WO2007002388A2 - Form for casting light weight composite concrete panels - Google Patents
Form for casting light weight composite concrete panels Download PDFInfo
- Publication number
- WO2007002388A2 WO2007002388A2 PCT/US2006/024466 US2006024466W WO2007002388A2 WO 2007002388 A2 WO2007002388 A2 WO 2007002388A2 US 2006024466 W US2006024466 W US 2006024466W WO 2007002388 A2 WO2007002388 A2 WO 2007002388A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- concrete
- vertical wall
- wall
- pouring pad
- frame
- Prior art date
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/34—Moulds, cores, or mandrels of special material, e.g. destructible materials
- B28B7/348—Moulds, cores, or mandrels of special material, e.g. destructible materials of plastic material or rubber
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
- B28B23/022—Means for inserting reinforcing members into the mould or for supporting them in the mould
- B28B23/024—Supporting means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/0002—Auxiliary parts or elements of the mould
- B28B7/0011—Mould seals
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
- E04C2/384—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a metal frame
Definitions
- the present application is directed to forms for forming concrete, and in particular forms for casting light weight composite concrete panels.
- Composite concrete and steel frame panels have been used to construct buildings, and in particular as exterior cladding panels in industrial, commercial and residential structures. It is well known to assemble composite building panels at one location and to transport the panels to a construction site for use in fabricating structures. The use of prefabricated building components substantially reduces the labor costs at both the manufacturing and assembly processes.
- Composite concrete panels such as those disclosed in PCT Application Serial No. PCT/US2004/023155 to Smith, which is incorporated herein by reference, are made of metal frames partially imbedded in concrete for providing exterior wall systems. In many cases, the panels are supported on the building structure, and are not intended to bear any loading other than wind loading, however composite panels can also be used in load bearing applications.
- the panel includes a concrete slab having a finished exterior surface. Structural steel studs, such as C-shaped channels, are assembled into a frame and the frame is partially embedded into the concrete slab.
- the slab is light weight concrete, such a foam concrete, as disclosed in the above referenced Smith PCT application. Mechanical systems, insulation and wall board or other interior finish are installed on the interior of the panel.
- composite concrete panels are formed by assembling an outer form comprised of wood or metal rails on a pouring pad. Interior forms can be placed with the outer from to block-out apertures for doors and windows.
- the outer and optional inner forms define a volume into which concrete is poured.
- a steel frame, and reinforcing rods or mesh are embedded in the concrete.
- the steel can be assembled and placed within the form before the concrete is poured, or can be lowered and pressed into the concrete shortly after the concrete is poured. It is generally necessary to seal the outer and interior form members to the pouring pad. This is conventionally done with plastic sheeting or by caulking between the forms and the pouring pad to prevent the seepage of concrete underneath the forms. After at least partial curing of the concrete panel, the form members are stripped and removed.
- FIG. 1 is a cross-section through a first embodiment of a concrete form of the invention secured to a frame and retaining concrete slurry.
- FIG. 2 is a cross-section through two adjacent composite concrete panels formed with the first embodiment form.
- FIG. 3 is a partially cut away perspective view of a second embodiment of a concrete form of the invention.
- FIG. 4 is a partially cut away perspective view of a third embodiment of a concrete form of the invention.
- a first embodiment of a concrete form 10 is shown attached to a steel frame 12 with fastener 14.
- a layer of reinforcing material 16 such as a slit and expanded steel mat, is secured to the frame.
- the reinforcing material and a portion of the steel frame member are partially embedded in light-weight concrete 18, as disclosed in PCT Application Serial No. PCT/US2004/023155.
- the form 10 functions to retain concrete slurry 18, space the steel frame 12 a predetermined distance D above pouring pad 20, and seal the form to the pouring pad.
- the form 10 comprises a vertical wall 22 having an upper portion 24 and a lower portion 26.
- the upper vertical wall portion is configured to be fastened to the frame member 12 with fastener 14.
- a shoulder 28 is formed between the upper and lower wall portions.
- the lower vertical wall portion is horizontally offset from said upper wall portion.
- a sealing member, namely, lip 30 extends at an obtuse angle from said lower vertical wall and is configured to form an obtuse angle with the pouring pad.
- the lip is preferably flexible and resilient, but with sufficient strength to support the frame.
- the shoulder 28 functions as a marker to locate the frame at a predetermined distance D above pouring pad 20.
