US20120079783A1

US20120079783A1 - Simplified non-polystyrene permanent insulating concrete form building system

Info

Publication number: US20120079783A1
Application number: US13/101,314
Authority: US
Inventors: Michael Edward Nylin
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-09-19
Filing date: 2011-05-05
Publication date: 2012-04-05

Abstract

A simplified insulating concrete form building system comprised of forms made from wood chips or other organic fibers, embedded in a Portland cement matrix, molded and trimmed into various shapes and sizes. The forms are held in position within the wall by means of unique, simplified form geometry and an internal fastening clip which combine to improve alignment and stability of the wall prior to filling the forms with concrete. The simplified geometry reduces worker error in orienting the form correctly within the wall thereby reducing handling and corresponding fatigue. The form's smooth faces provide more compact palletized shipments of forms, thereby reducing cost and damage in shipment. Concrete reinforcement bars are held within forms using a system of reinforcement bar holders which enables the precise positioning of the reinforcement within the wall, thereby increasing speed and accuracy of construction as well as structural performance of the wall assembly.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application contains subject matter which is related to the subject matter of the following co-pending application. Each of the below listed applications is hereby incorporated herein by reference in its entirety:
The present application is a continuation-in-part of an application entitled “SIMPLIFIED NON-POLYSTYRENE PERMANENT INSULATING CONCRETE FORM BUILDING SYSTEM”, Inventor Michael Edward Nylin, filed Sep. 18, 2007, Ser. No. 11/901,517; which is a non-provisional application that claims the benefit of provisional patent application entitled “A SIMPLIFIED NON-POLYSTYRENE PERMANENT INSULTING CONCRETE FORM BUILDING SYSTEM”, Inventor Michael Edward Nylin, filed Sep. 19, 2006, Ser. No. 60/845,607.

TECHNICAL FIELD OF THE INVENTION

This invention relates an improved, strong, non-polystyrene insulating concrete form building system which is comprised of a simplified form geometry with smooth, non-articulated ends and side walls, self-aligning ribs and grooves for locking courses of the forms together, a web fastening clip internal to the insulating concrete form which holds the end webs of adjacent insulating concrete forms tightly together, thereby working in tandem with the aforementioned self-aligning ribs and a system of internal reinforcement bar holders which ensures the precise positioning of single or multiple reinforcement bars both in both the horizontal and vertical planes of the wall.

