall form constructed in accordance with claim 10 wherein insulating pads are provided, said pads being nestably received within the flanges of each pan.
15. A wall form constructed in accordance with claim 10 further including wall tie means, said wall tie means comprising a rod having parallel depending legs at the opposite ends thereof, each pan having an inwardly projecting protuberance formed in its face, the legs of each wall tie means engaging the protuberances of opposite pans in opposed courses, the wall form further including a poured concrete core between the courses, whereby the wall tie means prevents buckling when the concrete is poured into the form.
16. A wall form for concrete wall construction, said form comprising a plurality of edge abutting modular pans, each pan being formed of sheet metal and having a substantially planar rectangular face, the faces of several pans being substantially vertical and aligned along a substantially horizontal course, a second course of like pans, the second course being spaced from the first course, means securing adjacent pans of each course together, means maintaining a spaced parallel relationship between courses, means forming an opening through the wall form, said opening means including a frame member, said frame member including a first portion, said first portion being of a width at least equal to the distance between the courses, the width of said first portion bridging pans in opposed courses in a plane perpendicular to the planes of the courses, a second portion, said second portion including a flange extending perpendicularly to the first portion and overlying an area of the face of a pan in one of the courses and means for anchoring the frame member to a concrete core to be poured into the form.
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US3881291A (en) * 1973-07-19 1975-05-06 Melvin E Layne Panel mold for forming composite concrete-reinforced walls
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US4442644A (en) * 1981-06-22 1984-04-17 Mod-Lok Industries, Ltd. Frame member for use with construction blocks
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US4703602A (en) * 1985-09-09 1987-11-03 National Concrete Masonry Association Forming system for construction
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US4870792A (en) * 1987-01-12 1989-10-03 Legris Sa Passage of pressurized fluids through masonry work
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US5586416A (en) * 1995-03-22 1996-12-24 Hess, Iii; John Concrete form with integral drain
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US20060117704A1 (en) * 2004-12-06 2006-06-08 Young-Ho Yoon Built-up type box-shaped steel column for filling concrete therein and manufacturing method thereof
US20070095014A1 (en) * 2003-05-05 2007-05-03 Christopher Nilsen Consumable assembly for forming a concrete wall structure, a concrete wall structure formed with the assembly and a side plate for use in the assembly
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US20080086968A1 (en) * 2005-05-31 2008-04-17 Robert Kitchen Wall construction
US20080104911A1 (en) * 2006-11-08 2008-05-08 Jarvie Shawn P Insulated concrete form
US20090188203A1 (en) * 2006-03-03 2009-07-30 Fox Michael C Suspended electrical service conduit system and method of use
US7793477B1 (en) 2002-09-06 2010-09-14 Epic Metals Corporation Roof deck and method of manufacturing a clip
US20110203202A1 (en) * 2008-10-24 2011-08-25 2158484 Ontario Inc. Concrete form block and form block structure
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US8826613B1 (en) * 2012-02-29 2014-09-09 David J Chrien Utility trench system components
US9157233B2 (en) 2010-04-30 2015-10-13 Ambe Engineering Pty Ltd System for forming an insulated concrete thermal mass wall
US20160123608A9 (en) * 2005-05-06 2016-05-05 HVAC MFG, Inc. Hvac system and zone control unit
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US10132080B2 (en) * 2017-02-21 2018-11-20 Iconx, Llc Insulated concrete panel tie
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Cited By (47)

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US3742666A (en) * 1971-09-07 1973-07-03 Anvan M E Syst Inc Unitized utility distribution system
US4149349A (en) * 1971-11-08 1979-04-17 Arcadia Enterprises Corp. Wall forming assembly
US3881291A (en) * 1973-07-19 1975-05-06 Melvin E Layne Panel mold for forming composite concrete-reinforced walls
US3953910A (en) * 1975-02-12 1976-05-04 Arthur Farb Anchoring method and article
WO1980000859A1 (en) * 1978-10-19 1980-05-01 I Cialente Planking consituting a finished wall for reinforced or ferro-concrete building
