US3728838A - Method for making cast-in-place concrete structures - Google Patents

Method for making cast-in-place concrete structures Download PDF

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US3728838A
US3728838A US00176891A US3728838DA US3728838A US 3728838 A US3728838 A US 3728838A US 00176891 A US00176891 A US 00176891A US 3728838D A US3728838D A US 3728838DA US 3728838 A US3728838 A US 3728838A
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concrete
forms
roof
wall
forming
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R Stout
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G11/00—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs
    • E04G11/06—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs for walls, e.g. curved end panels for wall shutterings; filler elements for wall shutterings; shutterings for vertical ducts
    • E04G11/08—Forms, which are completely dismantled after setting of the concrete and re-built for next pouring
    • E04G11/12—Forms, which are completely dismantled after setting of the concrete and re-built for next pouring of elements and beams which are mounted during erection of the shuttering to brace or couple the elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/16—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material
    • E04B1/161—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material with vertical and horizontal slabs, both being partially cast in situ
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G11/00—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs
    • E04G11/06—Forms, shutterings, or falsework for making walls, floors, ceilings, or roofs for walls, e.g. curved end panels for wall shutterings; filler elements for wall shutterings; shutterings for vertical ducts
    • E04G11/20—Movable forms; Movable forms for moulding cylindrical, conical or hyperbolical structures; Templates serving as forms for positioning blocks or the like
    • E04G11/22—Sliding forms raised continuously or step-by-step and being in contact with the poured concrete during raising and which are not anchored in the hardened concrete; Arrangements of lifting means therefor
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G17/00—Connecting or other auxiliary members for forms, falsework structures, or shutterings
    • E04G17/04—Connecting or fastening means for metallic forming or stiffening elements, e.g. for connecting metallic elements to non-metallic elements
    • E04G17/042—Connecting or fastening means for metallic forming or stiffening elements, e.g. for connecting metallic elements to non-metallic elements being tensioned by threaded elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G17/00—Connecting or other auxiliary members for forms, falsework structures, or shutterings
    • E04G17/16—Members, e.g. consoles, for attachment to the wall to support girders, beams, or the like carrying forms or moulds for floors, lintels, or transoms

Definitions

  • ABSTRACT ⁇ g 6 ill A complete monolithic concrete structure having any 5 desired architectural form and appearance is constructed in a series of operations wherein the founda- 56] References Cited tion, the interior and exterior walls, and the roof are cast-in-place. The foundation and walls are sequen- UNITED STATES PATENTS tially formed by first temporarily interconnecting a plurality of relatively small concrete forms, after 11229365 6/1917 f "249/27 which moist concrete is allowed to cure within the i322 forms. A temporary supporting structure is then 7/1909 Neil u 25/! T erected to support the roof form.
  • the present invention relates to a system for producing buildings, and more particularly, a method of making a monolithic cast-in-place house, building or like structure, wherein, in a series of steps, the foundation, l
  • the system involves the construction of a foundation, a wall, and a roof, each of which is formed by temporarily interconnecting a series of relatively small lightweight concrete forms.
  • masonry houses made of brick require the individual laying of many bricks, stone or the like along with the construction of the structural members of the house, the plastering of the interior walls for appearance purposes, the laborious chiselling out of the windows and door frames, and the additional chiselling ofthe masonry materials for accommodating plumbing, electric and gas conduits.
  • known techniques for forming a masonry house are expensive, time-consuming and require skilled craftsmen.
  • the construction industry has long sought a system for creating a commercially acceptable built in-place" house made of concrete material.
  • the construction industry has attempted, without success, to develop a system of making a house by casting concrete.
  • One technique involves the preliminary erection of a structural steel skeleton arrange-ment made of l-beams, followed by the placing of large slabs of concrete panels (which are pre-cast at a factory) between the beams.
  • the concrete panels are usually very large, in order to minimize the cost of construction, and hence resort must be made to the use of heavy equipment to transport the panels and to position the panels between the l-beams.
  • a second known technique involves the use of extremely large concrete forms, some large enough to complete major wall portions of a building structure.
  • One obvious disadvantage of this system is the requirement for heavy equipment for transporting and positioning the forms. After the forms are in position, moist concrete is poured or cast-in-place at the site of the building structure. Besides the disadvantage attendant with the weight and bulk of the forms, which necessitates heavy construction equipment and thereby increases the cost of construction, this technique has the disadvantage of only being capable of producing one type or design of building.
  • the roof structure was often constructed using standard techniques which employed many different building materials, such as wood, structural members, planking or sheathing, and a conventional roofing material.
  • Another known technique for forming cast-in-place masonry buildings was to employ a plurality of individual forms which are temporarily secured together to form two spaced wall members providing a form for casting concrete. Often these individual forms were made of heavy metal which necessitated the use of construction equipment, with the forms being so constructed that only one design or type of structure could be made. Furthermore, the forms were employed for making the walls of the building, after which conventional techniques were employed for completing the structure. In addition, the appearance of the resulting wall was frequently unacceptable because of the joint lines formed in the concrete, and hence finishing of the wall (e.g., plastering) was often added as an additional step of construction; hence, the cost of construction was increased by. the requirement for additional construction materials and skilled labor.