BACKGROUND OF THE INVENTION

The non-polystyrene insulating concrete form has been in use as a building component for several decades, most notably in Europe in the western hemisphere. While the technology of wood-cement or wood-concrete products, as they are generically called, was already underway in Europe during the 1930's, the real impetus for such a building system in the western hemisphere can be traced to the widespread destruction of buildings that resulted from World War II. The European reconstruction period began with much rubble (including many partially destroyed building timbers) and a short supply of Portland cement. Necessity often being the mother of invention, the Germans and Austrians pioneered a way to recycle much of the destroyed timbers into chips of wood, treating the wood chips to isolate the organic sugar compounds in them to prevent these compounds from leaching out of the wood chips and interfering with the chemical reaction known as hydration process that takes place when Portland cement is mixed with water. These coated chips would then be mixed with Portland cement and water to create a fictile, moldable matrix. The forms molded of this matrix are used to create wall assemblies by dry-stacking the forms (i.e. using no mortar between the forms), inserting reinforcement bars within the internal voids of the forms and then filling the forms with concrete. The forms stay permanently in place, thereby becoming part of the wall assembly and provide excellent fire, mold, and termite resistance. These forms also have excellent thermal insulation and sound attenuation characteristics.
In comparison to polystyrene insulating concrete forms in current use in North America, the wood concrete forms have several advantages. The fabrication of the wood concrete forms is not a petroleum-based in their manufacturing process. Instead, the process uses a high percentage of recycled materials from post-industrial wood source that would otherwise end up in the earth's landfills. The manufacturing process for the wood concrete forms also uses organic, non-toxic materials. The wood concrete is highly flame- and smoke-resistant when subjected to the heat of flame and it will not give off toxic vapors or fumes as will polystyrene when it is melts in the presence of flame. Termites will not eat the wood concrete forms nor will other wood-eating vermin. Unlike the case with polystyrene forms, fasteners such as nails or screws may be attached anywhere on the form with excellent holding power. Another advantage over polystyrene is that stuccos, plasters and other finishes may be directly applied to the wood-concrete forms without additional sub-surface preparation. Furthermore, the wood concrete wall system is hygroscopic, that is, the wall system “breathes”, taking on and giving off water vapor as it seeks ambient humidity levels. This breathing characteristic of the wood concrete form prevents the accumulation of excessive moisture in the wall thereby preventing growth of molds and mildews that have been known to occur in other non-breathing wall systems. The incursion of molds and mildews has been on the rise in new construction using traditional “stick-built” construction methodologies cases especially when the stick-built construction is too tightly sealed with building wraps and/or sealants. The stick-built approach will often trap moisture within walls, creating a favorable environment for mold and mildew growth. These molds are suspected to be one of the lead causes in the growing number of asthma and other respiratory ailments experienced in recent years, especially amongst children.
While the wood-concrete insulating form technology was primarily pioneered within the western hemisphere on the European continent, there have been a small number of manufacturers in North America, though their products have not, until recently, attracted much interest in the North American construction industry. One of the primary reasons for wood concrete's failure to gain widespread market acceptance in North America has been the entrenched mindset of the North American construction industry. That mindset has been one which is predominated by the plywood and dimension lumber based construction processes.
For the time when virgin forests of “old wood” were plentiful in North America, stick-built construction remained economical in the short term. In more recent times however, there has been a growing awareness and understanding of the negative environmental implications attendant to the denuding of the earth's forests. This awareness has fostered interest in alternative methodologies of construction which are more environmentally responsible over the longer term. Such new interest is evident in the increasing commitment levels to “green” or environmentally sustainable architecture and construction methods in both the public and private sectors. With its characteristically high recycled material content, its excellent thermal and sound insulating properties, its hygroscopic nature, ease of construction and the durable, strong structure it produces, it appears the time for the non-polystyrene insulating concrete form in North America may have arrived.
As already noted, the majority of development of the wood concrete technology has occurred in the western hemisphere on the European continent. Within the wood concrete insulating concrete form manufacturing community, the most common product designs produced by the most prominent European manufacturers (e.g., DURISOL, THERMOSPAN, ISOSPAN, BRISOLIT, etc.) come in a variety of geometric sizes and shapes with optional insulation inserts available to increase the form's thermal and sound insulation properties beyond that of the basic form.
Virtually all of these wood-concrete forms include some type of articulated “male-female” end configurations. The reason for these male-female end configurations is an attempt by the manufacturer to facilitate a planar alignment of the forms during the process of assembling a wall. Another purpose of the male-female end shape is to interlock the wall forms so that relative movement between forms is resisted during the placement of reinforcing steel and, subsequently, the concrete within the forms. While this type of end configuration may provide a limited degree of interlocking of forms on a particular course within the wall, it does little or nothing at all to interlock successive courses in the wall together. As such, even with the interlocking end configuration, an accidental bumping of the wall by a construction worker or a piece of construction machinery can severely misalign the wall assembly prior to its being filled with reinforced concrete.
Such use of asymmetrical, male-female ends on the forms creates two major disadvantages for wall assembly. First, care must be taken to orient the form properly in the wall with respect to adjacent forms so as to prevent improperly mating male-to-male or female-to-female end configurations. Such mistakes made by construction workers in this regard require additional handling by the worker to re-orient the form properly, thereby increasing worker fatigue. Secondly, at wall openings such as at doors and windows, the male-female end of the form located at the jamb (i.e., the side of the opening) of a door or window has to be smoothed by sawing, sanding or some other alternative course of action before window or door installation may proceed. This also can slow down the assembly of the wall.
While the use of a male-female end configuration may offer some limited resistance to lateral movement which might occur in an accidental bumping of the wall during its construction or while waiting for the wall to be filled with concrete, the disadvantages of incomplete, multi-axis lateral stability in terms of bumping resistance, the possibility of mis-orientation of the form and the aforementioned required additional cutting or smoothing of the form at door and window jambs are serious drawbacks to an efficient construction process. Examples of these varying male-female end configurations may be found on the manufacturers' websites. Most notable European manufacturers for illustrating this male-female end configuration are DURISOL of Austria (www.durisol.at), THERMOSPAN of Austria (www.thermospan.at), ISOSPAN (www.isospan.eu) and BRISOLIT of Germany (www.brisolit.de).
In addition, as illustrated by the K-X FASWALL system (www.faswall.com), the asymmetrical end configurations frequently require a special form for use at corners of buildings. As is the case with the FASWALL form, this can have a significant negative constraining impact on the overall design of the building and/or the ease of construction if the dimensions of the corner forms do not readily conform to the overall design module of the construction project. This violation of design modularity will frequently require additional cutting of forms at the construction site.
Finally, in many building designs, especially those which employ structural engineers to calculate precise number and sizes of structural members, reinforcement bars, etc., the precise placement of the reinforcement bars within the concrete and the assurance of complete concrete cover surrounding the bars can be critical factors in the building's structural performance. Many manufacturers' non-polystyrene insulating concrete forms use a somewhat “hit-and-miss” approach with respect to the placement of the reinforcement bars. Accordingly, the precise location and/or orientation of the steel within the core and/or relative to other reinforcement bars within the form simply cannot often be assured.
In view of the non-polystyrene insulating concrete forms currently available, a new insulating concrete form which does not require asymmetrical male/female end configurations for interlocking or alignment of the forms within the wall assembly nor any special corner forms and which actually increases the stability of the form within the wall assembly while providing for the ability to precisely position reinforcement bars within the form would be a significant improvement.
For these reasons and shortcomings as well as other reasons and shortcomings there is a long felt need that gives rise to the present invention.

