Foundation construction method

• US 6,134,861 A
• Filed: 08/09/1999
• Issued: 10/24/2000
• Est. Priority Date: 08/21/1996
• Status: Expired due to Term

• Current Assignee: TF System-The Vertical ICF, Inc.
• Original Assignee: Gerald T. Spude
• Inventors: Spude, Gerald T.
• Primary Examiner(s): Friedman, Carl D.
• Assistant Examiner(s): WILKENS, KEVIN DOUGLAS
• Application Number:
  US09/370,312
• Time in Patent Office: 442 Days
• Field of Search: 52/169.12, 52/202, 52/285.1, 52/344, 52/477, 52/515, 52/585.1, 52/586.1, 52/586.2, 52/592.1, 52/745.09, 52/745.1, 52/747.12 , 52/763, 52/765, 52/780, 52/781.3, 52/DIG. 3
• US Class Current: 52/745.1
• CPC Class Codes: E02D 27/02 Flat foundations without substantial excavation E02D27/04, E02D27/08 take precedence
• CPC Class Codes: E04B 1/34342 Skirtings therefor
• CPC Class Codes: E04B 2/8652 with ties located in the joints of the forms
• CPC Class Codes: E04B 2002/867 Corner details
• CPC Class Codes: E04B 2002/8688 Scaffoldings or removable supports therefor
• CPC Class Codes: Y10S 52/03 Trailer or mobile home skirt

Abstract

A building system and apparatus for forming a wall. U-shaped channels and H-shaped or T-shaped members coupled at their sides by rigid links hold foam panels in a desired spaced relationship. Vertically oriented panels aligned and connected by T-shaped members or horizontally oriented panels stacked with and connected by H-shaped members are inserted into the U-shaped channels to form a structure of the desired length. Concrete is poured between the panels and members where it hardens to form a structural wall. The planar surfaces of the U-shaped, H-shaped and T-shaped members enable the members to be extruded, or roll formed, thereby substantially reducing member production costs. Furthermore, widely available conventional foam panels can be used, reducing panel production costs.

Claims

1. A method of forming a wall between a base and an upper support located above the base, the method comprising the steps of:

coupling at least one elongated U-shaped lower member to the base;

coupling at least one elongated U-shaped upper member to the bottom of the upper support vertically above the at least one lower member;

inserting a first substantially vertically oriented planar panel within the lower and upper members to form a vertically oriented wall;

inserting an elongated connecting member substantially vertically between the lower and upper members along a substantially vertical edge of the first panel;

inserting a second substantially vertically oriented planar panel substantially vertically within the lower and upper members to form a substantially vertically oriented wall, such that the elongated connecting member fits substantially vertically along a substantially vertical edge of the second panel between the first and second panels; and

then

coupling the elongated connecting member to at least one of the first and second panels.

2. The method as claimed in claim 1, wherein the steps of inserting the first and second planer panels includes sliding the first and second panels substantially horizontally between the lower and upper members.

3. The method as claimed in claim 1, wherein the connecting member is concealed upon insertion of the second panel.

4. The method as claimed in claim 1, further comprising the step of coupling the first and second panels to the lower and upper members.

5. The method as claimed in claim 1, further comprising the step of applying a skin coating of material to a side of the wall after assembly to give the wall a uniform appearance.

6. The method as claimed in claim 1, further comprising the step of inserting a first flange of the connecting member into a substantially vertical slot in the substantially vertical edge of the first panel and a second flange of the connecting member into a substantially vertical slot in the substantially vertical edge of the second panel.

7. The method as claimed in claim 6, wherein the connecting member is T-shaped.

8. The method as claimed in claim 1, further comprising the step of inserting a third flange of the connecting member into a second substantially vertical slot in the substantially vertical edge of the first panel and a fourth flange of the connecting member into a second substantially vertical slot in the substantially vertical edge of the second panel.

9. The method as claimed in claim 8, wherein the connecting member is H-shaped.

10. A method of forming a wall between a base and a support located at a higher elevation than the base, the method comprising the steps of:

coupling a lower member to the base;

coupling an upper member to the support;

sliding a first panel substantially horizontally between the lower and upper members; and

then

coupling a connecting member to the first panel;

sliding a second panel substantially horizontally between the lower and upper members;

coupling the connecting member to the second panel to couple the first panel to the second panel.

11. The method as claimed in claim 10, further comprising the step of coupling the first and second panels to the lower and upper members.

12. The method as claimed in claim 10, further comprising the step of applying a skin coating of material to a side of the wall after assembly to give the wall a uniform appearance.

13. The method as claimed in claim 10, wherein the step of coupling the connecting member to the first panel includes inserting a first flange of the connecting member into a slot in an edge of the first panel.

14. The method as claimed in claim 13, wherein the step of coupling the connecting member to the second panel includes inserting a second flange of the connecting member into a slot in an edge of the second panel.

15. The method as claimed in claim 14, wherein the connecting member is an elongated T-shaped member.

16. The method as claimed in claim 14, wherein the step of coupling the connecting member to the first panel includes inserting a third flange of the connecting member into a second slot in the edge of the first panel.

17. The method as claimed in claim 16, wherein the step of coupling the connecting member to the second panel includes inserting a fourth flange of the connecting member into a second slot in the edge of the second panel.

18. The method as claimed in claim 17, wherein the connecting member is H-shaped.

19. A method of forming a wall between a base and an upper support located above the base, the method comprising the steps of:

coupling at least one U-shaped lower member to the base;

coupling at least one U-shaped upper member to a portion of the upper support above the at least one lower member;

sliding a first panel substantially horizontally between the lower and upper members;

inserting an elongated connecting member between the U-shaped upper and lower members; and

then

coupling the connecting member to the first panel; and

sliding a second panel substantially horizontally between the lower and upper members to form a substantially vertically oriented wall.

20. The method as claimed in claim 19, further comprising the step of coupling the first and second panels to the lower and upper members.

21. The method as claimed in claim 19, further including the step of applying a skin coating of material to a side of the wall after assembly to give the wall a uniform appearance.

22. The method as claimed in claim 19, wherein the first and second panels angularly adjoin one another.

23. The method as claimed in claim 19, further comprising the step of coupling the elongated connecting member to the second panel.

24. The method as claimed in claim 23, wherein the steps of coupling the elongated connecting member to the first and second panels includes the steps of:

inserting a first flange of the connecting member into a slot in an edge of the first panel; and

inserting a second flange of the connecting member into a slot in an edge of the second panel.

25. The method as claimed in claim 24, wherein the connecting member is T-shaped.

26. The method as claimed in claim 24, wherein the steps of coupling the elongated connecting member to the first and second panels further includes the steps of:

inserting a third flange of the connecting member into a slot in an edge of the first panel; and

inserting a fourth flange of the connecting member into a slot in an edge of the second panel.

27. The method as claimed in claim 26, wherein the connecting member is H-shaped.