  • finishing of the wall e.g., plastering
  • Concrete is the most desirable construction material because it is the most inexpensive and readily available permanent building material, and it is fireproof, rotproof vermin-proof, earthquake-proof, and weatherproof. Furthermore, concrete may be poured or cast in place. Prior systems for concrete masonry structures often required heavy construction equipment, additional finishing processes, and, most importantly, do not result in a low-cost, complete masonry structure. More particularly, thousands of attempts have been made by giants of the construction industry to perfect a commercially acceptable built-in-place house of concrete, and a system to produce the house, including such names as Thomas A. Edison (see U.S. Pat. No. 1,123,266, which issued on Jan. 5, 1915), and many, many others. None of these systems were successful as to commercial success, for the following primary reasons:
  • the appearance of the built-in-place concrete house produced with the previous systems were unacceptable because of many ugly imperfections of the concrete.'ln order to cure these defects, further finishing operations were required, thereby increasing the cost of construction. Furthermore, the prior art systems were difficult to erect and were incomplete, and this further reduced the economy of the cast-in-place concrete house.
  • the system of the present invention has solved these problems by employing a concrete form which will economically produce beautiful designs and architectural results in the concrete. With the system of the present invention, no further finishing is required to the concrete surface.
  • the prior art systems required large forming surfaces which necessitated heavy, expensive machinery and were limited to a few plans or designs, etc.
  • the system of the present invention goes together like a huge erector set, with no sections larger than one man can handle.
  • the sections employed in the system of the present invention can be put together by unskilled men using mass production techniques.
  • the innovative hardware used in the system of the prevent invention renders the system simplicity itself.
  • the system of the present invention is the only system that solves all of the many problems of the erection of a complete built-in-place structure, and will produce an economical low-cost house. It is the only system that allows for adaptability to any plan, dimension and architectural style desired. This is quite remarkable, considering the many thousands of different plans, with openings of various sizes, intermediate floors of all sizes and requirements, roofs of various pitches and sizes, etc. All this is accomplished with a simple basic architectural form forming a basic module employed in the system of the present invention.
  • the system of the present invention also accommodates window and door openings, electrical work, plumbing work, and other service lines.
  • Another object of this invention is to provide a system for making a cast-in-place building structure that allows for adaptability to any plan, dimension, and archictectural style and design, including window and door openings of various sizes, multi-story building structures, intermediate floors of all sizes and requirements, a roof of various pitch, size and overhang structure, and including electrical and plumbing conduits embedded in the cast-in-place masonry wall structure.
  • Another object of the invention is to provide a system of making a cast-in-place masonry building structure which does not require the use of heavy construction equipment, in that all of the forms and hard ware used in the system may be easily handled by a single laborer.
  • a further object of the invention is to provide a system of making a cast-in-place masonry building structure in a minimum of time, and with a minimum amount of materials in order to insure an attractive and structurally sound building.
  • system of the present invention which employs a plurality of small (ranging from 2 X 2 inches through 24 X 24 inches) architectural forms, along with associated specifically developed hardware for temporarily securing the architectural forms together to define the foundation, wall and roof forms into which moist concrete material is cast-in-place.
  • the site on which the building is to be constructed is prepared by levelling and compacting, along with the temporary interconnection of an array of architectural forms (of a size which is easily handled by a single laborer) to define the foundation form.
  • the various service lines such as plumbing, electricity and gas are positioned within the foundation form, as well as the requisite structural reinforcing bars which extend within the plane of the foundation and the upstanding reinforcing bars which will subsequently be embedded within the wall structure.
  • Moist concrete is then poured into the foundation form and allowed to cure.
  • a group of architectural forms are temporarily secured together to define two spaced wall forms, including both interior and exterior walls, and including suitable openings for holding frames for windows and doors.
  • the spaced wall forms rest on the slab of the foundation, and are held in spaced relationship by a plurality of wall tie members extending between said wall forms.
  • the wall forms are constructed, and are interconnected, such that both sides of the resulting masonry walls are architecturally acceptable, without unsightly joint lines or concrete imperfections.
  • the various service lines are positioned between the wall forms prior to the pouring of moist concrete.
  • the architectural wall forms are removed, and a temporary arrangement of shoring members, designed for the system of the present invention, is placed within the building structure. If desired, specially designed roofsupporting brackets are secured to the wall ties on the exterior of the building for supporting overhanging portions of the roof form.
  • FIG. 1 is a partial perspective view of two architectural forms used in the system of the present invention, and shows the inside surfaces of the forms;
  • FIG. 2 is a perspective, partial sectional view of the foundation of the house made according to the system of the present invention, and shows the array of architectural forms used for defining the foundation;
  • FIG. 2A is a sectional view taken along line 2A-2A in FIG. 2;
  • FIG. 3 is a perspective view, partially in section, of the interior and exterior walls of the house made according to the system of the present invention, and shows the groups of architectural forms which are temporarily secured together to define the arrangement of two spaced wall forms;
  • FIGS. 3A through 3K are detailed views of the various pieces of specially developed hardware used in the system ofthe present invention.
