IMPROVED SYSTEM FOR WALL CONSTRUCTION OF CONCRETE FORMWORK
TECHNICAL FIELD The present invention relates in general to an insulating system for construction of concrete shuttering wall and, more particularly, to a formwork that is provided by expanded polystyrene side walls between which channels are formed and in which concrete is poured in the form of grout and with which it becomes a part of the structure of a permanent wall.
Prior Art For several decades it has been known to use insulating systems for construction of wall concrete formwork as a means of eliminating the use of formwork made of metal or wood for construction at the foot of the construction site of concrete walls for buildings . Although the use of formwork or formwork made of metal or wood provides a reliable means of making wall structures, this use has the disadvantage that formwork is difficult to handle. 136454
JA-fc »??.? He ?? inconveniences to use and should be removed once the concrete is hard enough to allow its removal so that they do not end up forming a part of the wall structure. This type of activity is an intense job and, in particular, when placing the forms or forms to pour the concrete, it originates a substantial amount of work at the foot of the work. Currently, competitive insulating systems for construction of concrete formwork employ
10 use of expanded polystyrene material and fall within two basic categories, block style and sheet style. Block style systems use a molded block for expanded polystyrene construction, in which system a block configuration is stacked.
15 construction in order to form the concrete walls. The block style systems are easy to use, although to assemble them a substantial amount of work is required at the foot of the work. Typically, the blocks incorporate internal clips or brackets that are designed from
20 way they can strengthen the joints between the blocks. One of the main disadvantages of block style systems is that they do not easily accommodate the placement of window or door openings, which limits their use
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practical, mainly to separate wall systems or simple structures such as garages. In U.S. Patent No. 5, 465, 542, an example of a block style system that differs from normal block systems is described because, preferably, the blocks described have embedded tie strips for attachment of the wall coverings to them. Sheet or sheet style systems use two molded sheets of expanded polystyrene, one on each side of the formwork. Typically, the leaves are kept separated by a system of clips or brackets that have to be assembled at the foot of the work, which is difficult to handle and creates an intense job. Different methods have been invented to seal the joints between the leaf systems, although again, all generate an intense work. None of the leaf systems incorporate features that facilitate the placement of windows or doors, which once again, gives rise to an expensive job at the foot of the work. Another major disadvantage experienced by both competitive systems is that they do not support concrete without additional reinforcement (external formwork or shoring), in order to prevent the concrete from breaking along the formwork when it is poured. In the Patent
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No. 3,788,020 discloses an example of the blade style system and includes, in one embodiment, a pair of separate panels that are connected together by means of fire resistant tension members. Although the competitive insulating systems of concrete formwork have many disadvantages, are gaining acceptance in the industry due to the energy savings and comfort they bring to the construction structure. The use of competitive systems has been recognized for its unique merits of energy saving. Also, building codes are requiring insulation in basements and foundation walls. In this way, the insulating systems of concrete formwork have experienced an acceptance, which is particularly increasing, as systems for basements and foundation walls of construction even when they do not provide any savings, from the point of view of construction work, with respect to conventional construction methods. However, its acceptance by large contractors and real estate companies is still very limited. The present invention provides an insulating system for construction of concrete formwork that greatly diminishes the amount of work that is
requires at the foot of the work and provides a system in which windows and doors can be easily accommodated.