SUMMARY OF THE INVENTION

The shortcomings of the prior art are overcome and additional advantages are provided through the provision of a system for securing non-polystyrene insulated concrete forms and positioning reinforcement bars during construction of a concrete structure, the system comprising at least one of a non-polystyrene insulated concrete form and at least one of a fastening clip, the fastening clip having a top member, the top member further comprises at least one of a receptacle integrally formed in the top member, the receptacle locates, orientates, and fastens with at least one of a reinforcement bar holder, the fastening clip holds together at least two of the non-polystyrene insulating concrete form, the fastening clip further comprises at least two of a clamping leg which are juxtaposed, wherein when the fastening clip is applied to at least two of the non-polystyrene insulating concrete form each of the clamping leg grips at least one of the non-polystyrene insulating concrete form.
Additional shortcomings of the prior art are overcome and additional advantages are provided through the provision of a system for securing non-polystyrene insulated concrete forms and positioning reinforcement bars during construction of a concrete structure, the system comprising at least one of a non-polystyrene insulated concrete form and at least one of a fastening clip, the fastening clip having a top member, the top member further comprises at least one of a receptacle integrally formed in the top member, the receptacle locates, orientates, and fastens with at least one of a reinforcement bar holder, the fastening clip holds together at least two of the non-polystyrene insulating concrete form and a horizontal reinforcement bar holder, used in combination with the fastening clip, further comprises a first end and a second end, a saddle disposed and integrally formed at the first end, a base is integrally formed between the first end and second end, the base comprising a plurality of removable extensions, a locator tab is integrally formed at the second end, the locator tab thickness and length are sized to fit into a slot formed in a structural cross member of a non-polystyrene insulated concrete form, the locator tab is shaped at the second end and has a plurality of gripping teeth integrally formed therein which cause the horizontal reinforcement bar holder to be friction fit and retained within the slot, wherein the saddle engages a horizontally orientated reinforcement bar, the locator tab is inserted into the non-polystyrene insulating concrete form, the base contacts the surface of the non-polystyrene insulating concrete form creating a fixed distance between the non-polystyrene insulating concrete form and the horizontally orientated reinforcement bar and supporting the horizontally orientated reinforcement bar in predetermined and precise location within horizontal cavities of the non-polystyrene insulating concrete form.
Additional shortcomings of the prior art are overcome and additional advantages are provided through the provision of a system for securing non-polystyrene insulated concrete forms and positioning reinforcement bars during construction of a concrete structure, the system comprising at least one of a non-polystyrene insulated concrete form. A fastening clip having a top member, the top member further comprises at least one of a receptacle integrally formed in the top member, the fastening clip holds together at least two of the non-polystyrene insulating concrete form and a reinforcement bar holder having at least two of a parallel leg contoured and integrally formed to form a saddle between the interior surfaces of the parallel leg, the saddle is orientated to support a reinforcement bar and a connector integrally formed on the other end, the connector comprising a cross member and at least two of a connector leg, one end of the connector leg being integrally formed with the cross member and the other end of the connector leg comprising a foot, each of the foot being orientated on the connector leg, the connector leg either fastens with at least one of the receptacles which locates, orientates, and fastens the reinforcement bar holder with the top member or fastens with a second reinforcement bar holder, wherein the reinforcement bar holder supports the reinforcement bar in predetermined and precise location within the non-polystyrene insulated concrete form.
Additional shortcomings of the prior art are overcome and additional advantages are provided through the provision of an improved, strong, non-polystyrene insulating concrete form building system which is comprised of a simplified form geometry with smooth, non-articulated ends and side walls, self-aligning ribs and grooves for locking courses of the forms together, a web fastening clip internal to the insulating concrete form which holds the end webs of adjacent insulating concrete forms tightly together, thereby working in tandem with the aforementioned self-aligning ribs and a system of internal reinforcement bar holders which ensures the precise positioning of single or multiple reinforcement bars both in both the horizontal and vertical planes of the wall. This building system enhances construction speed and wall assembly stability prior to filling the forms with concrete and provides the option for creating half-forms whenever required at the construction site.
Additional shortcomings of the prior art are overcome and additional advantages are provided through the provision of a non-polystyrene insulating concrete wall form building system comprised of a wall form used within, at the corners of, at openings in and at the end of a reinforced concrete wall assembly with all such form configurations derived from a single basic form, thereby enhancing the modularity of architectural planning and the efficiency of constructing the wall assembly at a construction site.
Additional shortcomings of the prior art are overcome and additional advantages are provided through the provision of a non-polystyrene insulating concrete wall form building system comprised of a wall form which, by virtue of its molded geometry, may be easily converted at the construction site into two half-forms having the same fundamental assembly characteristics as the form from which the half forms were derived.
Additional shortcomings of the prior art are overcome and additional advantages are provided through the provision of a non-polystyrene insulating concrete wall form building system comprised of a wall form which has smooth, non-articulated vertical faces, thereby eliminating construction worker concern regarding the form's end-for-end orientation during assembly thus speeding construction, reducing errors, unnecessary handling and damage of forms and corresponding worker fatigue.
Additional shortcomings of the prior art are overcome and additional advantages are provided through the provision of a non-polystyrene insulating concrete wall form building system comprised of a wall form which has self-aligning ribs on the bottom of the forms and grooves to receive the ribs on the top of the forms, thereby providing a means of locking successive courses of forms together thus strengthening and stabilizing the wall system against unforeseen lateral forces applied to the wall system prior to filling the forms with concrete.
Additional shortcomings of the prior art are overcome and additional advantages are provided through the provision of a non-polystyrene insulating concrete wall form building system comprised of a wall form which includes a mechanism for clamping adjacent wall forms tightly together within the courses of the wall, thereby enhancing wall strength and stability against any unforeseen lateral forces applied to the wall system prior to filling the forms with concrete.
Additional shortcomings of the prior art are overcome and additional advantages are provided through the provision of a non-polystyrene insulating concrete wall form building system comprised of a wall form which includes, a mechanism for precisely positioning horizontal and vertical concrete reinforcement bars within the form, thereby enhancing the structural performance of the final wall structure.
Additional shortcomings of the prior art are overcome and additional advantages are provided through the provision of a non-polystyrene insulating concrete wall form building system comprised of a wall form, the geometry of the wall form's vertical cores and middle web being such that the forms may be stacked longitudinally in both running bond and stack bond configurations while ensuring that no air pockets, ledges or otherwise incomplete concrete fill occurs within the forms' cores.
Additional shortcomings of the prior art are overcome and additional advantages are provided through the provision of a stack bond configuration transverse to the more conventional longitudinal direction in cases where, a thicker, “super insulated” wall assembly might be desired for climates that have extreme temperatures. This orientation of the forms 90° to the longitudinal orientation provide enhanced thermal properties for the wall assembly due to the greater depth of insulation in the outside cores. In an exemplary embodiment of the present invention, because of the non-polystyrene insulating concrete form's unique proportions and smooth-ended geometry, this transverse orientation is possible without disrupting the required alignment of form cores required for proper structural performance.
Additional shortcomings of the prior art are overcome and additional advantages are provided through the provision of, from logistical and customer value perspectives, a palletized shipping configuration of insulating concrete forms which is more dense and less prone to form breakage as a result of the present invention smooth end configurations.
Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention. For a better understanding of the invention with advantages and features, refer to the description and to the drawings.