  • FIG. 4 is an exploded perspective view ofa portion of the groups of architectural forms which are temporarily secured together to define the wall forms for use in the system of the present invention
  • FIG. 5 is a plan view of the outside portions of a group of architectural forms which are temporarily secured together to define one of the two spaced wall forms for use in the system of the present invention, and shows the openings in the wall form for a window and a door;
  • FIG. 5A is a sectional view taken along line 5A-5A in FIG. 5 and includes the interior wall forms;
  • FIG. 6 is a perspective view, partially in section, of a roof form for use in the system of the invention.
  • FIGS. 6A through 6H are detailed views of various pieces of specially developed hardware used in the system of the present invention.
  • FIGS. 7, 8, and 9 illustrate in sequence a modified embodiment of the system of the present invention in which a two-story building structure is formed.
  • FIG. 9A is a detailed view of a specially developed roof bracket used in the system of the present inventron.
  • FIG. 1 illustrates two architectural forms 10 and 10a which are of the type which may be used in the system of the present invention.
  • Forms 10 and 10a form the subject matter of U.S. Pat. No. 3,307,822 entitled CONCRETE WALL CONSTRUCTION FORM, which issued on May 7, 1967, to the inventor of the subject application, Robert K. Stout.
  • the invention will be described with respect to the architectural forms 10 and 10a, it is readily apparent that any type of masonry form capable of producing an architectural masonry structure may also be employed.
  • the use of forms as disclosed in the above-identified patent, as well as other concrete forms has been extremely limited in that, heretofore, the construction industry has lacked a system for building a complete structure. Hence, such forms have been primarily employed for building walls, fences and the like, after which conventional processes were employed for completing the structure.
  • the system of the present invention is the first system to employ the forms to completely construct a building structure.
  • Each architectural form, 10 and 10a is preferably constructed of cast aluminum, but magnesium or other lightweight metal or plastic can be used. These forms are preferably made in a wide variety of sections (square or rectangular) ranging from 2 X 2 inches to 24 X 24 inches, so as to facilitate handling by a laborer, and to allow for adaptability of the present system to any desired plan, dimension and architectural style of the resulting monolithic building structure. Of course, larger architectural forms may also be used when warranted in light of the resulting building structure.
  • Each architectural form comprises a relatively thin sheet 12 of metal which has the overall dimensions of the desired form.
  • Sheet 12 includes an outside surface 14 and an inside surface 16.
  • a flange 18 on the perimeter of sheet 12 extends outwardly from the inside surface 16 of sheet 12 and protrudes beyond the outside surface 14 at a right angle thereto.
  • a plurality of slot indentations 20 are imposed on the outside surface of flange l8 and these slot indentations are perpendicularly disposed with respect to the plane of sheet 12.
  • Holes 22 can extend through flange 18 in each one of the slot indentations 20 for a reason tov be seen hereafter.
  • Reinforcing bar members 24 project from the outside surface 14 of metal sheet 12 and have a thickness substantially equal to the width of flange 18, which extends around the periphery of sheet 12.
  • the function of the bar members 24 is to reinforce metal sheet 12 and this reinforcement could obviously assume several different patterns.
  • the inside surfaces of forms and 10a are substantially identical, and comprises an architectural brick arrangement formed by a plurality of elongated narrow bars 30 horizontally extending across the inside surface 16, and a plurality of non-continuous verticalbars 32 on the same surface to complete the brick pattern.
  • the vertical bars 32 adjacent the side edges of surface 16 have a width equal to only half that of the vertical bars 32.
  • the bars 30' at the top and bottom of surface 16 are half the width of the horizontal bars 30. It should also be noted that the bars 32 have been alternatively discontinued.
  • the area of the inside surface 16 between the bars 30 and 32 is shown to be rough and irregular, and is comprised of a plurality of small arcuate indentations and protruding portions of different sizes located in an irregular and non-symmetrical pattern.
  • the adjacent side edges of the forms 10 and 10a match and register with each other to better hide any seam between adjacent forms.
  • the indentations and protruding portions are substantially arcuate in shape to avoid any sharp lines or edges.
  • the vertical side edges of each form be identical so that when a plurality of such forms are aligned in side by side abutting relation, the adjacent vertical side edges of the forms will register with each other. The registration of adjacent side forms insures that the resulting concrete structure provides an architectural finish which will not necessitate further finishing processes.
  • each architectural form is formed in the flange l8 of each architectural form.
  • the architectural forms which are employed for forming the outer periphery of a surface such as the foundation and the roof do not include the slot indentations 20.
  • the latter are provided in an architectural form in order to accommodate a wall tie for maintaining the spacing between two spaced wall forms that are employed for forming the upstanding walls of a building structure.
  • such wall forms also include holes 23 for maintaining alignment and securing together adjacent architectural forms. Further details relative to the type of form used during the several steps of the subject system will be discussed hereinafter.
  • the first step in the system of the subject invention comprises the formation of the floor or foundation.
  • the site on which the masonry house is to be constructed is first levelled, after which the ground G is compacted, and a peripheral trench 40 is dug for defining the peripheral footing of the resulting floor structure.
  • interior trenches 40 may also be prepared for providing footings for the interior walls of the structure.
