US3827208A

US3827208A - Finishing method

Info

Publication number: US3827208A
Application number: US00264013A
Authority: US
Inventors: J Elliott
Original assignee: Individual
Current assignee: Individual
Priority date: 1972-06-19
Filing date: 1972-06-19
Publication date: 1974-08-06
Anticipated expiration: 1991-08-06

Abstract

A finishing plug is pre-cast from a mixture of Portland cement, sand, and water and is shaped similarly to plastic cones of the type used to position wall forms during the construction of concrete walls. The finishing plug has a flat end surface and is mounted in a hole remaining in a concrete wall following the removal of a plastic cone from the wall with the end surface of the plug flush with the wall surface. This is preferably accomplished by first coating the finishing plug with a liquid cementuous material and then inserting the plug into the hole. The finishing plug is shorter than the plastic cone so as to accommodate a tie rod portion which may project into the hole.

Description

llnited States Patent 1191 ElllOtt Aug. 6, 1974 FINISHING METHOD Primary Examiner-Price C. Faw, Jr. [76] Inventor: James Madison Elliott, 3509 Attorney Agent or F'rm R'chardS Hams &

Matador, Garland, Tex. 75042 Medlock [22] Filed: June 19, 1972 57 ABSTRACT [2]] Appl. No.: 264,013 A. finishing plug is pre-cast from a mixture of Portland cement, sand, and water and is shaped similarly to plastic cones of the type used to position wall forms 3 gd g g gg during the construction of concrete walls. The finish- [58] Field of Search 52/741, 744, 127; 156/71, mg Plug h a l end Surface and l 3 156/293 hole remammgnn a concrete wall following the removal of a plastic cone from the wall with the end surface of the plug flush with the wall surface. This is [56] References Cited preferably accomphshed by first coating the finishing UNITED STATES PATENTS plug with a liquid cementuous material and then in- 2,728,l27 l2/l955 Armstrong 52/127 erting the into the hole The finishing plug is g; g z

shorter than the plastic cone so as to accommodate a n erson 3,724,060 4/1973 McElroy 52/741 x rod porno whlch my project "n the holej 10 Claims, 4 Drawing Figures o O 5 2- l v a v o a 0 w u a l/ 1 FINISHING METHOD BACKGROUND AND SUMMARY OF THE INVENTION This invention relates to finishing plugs, and more particularly to a method of and apparatus for forming flush wall surfaces on concrete walls.

It is common practice in the construction industry to maintain a predetermined spaced relationship between opposed wall forms by means of tie rod assemblies. These assemblies comprise steel tie rods having opposed shoulders and weakened sections adjacent the shoulders. A pair of rigid plastic cones are mounted on each tie rod on opposite sides of the shoulders.

In use, tie rod assemblies are installed between opposed wall forms and include portions projecting through the forms. Wedging apparatus is then positioned between the projecting ends of the tie rods and the wall forms and is utilized to force the wall forms inwardly. This causes the wall forms to engage the plastic cones and the plastic cones to engage the shoulders on the tie rods. By this means there is formed a very rigid assembly characterized by the desired spaced relationship between the opposed wall forms.

After all of the tie rod assemblies have been installed between a pair of opposed wall forms, concrete is poured into the space between the forms. The concrete is allowed to set whereby a concrete wall is formed between the forms. The Wedging apparatus and the wall forms are then removed and are retained for subsequent utilization.

After the forms have been removed, the projecting ends of the tie rod assemblies are broken away. This is easily accomplished by simply twisting the projecting ends of each tie rod, whereby the tie rod snaps at its weakened sections. The projecting ends and the plastic cones are then pulled out of the wall and are discarded. At this point the wall comprises opposed wall surfaces which are substantially flat but which have holes in them corresponding in size and shape to the plastic cones of the tie rod assemblies.

Heretofore it has been the practice to fill the holes remaining in the concrete wall following the removal of plastic cones from the wall with a concrete mixture. There are several disadvantages to this procedure. Thus, union regulations require that the holes be filled by a relatively highly paid laborer known as a finisher". It may also be necessary to employ an additional laborer merely to keep the concrete mixture at the proper consistency. The net result is that the costs in volved in filling holes in concrete walls by this procedure are relatively high.