BRIEF DESCRIPTION OF THE FIGURES

The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

FIGS. 1A-1J illustrate examples of the non-polystyrene insulated concrete form which is part of the simplified non-polystyrene permanent insulating concrete form building system;

FIGS. 2A-2R illustrate examples of the simplified non-polystyrene permanent insulating concrete form building system; and

FIG. 3 illustrates one example of a method of securing non-polystyrene insulated concrete forms and positioning reinforcement bars during construction of a concrete structure.

The detailed description explains the preferred embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.

REFERENCE NUMERALS IN THE FIGURES

- 100, 100A-D Non-polystyrene insulated concrete form
- 101 Smooth, unarticulated non-polystyrene insulated concrete form end face
- 102 Smooth, unarticulated non-polystyrene insulated concrete form side wall
- 103 Vertical core
- 104 Double middle web
- 105 Insulation insert cavity
- 106 Insulation insert retaining tab
- 107 Self-aligning grooves
- 108 Self-aligning ribs
- 109 Horizontal bond beam cavity
- 110 Middle web integral slot
- 111 Saw kerf to create non-polystyrene insulated concrete half form
- 112 Concrete fill
- 113 Insulation
- 200 Fastening clip
- 201 Horizontal reinforcement bar holder snap-off base extension
- 202 Clamping leg support
- 203 Receptacle
- 204 Upper lateral cross member
- 205 Clamping leg
- 206 Lower lateral cross member
- 207 Foot
- 208 Reinforcing ribs
- 209 Gripping teeth
- 210 Horizontal reinforcement bar holder
- 211 Horizontal reinforcement bar
- 212 Horizontal reinforcement bar holder saddle
- 213 Vertical reinforcement bar
- 214 Horizontal reinforcement bar holder leg
- 215 Horizontal reinforcement bar holder locator tab gripping teeth
- 216 Horizontal reinforcement bar holder base
- 218 Horizontal reinforcement bar holder locator tab
- 219 Vertical-to-horizontal reinforcement bar holder connector transverse cross member
- 220, 220A-B Reinforcement bar holder
- 221 Reinforcement bar holder assembly
- 222 Reinforcement bar holder saddle also referred to as a second saddle
- 223 Reinforcement bar holder connector leg
- 224 Reinforcement bar holder connector
- 225 Reinforcement bar holder connector foot
- 226 Reinforcement bar holder base
- 227 Saddle leg
- 228 Reinforcement bar holder
- 229 Saddle
- 230 Clip alignment holder
- 231 Clearance support