  • an array of architectural forms 10 are temporarily interconnected by means of suitable pin and wedge arrangements (to be described with reference to FIG. 3E hereinafter) and provided about the entire periphery of the floor area, with the array of architectural forms being fixed in place by means of stakes 42.
  • the various service conduits including electrical wiring (not shown) and plumbing lines 44 are placed within the confines of the floor area, as well as a network of reinforcing bars 46, the extent of which is determined by the desired structural characteristic of the resulting structure.
  • upstanding reinforcing bars 48 are provided about the periphery of the floor structure, as well as within the interior of the floor structure corresponding to the location of the interior walls.
  • moist concrete 50 is poured and levelled within the confines of the foundation forms, and it is suggested that a V-groove 52 be provided about the periphery of the floor spaced from the form to cooperate with the upstanding walls to define a moisture joint or barrier for the resulting house structure.
  • the foundation forms may be removed, preparatory to the erecting of the wall forms.
  • the next step in the system of the present invention is the erection of the wall forms which are mounted on the concrete floor, preferably spaced within an inch or two of the outer periphery of the floor area.
  • the architectural for ms employed for forming the wall form are of the type which include the slot indentations 20 in order to receive wall ties that function to maintain the proper spacing between the interior and exterior wall forms as described hereinafter.
  • this step in the system of the subject invention involves the formation of a continuous arrangement of two-spaced concrete wall forms by the temporary interconnection of a group of architectural forms, with the arrangement defining the upstanding exterior and interior walls of the house.
  • the wall forms are defined by an interior group of wall forms and an exterior group 62 of wall forms, with the inside surfaces 16 of the forms facing toward the area where the concrete is to be poured.
  • the resulting wall structure as shown at the top of FIG. 3, is architecturally finished both on the exterior surface thereof and the interior surface thereof.
  • the arrangement of the wall forms 60 and 62 is continuous to include, besides the outer peripheral wall of the house, an interior wall, designated by numeral 64, and an extension of the house, generally designated by numeral 66. In interconnecting the various wall forms, openings are left for the windows 68 anddoors, one of which is shown at 70.
  • FIG. 3A illustrates in detail the interconnection between two adjacent architectural panels 10 and 10a.
  • fastening means including a pin 76 (see detail FIG. 3E) having a slot 77 and cooperating wedge 78 (see detail FIG. 3F) are employed.
  • Extending between the interior 60 and exterior 62 wall forms are a plurality of wall ties 74 (see detail FIG. 36).
  • a wall tie 74 is positioned within the aligned slot indentations 20 in the respective panels, after which the pin 76 is positioned within the aligned holes 22 and the hole 75 in the wall tie 74, and the wedge 78 is then positioned within the slot 77 of pin 76.
  • Additional pins 80 are then passed through the aligned holes 23 in order to insure proper alignment between the adjacent forms.
  • additional pins are provided between the adjacent forms disposed above and below said panels and 10a. If desired, the additional pins may be in the form of nuts and bolts.
  • FIG. 3B a modified form of temporary interconnecting fastening means is illustrated for those instances wherein a smaller architectural form 10b is to be provided between forms 10 and 10a.
  • Form 10b is generally similar to forms 10 and 10a, and includes slot indentations 20.
  • a fastener comprising an elongated pin 90 which is slotted as at 92, 92 at its opposite ends, and a pair of wedges 94 and 94 are employed.
  • Pin 90 is long enough to extend through the two abutting slot indentations of the adjacent panels, so that a single temporary fastening means is employed for securing the three panels together.
  • suitable wall ties 74 are employed, as well as aligning pins 80.
  • FIG. 3C illustrates in detail a device employed in the system of the present invention in order to insure the alignment of the wall forms.
  • a Z- shaped member 100 is provided with suitable apertures for cooperating with the rib reinforcing portions 24 of the architectural forms so as to define a bracket for holding a straight-edge, such as a 4 X 4 inch wood member.
  • a plurality of U- shaped members 100 are fixed to the upper panels on the exterior wall form 62, and a straight-edge 102 is slipped into the members 100, and is effective to maintain the alignment of the wall member during the concrete pouring operation.
  • a similar arrangement may be provided on the interior wall form 60.
  • the U- shaped member may be secured to the architectural forms by temporary fastening means of the type illustrated in FIG. 3A.
  • the U-shaped members may be secured to the architectural forms by a quick clamp 104 of the type illustrated in FIG. 3I.
  • the quick clamp 104 comprises a U-shaped member having an upstanding pin 106 for passage through the associated form, with one leg 108 of the quick clamp 104 being inclined relative to the other leg I10 whereby, after the pin I06 is inserted through a hole in the form, the quick clamp is rotated about the pin 106 and the relative incline between surfaces 108 and 110 results in a wedging action thereby securely holding the abutting form members together.
  • the quick clamp 106 may also be employed for maintaining adjacent architectural forms together.
  • each corner brace 114 includes a turnbuckle 116 terminating in opposed pins 118 which are adapted to fit within the holes 23 in adjacent architectural forms.
  • the window frames and door jambs are temporarily connected to the wall forms for use as part of the form structure preparatory to the pouring of concrete.