Description of the Invention A first embodiment of the present invention provides an insulating system for concrete formwork wall construction having elongated and separated side walls that are made of expanded polystyrene, each of which has opposite internal surfaces that are formed with longitudinally spaced shoulders that face in a vertical direction, which end in substantially flat surfaces that contact one another to serve as a concrete wall formwork. The separate projections define channels so that they can receive the concrete poured into them. Preferably, the polystyrene side walls are formed by cutting a single sheet of expanded polystyrene into two generally equal portions. It is preferred that the upper and lower edges of the projections of the side walls have upper and lower ends that are separated from the edges of the side wall for the purpose
It is necessary to provide the upper and lower areas, which receive the concrete between the side walls that are in communication with the channels between the projections. To form the windows and the portals, the projections of the side walls have opposite split portions so that they can receive the separating members that are located between the side walls, these spacer members are of the shape of the window or portal that is desired. A second embodiment of the present invention provides an insulating system for concrete formwork wall construction having elongated and separated side walls that are made of expanded polystyrene with partitioning members that are located between the side walls. Each dividing member is constituted of the upper and lower surfaces and of two flat sides, one of which joins a side wall and the other side is joined to the second side wall. The dividing members are longitudinally spaced along the side walls so that channels are formed between the dividing members. The upper and lower surfaces of the dividing members are separated from the upper and lower edges of the side walls in order to provide the upper and lower areas, the
l-áa-ij-kii-A- • - * '- * ¿* ft "which receive the concrete between the side walls that are in communication with the channels between the dividing members. To form the windows and the portals, the dividing members are cut and joined with the first side wall so that a wall is created in the shape of the desired window or door. A separator is inserted into the wall and the second side wall joined. A third embodiment of the present invention provides an insulating system for concrete wall construction including a formwork, which is molded in one piece in order to provide a structure, similar in some way to the structure of the first two modalities when they are assembled together However, what makes this modality even more a work saving device, is the fact that the formwork assembly is not required. A barrier of plastic material can be laminated to the outer surface of one or both of the side walls of the present invention whereby the need for a finish coating is nullified and a barrier against moisture, rodents and many insects is provided. This is advantageous, above all, where the formwork is used in grading positions, it is
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say in layers of land that support a concrete slab. Preferably, this plastic barrier is in the form of an ABS plastic sheet with a thickness of about 1.58 mm (1/16"). The foregoing advantages and other advantages of the present invention will appear from the following description. description, reference is made to the accompanying drawings, which are part of the same, and in which is shown by way of illustration and not as limitation, a specific formwork by means of which the invention can be realized. This mode (s) does not represent the full scope of the invention, since rather the invention can be employed in a variety of embodiments, and in this document reference is made to the claims to interpret the breadth of the invention.
Brief Description of the Drawings Figure 1 is a side perspective view of a first preferred embodiment of an insulating system for concrete formwork wall construction of the present invention;
Figure 2 is a side elevational view of a side wall that is used to form a portion of the embodiment of Figure 1, the other side wall of the embodiment is a mirror image of which is shown; Figure 3 is a plan view of the side wall of Figure 2; Figure 4 is a plan view of the embodiment of Figure 1; Figure 5 is an end elevational view of the embodiment of Figure 1; Figure 6 is a cross-sectional view taken along line 6-6 of Figure 4; Figure 7 is an elongated fragmentary view of one end of the embodiment shown in Figure 4; Figure 8 is a side elevational view of a rebar clamp or jaw that is employed in the embodiment of Figure 1; Figure 9 is a side elevation view of the rebar clip of Figure 8 together with a segment of a rebar or rebar; Figure 10 is a plan view of a rebar and rebar clip of Figure 9;
Figure 11 is an end elevational view of one of the side walls of the embodiment of Figure 1, together with a window separator that is attached thereto; Figure 12 is a side elevational view of the side wall of Figure 10; Figure 13 is a side perspective view of a second preferred embodiment of an insulating system for concrete formwork wall construction of the present invention; Figure 14 is a plan view of two shuttering of the concrete shuttering wall construction system of Figure 13 attached end-to-end; Figure 15 is an expanded perspective view of Figure 14; Figure 16 is a cross section of Figure 13 along line 16-16 where a wall and a separator are shown assembled; Figure 17 is an end view of Figure 16; Figure 18 is a side perspective view of a third preferred embodiment of an insulating system for concrete formwork wall construction of the present invention; Figure 19 is an end view of Figure 18; and Figure 20 is a plan view of two formworks of the concrete formwork wall construction system of Figure 13 attached end-to-end. Ways of Carrying Out the Invention The present invention provides an improved insulating system for concrete formwork wall construction that can be used advantageously in the construction industry as a fast and efficient means to provide insulating foundations, basements and concrete walls by above level in a way that eliminates a substantial amount of construction work at the foot of the work and that dramatically reduces construction times at the foot of the work and completion. The system of the present invention offers a greater versatility than that available by means of concrete block insulation systems based on blocks or sheets that are currently used, and is suitable and capable of being applied in grading applications.