DETAILED DESCRIPTION OF THE INVENTION

Use of the term ‘course’, in the present invention and as used in the building trade, is intended to mean a continuous and usually horizontal range of brick, shingles, non-polystyrene insulated concrete forms, or other materials as in a wall, roof, or other structure.
Turning now to the drawings in greater detail, it will be seen that in FIGS. 1A-1J there are illustrated examples of the non-polystyrene insulated concrete form which is part of the simplified non-polystyrene permanent insulating concrete form building system.
In an exemplary embodiment the simplified insulating concrete form building system is illustrated in FIGS. 1A to 1J. Referring to FIG. 1A there is illustrated one example of a non-polystyrene insulated concrete form 100 further comprising smooth non-articulated end faces 101, smooth non-articulated side walls 102, vertical cores 103, double middle web 104 with its middle web integral slot 110 which extends across the non-polystyrene insulated concrete form 100 to the inside faces of the side walls 102 and completely through the non-polystyrene insulated concrete form 100 from top to bottom. The non-polystyrene insulated concrete form 100 further comprising insulation insert cavities 105 each cavity 105 having two insulation retaining tabs 106, self-aligning assembly grooves 107, and self-aligning assembly ribs 108 which correspond to the self-aligning assembly grooves 107 when the non-polystyrene insulated concrete forms 100 are stacked. In an exemplary embodiment, for example and not a limitation, non-polystyrene insulated concrete form 100 can be twelve inches high×twelve inches wide×twelve inches long, or other dimensions, as may be required and/or desired in a particular embodiment.
In an exemplary embodiment, it is the non-polystyrene insulated concrete form 100 smooth-faced geometry, self-aligning ribs 108 and grooves 107 and internal double middle web 104 with its middle web integral slot 110, among other features, which, when combined with the present inventions fastening clip 200 and reinforcement bar holders 210 and/or 220, cooperate to provide a system for securing non-polystyrene insulated concrete forms and positioning reinforcement bars during construction of a concrete structure. In this regard, an advantage of the present invention over the prior art wall forms include design modularity, speed of assembly, accuracy in reinforcement bar positioning, with its attendant assurance of complete concrete cover of the reinforcement bar, increased stability during construction and less susceptibility to shipping damage.
In an exemplary embodiment, the non-polystyrene insulated concrete form 100 is molded from a mixture of hardwood and/or softwood chips coated with organic, non-toxic chemical compounds used to isolate the chips' inherent organic sugars. The coated chips are then mixed with Portland cement and water to create a fictile, moldable mixture. Ideally, the wood chips are created from clean, post-industrial waste wood such as might come from lumber mills, pallet re-manufacturers, etc. However, the non-polystyrene insulated concrete form's mixture can consist of organic chips, strands or fibers of materials other than hardwood or softwood. These alternative materials could include but not be limited to bamboo, coconut shells or rice hulls, etc., provided these materials have sufficient strength, durability and other characteristics to make a suitable non-polystyrene insulated concrete form 100.
This mixture of treated wood chips, Portland cement and water is formed in a mold, cured for a period of time to facilitate the time-dependent strengthening of the Portland cement and then trimmed to final dimension and particular use configuration such as a straight, corner or end-of-wall non-polystyrene insulated concrete form 100.
Referring to FIG. 1B there is illustrated one example of the non-polystyrene insulated concrete form 100 further comprising a horizontal bond beam cavity 109, which is cut longitudinally completely across top and bottom of the non-polystyrene insulated concrete form 100.
Referring to FIG. 1C there is illustrated one example of the non-polystyrene insulated concrete form 100 further comprising the horizontal bond beam cavity 109 cut into the form 100 on the top and bottom of the form 100 at a 90 degree angle. In this exemplary embodiment, non-polystyrene insulated concrete form 100 is configured for use, by the horizontal bond beam cavity 109 being cut at a 90 degree angles as a corner non-polystyrene insulated concrete form 100.
Referring to FIG. 1D there is illustrated one example of a non-polystyrene insulated concrete form 100 further comprising the horizontal bond beam cavity 109 cut longitudinally into non-polystyrene insulated concrete form 100 on the top and bottom of the form but short of one end of the non-polystyrene insulated concrete form 100. In this exemplary embodiment, non-polystyrene insulated concrete form 100 is configured for use, by the horizontal bond beam cavity 109 cut being short of one end of the non-polystyrene insulated concrete form 100 for use at window, door and other opening jamb locations and as an end-of-wall non-polystyrene insulated concrete form 100.
Referring to FIG. 1E there is illustrated examples of non-polystyrene insulated concrete form 100A-D. In this regard, in an exemplary embodiment, for example and not a limitation, non-polystyrene insulated concrete forms can be formed and cut to suit the design need, as may be required and/or desired for a particular embodiment. As an example, non-polystyrene insulated concrete form 100A-C illustrates a straight form configuration. Corner and end-of-wall non-polystyrene insulated concrete form 100A-C is equally possible with appropriate cuts as previously disclosed.
Furthermore, any of the straight non-polystyrene insulated concrete form 100A-C may be used as a lintel non-polystyrene insulated concrete form 100D to span openings in the wall for windows, doors, etc. at the opening's head location. These lintel non-polystyrene insulated concrete forms may be created by removing one of the non-polystyrene insulated concrete form's end webs and the double middle web 104. Use of these lintel non-polystyrene insulated concrete forms is also shown in FIG. 1I.
In an exemplary embodiment, the non-polystyrene insulated concrete form 100A-D illustrated can be twelve inches high×twelve inches wide×twenty four inches long straight non-polystyrene insulated concrete form, or an eight inch high×twelve inch wide×twenty four inch long straight non-polystyrene insulated concrete form, or a twelve inch high×eight inch wide×twenty four inch long straight non-polystyrene insulated concrete form, or other dimensions, as may be required and/or desired in a particular embodiment.