  • the window and door frames are held to the architectural forms by means of specially designed whaler clamps, designated by the numeral 120, one of which is illustrated in detail in FIG. 3H.
  • the whaler clamp 120 is generally U-shaped in configuration, and includes a pin 122 adapted to fit within a hole 23 in the associated architectural form.
  • the opposite leg portion of the whaler clamp is inclined so as to frictionally grip the opposite architectural form.
  • FIG. 3J illustrates a scaffold bracket which may be secured to the wall forms 60, 62 for providing sup- I port for scaffold 132.
  • the scaffold bracket 130 includes a U-shaped edge portion 134 which attaches to one of the architectural forms, with the lower end 136 of the scaffold bracket 130 resting against a lower portion of the form.
  • FIG. 4 illustrates an exploded view of the various architectural forms which are temporarily assembled in order to form the interior and exterior wall forms 60 and 62.
  • the architecturally finished or inside surfaces 16 of the forms are in facing relationship whereby both the interior and exterior surfaces of the resulting wall structure are architecturally finished, and do not require additional finishing processes.
  • FIG. 4 also illustrates an exterior angle bracket 140 which is employed at the junction of the exterior wall forms 62. Angle bracket 140 is provided with'a plurality of holes 142 corresponding to the holes 22 and 23 in the adjacent architectural forms.
  • FIG. 4 illustrates the various different sized architectural forms which may be employed for forming the wall forms 60, 62.
  • FIGS. 5 and 5A illustrate an assembled wall form, including openings for a door and window.
  • the arrangement of the architectural forms as shown in FIGS. 3-5 provides a continuous arrangement of two-spaced concrete wall forms which are formed by the temporary interconnection of a plurality of architectural forms.
  • the arrangement defines the upstanding exterior and interior walls of the house, with spaced walls being interconnected by a plurality of wall ties. Since the wall forms are formed by interconnecting a plurality of relatively small architectural forms, it is readily apparent that heavy construction equipment is not required to reach this stage of the system of the present invention, nor is it required in order to complete the masonry building structure.
  • greatly facilitates the erection of the wall forms, as well as facilitating the removal of the wall forms upon completion of the formation of the walls.
  • Moist or uncured concrete is poured in the space defined between the two-spaced concrete wall forms 60 and 62, and allowed to cure.
  • the concrete may be poured to a point level with the upper edge of the wall forms, in which case a flat roof would be obtained, or alternatively, the uncured concrete may be poured and finished in a manner so as to be inclined from one end of the house to the other, in which case an inclined roof structure may then be constructed.
  • the architectural forms are removed, and the wall ties 74 may also be removed, with the resulting holes left by the wall ties being filled with a suitable caulking compound.
  • 3K illustrates an alternate form of wall tie wherein the tie 134 is tapered both in width and along its length thereby enabling its easy removal from the cured concrete wall. It should be understood that certain of the wall ties may be maintained in place and employed during the construction of the roof structure during the final step of the system of the present invention. Also, the wall ties may be constructed to include lines of weakened areas so that those portions of the tie extending beyond the resulting wall may be readily snapped off, thereby leaving the bulk of the tie within the wall for structural purposes.
  • a temporary arrangement of shoring members is constructed within the enclosure defined by the exterior walls. This may be accomplished through the use of a plurality of jacks 150, one of which is shown in detail in FIG. 6A.
  • Jack 150 is of the variable length type, and its upperend is suitably configured to accept a jack head 152, shown in detail in FIG. 6B.
  • the upper end of the jack head 152 includes a U-shape member having a pair of aligned holes 152', and a pivot top 154 (See FIG.
  • Pivot top 154 comprises a generally elongated U-shape member designed to accommodate an elongated structural beam member 156.
  • a plurality of jacks are aligned along two walls of the structure, with each aligned arrangement ofjacks accommodating two parallel structural beam members 156.
  • Extending between and transverse to the longitudinal axis of the generally parallel structural beam members 156 are a plurality of telescoping support beams 160.
  • each telescoping beam 160 includes on the opposite ends thereof flanges 162 adapted to rest on the respective beams 156, 156.
  • the combination of the jacks, the structural members 156, and the arrangement of telescoping beams 160 provides a temporary structure for supporting a plurality of interconnected architectural forms 10.
  • the latter are shown in FIG. 6 as being of the smooth type, whereby the interior surface of the resulting roof will be smooth.
  • the overhang brace illustrated in FIG. 6E is of the variable angle type, and is generally designated by numeral 170, and includes a support leg 172 which includes apertures for connection to wall ties extending in the wall portion of the masonry wall. Secured to the upper end of the support leg 172 is a fixed arm 174, having pivotally connected at its outer end thereof a second arm 176. Arm 176 may be inclined relative to fixed arm 174 by means of a threaded screw arrangement 178, whereby the variable angle overhang brace may be adjusted to any desired pitch of the roof.
  • FIG. 6F illustrates a second form of overhang brace which is of the fixed type, and is designated by numeral 180.
  • Fixed overhang brace 180 comprises a support leg 182, to which is fixed an arm 184 disposed at a right angle to the leg 182, and an angle support leg 186.
