WO2014138755A2

WO2014138755A2 - Keyway mold & method of constructing concrete walls

Info

Publication number: WO2014138755A2
Application number: PCT/US2014/037036
Authority: WO
Inventors: Christopher J. COLLINS; Dean GIARDINI
Original assignee: Collins Christopher J; Giardini Dean
Priority date: 2013-03-06
Filing date: 2014-05-06
Publication date: 2014-09-12
Also published as: WO2014138755A3

Abstract

A keyway mold (1) and method of use allows a concrete wall (15) having multiple interlocking sections (14) to be poured continuously without having to wait for individual wall sections to dry prior to pouring additional intermediary wall sections. The keyway mold is a planar panel (3) having an interlocking concave indentation (10) proximate to a central section (11). Using the keyway mold of the present invention, two interlocking sections (14) slay be poured at one time with a mortise (12) section of the first section of section of concrete wall (15) being formed simultaneously with a tenon (13) portion located on the second section of wall. The keyway mold may then be left in the concrete wall between the two interlocking sections after the concrete wall is cured.

Description

5

TITLE OF THE I VENTIO :

KEY WAV MOLD AND METHOD OF CONSTRUCTfNG CONCRETE WALLS

Patent A lication of

Christopher J. Collins and Dean Gi rdini

CROSS -R EFERENCES TO RELATED APPUCATTONS

Not Applicable,

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

No; Applicable. iCROHCHE APPENDIX

^'No? Applicable ree ber

DESCRIPTION

Title of the Invention; Keyway Moid and. Method of Constructing Concrete Walls

1 , Technical. Field..

This invention relates to the cortstractio« of retaining, gravity and barrier walls from concrete, and more particuiafsy. a keyway moid and method of use in pouring such walls in a continuous manner while simultaneously forming keyways between the sections of the wail, thereby preventing the need to form walls individually in alternating fashion,

2, Background Art.

A keyway s found in a wall made of concrete, such as a retaining wall or gravity wall, where there is at least two separately poured wail sections on which She ends abut each other. Ilse keyway acts like a mortise and tenon, thereby interlocking the ends of the wall sections together nd creating a stronger connection than, simply abutting the two ours end to end wstis noshing to conxsect them.

However, forming concrete walls and creating keyways in the widely used conventional manner in sections of a concrete wail can be time consuming and costly as the wall must be poured and dried in separate aliemat g sections and cannot be created using a continuous pour. First, a concave keyway is formed In the center of an end of the first wall section poured. This is accomplished using a wooden form, such as a 2x4 placed in she form at one end of the wall section, that must be chipped out and removed front the concrete after the concrete has dried. After the first wall section has dried a second wall section may then be posxted abutting the first wall section with the concave portion of the keyway in the fast wall section acting as a form to crease the tenon portion of the keyway that inserts into the second wall section. A. bond breaker, such as felt paper is placed over the end of the first wall section prior so pouring the second wall section to ensure the concrete of the second wail does not cure to the first section of the wall. Therefore the wall sections may be removed from each other. This is a very aw consuming process due to the fact that wall sections must be poured and cured separately. For example, a Inst wail section is poured, then the second wall section mast be measured and skipped, then the third wall section is poured and so on. After the first wall section is cured, the 2x4 wood piece is removed front the first wall section and then the second section is poured to connect the first and third wall pottsosis.

Therefore, a need exists for a mold and method of using the keyway mold that allows individuals so pour multiple sections of a concrete wall at one time while still creating keyway molds between each section of the concrete wail to tereosrnecs ihe sections of the wall for strength and support.

SUMMARY OF INVENTION

The primary objection of ihe present invention is to provide a keyway mold and method of using the keyway mold that allows individuals to pour multiple sections of concrete wall at one time while still cte&fing keyway molds between each section of concrete wall

The present invention fulfills the above and other objects by providing a. keyway mold that allows a concrete wall having multiple sections to be poured continuously without having to wait for individual wail sections to dry prior to pouring additional mterirrcdiary wall sections. The preset invention is a planar panel with a mortise located thereon that forms a mortise on ait end of a first section of concrete wall and a tenon on an opposing second section of concrete wall. The planar panel has edges that are substantially shaped like a desired shape of the concrete wail, to he poured and the keyway moid is placed between ami perpendicular io outer walls rhat form a mold so form she outer surfaces snd shape of that concrete wall sections being constructed. Using the keyway mold and me£hod of use, two interlocking sections may then be poured at one time wit she concave section of the first wall section being formed simultaneously with the tenon portion located on the second wall. The keyway moid may then be left in the wall after it is cared and she outer walls of the form may be removed to reveal the cured outer surfaces of the concrete wall. This method, results in significant t me and labor savings as a wall may be poured continuously as opposed to moving back, and forth to poor the concrete the separate sections of the concrete wail. The concrete walls illustrated herein have the shapes of typical gravity and barrier walls, .however the keyway mold of the present invention may be used to create a concrete wail having multiple interlock sections of any shape-, such as extd walls, traffic railings, pedestrian railings, bicycle railings, sound barrier wails, permanent retaining walls, sea walls and so forth.