Referring to FIG. 1F there is illustrated one example of the non-polystyrene insulated concrete form 100 which can comprise optional insulation 113 inserted into insulation insert cavity 105, for improved thermal and sound insulation. In an exemplary embodiment, the non-polystyrene insulated concrete form 100 can further comprise insulation 113.
Referring to FIG. 1G there is illustrated one example of the non-polystyrene insulated concrete form 100 cut the depth of and through the non-polystyrene insulated concrete form 100 side walls 102. The saw kerf 111 illustrated would normally be made, in an exemplary embodiment, with a circular, reciprocating, chain or other suitable saw across the side walls and in alignment with the non-polystyrene insulated concrete form's middle web integral slot 110, located in the double middle web 104, thereby creating two halves of the non-polystyrene insulated concrete form 100A-B. In an exemplary embodiment, such saw kerf 111 can be a ⅛ inch saw kerf, or other dimension saw kerf, as may be required and/or desired in a particular embodiment. In addition, this cut is typically made in alignment with the double middle web's molded-in slot 110. In this regard, by cutting through the side walls in this manner, two smaller non-polystyrene insulated concrete forms 100A and 100B may be created at the construction site when needed.
Referring to FIG. 1H there is illustrated one example of an embodiment of four horizontal reinforcement bars 211, placed in a single horizontal cavity within two stacked non-polystyrene insulated concrete forms 100A and 100B. In an exemplary embodiment, this can be accomplished by inserting the horizontal rebar holders 210 and/or 220 (not shown in this Figure) in both upright and upside down positions in the middle double middle web integral slot 110 located in each of the two non-polystyrene insulated concrete forms 100A-B, each having horizontal bond beam cavity 109 aligned to allow the reinforcement bar 211 to extend through each of the non-polystyrene insulated concrete forms 100A-B.
Referring to FIG. 1I there is illustrated one example of an exemplary embodiment of a wall assembly located at the corner of a building and highlighted for illustrative purposes non-polystyrene insulated concrete forms 100A-C. In this regard, the non-polystyrene insulated concrete forms 100A illustrates a straight configuration, the non-polystyrene insulated concrete forms 100B illustrates a corner configuration, and the non-polystyrene insulated concrete forms 100C illustrates an end-of-wall configuration. The Figure illustrates how elements of the present invention building system can be combined to create a corner wall assembly. As illustrated, the standard straight non-polystyrene insulated concrete form 100A, the corner non-polystyrene insulated concrete form 100B, and the end-of-wall non-polystyrene insulated concrete form 100C, are all used in the exemplary wall assembly. Portions of the non-polystyrene insulated concrete forms have been removed from the Figure for clarity to illustrate the position of vertical reinforcement bars 213 and horizontal reinforcement bars 211 as well as the concrete fill 112.
In an exemplary embodiment, as an appropriate height of wall is reached, concrete is placed within the non-polystyrene insulated concrete forms covering the reinforcement bars 211 and their holders and filling the non-polystyrene insulated concrete forms with concrete completely.
Referring to FIG. 1J there is illustrated one example of an exemplary embodiment of straight non-polystyrene insulated concrete forms 100, wherein the non-polystyrene insulated concrete forms 100 are placed in an orientation transverse to the usual longitudinal direction so as to create a more heavily insulated, thicker wall for use in environments of climatic extremes. This orientation is accomplished by simply changing the orientation of the non-polystyrene insulated concrete forms 100 horizontal bond beam cavity 109 by 90 degrees.
Referring to FIGS. 2A-2R there is illustrated examples of the simplified non-polystyrene permanent insulating concrete form building system. In an exemplary embodiment the non-polystyrene insulated concrete forms can be used with a plurality of fasteners and reinforcement bar holders to effectuate a system for securing non-polystyrene insulated concrete forms and positioning reinforcement bars during construction of a concrete structure. The Figures illustrate exploded and assembled isometric views of the present invention fastening clip 200 and various horizontal and vertical reinforcement bar holders 210 and 220 as well as these holders' positions within wall assemblies. The non-polystyrene insulated concrete forms, fasteners 200, holders 210, 220, and 228, and the various other elements of the present invention operate together as a simplified non-polystyrene permanent insulating concrete form building system.
In an exemplary embodiment, the fastening clips 200 and the reinforcement bar holders 210, 220, 228 can be injection molded from reinforced nylon. However, they may also be manufactured by other molding, extruding, stamping or other suitable forming processes, as may be required and/or desired in a particular embodiment. They may also be made from other materials such as polypropylene, poly-vinyl chloride or any other material which provides suitable strength and flexibility characteristics.
Referring to Figure FIG. 2A there is illustrated one example of a fastening clip 200, used for clamping together adjacent non-polystyrene permanent insulating concrete forms 100. The fastening clip 200 further comprises a pair of clamping leg supports 202, each comprising a transverse top member integrally formed with a clamping leg 205, and a foot 207 on the free end of each of the clamping leg 205. This provides a narrowed aperture at the location of the foot 207 to facilitate the tightest possible positioning of the fastening clip 200 over two non-polystyrene permanent insulating concrete form 100's abutted webs. The pair of legs 205 is connected by a lateral top member 204, and two lower lateral cross members 206, which also include web-gripping teeth 209. The gripping teeth 209 are integrally molded at an angle so as to give the teeth 209 a type of one-way action. In this regard, positioning the fastening clip 200 over the non-polystyrene permanent insulating concrete forms 100 abutted webs is easily done as the fastening clip 200 is pushed down over the webs but then hard to subsequently remove as the fastening clip 200's, teeth 209, tend to bite into the non-polystyrene permanent insulating concrete form 100 surface. The fastening clip 200 can be removed as a conscious act but will not come loose by merely bumping the two non-polystyrene permanent insulating concrete forms 100. This one-way action of the gripping teeth 209 provides a more solid connection at the non-polystyrene permanent insulating concrete forms 100 abutted webs. Each of the clamping leg 205 also includes integral reinforcing ribs 208, formed into the legs 205, and the transverse top member clamping leg support 202, so as to increase the clamping pressure as the legs 205 are spread apart when the fastening clip 200 is forced down over adjacent non-polystyrene permanent insulating concrete forms 100 abutted webs. The outside surfaces of the upper and lower transverse cross members 204 and 206 also provide a place for embossing or otherwise imprinting important marketing information such as brand name, web site location, etc., or assembly information, as may be required and/or desired in a particular embodiment.