Another disadvantage to the present procedure is that due to shrinkage, each hole must be filled twice. That is, each hole is initially filled with the concrete mixture which is then allowed to set. As the concrete sets a dimple is formed which must subsequently be filled in order to provide a completely flush wall surface. The necessity of filling each hole twice causes the work of filling the holes to proceed quite slowly. By way of example, a finisher/ laborer team is typically able to finish an average of only about twenty holes per hour.

The present invention comprises an improved method of and apparatus for filling holes resulting in concrete walls from the removal of the plastic cones therefrom. In accordance with the broader aspects of the invention, there is provided precast concrete finishing plugs which are similar in shape to the plastic cones. Following removal of the plastic cones from the wall the finishing plugs are mounted in the holes, whereby the holes are filled and a flush wall surface is formed.

In accordance with more specific aspects of the invention, the finishing plugs are identical in shape to the outer portions of the plastic cones, but are substantially shorter than the plastic cones. By this means there is provided a void space at the inner end of each hole in the wall which accommodates any portion of the tie rod assembly that may project into the hole. The plugs are preferably installed by first coating the plugs with a liq uid cementuous material and then tapping the plugs into the holes in the wall. After the liquid cementuous mixture sets, the plugs are permanently retained.

DESCRIPTION OF THE DRAWINGS A more complete understanding of the invention may be had by referring to the following detailed description when taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is an illustration of a wall form assembly which is utilized prior to the present invention to construct a concrete wall;

FIG. 2 is an illustration of a concrete wall constructed by a means of the wall form assembly shown in FIG. 1;

FIG. 3 is a perspective view of a finishing plug incorporating the present invention; and

FIG. 4 is an illustration of the results obtained by means of the invention.

DETAILED DESCRIPTION Referring now to the drawings and particularly to FIG. 1, there is shown a wall form assembly 10 which is utilized prior to the present invention to construct a concrete wall. The wall form assembly 10 includes a plurality of tie rod assemblies 12 each comprising an elongate central portion 14 and a pair of end portions 16. The central portion 14 is provided with opposed shoulders 18 and the end portions 16 are connected to the central portion 14 at weakened sections 20 located adjacent the shoulders 18. The end portions 16 extend to heads 22 comprising the opposite ends of the tie rod assembly 12.

Each tie rod assembly 12 further includes a pair of rigid cones 24 which are slidably received on the end portions 16 on the opposite sides of the shoulders 18. The cones 24 are typically formed from plastic and have the cross-section illustrated in FIG. 1. However, it will be understood that the cones 24 may comprise other cross-sections and may be formed from materials other than plastic, if desired.

In addition to the tie rod assemblies 12, the wall form assembly 10 includes opposed wall forms 26. The forms 26 are typically formed from wood or steel and are provided with spaced apertures 28. The diameters of the apertures 28 are such that the heads 22 of the tie rod assemblies 12 pass through the apertures 28 but the cones 24 do not.

In the use of the wall form assembly 10, the wall forms 26 are erected in spaced relation and the tie rods assemblies 12 are mounted between the forms 26 with the end portions 16 projecting through the apertures 28. A pair of wooden blocks 30 are then positioned adjacent each aperture 28 and a wedge 32 is engaged with each end portion 16 of each tie rod assembly 12. Each wedge 32 comprises a keyhole shaped slot 34 including a large diameter portion 36 which receives the head 22 at one end of a tie rod assembly 12 and a narrow portion 38 extending angularly outwardly from the large diameter portion 36.

After the wedges 32 are engaged with the tie rod assemblies 12 they are driven downwardly (FIG. 1). This applies an outwardly directed force to the tie rod assemblies l2 and an inwardly directed force to the blocks 30 and the wall forms 26. By this means the wall forms 26 are urged into engagement with the rigid cones 24, and the cones 24 are urged into engagement with the shoulders 18. Thus, when all the wedges 32 of the wall form assembly have been fully seated the component parts of the wall form assembly 10 comprise a rigid structure which functions to maintain the wall forms 26 in the desired spaced relationship.

Upon completion of the foregoing procedure concrete is poured into the space between the wall forms 26. The concrete is allowed to set, whereupon the wedges 32, the wooden blocks 30 and the wall forms 26 are removed and are retained for subsequent use. The end portions 16 and rigid cones 24 of the tie rod assemblies 12 are then removed by twisting the end portions 16 to break the tie rod assemblies 12 at the weakened sections 20 and then pulling both the end portions 16 and the rigid cones 24 out of the concrete wall.