- This distance D can vary as determined by the architect or engineer. Typically, distance D is about one inch.
- the lip 30 functions as a lip seal to seal the form to the pouring pad. Because the flexible lip is set at an obtuse angle, as shown in FIG. 1, the weight of the concrete slurry 18 will force the lip downwardly into sealing engagement with pouring pad 20.
- the composite concrete panel is preferable manufactured by first assembling the steel frame, and placing the frame upside down on the pouring pad. Reinforcing steel is then secured to the top of the upside down frame. Form members 10 are then fastened to the outer perimeter of the steel frame and such interior apertures as may be desired. Because the frame is upside down, the forms are secured upside down, that is with the Hp 30 extending in an upward and inward direction.
- the shoulder 26 is nested with the edge of the frame, facilitating quick and easy assembly with no need to measure distances.
- the form members are secured to the frame with fasteners 14, such as screws. After the forms are in place, the assembly is flipped over, so that lips 30 engage the pouring pad 20. Then the concrete can be poured into the interior of the form.
- the concrete is preferably a light weight concrete, such a foam concrete. Because the concrete is light weight the plastic forms 10 have sufficient strength to retain the concrete without need for timber or steel rails or other substantial structural elements. When the concrete has at least partially cured, the forms may be optionally stripped and removed by removing the fasteners. It is desirable however to leave the forms in place during storage and transport to protect the edges of the composite concrete panels.
- Fig. 2 shows two concrete panels 32a and 32b fabricated using forms 10. Adjacent panels 32a and 32b are joined together with a plurality of fasteners, e.g. screw 34, extending between frame members 12a and 12b.
- the lip 30 of form 10 functions to form chamfers 36a and 36b on the edge of each concrete panel.
- the horizontal offset between the lower 26 and upper 24 wall portions creates a desirable reveal 38 between panels 32a and 32b.
- the reveal is preferably filled with a sealing material 40, such as caulk or grout.
- Fig. 3 illustrates a second embodiment 110 of the concrete form of the invention.
- Form 110 comprises an "L" shaped member for supporting a frame member 112 of a composite concrete panel above a pouring pad 120.
- the form member 110 is attached to the frame member 112 with fasteners 114.
- the form members 110 are preferably disposed on the perimeter of a frame assembly 18 to permit the flow of concrete slurry (not shown) to partially embed the frame assembly in a concrete slab.
- the form member 110 comprises a vertical wall 122, and a sealing member comprising a horizontal leg 129 and seal 130.
- the seal 130 sealingly engages the pouring pad 120.
- Seal 130 prevents the seepage of concrete slurry under the form member 110 obviating the need to wrap the forms in plastic or the need to caulk the perimeter of the forms.
- the seal 130 deforms against the pouring pad 120 to retain the concrete slurry within the confines of the form.
- the vertical wall 122 has at least one, but preferably plural markers for setting the height of frame 112 above the pouring pad 120.
- the markers comprise ridges 127 disposed on an inside surface 121 for indexing the relative location of the frame member 112 with the form member 110 and pouring pad 120.
- raised ridges 127 are disposed on the inside surface 121, it is contemplated that other indicators may be used, such as a shoulder, recessed grooves, lines or spaced markers.
- a plurality of ridges are disposed at vertically spaced intervals to facilitate selection of different heights for spacing the frame above the pouring pad and thereby the concrete cover over the frame and reinforcing materials.
- Form members 110 are optionally removed from the panel after the concrete is cured.
- the horizontal leg 129 will cause the perimeter edges of the concrete panel to be slightly recessed with respect to an outer face of the concrete panel. If desired, grout or caulking can be added around the perimeter of the concrete panel to provide a flush finish with the remainder of the concrete panel.
- One or more ribs 137 are preferably disposed on the interior surface of leg 129 which will form corresponding grooves in the edges of the concrete panel to improve bonding of the grout or caulk to the panel.
- the form member 110 optionally may be permanently or temporally retained on the concrete panel. It is desirable to retain the form on the panel during storage and transport to protect the panel edges from damage. Referring now to FIG.
- a third embodiment of the concrete form 210 of the invention is shown.
- the features of the third embodiment that correspond to like features of the first and second embodiments have the same reference numerals, but in the 200 series.
- the third embodiment is similar to the second embodiment, except that horizontal leg 229 is directed outwardly rather than inwardly.