The above and other objects, features and advantages of the pa-sent invention should become even more readily apparent so those skilled in the art upon a reading of the following detailed description in conjunction wit she drawings wherein there is shown and described illustrative embodiments of the invention . BRIEF DESCRIPTION; OF DRAWINGS

FIG. \ is a front perspective vsew of a keyway moid of the present invention shaped to form, a gravity wall;

FIG. 2 is a rear perspective view of a keyway moid of the present invention shaped to form a gravity wail;

^'FIG. 3 is a side perspective side view of a keyway moid of the present invention locked in place between two outer form wails;

FIG. 4 is an exploded view of cured Interlocking sections of a concrete wall and a keyway mold of the presnt invention;

FSG. 5 is a front perspective view of a keyway moid of the present invention shaped to match the shape of an interlocking barrier wail;

FIG. 6 is a rear perspective view of a keyway mold of the present invention shaped to match the shape of an interlocking barrier wail;

F G. ? is a front perspective view of a keyway moid of the present invention shaped to form gravity wall and having a preformed chamfer located thereon;

FIG. 8 is a rear perspective view of a keyway moid oi the present invention shaped to form a gravity wail and having a preformed chamfer located thereon;

FIG, 9 is a top view of a keyway mold of the present invention shaped to .form a gravity wall and having a preformed chamler located thereon; and

FIG, 10 is a front perspective view of a keyway moid of the present invention having sleeves located thereon.

For purposes of describing the preferred embodiment, the terminology used in reference to the numbered accessories in the drawings is as follows:

REFERENCE NUMERALS IN THE DRAWINGS

i keyway mold, generally 2 gravity wail

3 planar panel 4 front surface

5 rear surface 6 lower edge

7 uppe edge 8 right side edge

9 left side edge 10 concave indentation π central section of planar panel 12 mortise j tenon 14 interlocking section of concrete wall i 5 concrete vva! i 6 outer form walls

I ? chamfer 18 aperture

1 sleeve 20 dowel

distal end of sleeve

DESCRIPTION Of EMBODIMENTS

With reference to FIGs, 1 and 2. a front perspective view arsd a rear perspective view, respectively, of a keyway mold i of the present invention shaped to fann an interlocking gravity wall 2 is illustrated. The keyway mold t is substantially triangular shaped and comprises a planar pane! 3 having a front surface 4, rear surface 5, lower edge 6. upper edge ?, right side edge 8 and left side edge 9. A concave indentation 10 is located proximate to a central section H of the planar pane! 3, As illustrated here, the concave indentation 10 is substantially rectangular shaped, however, the concave indentation may be any other shape that protrudes outward into an abutting concrete w ll section. W en concrete is poured on both sides of the keyway mold L a mortise 12 and tenon 13 are crested on opposing sides of the .keyway moid 1 to create interlocking sections 1 of a concrete wall 15, as illustrated in F G. 4. An additional feature of the keyway moid may be a layer of sabstance to allow the interlocking sections 14 to be more easily removed from each, other, such as rubber and so forth.

With reference to FIG. 3, a side perspective side view of a keyway mold I of the present invention locked in place between two outer form walls 16 is illustrated. The keyway mold 1 is placed between and perpendicular to outer form walls 16 that form a mold to form outer surfaces 16 of the interlocking sections 14 of s concrete wail 15. The keyway mold 1 is held in place by chamfers 17 or other means. After the outer form wails 16 are removed from the cured concrete wall sections 14 the keyway moid is left within between the wall sections and illustrated in FIG 4.

With reference to F G 4, an exploded view of cured interlocking sections 14 of a concrete wall 15 and a keyway moid I of the present invention are illustrated, which is self explanatory when viewed in conjunction with the description of the device arsd method described herein. With reference kt FJGs 5 and 6, a front perspective view and a re r perspective view.

130 respectively, of a keyway mold I of the present invention shaped to match the shape of an interlocking ha rier wall 2 is illustrated. The keyway moid is substantially shaped on the edges in the shape of a desired barrier concrete wail and comprises a planar panel 3 having a front surface 4, rear surface 5, lower edge 6, upper edge ?₍ right side edge 8 and lei! side edge 9, As illustrated here, the concave indentation 10 is substant ally rectangular shaped. Whets

135 concrete is poured on both sides of the keyway moid I , a mortise 12 and tenon 13 are created on opposing sides of the keyway moid i to create interlocking sections 14 of a concrete wail 15, as illustrated in FIG 4.