Referring now to FIG. 2, the result of the foregoing steps is a concrete wall 40. The wall 40 comprises opposed wall surfaces 42 having conical holes 44 formed in them. The holes 44 in the wall 40 correspond in size and shape to the rigid cones 24 of the tie rod assemblies 12. lt will be noted, however, that ends of the central portions 14 of the tie rod assemblies 12 may extend into the holes 44.

In many instances the holes 44 in the wall 40 do not present a problem. Thus, if a particular wall surface 42 will be unexposed, or if a wall surface 42 will be covered with bricks, paneling, etc., the holes 44 in the wall surface are simply left unfilled. On the other hand, if a particular wall surface 42 will be painted or will be covered with wallpaper or the like, the wall surface must be completely flush. Heretofore this has been accomplished by filling the holes 44 in the wall surface 42 with a wet concrete mixture.

The use of wet concrete to fill holes in a concrete wall is disadvantageous for a number of reasons. First, the concrete must be hand packed into the holes by a relatively highly paid laborer known as a finisher. Second, it is necessary to employ a second laborer merely to maintain the concrete mixture at the proper consistency. Third, due to shrinkage the initial quantity of concrete in each hole 44 forms a dimpled outer surface of the type illustrated in FIG. 2 by the dashed line 46. It is therefore necessary to refill each hole with additional concrete in order to provide a completely flush wall surface.

Because of the foregoing factures, the average rate at which holes in concrete walls can be filled by each finisher/laborer team is about 20 holes per hour. Due to the wages that must be paid to the finisher and to the laborer, the resulting cost of filling each hole is more than $1. It will therefore be appreciated that in a case of a typical concrete wall, the cost of filling the holes in the wall adds materially to the overall cost of finishing the wall.

Referring now to FIG. 3, there is shown a finishing plug 50 comprising the present invention. The plug 50 is precast from a mixture of Portland cement, sand and water and is substantially identical in shape to the rigid cones 24 of the tie rod assemblies 12 that were used in forming the concrete wall 40. More particularly, the finishing plugs 50 are identical in size and shape to the outer portions of the holes 44 in the wall 40, but are substantially shorter than the holes so as to accommodate the ends of the central portions 14 of the tie rod assemblies 12 which may extend into the holes. Each finishing plug 50 comprises a flat, circular end surface 52 which is identical in diameter to the diameter of the holes 44 at the wall surface 42.

In the practice of the invention, the finishing plugs 50 of the type shown in FIG. 3 are manufactured at a facility remote from the construction site and are thereafter transported to the construction site in bulk. Prior to installation the finishing plugs 50 may be pre-soaked in water, if desired. Also prior to installation there is prepared a liquid cementuous material comprising one pint Grace Darweld C or equivalent, about one quart water depending on temperature, and one gallon Portland cement. The resulting mixture is stirred to the consistency of paint, whereupon 50 to finishing plugs 50 are placed in the material. The finishing plugs 50 are then placed in the holes 44 of the concrete wall 40 and are tapped into the holes until the end surfaces 52 of the finishing plugs 50 are flush with the wall surface 42 of the wall 40. The liquid cementuous material is then allowed to set, whereupon there is provided a completely flush wall surface.

The results of the use of the invention are illustrated in FIG. 4. Each finishing plug 50 is snugly engaged with the interior of its corresponding hole 44 in the wall 40, and the end surface 52 of each plug 50 extends flush with the wall surface 42 of the wall 40. However, the innermost portion of the hole 44 is left open so as to accommodate the end of the central portion 14 of the tie rod assembly 12 which may project into the hole 44. The open interior of the hole 44 also creates a partial vacuum which tends to retain the finishing plug 50 in the hole 44 until the liquid cementuous material is set.

When finishing plugs 50 have been installed in all of the holes 44 in a particular wall surface 42 and the liquid cementuous material that was utilized in installing the finishing plugs has set, the wall surface 42 is sanded. It has been found that following sanding it is impossible to distinguish the portions of the wall surface 42 comprising the end surfaces 52 of the finishing plugs 50 from the remainder of the wall surface. On completion of the sanding operation, the wall surface is ready for further finishing, such as the application of wall paper, painting, or the like.