Referring to FIG. 2B there is illustrated one example of a fastening clip 200 and a pair of reinforcement bar holders 228. In an exemplary embodiment, a system for securing non-polystyrene insulated concrete forms and positioning reinforcement bars during construction of a concrete structure can comprise at least one of a non-polystyrene insulated concrete form 100 and a fastening clip 200 which can have a top member 204, the top member 204 can further comprise at least one of a receptacle 203 integrally formed in the top member 204, the receptacle 203 locates, orientates, and fastens with at least one of a reinforcement bar holder 228, the fastening clip 200 holds together at least two of the non-polystyrene insulating concrete form 100, the fastening clip 200 further comprises at least two of a clamping leg 205 which are juxtaposed, wherein when the fastening clip 200 is applied to at least two of the non-polystyrene insulating concrete form 100 each of the clamping leg 205 grips at least one of the non-polystyrene insulating concrete form 100.
In another exemplary embodiment, each of fastening clip 200 clamping leg 205 disposed are at either end of the top member 204 and one end of the clamping leg 205 is formed integrally with the top member 204 the other end of the clamping leg 205 is a free end, each of the clamping leg 205 forms an acute angle to the longitudinal axis of the top member 204, the longitudinal axis being the axis which traverses the top member 204 between each of the clamping leg 205, wherein the distance between each of the clamping leg 205 measured between attach points with the top member 204 is greater than the distance measured between each of the free ends, creating a friction fit with at least two of the non-polystyrene insulating form 100.
In another exemplary embodiment, each of the clamping leg 205 further comprises a foot 207 formed integrally with the free end of the clamping leg 205, the foot 207 curving outwardly from the clamping leg 205 forming a widened aperture between each of the clamping leg 205.
In another exemplary embodiment, each of the clamping leg 205 are connected to one end of each of at least two of a lower cross member 206, the other end of each of the lower cross member 206 is integrally formed into an upper cross member 204, and each of the clamping leg 205 comprising a plurality of gripping teeth 209 integrally formed with and located on the interior surface of each of the clamping leg 205.
In another exemplary embodiment, a horizontal reinforcement bar holder 228 comprises a first end and a second end, a saddle 229 disposed and integrally formed at the first end, the second end is attachable to the fastening clip 200, wherein the saddle 229 engages a horizontally orientated reinforcement bar 211 (not shown in this Figure) creating a fixed distance between the non-polystyrene insulating concrete form and the horizontally orientated reinforcement bar 211. Furthermore the horizontal reinforcement bar holder 228 can further comprise a reinforcement bar holder base 226 which can be utilized to interlock the horizontal reinforcement bar holder 228 by way of the reinforcement bar holder base 226 with the fastening clip 200, receptacle 203. The saddle 229 can be used to hold reinforcement bars 211 of a range of diameters in precise locations within the concrete form.
Referring to FIG. 2C there is illustrated one example of an exemplary embodiment of a fastening clip 200 and a reinforcement bar holder 220. Fastening clip 200 can be configured with a pair of legs 205 each having a foot 207 and gripping teeth 209 disposed thereon. The legs 205 are integrally formed into a top member 204. A plurality of receptacles 203 are formed into the top member 204. Also illustrated is horizontal bar holder 220. The receptacle 203 can optionally locate, orientate, and fasten with at least one of a reinforcement bar holder 220.
Also illustrated in FIG. 2C is one example of a reinforcement bar holder 220, which includes a reinforcement bar saddle 222 formed by a pair of parallel saddle legs 227, and two of a connector 224. The connector 224 is comprised of at least one of a transverse cross member 219, two legs 223, and two tapered feet 225. Saddle 222 snaps to reinforcement bars 211 and 213. The saddle 222 can be used to hold reinforcement bars 211 of a range of diameters in precise locations within the concrete form. Also illustrated is a clip alignment holder 230 integrally formed on the end of top member 204. The clip alignment holder 230 aligns the fastening clip 200 in the center of the horizontal bond beam cavity 109. Furthermore, also illustrated is a clearance support 231 integrally formed on the underside surface of top member 204. The clearance support 231 raise the fastening clip top member 204 slightly off the surface of the form 100 to allow clearance of the feet 225 when the reinforcement bar holder 220 is inserted into the receptacle 203. This prevents interference and damage of the feet 225 and/or surface of form 100 from occurring.
In another exemplary embodiment, at least one of a non-polystyrene insulated concrete form 100 and a fastening clip 200 having a top member 204, the top member 204 further comprises at least one of a receptacle 203 integrally formed in the top member 204, the fastening clip 200 holds together at least two of the non-polystyrene insulating concrete form 100. A reinforcement bar holder 220 having at least two of a parallel saddle leg 227 contoured and integrally formed to form a saddle 222 (also referred to as a second saddle 222) between the interior surfaces of the parallel saddle leg 227, the saddle 222 is orientated to support a reinforcement bar 211 and at least one of a connector 224 integrally formed on the other end, the connector 224 comprising a cross member 219 and at least two of a connector leg 223, one end of the connector leg 223 being integrally formed with the cross member 219 and the other end of the connector leg 223 comprising a foot 225, each of the foot 225 being orientated on the connector leg 223, the connector leg 223 either fastens with at least one of the receptacles 203 which locates, orientates, and fastens the reinforcement bar holder 220 with the top member 204 or fastens with a second reinforcement bar holder 220, wherein the reinforcement bar holder 220 supports the reinforcement bar 211 or 213 in predetermined and precise location within the non-polystyrene insulated concrete form 100.