With reference to Fl^'Gs ?, 8 and. 9, a front perspective view, a rear perspective view and a top view, respectively, of a keyway mold 1 of the present invention shaped to form

140 an interlocking gravity wall 2 and having a chamfer 17 located thereon is illustrated. The chamfer ! ^'7 is located on right side edge 8 and/or lets side edge 9 of the planar panel 3 and Is provided to allow the keyway moid I to be more easily and quickly secured between two outer form walls 16 when, constructing a mold prior to porting a concrete wall. Apertures 18 may also be iocated on the preformed chamfers 1 ? to provide pilot holes for nailing or

145 screwing the keyway mold 1 to the outer form walls 1 6.

With reference to FIG S O, a front perspective view of a keyway moid I of the present invention having sleeves 19 iocated thereon is illustrated. The one or more sleeves 19 extend preferably from the front surface 4 or the rear surface 5 and act to provide a ^'holding means for a dowel 20. or reinforcing bar to provide additional structural, support to the concrete wall.

150 The sleeves 19 ate also preferably closed on a distal end 21 to prevent concrete front entering the sleeves 1 9 on both sides, thereby making it easier io separate two section of wail if needed in the future.

t is to be understood that while a preferred embodiment of the invention is illustrated, it is not to be limited to the specific form or arrangement of parts herein described -and shown. 155 It will be apparent to those skilled In the art that various changes may be made without departing from tire scope of the invention and the invention is no; to be considered iimited io what is shown and described in the specification and drawings.

Claims

Having described my invention, 1 clahs:

Claim I . A keyway rnoki for forming interlocking sections of concrete wall comprising: a planar pane! having a front surface, a rear surface, a lower edge, an upper edge, aS right side edge and lei- side edge; and

as ast one concave indentation located proximal to central section of the planar panel.

Claim 2. The key way moid of claim 1 wherein:

0 the at least one concave indentation is substantial ly rectanguhsc shaped.

Claim 3. The keyway mold of claim 1 wherein:

the planar panel is substantially triangle-shaped. S Claim 4. The keyway mold of claim 1 farther comprising:

at least^, two outer form wails that form outer surfaces of the interlocking sections of concrete wall to hold the keyway mold in place between at least two interlocking sections of concrete walls. Claim 5. The keyway moid of claim 4 farther comprising:

the ke way mold is connected to the outer orm wails via chamfers located on she outer form walls.

Claim 6. The keyway mold of claim 1 further comprising:

a preformed chamfer located on the right side edge of the planar panel.

Claim 7. The keywa mold of claim 1 further comprising:

a preformed chamfer located on the left side edge of the planar panel. Clai S. The keyway moid of claim 1 further comprising:

at least one sleeve extending from the planar panel. Claim 9. A keywa moid for forming interlocking sections of concrete wall comprising: a planar panel having a front surface, a rear surface, a lower edge, an upper edge, a ί 95 right side edge .sad left side edge;

at least one concave indentation located proximal to a central section of the planar pane;; and

at least two outer form walls (hat form outer surfaces of the interlocking sections of concrete wall to hold the keyway mold m place between &i leas; two imerlockiag sections of 200 c ncrete -walls.

Claim 10. The keyway mold of claim 9 whereat:

the a? least one concave in exation is substantially rectangular shaped.

205 Claim 1 I . The keyway mold of claim 9 wherein:

the planar pane! is substantially triangle-shaped.

Claim 12. The keyway mold of claim 9 further comprising:

the keyway mold is connected to the outer form walls via chamfers,

210

Claim 13. The key way mold of claim 9 further comprising:

a preformed chamfer located n the right side edge of the planar panel.

Claim 4. The keyway moid of claim.9 further cemprisixsg:

21 a preformed chamfer located on the left side of the planat panel.

Claim 15. The keyway mold of claim 9 further comprising:

at least one sleeve extending from the planar panel.

220 Claim 16. A method of constructing an interlocking concrete wall using at least one keyway mold having a planar panel having a front surface, a tear surface, a lower edge, an upper edge, a right side edge, a left side edge, at least one concave Indentation located proximal to a central section of the planar panel and at least two outer form walls, said method comprising the steps of: a. placing the at feast two outer form yt&lte m a substantially parallel position in {^••elation to each osher wherein the at Seas? two outer form waits extend upward from the groond; and

b. placing the at least one key ay moid between the at bast two outer form walls in a positioo that is perpendicular to the at least two outer form wails; and

c. pouring concrete between the at least two outer form walls and the at least one keyway mold.

Claim 17. The method of da s 15 further comprising the steps of:

allowing the concrete to cure; and

removing the at least two outer form walls from the concrete to reveal outer surfaces of the interlocking concrete wail ,