The use of the present invention results in numerous advantages over the prior art. First, the holes in a wall may be filled about twenty times faster by means of finishing plugs incorporating the present invention than by means of packing the holes with concrete. Thus, the wall surface is ready for sanding and final finishing much more quickly than would otherwise be the case. Second, although it is necessary to employ a finisher to install the finishing plugs, it is not necessary to employ a laborer to assist the finisher. These factors result in an overall reduction of the cost of filling each hole in a concrete wall by at least 80 percent. This in turn materially reduces the overall cost of finishing the wall surface.

Those skilled in the art will appreciate the fact that the present invention is readily adaptable to various particular requirements. Thus, the shape of the finishing plugs may be altered in order to match the shape of particular plastic cones. The mixture used in casting the finishing plugs may also be altered, if desired. Finally, any suitable rigid cementuous material may be used in installing the finishing plugs.

Although preferred embodiments of the invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it 1 will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications, and substitutions of parts and elements without departing from the spirit ofthe invention.

What is claimed is:

1. A wall construction process including the steps of:

casting a concrete wall of the type comprising a wall surface having a plurality of exposed holes in it at least some of which extend to exposed tie rod end portions; casting concrete finishing plugs each shaped substantially identically to the portion of each hole in the wall adjacent the wall surface and each substantially shorter than the holes; and mounting the concrete plugs in the holes to fill the portions of the holes adjacent the wall and thereby form a flush wall surface. 2. The wall construction process according to claim 1 wherein the step of casting a concrete wall is further characterized by:

engaging a wall form with rigid cones to position the wall form; filling the space adjacent the wall form and the cones with concrete; setting the concrete; and thereafter removing the wall form and the rigid cones and thereby exposing the wall surface and the holes therein. 3. The wall construction process according to claim 1 wherein the step of casting concrete finishing plugs is further characterized by forming the plugs having a substantially flat end surface and a periphery at the end surface which is substantially identical to the periphery of the holes in the wall at the wall surface.

4. A process for constructing a wall including the steps of:

installing tie rod assemblies each including a rod having opposed shoulders and plastic cones positioned on opposite sides of the shoulders between opposed forms with the cones engaging both the forms and the shoulders of the tie rods to maintain a predetermined spacing between the forms; casting a cementuous material in the space between the forms and thereby forming a wall; subsequently removing the forms and thereby exposing opposed wall surfaces; removing the plastic cones from at least one side of the wall and thereby exposing conical holes in at least one of the wall surfaces; and

thereafter mounting a preformed finishingplug similar in shape to the plastic cones and having a substantially flat end surface which is substantially equal in diameter to the diameter of the holes at the wall surface in each of the holes with the end surface of the finishing plug extending flush with the wall surface and with the finishing plug snugly received in the hole so as to be at least partially mechanically retained therein.

5. The process for constructing a wall according to claim 4:

wherein the tie rods further comprise portions ini tially projecting through the forms;

wherein the step of removing the plastic cones includes the step of removing the projecting portions of the tie rods; and

wherein the step of mounting preformed finishing plugs in the holes is further characterized by mounting finishing plugs which are substantially identical in shape to the plastic cones but which are substantially shorter than the plastic cones so as to accommodate portions of the tie rod projecting into the holes in the wall.

6. A process for constructing concrete walls compriserecting a wall form assembly comprising spaced forms, tie rods extending between the forms, and members mounted on the tie rods and engaging the forms to maintain a predetermined spacing therebetween;

filling the space between the forms with concrete;

allowing the concrete to set and thereby forming a wall;

subsequently removing the forms and thereby exposing at least one wall surface;

removing the forms engaging members from at least one end of each tie rod and thereby exposing holes corresponding in shape to the forms engaging members in the exposed wall surface;

forming finishing plugs which are substantially identical in shape to but shorter than the forms engaging members; applying a bonding agent to each finishing plug; positioning a finishing plug in each exposed hole in the wall surface with the end of the plug extending substantially flush with the wall surface and thereby providing an open space at the bottom of the hole for accommodating the tie rod end; and

setting the bonding agent to secure the finishing plugs in the holes.

7. The process for constructing concrete walls according to claim 6 further characterized by:

casting concrete finishing plugs each having a substantially flat end surface; and

positioning the finishing plugs in the exposed holes in the wall surface with the end surfaces of the plugs extending flush with the wall surface.