US4348847A (en) * 1980-10-06 1982-09-14 Mod-Lok Industries Ltd. Spacer extender
US4442644A (en) * 1981-06-22 1984-04-17 Mod-Lok Industries, Ltd. Frame member for use with construction blocks
WO1985003966A1 (en) * 1984-03-02 1985-09-12 Jean Debuyst Structural elements and method for making the same
US4700523A (en) * 1984-12-28 1987-10-20 Fujikigyo Co., Ltd. Reinforcing frame work for constructing reinforced concrete structure
US4703602A (en) * 1985-09-09 1987-11-03 National Concrete Masonry Association Forming system for construction
US4870792A (en) * 1987-01-12 1989-10-03 Legris Sa Passage of pressurized fluids through masonry work
US4850170A (en) * 1987-02-19 1989-07-25 Douglas Hugh W Structural members and construction methods
US5120162A (en) * 1990-10-03 1992-06-09 Parker Alton F Building foundation form with integral drain
US5475950A (en) * 1993-08-25 1995-12-19 Palmer; Thomas M. Foundation footing form assembly
US5586416A (en) * 1995-03-22 1996-12-24 Hess, Iii; John Concrete form with integral drain
US5640823A (en) * 1995-06-30 1997-06-24 Bergeron; Mark Vertical movement clip for attaching a building member to a beam having a channel therein
DE19822233A1 (en) * 1998-05-07 1999-11-11 Mueller Holtz Christoph System for concrete building
US9038338B2 (en) * 1998-10-19 2015-05-26 Bailey Metal Products Limited Insulated concrete form wall having a bracket attaching a rim joist thereto
US20060059847A1 (en) * 1998-10-19 2006-03-23 John Rice Bracket for concrete forms
US20150052839A1 (en) * 1998-10-19 2015-02-26 International Steel Corporation Bracket for concrete forms
US6349520B2 (en) * 1999-01-18 2002-02-26 K-Wall Poured Walls, Inc. Insulated concrete wall system
US7793477B1 (en) 2002-09-06 2010-09-14 Epic Metals Corporation Roof deck and method of manufacturing a clip
US20040118074A1 (en) * 2002-12-19 2004-06-24 Quintile Mark J. Construction anchoring devices
US20070095014A1 (en) * 2003-05-05 2007-05-03 Christopher Nilsen Consumable assembly for forming a concrete wall structure, a concrete wall structure formed with the assembly and a side plate for use in the assembly
US20050055982A1 (en) * 2003-08-13 2005-03-17 Medina Mario A. Phase-change structural insulated panels and walls
US20060117704A1 (en) * 2004-12-06 2006-06-08 Young-Ho Yoon Built-up type box-shaped steel column for filling concrete therein and manufacturing method thereof
US7665259B2 (en) * 2004-12-06 2010-02-23 Korea National Housing Corporation Built-up rectangular steel column for filling concrete therein having L-shaped members and steel plates with curving projections and convex embossed portions
US20160123608A9 (en) * 2005-05-06 2016-05-05 HVAC MFG, Inc. Hvac system and zone control unit
US9677777B2 (en) * 2005-05-06 2017-06-13 HVAC MFG, Inc. HVAC system and zone control unit
US20080086968A1 (en) * 2005-05-31 2008-04-17 Robert Kitchen Wall construction
US20090188203A1 (en) * 2006-03-03 2009-07-30 Fox Michael C Suspended electrical service conduit system and method of use
US7770341B2 (en) * 2006-03-03 2010-08-10 Ductcrete, Inc. Suspended electrical service conduit system and method of use
US20070204547A1 (en) * 2006-03-03 2007-09-06 Fox Michael C Electrical service conduit system and method of use
US20080104911A1 (en) * 2006-11-08 2008-05-08 Jarvie Shawn P Insulated concrete form
WO2008057663A2 (en) * 2006-11-08 2008-05-15 Nova Chemicals Inc. Insulated concrete form
WO2008057663A3 (en) * 2006-11-08 2009-04-09 Nova Chem Inc Insulated concrete form
US10472821B2 (en) * 2007-02-02 2019-11-12 Les Materiaux De Construction Oldcastle Canada, Inc Wall with decorative facing
US20180044915A1 (en) * 2007-02-02 2018-02-15 Les Materiaux De Construction Oldcastle Canada, Inc. Wall with decorative facing
US20110203202A1 (en) * 2008-10-24 2011-08-25 2158484 Ontario Inc. Concrete form block and form block structure
US8443560B2 (en) * 2008-10-24 2013-05-21 2158484 Ontario Inc Concrete form block and form block structure
US9157233B2 (en) 2010-04-30 2015-10-13 Ambe Engineering Pty Ltd System for forming an insulated concrete thermal mass wall
US10273647B2 (en) 2010-09-28 2019-04-30 Les Materiaux De Construction Oldcastle Canada, Inc. Retaining wall
US20140360114A1 (en) * 2012-02-29 2014-12-11 David J. Chrien Utility trench system components
US8826613B1 (en) * 2012-02-29 2014-09-09 David J Chrien Utility trench system components
US9068341B2 (en) * 2012-02-29 2015-06-30 David J Chrien Utility trench system components
WO2013131535A1 (en) * 2012-03-09 2013-09-12 Kompoferm Gmbh Formwork element
US10132080B2 (en) * 2017-02-21 2018-11-20 Iconx, Llc Insulated concrete panel tie

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