Method of forming concrete structures using panels having flexible barriers

• US 20040035084A1
• Filed: 10/02/2003
• Published: 02/26/2004
• Est. Priority Date: 04/12/2001
• Status: Active Grant

• Current Assignee: Philip T. Ward
• Original Assignee: Philip T. Ward
• Inventors: Ward, Philip T.
• Granted Patent: US 6,969,041 B2
• Time in Patent Office: Days
• US Class Current: 52/742.14
• CPC Class Codes: B28B 7/0011 Mould seals
• CPC Class Codes: B28B 7/0014 Fastening means for mould parts, e.g. for attaching mould walls on mould tables; Mould clamps clamping means specially adapted for counteracting a pressure being applied on a slip or on the moulded article in the mould B28B1/266
• CPC Class Codes: B28B 7/0055 Mould pallets; Mould panels
• CPC Class Codes: E04G 11/10 of elements without beams which are mounted during erection of the shuttering to brace or couple the elementsE04G11/18 takes precedence
• CPC Class Codes: E04G 17/001 Corner fastening or connecting means for forming or stiffening elements forms for rooms as a whole E04G11/02; forms for vertical ducts E04G11/06; forms for columns E04G13/02
• CPC Class Codes: E04G 17/047 simultaneously tying two facing forms

Abstract

A forming panel and method for using the same in construction of self-sustaining concrete wall structures is provided wherein a flexible barrier element is provided along a margin on the forming panel for impeding the flow of water and fine particles of a concrete mix pour past the barrier element. The margin may be along the perimeter edge of the forming panel or along an opening interior to the perimeter of the forming panel. When located near the perimeter, the flexible barrier element may be positioned in a slot extending parallel to the margin and located in the frame. When located near an interior opening, the barrier element may be provided on a reinforcing member positioned around the opening or on a door which shifts to improve access through the opening during placement of forming ties or the like. The forming panel may be coupled with adjacent forming members to provide a wall system, and two wall systems may be connected by forming ties to provide a channel for receipt of a concrete pour therebetween.

Claims

1. In a method of forming self-sustaining concrete structures from flowable concrete pours, the improvement comprising:

installing a flexible barrier element on at least a first forming panel;

combining the first forming panel with other panels to create a form into which flowable concrete is poured and retained as it cures;

using the barrier element to reduce leakage from between the first forming panel and an adjacent panel during the formation process;

removing the first forming panel from the concrete structure after curing without removing the barrier element from the first forming panel; and

reusing the first forming panel to create another form.

2. In a method as claimed in claim 1,

further comprising installing a flexible barrier element on at least a second forming panel and positioning said first and second forming panels adjacent one another as part of a form,

further comprising using the barrier elements on the first and second forming panels to reduce leakage between the first and second forming panels during the formation process.

3. In a method as claimed in claim 2,

said barrier elements on the first and second forming panels engaging one another when the first and second forming panels are positioned adjacent one another as part of a form.

4. In a method as claimed in claim 3,

further comprising placing at least one tie bar between the adjacent first and second forming panels,

said barrier elements on the first and second forming panels engaging opposite sides of the tie bar when the first and second forming panels are positioned adjacent one another as part of a form.

5. In a method as claimed in claim 3,

said barrier elements on the first and second forming panels projecting outwardly from their respective forming panels at an oblique angle relative thereto and generally toward the concrete pour.

6. In a method as claimed in claim 5,

each of said barrier elements comprising a brush strip having bristles.

7. In a method as claimed in claim 1,

said first forming panel having a front face disposed for engaging the concrete pour during the formation process and a member extending rearwardly away from said front face along a margin of the first forming panel,

said installing step including supporting said barrier element on said member.

8. In a method as claimed in claim 7,

said barrier element projecting outwardly from said member at an oblique angle relative thereto and generally toward said front face.

9. In a method as claimed in claim 8,

said barrier element comprising a brush strip having bristles.

10. In a method as claimed in claim 7,

said barrier element comprising a brush strip having bristles.

11. In a method as claimed in claim 1,

said barrier element comprising a brush strip having bristles.

12. A method of forming self-sustaining concrete structures from flowable concrete pours comprising the steps of:

providing a first forming panel having a face plate presenting a first surface oriented for receiving concrete thereagainst, a second surface angled relative to the first surface, an elongated margin therebetween, and an elongated flexible barrier element mounted on said forming panel proximate said margin;

pouring a concrete mix along at least a portion of said first surface in engagement with at least a portion of said margin;

allowing said concrete to cure to a hardened state while impeding the flow of the concrete mix past the flexible barrier; and

removing the forming panel from the cured concrete structure.

13. A method as set forth in claim 12, further including the steps of providing a second forming panel adjacent to the first forming panel and connecting the first forming panel to the second forming panel wherein a gap is provided therebetween to position the flexible barrier element in the gap.

14. A method as set forth in claim 13, including the step of providing a tie element and coupling the tie element to at least one of said first and second forming panels wherein at least a portion of the tie element is positioned in the gap and the flexible barrier element is in engagement with the tie element.

15. A method as set forth in claim 13, wherein a second flexible barrier element is mounted on said second forming panel in substantial opposition to the flexible barrier element of said first forming panel.

16. A method as set forth in claim 12, wherein said forming panel includes a perimeter and has an opening in said face plate interior to said perimeter, said margin at least partially defining said opening, and including the steps of passing a tie element through said opening and coupling the tie element to the forming panel with the flexible barrier element in engagement with the tie element.