Wall Forming Apparatus

• US 20200131763A1
• Filed: 10/31/2018
• Published: 04/30/2020
• Est. Priority Date: 10/31/2018
• Status: Abandoned Application

• Current Assignee: Radius Track Corporation (Simpson Manufacturing Company Incorporated)
• Original Assignee: Radius Track Corporation (Simpson Manufacturing Company Incorporated)
• Inventors: Mears, Charles W.
• Application Number:
  US16/177,287
• Publication Number:
  US 20200131763A1
• Time in Patent Office: Days
• CPC Class Codes: E04B 1/3205 Structures with a longitudinal horizontal axis, e.g. cylindrical or prismatic structures
• CPC Class Codes: E04B 2/847 the form leaf comprising an insulating foam panel
• CPC Class Codes: E04B 2/8635 with ties attached to the inner faces of the forms E04B2/8611 and E04B2/8623 take precedence
• CPC Class Codes: E04B 2001/3264 hardened in situ
• CPC Class Codes: E04B 2103/02 of ceramics, concrete or other stone-like material
• CPC Class Codes: E04C 2003/0473 U- or C-shaped
• CPC Class Codes: E04C 3/07 at least partly of bent or otherwise deformed strip- or sheet-like material
• CPC Class Codes: E04C 5/04 Mats combined with reinforcing elements protruding out of the plane of the mat E04C5/0627; three-dimensional mats E04C5/0636; bases for plaster E04F13/04

Abstract

A barrier forming system is described that includes a plurality of studs, rails and barrier reinforcement members interconnected between top and bottom plates. The interconnected studs, rails, reinforcement members, top plate and bottom plate may be precisely bent or curved in either or both the vertical and horizontal directions. The interconnected studs, rails, barrier reinforcement members, top plate, and bottom plate may be embedded in a filler material to form a curved concrete barrier having a complex geometry.

Claims

1. A barrier forming apparatus for load bearing surface structures, the barrier forming apparatus comprising:

corrugated spaced apart studs defining a curvature of the barrier;

a top plate coupled to top ends of the studs;

a bottom plate coupled to bottom ends of the studs;

first rails that correspond with the studs, the first rails being coupled to first edges of the corresponding studs;

second rails that correspond with the studs, the seconds rails being coupled to second edges of the corresponding studs;

wherein an inner side of the curvature of the barrier is defined by the first rails and first edges of the studs;

wherein an outer side of the curvature of the barrier is defined by the second rails and the second edges of the studs; and

a filler material that embeds the studs and rails.

2. The barrier forming apparatus as recited in claim 1, further including a first barrier reinforcement network coupled to the first edges of the studs and coupled to the first rails.

3. The barrier forming apparatus as recited in claim 1, further including a second barrier reinforcement network coupled to the second edges of the studs and coupled to the second rails.

4. The barrier forming apparatus as recited in claim 1, wherein the top plate and the bottom plate are constructed from a corrugated plate.

5. The barrier forming apparatus as recited in claim 1, further including a sheathing attached to the first rails.

6. The barrier forming apparatus as recited in claim 1, further including clips that couple the studs and first rails together.

7. The barrier forming apparatus as recited in claim 1, further including clips that couple the studs and second rails together.

8. The barrier forming apparatus as recited in claim 1, wherein the filler material is of the shotcrete type.

9. The wall forming apparatus as recited in claim 1, wherein the inner side and outer side of the barrier are exposed above ground level.

10. A barrier forming apparatus for concrete wall structures, the barrier forming apparatus comprising:

corrugated spaced apart studs defining a curvature of the concrete wall;

a top plate coupled to top ends of the studs;

a bottom plate coupled to bottom ends of the studs;

first rails that correspond with the studs, the first rails being coupled to first edges of the corresponding studs;

a first wall reinforcement network coupled to the first edges of the studs and coupled to the first rails;

second rails that correspond with the studs, the seconds rails being coupled to second edges of the corresponding studs;

a second wall reinforcement network coupled to the second edges of the studs and coupled to the second rails;

wherein an inner side of the curvature of the concrete wall is defined by the first rails and first edges of the studs;

wherein an outer side of the curvature of the concrete wall is defined by the second rails and the second edges of the studs; and

concrete that embeds the studs and rails.

11. The barrier forming apparatus as recited in claim 10, wherein the first wall reinforcement network is comprised of a mesh of rebar.

12. The barrier forming apparatus as recited in claim 10, wherein the second wall reinforcement network is comprised of a mesh of rebar.

13. The barrier forming apparatus as recited in claim 10, wherein the top plate and the bottom plate are constructed from a corrugated plate.

14. The barrier forming apparatus as recited in claim 10, further including a sheathing attached to the first rails.

15. The barrier forming apparatus as recited in claim 10, further including clips that couple the studs and first rails together.

16. The barrier forming apparatus as recited in claim 10, further including clips that couple the studs and second rails together.

17. The barrier forming apparatus as recited in claim 10, wherein the concrete is of the shotcrete type.

18. The barrier forming apparatus as recited in claim 10, wherein the inner side and outer side of the concrete wall are exposed above ground level.

19. A method of forming a barrier, the method comprising the steps of:

determining a desired horizontal curvature of the barrier;

determining a desired vertical curvature of the barrier;

bending a top plate and bending a bottom plate to match the desired horizontal curvature of the barrier;

bending studs and bending rails to match a desired vertical curvature of the barrier;

aligning bent studs with the top plate and bottom plate;

fastening the bent studs to the top plate and the bottom plate;

fastening rails to the studs;

wherein an inner side of the curvature of the barrier is defined by first rails and first edges of the studs;

setting barrier reinforcement members between the studs and rails;

attaching sheathing to the first rails; and

embedding the studs and rails in a filler material.

20. The method as recited in claim 19, further including the steps of smoothing the filler material and curing the filler material.