interior and exterior, above level and in multiple floors of a building. Referring now to Figure 1, a first preferred embodiment of an insulating system for concrete formwork wall construction is shown generally at point 10. Those skilled in the art should understand that the embodiment shown is only a section of the entire system, each of the sections is identical in construction except for those sections that might have doors or windows. The system 10 provides a formwork that is placed on top of a foundation shoe 11 of the standard type and includes a pair of elongated walls 12 and 13 made of expanded polystyrene. The angles 14 that are separated are secured to the shoe 11 at the base of each of the side walls 12 and 13 to hold them in place with respect to the shoe 11. As seen in Figures 2 and 3, a side wall 16 is shown, which can serve as any of the side walls 13 or 14. The side wall 16 has an outer surface 17 (only indicated in Figure 3) and an inner surface 18 that are provided with the longitudinally separated projections that are oriented in vertical direction 19, which protrude outwardly from the inner surface 18. As seen in Figure 2, the projections 19 have the upper and lower ends 20 and 21, respectively, which are separated from the upper and lower edges 22 and 23, respectively, of the side wall 16. As seen more clearly in Figure 3, each of the projections 19 is formed with at least three sides, with two side portions inclined 24 terminating on an outer flat surface 25 in order to provide the channels 26 between the projections 19 which are of the mirror image shape of the projections 19 so that the two side walls 16 can cut It can be made from a single sheet of expanded polystyrene by means of a hot wire and can also increase the strength of the system 10. Preferably, the side edges 27 and 28 of the side wall 16 are formed so as to be coupled together with one another. adjacent lateral wall 16. Side edge 27 includes a narrow projecting portion 29 and side edge 28 includes a recessed portion 30 of the same dimension, generally, as that of projecting portion 29. It is also preferred, that the outer surface 17 of the side wall includes a plurality of recessed and spaced strips that align in a vertical direction
the"* ,? , 31, which can be used to join the finishing materials with the side wall 16 once the insulating structure of the concrete wall is completed. Referring now to Figure 4, the side walls 12 and 13 are positioned with respect to each other, so that the flat surfaces 25 of their projections 19 contact one with respect to the other in order to serve as dividers between the two. the side walls. In this position, the channels 26 that are between the projections 19 form a fence to receive the concrete that is in a hexagonal shape. This type of formwork reduces the amount of compression of the projections 19 when a compression force is applied on the side walls 12 and 13 due to the reduced width of the dividers in their middle part. Additionally, as shown in Figure 5, because the upper 20 and lower portions 21 of the shoulder are spaced apart from the upper and lower edges 22 and 23 of the side wall, respectively, the upper areas are provided and lower, which receive the concrete, respectively, and are in communication with the channels 26 between the projections 19. To strengthen the wall structure provided by the formwork system 10, rebar rods or reinforcing bars are placed. within the channels 26 (Figures 4, 6 and 7) by means of clips 36 which center the press-on rebound, as seen more clearly in Figures 8, 9 and 10. The clips or jaws 36 are relatively thin and are they form in a rectangular manner with a central cutting portion 37 which provides two fins 38 for securing them around the rebar or rebar 35 as shown in Figure 9. Preferably, the clips or jaws 36 are formed an of a semi-rigid plastic material that is capable of flexing for the placement of the rebar 35 therein, although they are sufficiently strong in order to keep the rebar in a suitable position that is centered within the channels 26. By use of the clips 36 the rebar can be properly positioned within the channels 26 in a fast and efficient manner. The use of the sidewalls 12 and 13 provides a durable and durable insulating wall structure that is shuttered without windows or doors. In order to provide windows or doors in the structures produced by the shuttering system 10, together with the spacer 43, the side wall 42 is used as shown in Figures 11 and 12. The side wall 42 differs from the side walls. 