8. The process for constructing concrete walls according to claim 7 wherein the forms engaging members are conical in shape so that the step of removing the forms engaging members produces conical holes in the exposed wall surface and wherein the step of casting finishing plugs comprises casting conical members which are substantially identical in shape to but which are substantially shorter than the conical forms engaging members.

adjacent the wall surface; subsequently presoaking the finishing plugs in water;

coating the presoaked finishing plugs with a liquid cementuous material;

positioning the coated finishing plugs in the holes to partially fill the holes and thereby form a flush wall surface; and

setting the liquid cementuous material to retain the finishing plugs in the holes.

Claims

1. A wall construction process including the steps of: casting a concrete wall of the type comprising a wall surface having a plurality of exposed holes in it at least some of which extend to exposed tie rod end portions; casting concrete finishing plugs each shaped substaNtially identically to the portion of each hole in the wall adjacent the wall surface and each substantially shorter than the holes; and mounting the concrete plugs in the holes to fill the portions of the holes adjacent the wall and thereby form a flush wall surface.

2. The wall construction process according to claim 1 wherein the step of casting a concrete wall is further characterized by: engaging a wall form with rigid cones to position the wall form; filling the space adjacent the wall form and the cones with concrete; setting the concrete; and thereafter removing the wall form and the rigid cones and thereby exposing the wall surface and the holes therein.

3. The wall construction process according to claim 1 wherein the step of casting concrete finishing plugs is further characterized by forming the plugs having a substantially flat end surface and a periphery at the end surface which is substantially identical to the periphery of the holes in the wall at the wall surface.

4. A process for constructing a wall including the steps of: installing tie rod assemblies each including a rod having opposed shoulders and plastic cones positioned on opposite sides of the shoulders between opposed forms with the cones engaging both the forms and the shoulders of the tie rods to maintain a predetermined spacing between the forms; casting a cementuous material in the space between the forms and thereby forming a wall; subsequently removing the forms and thereby exposing opposed wall surfaces; removing the plastic cones from at least one side of the wall and thereby exposing conical holes in at least one of the wall surfaces; and thereafter mounting a preformed finishing plug similar in shape to the plastic cones and having a substantially flat end surface which is substantially equal in diameter to the diameter of the holes at the wall surface in each of the holes with the end surface of the finishing plug extending flush with the wall surface and with the finishing plug snugly received in the hole so as to be at least partially mechanically retained therein.

5. The process for constructing a wall according to claim 4: wherein the tie rods further comprise portions initially projecting through the forms; wherein the step of removing the plastic cones includes the step of removing the projecting portions of the tie rods; and wherein the step of mounting preformed finishing plugs in the holes is further characterized by mounting finishing plugs which are substantially identical in shape to the plastic cones but which are substantially shorter than the plastic cones so as to accommodate portions of the tie rod projecting into the holes in the wall.

6. A process for constructing concrete walls comprising: erecting a wall form assembly comprising spaced forms, tie rods extending between the forms, and members mounted on the tie rods and engaging the forms to maintain a predetermined spacing therebetween; filling the space between the forms with concrete; allowing the concrete to set and thereby forming a wall; subsequently removing the forms and thereby exposing at least one wall surface; removing the forms engaging members from at least one end of each tie rod and thereby exposing holes corresponding in shape to the forms engaging members in the exposed wall surface; forming finishing plugs which are substantially identical in shape to but shorter than the forms engaging members; applying a bonding agent to each finishing plug; positioning a finishing plug in each exposed hole in the wall surface with the end of the plug extending substantially flush with the wall surface and thereby providing an open space at the bottom of the hole for accommodating the tie rod end; and setting the bonding agent to secure the finishing plugs in the holes.

7. The process for constructing concrete walls according to claim 6 further characterized by: casting concrete finisHing plugs each having a substantially flat end surface; and positioning the finishing plugs in the exposed holes in the wall surface with the end surfaces of the plugs extending flush with the wall surface.

9. The process for constructing concrete walls according to claim 8 including the additional steps of presoaking the finishing plugs in water and thereafter coating the finishing plugs with a liquid cementuous material prior to positioning the plugs in the exposed holes of the wall surface.

10. A wall construction process including the steps of: casting a concrete wall of the type comprising a wall surface having a plurality of exposed holes in it; casting concrete finishing plugs shaped substantially identically to the portion of each hole in the wall adjacent the wall surface; subsequently presoaking the finishing plugs in water; coating the presoaked finishing plugs with a liquid cementuous material; positioning the coated finishing plugs in the holes to partially fill the holes and thereby form a flush wall surface; and setting the liquid cementuous material to retain the finishing plugs in the holes.