- the frame 212 is mounted to the inside surface 221 of vertical wall 222. Concrete is poured onto the pouring pad 220 to a desired height, preferably embedding a portion of the frame assembly 212. A seal 230 on the bottom surface of leg 229 retains the concrete within the confines of the form.
- a single form may be used in either of the orientations shown in the second and third embodiments. Markers may be placed on both sides of the vertical wall 122, 222. Thereby, the form is reversible and can be used in either orientation.
- the form members 10, 110, 210 can be inexpensively manufactured of extruded plastic or other material having sufficient strength to hold the frame member above the pouring pad and retain concrete slurry.
- lip seal 30 is preferably integrally formed with vertical wall 22.
- seal 130, 230 may be made separately and attached to form member 110, 210. Seal 130, 230 preferably has a greater resiliency, i.e. is softer, than the form member 110, 210.
Abstract
Description
Claims
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP06773835A EP1896234A4 (en) | 2005-06-24 | 2006-06-23 | Form for casting light weight composite concrete panels |
NZ565128A NZ565128A (en) | 2005-06-24 | 2006-06-23 | Form for casting light weight composite concrete panels |
MX2007016304A MX2007016304A (en) | 2005-06-24 | 2006-06-23 | Form for casting light weight composite concrete panels. |
AU2006262036A AU2006262036B2 (en) | 2005-06-24 | 2006-06-23 | Form for casting light weight composite concrete panels |
CA002613092A CA2613092A1 (en) | 2005-06-24 | 2006-06-23 | Form for casting light weight composite concrete panels |
US11/922,748 US20090224134A1 (en) | 2005-06-24 | 2006-06-23 | Form for Casting Light Weight Composite Concrete Panels |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US69382305P | 2005-06-24 | 2005-06-24 | |
US60/693,823 | 2005-06-24 |
Publications (3)
Publication Number | Publication Date |
---|---|
WO2007002388A2 true WO2007002388A2 (en) | 2007-01-04 |
WO2007002388A3 WO2007002388A3 (en) | 2008-01-10 |
WO2007002388A4 WO2007002388A4 (en) | 2010-04-29 |
Family
ID=37595870
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2006/024466 WO2007002388A2 (en) | 2005-06-24 | 2006-06-23 | Form for casting light weight composite concrete panels |
Country Status (7)
Country | Link |
---|---|
US (1) | US20090224134A1 (en) |
EP (1) | EP1896234A4 (en) |
AU (1) | AU2006262036B2 (en) |
CA (1) | CA2613092A1 (en) |
MX (1) | MX2007016304A (en) |
NZ (1) | NZ565128A (en) |
WO (1) | WO2007002388A2 (en) |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN105672647B (en) * | 2015-12-31 | 2018-10-02 | 广东建星建造集团有限公司 | Aluminum template system |
US11299886B2 (en) * | 2019-04-24 | 2022-04-12 | Protectiflex, LLC | Composite stud wall panel assembly |
Family Cites Families (32)
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US1399088A (en) * | 1920-08-09 | 1921-12-06 | Seymour William | Reinforced building unit |
US1636396A (en) * | 1922-03-02 | 1927-07-19 | William E Urschel | Building form |
US1593831A (en) * | 1925-06-01 | 1926-07-27 | King William | Method of making building material |
US1955584A (en) * | 1929-10-24 | 1934-04-17 | Elverton H Wicks | Plank construction system |
US1997809A (en) * | 1933-04-12 | 1935-04-16 | Cole Harry | Building construction |
US2807070A (en) * | 1954-08-02 | 1957-09-24 | Chester A Thomas | Apparatus for constructing prefabricated masonry walls |
US2804952A (en) * | 1955-03-09 | 1957-09-03 | Karl F Nothdurft | Window frame corner clip |
DE1434424C3 (en) * | 1963-07-10 | 1974-01-03 | Paul 4000 Duesseldorf Plueckebaum | Light metal formwork for concrete and reinforced concrete structures |
NL6401391A (en) * | 1963-10-07 | 1965-08-18 | ||