12 and 13 by the fact that the portions of the projections 19 of the side wall 42 are eliminated in order to provide a rectangular shaped wall 44 corresponding to the shape of an opening of the window to be formed by the use of the side wall 42. As an example, the side wall 42 is designed in order to provide a wall structure with a window. Once the portions of the ridges 19 for shuttering the wall 44 have been removed, the spacer 43 is installed on the side wall 42 in order to prevent the flow of concrete into the removed portions of the ridges 19 and channels 26. between them. When the wall structure is formed and cured, the opening formed by the separator 43 which is preferably formed of polystyrene can be cut. In this way, it can be seen that the formwork system 10 of the present invention can be used advantageously to quickly and efficiently form shuttering walls. Preferably, most of the work involved in shuttering the formwork system 10 can be completed outside the foot of the work site. For example, the side walls 12 and 13 can be provided quickly by use when cutting a single sheet of polystyrene with the help of a hot wire, in the particular configuration that is desired to include the windows or doors as appropriate. The two side walls that are formed by this cut are then glued together, along with the separators of doors or windows that are required and the position of the doors and windows are then marked on the side walls. The completely assembled formworks are then delivered to the foot of the work site for use. The system 10 can be made to be resistant to moisture, rodents and insects if a sheet of plastic material is laminated to the outer surface of a side wall that will be on the outside of the construction. It is preferred that this laminated sheet be made of an ABS plastic material and have a thickness of approximately 1.58 mm (1/16") This can also be assembled with the system outside the foot of the work site. 13, a second preferred embodiment of an insulating system for concrete shuttering wall construction is generally shown at point 60. Those skilled in the art should understand that the embodiment shown is only a section of the entire system, each one of the sections is identical in construction except for those sections that could have doors or windows.System 60 provides a formwork that is placed on top of a foundation shoe 62 of standard type and includes a pair of elongated side walls 64 and 66 made of expanded polystyrene, each of which has an inner surface 68, 70, an outer surface 72, an upper edge 74, 76 and an edge in. ferior 78, 80 and side edges 82, 84. Angles 86 that are spaced apart are secured to the shoe 62 at the bottom edges 78, 80 of the side walls 64 and 66 to hold them in place relative to the shoe 62. As seen in Figures 14 and 15, the two side walls 64 and 66 are separated by the dividing members that are oriented in vertical direction 90, which have two flat sides 92 and 94, a cross section having a mid point 96, and the upper and lower ends 98 and 100, respectively, which are spaced apart from the upper edges 74 and 76 and from the lower edges 78 and 80 of the side walls 64 and 66. Each of the partition members 90 is form so that the flat sides 92 and 94 are wider than the mid-point 96. When the longitudinally-separated dividing members 90 are joined with the inner surfaces 68 and 70 of the side walls 64 and 66, the channels 106 are formed between wed divisors 90. These channels 106 are preferably hexagonal in shape. The dividing members 90 which are positioned along the side walls 64 and 66 and as close as either to the side edges 82 or 84 of the side walls 64 or 66 are a symmetrical half of the dividing member which divides along the vertical axis transverse to the planes of the side walls leaving a third flat side 110. One of the dividing member means 118 is positioned so that its third flat side 110 is superimposed on one of the side edges 82 of the side walls 64 and 66, respectively, and the other is located just inside the lateral edge 84 of the side walls 64 and 66 of the system 60. As seen more clearly in Figure 14, this arrangement provides a formation by which the side walls 64 and 66 of the adjacent system 60 may be coupled together. It is also preferred that the outer surface 72 of the side wall includes a plurality of recessed and spaced strips of alignment that are aligned in vertical direction 112, which can be used to join the materials
You have to finish with the side walls 64 and 66, once the insulating structure of the concrete wall is completed. As shown in Figures 15, 16 and 17 in order to provide the windows or doors in the structures produced by the shuttering system 60, the dividing members 90 are cut and the remaining ones are used together with a separate 122. The members remaining dividers 90 are joined with the first of the side walls 64 by joining means such as gluing, so that a rectangular shaped wall 124 is formed which corresponds to the shape of the window opening. Next, the separator 122 is installed in the wall 124 and the remaining side wall 66 is joined to the divider member 90 by a similar joining means. When the wall structure is formed and cured, the opening formed by the separator 122, which preferably is formed of polystyrene, can be cut. Preferably, the majority of the work involved in shuttering the formwork system 60 can be completed outside the foot of the work site. For example, the dividing members 90 can be cut to admit the doors or windows, then the dividing