  • overhang braces 180 of the fixed type illustrated in FIG. 6F would be used along the left side of the house, while variable angle overhang braces 170 would be employed along the front edge, or pitched surface of the roof.
  • the edge of the roof form is defined by means of roof edge supports illustrated in FIGS. 66 and 6H.
  • the roof edge supports are secured to the flanges of the architectural forms disposed about the periphery of the roof form.
  • Roof edge support illustrated in FIG. 66 provides an arrangement wherein the upstanding surface 200 of the roof form is mounted flush with the architectural roof form, whereas roof support bracket 192 illustrated in FIG. 6H includes a stepped portion, which enables the upstanding surface 200 to be stepped in with respect to the edge of the roof.
  • the roof form is supported by the temporary arrangement of shoring members within the enclosure, and by the various overhang braces in a manner whereby a portion of the upstanding wall projects above the plane of the architectural roof forms.
  • FIGS. 7-9 illustrate a system for constructing a twostory house.
  • the steps involved in forming the foundation or floor and the walls, as well as the roof as described with reference to FIGS. l-6 are identical, except that, as shown in FIG. 7, the uppermost architectural form 10 is left in place and is employed during the formation of the second floor as the outer peripheral edge thereof.
  • the wall forms for forming the second story of the building structure are assembled, as shown in FIG. 8.
  • a bracing member 202 be provided at this time preparatory to the formation of the walls of the second story.
  • the roof is constructed in a generally. similar manner to that illustrated with reference to FIG. 6. This is shown in FIG. 9, with FIG. 9A illustrating in detail the variable angle overhang brace used for supporting the roof form.
  • the present invention provides a system for making a commercial acceptable built-in-place building structure of concrete.
  • the system of the present invention produces a finished result on both surfaces of the wall. This is due to the pattern which is an integral part of the architectural form. This feature is essential, as no further finishing is required on the wall surface. This is necessary to the overall economy of cast-in-place concrete structures.
  • the architectural forms employed in the present system go together like a giant erector set, with a simple pin and wedge fastener. This results in very significant savings in labor costs.
  • the present system is so simple that unskilled men can accomplish the same results as skilled brick layers and other craftsmen.
  • the system of the present invention is the only forming system which is completely designed to produce a castin-place house or other structures.
  • An architectural result in the concrete is absolutely essential to an acceptable cast-in-place concrete house.
  • special climatic conditions require special techniques and methods of construction. Therefore, people have rejected the cast-in-place concrete house, not only for an attractive appearance, but because they consider concrete to be cold, or that it retains heat, etc.
  • the system of the present invention is a complete system which has taken this into consideration and it has solved these problems.
  • One innovative method of providing comfort and insulated properties to the concrete is by incorporating special chemicals in the concrete which produce dead air spaces which provide insulation properties.
  • the system of the present invention may be employed for the construction of multi-story buildings, and allows for adaptability to any plan, dimension, and architectural style design. While the invention has been described in connection with several preferred procedures, it will be understood that it is not intended to limit the invention to those procedures. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
  • a method for making a cast-in-place concrete structure comprising the separate and sequential steps of:
  • said arrangement of wall forms defining the upstanding exterior and interior walls of the said concrete structure
  • a roof form by temporarily inter-connecting a plurality of architectural forms, and supporting said roof form on said arrangement of shoring members and said brackets, with the peripheral edge of said roof form being defined by a continuous upstanding member;
  • a method for making a cost-in-place concrete structure as in claim 1 wherein the step in forming the upstanding exterior and interior walls of the concrete structure includes placing and curing uncured concrete in the two-spaced concrete forms at an inclined angle from one end of the structure to the opposite end thereof in order to enable the roof to be formed at a desired pitch.
  • a method for making a cast-in-place concrete structure as in claim 1 wherein the step of forming a continuous arrangement of two-spaced concrete wall forms comprises constructing the wall forms to include openings for receiving the frames of doors and windows in the concrete structure, with the periphery of said openings being closed by cooperation of the wall forms and the window and door frames, said window and door frames being temporarily secured to the wall forms by Whaler brackets.
  • a method for making a cast-in-place concrete structure as in claim 1 including the additional step of securing straightening members to the two-spaced concrete wall forms prior to the pouring of moist concrete material therein.
  • first floor form of the concrete removing said temporary arrangement of shoring members and said floor form; along with the series of architectural forms defining the peripheral edge of said first floor;
  • securing overhang brackets to the upper wall form ties externally of the exterior walls of said second story in order to provide a temporary support for a roof form to enable the latter to extend beyond the peripheral edges of said upstanding exterior walls of said second stor and in. forming a roof form by temporarily lll erconnecting a plurality of architectural forms, and supporting said roof form on said arrangement of shoring members and said overhang brackets,
  • forming the roof of the multi-story concrete structure by pouring uncured concrete into confines of said roof form and allowing said concrete to cure; and v removing the first and second continuous arrangement of concrete wall forms, the temporary arrangement of the shoring members, the upper wall ties, the overhang brackets, and said roof form.