US3802147A (en) * | 1971-08-04 | 1974-04-09 | Wheeling Pittsburgh Steel Corp | Steel building components with attachment means for wall and floor surface elements |
US4027846A (en) * | 1971-12-28 | 1977-06-07 | Societe Les Coffrages Madernes | Panel for casting concrete |
US4602467A (en) * | 1984-07-02 | 1986-07-29 | Schilger Herbert K | Thin shell concrete wall panel |
US4649682A (en) * | 1984-07-23 | 1987-03-17 | Barrett Jr Dave D | Prefabricated building panel and method |
US4846437A (en) * | 1987-02-12 | 1989-07-11 | Fitzgerald Leonard R | Bracket for supporting concrete formwork |
US4909007A (en) * | 1987-03-19 | 1990-03-20 | Ernest R. Bodnar | Steel stud and precast panel |
US4930278A (en) * | 1988-06-02 | 1990-06-05 | In-Ve-Nit International Inc. | Composite cementitious building panels |
DE4019498C1 (en) * | 1990-06-19 | 1991-07-25 | Paschal-Werk G. Maier Gmbh, 7619 Steinach, De | |
DE4237595C2 (en) * | 1992-11-06 | 1994-10-20 | Oesterr Doka Schalung | Device for supporting a formwork element running perpendicular to the longitudinal axis of a formwork beam |
US5335472A (en) * | 1992-11-30 | 1994-08-09 | Phillips Charles N | Concrete walls for buildings and method of forming |
US5758463A (en) * | 1993-03-12 | 1998-06-02 | P & M Manufacturing Co., Ltd. | Composite modular building panel |
US5526629A (en) * | 1993-06-09 | 1996-06-18 | Cavaness Investment Corporation | Composite building panel |
US6041561A (en) * | 1997-08-22 | 2000-03-28 | Wayne Leblang | Self-contained molded pre-fabricated building panel and method of making the same |
US6398180B1 (en) * | 1999-10-14 | 2002-06-04 | Miller-Valentine Construction Inc. | Extruded plastic bulkhead device for forming concrete panels |
US6508043B1 (en) * | 2000-02-11 | 2003-01-21 | Art Bond | Building construction system and method |
US6668507B2 (en) * | 2000-12-08 | 2003-12-30 | Paulin A. Blanchet | Hurricane resistant precast composite building system |
US6540201B1 (en) * | 2001-02-26 | 2003-04-01 | White Cap Industries Incorporated | Tilt-up concrete panel forming system |
US6494008B1 (en) * | 2001-08-08 | 2002-12-17 | L. B. Foster Company | Dual section sound wall panel and method of manufacture |
US6883772B2 (en) * | 2001-12-21 | 2005-04-26 | Fukuvi Usa, Inc. | Extensions for apertures in panels |
US6821466B2 (en) * | 2001-12-21 | 2004-11-23 | Fukuvi Usa, Inc. | Extensions for apertures in panels |
AUPR984902A0 (en) * | 2002-01-08 | 2002-01-31 | Nicolo, Assunta | A device and system |
US6732995B2 (en) * | 2002-06-28 | 2004-05-11 | Fukuvi Usa, Inc. | Casting support and casting form |
WO2005010291A2 (en) * | 2003-07-21 | 2005-02-03 | Ecolite International, Inc. | Composite building panel and method of making composite building panel |
-
2006
- 2006-06-23 NZ NZ565128A patent/NZ565128A/en unknown
- 2006-06-23 EP EP06773835A patent/EP1896234A4/en not_active Withdrawn
- 2006-06-23 CA CA002613092A patent/CA2613092A1/en not_active Abandoned
- 2006-06-23 US US11/922,748 patent/US20090224134A1/en not_active Abandoned
- 2006-06-23 WO PCT/US2006/024466 patent/WO2007002388A2/en active Application Filing
- 2006-06-23 MX MX2007016304A patent/MX2007016304A/en unknown
- 2006-06-23 AU AU2006262036A patent/AU2006262036B2/en not_active Ceased
Non-Patent Citations (1)
Title |
---|
See also references of EP1896234A4 |
Also Published As
Publication number | Publication date |
---|---|
US20090224134A1 (en) | 2009-09-10 |
AU2006262036B2 (en) | 2009-02-26 |
EP1896234A2 (en) | 2008-03-12 |
CA2613092A1 (en) | 2007-01-04 |
AU2006262036A1 (en) | 2007-01-04 |
MX2007016304A (en) | 2008-03-05 |
WO2007002388A4 (en) | 2010-04-29 |
EP1896234A4 (en) | 2009-11-11 |
WO2007002388A3 (en) | 2008-01-10 |
NZ565128A (en) | 2009-11-27 |
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