members 90, can be placed and glued on the first side wall 64, the spacer 122 is placed accordingly, and then the dividing members 90 they can be glued with the second side wall 66. The location of the doors and windows is marked on the outside of the side walls and the completely assembled formworks are delivered to the foot of the work site for use. When the concrete is poured into the formwork 60, it will fill the channels 106. Because the upper ends 98 of the splitter member 90 and the lower ends 100 are separated from the upper edges 74, 76 and the lower edges 78, 80 of the side walls 64 and 66, the upper and lower areas 130 and 132 receiving the concrete are provided, respectively, and are in communication with the channels 106. To reinforce the wall structure provided by the formwork system 60, locate the rebar or reinforcement rods within the channels 106 by means described above and shown in Figures 4-10. The shuttering system 60 can be made to be resistant to water, rodents and insects, if a sheet of plastic 136 is laminated to the outer surface 72 of the side wall 64 which will be on the outside of the building. Preferably, this laminated sheet is manufactured from an ABS plastic material and has a thickness of approximately 1.58 mm (1/16") .This can also be assembled with the system outside the foot of the work site.As described above, the formwork provided by the systems 10 and 60 are designed to be constructed in pieces and then to be assembled together, preferably by gluing, however, the production of these formworks is not essential for the present invention as it is contemplated that Formworks falling within the scope and spirit of the present invention can be molded or extruded so as to provide an integral formwork that will not have to be assembled. Referring now to Figures 18-20, a third preferred embodiment of the invention is illustrated. present invention With reference first of all to Figure 18, an integral insulating system for the construction of Concrete formwork wall. In the same way, as provided in the first and second embodiments, the system 140 provides a formwork that is mounted on the upper part of a footing.
The standard type foundation 162 includes a pair of elongated side walls 164 and 166 made of expanded polystyrene, each of which has an inner surface 168, 170, an outer surface 172, an upper edge 174, 176, and a lower edge 178, 180 and the side edges 182, 184. The angles 186 that are separated are secured to the shoe 162 at the bottom edges 178, 180 of the side walls 164 and 166 to hold them in place with respect to the shoe 162. As shown in FIG. in Figures 18 and 19, the two side walls 164 and 166 are separated by the dividing members that are oriented in the vertical direction 190, which are formed entirely and serve as spacers between the side walls 164 and 166. Each of the members 190 has a cross section with a mid-point 196 (see Figure 20), and the upper and lower ends 198 and 200 (Figure 19), respectively, which are separated from the upper edges 174 and 176 and from the upper edges. lower edges 178 and 180 of the side walls 164 and 166, respectively. Each of the dividing members 190 is also enclosed so that its cross sections reach their largest width at midpoint 196. The dividing members 190
~ Í ¡A., k * .. i. i} Ú, ± * are longitudinally separated so that the channels 206 (Figure 20) are formed between the dividing members 190. These channels 206 are preferably hexagonal in order to provide a narrow median space between them that acts with the purpose of inhibiting the compression of the system 160 when a compressive force is applied on either or both side walls 164 and 166. When the concrete is poured into the system 160, it will fill the channels 206 to form the vertical columns. The upper and lower ends 198 and 200 of the dividing members 190, respectively, are spaced apart from the upper edges 174, 176 and from the lower edges 178, 180 of the side walls 164 and 166, so that the upper and lower areas 230 and 232 that receive the concrete, respectively, and are in communication with the channels 206. Preferably, the upper and lower ends 198 and 200, respectively, of the dividing members 190, include the channels cross sections 234 and 236 that serve to give resistance to these ends. In this way, the system 160 provides a formwork that is similar in construction to the
provided by systems 10 and 60, except that it does not have to be assembled. Although the invention has been described with respect to the three preferred embodiments thereof, it is understood that it is not limited, due to the changes and modifications that may be made therein, which are within the total scope that is intended of the invention. invention as defined by the appended claims.
It is noted that in relation to this date the best method known by the applicant to carry out the aforementioned invention is the conventional one for the manufacture of the objects or products to which it refers.
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