  • a method for making a cast-in-place concrete structure as in claim 5 wherein in the steps in forming the continuous arrangement of two-spaced concrete wall forms for the first and second story walls, leaving openings for receiving the frames of doors and windows in the concrete structure, with the periphery of said openings being closed by cooperation of the wall forms and the window and door frames, said window and door frames being temporarily secured to the wall forms by whaler brackets.
  • a method for making a multi-story cast-in-place concrete structure as in claim 5 comprising the further steps of repeating steps (f) through (m) prior to the steps of constructing the roof form and forming the roof of the-concrete structure in order to form additional stories for the concrete structure.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Forms Removed On Construction Sites Or Auxiliary Members Thereof (AREA)
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US00176891A 1971-09-01 1971-09-01 Method for making cast-in-place concrete structures Expired - Lifetime US3728838A (en)

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JP (1) JPS4835634A (xx)
AU (1) AU474681B2 (xx)
BR (1) BR7204791D0 (xx)
CA (1) CA966684A (xx)
CY (1) CY841A (xx)
DE (1) DE2241589A1 (xx)
ES (1) ES406103A1 (xx)
FR (1) FR2150946B1 (xx)
GB (1) GB1390059A (xx)
HK (1) HK55676A (xx)
IL (1) IL38501A (xx)
KE (1) KE2618A (xx)
MY (1) MY7600121A (xx)
NL (1) NL7211431A (xx)
OA (1) OA04165A (xx)
TR (1) TR17420A (xx)
ZA (1) ZA725784B (xx)
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US3817006A (en) * 1972-10-27 1974-06-18 Bracing Syst Inc Apparatus for supporting masonry walls against wind damage during construction
US5039059A (en) * 1989-05-08 1991-08-13 Symons Corporation Waler bracket for concrete forming structure
US6065254A (en) * 1999-03-19 2000-05-23 Lanka; Richard Adjustable, foldable support brace
WO2002018119A2 (en) * 2000-09-01 2002-03-07 Yoder Sheldon V Dynamic flexible extruding building method and apparatus and construction material used therewith
US6539677B1 (en) 2001-05-18 2003-04-01 Richard I. Lanka Form brace with adjustable face
US7070158B1 (en) * 2003-09-26 2006-07-04 Usa Form, Inc. Support system for concrete column formwork and related bracket
CN102995892A (zh) * 2011-09-09 2013-03-27 卢明德 现浇式墙体模具
CN106351440A (zh) * 2016-10-25 2017-01-25 山东莱钢建设有限公司 一种钢板约束混凝土剪力墙及其钢模板
CN106555474A (zh) * 2015-09-30 2017-04-05 李宜君 凹字型建筑物模板组施工方法
CN106555473A (zh) * 2015-09-30 2017-04-05 李宜君 凹字型楼层成型装置的胶条式缩放结构
CN106555471A (zh) * 2015-09-30 2017-04-05 李宜君 凹字型楼层成型装置的外墙模具组设构造
CN106555475A (zh) * 2015-09-30 2017-04-05 李宜君 凹字型建筑物施工方法
CN106555479A (zh) * 2015-09-30 2017-04-05 李宜君 凹字型楼层成型装置的吊装设备
CN106555472A (zh) * 2015-09-30 2017-04-05 李宜君 凹字型楼层成型装置的胶覆式缩放结构
US20190040619A1 (en) * 2017-08-01 2019-02-07 SkyStone Group LLC Modular assemblies and methods of construction thereof
US11066824B2 (en) 2018-03-27 2021-07-20 Ccs Contractor Equipment & Supply, Llc Ground anchor bracket with simulated slab support for concrete wall braces
CN113266151A (zh) * 2021-05-25 2021-08-17 玉溪市明瑞建设工程有限公司 一种房屋建筑整体浇注一次成型施工工艺

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WO2017129832A1 (es) * 2016-01-29 2017-08-03 Simplicity Works Europe, S.L. Sistema de construcción de edificaciones

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US3461639A (en) * 1967-05-09 1969-08-19 Ronald Earl Merrill Foundation wall construction and method of constructing same
US3490729A (en) * 1967-04-07 1970-01-20 Dillin & Luce Form assembly for molding monolithic concrete building
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US929470A (en) * 1909-01-25 1909-07-27 Roy N Neil Concrete-mold.
US1129144A (en) * 1912-01-31 1915-02-23 Blaw Collapsible Steel Ct Ing Company Mold.
US1229365A (en) * 1913-07-21 1917-06-12 Cris W Wiegand Structural fastener.
US1579822A (en) * 1923-03-23 1926-04-06 Arthur K Knickerbocker Toy
US1828876A (en) * 1929-03-13 1931-10-27 Daniel R Cohen Electric conduit securing device
US2157992A (en) * 1936-12-16 1939-05-09 Leonard C Smith Building block and assembly thereof
US2523131A (en) * 1947-12-01 1950-09-19 Clifford M Martin Form for molding concrete walls
AT189778B (de) * 1955-06-25 1957-05-10 Katzenberger Tech Buero Fuer N Verfahren zur Herstellung von Bauwerken aus Stahlbetonfertigteilsäulen
FR1215354A (fr) * 1958-11-21 1960-04-19 Supports de coffrages pour hourdis et ceintures en béton armé
US3072996A (en) * 1959-09-04 1963-01-15 Gerald E Mcguire Roof structure form employing radial cables
US3307822A (en) * 1963-01-07 1967-03-07 Internat Concrete Systems Comp Concrete wall construction form
US3405903A (en) * 1966-09-21 1968-10-15 Futura Roofs Inc Form structure for roof slab and truss
US3490729A (en) * 1967-04-07 1970-01-20 Dillin & Luce Form assembly for molding monolithic concrete building
US3461639A (en) * 1967-05-09 1969-08-19 Ronald Earl Merrill Foundation wall construction and method of constructing same
US3614051A (en) * 1969-12-15 1971-10-19 Precise Forms Inc Ledger form for concrete structures

Cited By (26)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3817006A (en) * 1972-10-27 1974-06-18 Bracing Syst Inc Apparatus for supporting masonry walls against wind damage during construction
US5039059A (en) * 1989-05-08 1991-08-13 Symons Corporation Waler bracket for concrete forming structure
US6065254A (en) * 1999-03-19 2000-05-23 Lanka; Richard Adjustable, foldable support brace
WO2002018119A2 (en) * 2000-09-01 2002-03-07 Yoder Sheldon V Dynamic flexible extruding building method and apparatus and construction material used therewith
WO2002018119A3 (en) * 2000-09-01 2002-06-13 Sheldon V Yoder Dynamic flexible extruding building method and apparatus and construction material used therewith
US6539677B1 (en) 2001-05-18 2003-04-01 Richard I. Lanka Form brace with adjustable face
US7070158B1 (en) * 2003-09-26 2006-07-04 Usa Form, Inc. Support system for concrete column formwork and related bracket
CN102995892A (zh) * 2011-09-09 2013-03-27 卢明德 现浇式墙体模具
CN102995892B (zh) * 2011-09-09 2015-04-01 卢明德 现浇式墙体模具
CN106555471A (zh) * 2015-09-30 2017-04-05 李宜君 凹字型楼层成型装置的外墙模具组设构造
CN106555474B (zh) * 2015-09-30 2018-11-20 李宜君 凹字型建筑物模板组施工方法
CN106555473A (zh) * 2015-09-30 2017-04-05 李宜君 凹字型楼层成型装置的胶条式缩放结构
CN106555479B (zh) * 2015-09-30 2019-12-24 李宜君 凹字型楼层成型装置的吊装设备
CN106555475A (zh) * 2015-09-30 2017-04-05 李宜君 凹字型建筑物施工方法
CN106555479A (zh) * 2015-09-30 2017-04-05 李宜君 凹字型楼层成型装置的吊装设备
CN106555472A (zh) * 2015-09-30 2017-04-05 李宜君 凹字型楼层成型装置的胶覆式缩放结构
CN106555472B (zh) * 2015-09-30 2018-11-20 李宜君 凹字型楼层成型装置的胶覆式缩放结构
CN106555473B (zh) * 2015-09-30 2018-11-20 李宜君 凹字型楼层成型装置的胶条式缩放结构
CN106555474A (zh) * 2015-09-30 2017-04-05 李宜君 凹字型建筑物模板组施工方法
CN106555471B (zh) * 2015-09-30 2018-11-20 李宜君 凹字型楼层成型装置的外墙模具组设构造
CN106555475B (zh) * 2015-09-30 2019-03-01 李宜君 凹字型建筑物施工方法
CN106351440A (zh) * 2016-10-25 2017-01-25 山东莱钢建设有限公司 一种钢板约束混凝土剪力墙及其钢模板
US20190040619A1 (en) * 2017-08-01 2019-02-07 SkyStone Group LLC Modular assemblies and methods of construction thereof
US10538907B2 (en) * 2017-08-01 2020-01-21 SkyStone Group LLC Modular assemblies and methods of construction thereof
US11066824B2 (en) 2018-03-27 2021-07-20 Ccs Contractor Equipment & Supply, Llc Ground anchor bracket with simulated slab support for concrete wall braces
CN113266151A (zh) * 2021-05-25 2021-08-17 玉溪市明瑞建设工程有限公司 一种房屋建筑整体浇注一次成型施工工艺

Also Published As

Publication number Publication date
ZA725784B (en) 1973-07-25
IL38501A0 (en) 1972-03-28
CA966684A (en) 1975-04-29
CY841A (en) 1976-09-10
FR2150946B1 (xx) 1975-01-03
OA04165A (fr) 1979-12-15
MY7600121A (en) 1976-12-31
DE2241589A1 (de) 1973-03-15
TR17420A (tr) 1975-07-23
IL38501A (en) 1975-03-13
KE2618A (en) 1976-04-30
AU4613472A (en) 1974-03-07
AU474681B2 (en) 1976-07-29
NL7211431A (xx) 1973-03-05
BR7204791D0 (pt) 1973-07-12
ES406103A1 (es) 1976-01-16
ZM14372A1 (en) 1975-10-21
JPS4835634A (xx) 1973-05-25
GB1390059A (en) 1975-04-09
HK55676A (en) 1976-09-17
FR2150946A1 (xx) 1973-04-13

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