Referring to FIG. 2D-F there is illustrated one example of an exemplary embodiment of fastening two adjacent non-polystyrene insulating concrete forms 100A and 100B. FIG. 2D illustrates how the non-polystyrene insulating concrete forms 100A and 100B can be aligned by way of the non-polystyrene insulating concrete forms' horizontal bond beam cavities 109 prior to fastening with a fastening clip 200 and/or insertion of reinforcement bar holders 210 and/or 220 (not shown in this Figure). FIG. 2E illustrates the positioning of the non-polystyrene insulating concrete forms and fastening clip 200. FIG. 2F illustrates the final assembly.
Referring to FIG. 2G there is illustrated one example of a horizontal reinforcement bar holder 210 suitable for securing within saddle 212 a single horizontal reinforcement bar 211 (not shown in this Figure). The horizontal reinforcement bar holder 210 holder has a reinforcement bar saddle 212, two support legs 214, a base 216, two snap-off base extensions 201, and a locator tab 218 with integral gripping teeth 215. The saddle 212 can be used to hold reinforcement bars 211 of a range of diameters in precise locations within the concrete form.
In an exemplary embodiment, the horizontal reinforcement bar holder 210 has a reinforcement bar saddle 212 which can be used to hold reinforcement bars 211 of a range of diameters in precise locations within the concrete form. The reinforcement bar saddle 212 is connected to two support legs 214, which can be formed at various lengths and which rest on a base 216. The base 216 has two snap-off base extensions 201, which can be removed when more than one horizontal reinforcement bar holder is required in the same location. Each horizontal reinforcement bar holder 210 also has a locator tab 218, with integral gripping teeth 215 which can be integrally molded into the locator tab 218 so as to project outward from one face of the locator tab 218. The middle vertical portion of the locator tab 218 can provide a place for embossing or otherwise imprinting the locator tab with important marketing information such as brand name, web site location, etc., or assembly information, as may be required and/or desired in a particular embodiment.
In another exemplary embodiment, a horizontal reinforcement bar holder 210, used in combination with the fastening clip 200, comprises a first end and a second end, a saddle 212 disposed and integrally formed at the first end, a base 216 is integrally formed between the first end and second end, the base 216 comprising a plurality of removable extensions 201, a locator tab 218 is integrally formed at the second end, wherein the saddle 212 engages a horizontally orientated reinforcement bar 211, the locator tab 218 is inserted into a non-polystyrene insulating concrete form 100, the base 216 contacts the surface of the non-polystyrene insulating concrete form 100 creating a fixed distance between the non-polystyrene insulating concrete form 100 and the horizontally orientated reinforcement bar 211 and supports the horizontally orientated reinforcement bar 211 in a predetermined and precise location within horizontal cavities 209 of the non-polystyrene insulating concrete form.
Referring to FIGS. 2H-J there is illustrated one example of an exemplary embodiment of how a horizontal reinforcement bar holder 210, can be used to hold a horizontal reinforcement bar 211 in position within non-polystyrene insulating concrete forms 100A and 100B. Referring to FIG. 2H there is illustrated one example of the horizontal reinforcement bar holder 210 being located above the middle web integral slot 110 of a non-polystyrene insulating concrete form 100A.
Referring to FIG. 2I there is illustrated one example of the horizontal reinforcement bar holder 210 being shown in final position with its locator tab 218, inserted into the non-polystyrene insulating concrete forms 100 middle web integral slot 110. A reinforcement bar 211 is securely snapped into position by way of the reinforcement bar saddle 212.
Referring to FIG. 2J there is illustrated one example of two horizontal reinforcement holders 210, in final position, within two adjacent non-polystyrene insulating concrete forms 100A and 100B, held together at their end webs by a fastening clip 200. A single reinforcement bar 211 is located in final position within in the horizontal reinforcement bar holders 210, reinforcement bar saddles 212.
Referring to FIG. 2K there is illustrated one example of an exemplary embodiment of horizontal reinforcement bar holders 210A and 210B. In this exemplary embodiment, by breaking off the horizontal reinforcement bar holder's snap-off base extensions 201 (not shown in this Figure), on both ends of the horizontal reinforcement bar holder 210, two horizontal reinforcement bar holders 210A and 210B may be combined for those situations where additional horizontal reinforcement bars 211 are required in the same horizontal bond beam cavity 109.
Referring to FIG. 2L there is illustrated one example of the use of the double horizontal reinforcement bar holders 210 configuration previously described with two standard horizontal reinforcement bar holders 210A and 210B and two horizontal reinforcement bars 211A and 211B in a single horizontal bond beam cavity 109.
Referring to FIG. 2M there is illustrated one example of a reinforcement bar holder 220, which includes a reinforcement bar saddle 222 formed by a pair of parallel saddle legs 227, and a connector 224. The connector 224 is comprised of a transverse cross member 219, two legs 223, and two tapered feet 225.
In an exemplary embodiment, a reinforcement bar holder 220 comprises a saddle 222 integrally formed on one end which is orientated to support a reinforcement bar 211 and a connector 224 integrally formed on the other end, the connector 224 comprising a cross member 219 and at least two of a connector leg 223, one end of the connector leg 223 being integrally formed with the cross member 219 and the other end of the connector leg 223 comprising a foot 225, each of the foot 225 being orientated on the connector leg 223 to facilitate the reinforcement bar holder 220 fastening to a second reinforcement bar holder 220 or to the fastening clip 200, wherein the reinforcement bar holder 220 supports the reinforcement bar 211 in predetermined and precise locations within the non-polystyrene insulated concrete form.
Referring to FIG. 2N there is illustrated one example of a reinforcement bar holders 220A and 220B, juxtaposed in mirror image to one another and turned 90 degrees with respect to their longitudinal axes to facilitate attachment to each other so as to complete a vertical-to-horizontal reinforcement bar holder assembly. The assembly is made by sliding the tapered feet 225 of one reinforcement bar holder 220A over the other reinforcement bar holder until the feet snap into place above the transverse cross member 219, of the second reinforcement bar holder 220B. FIG. 2O illustrates the completed vertical-to-horizontal reinforcement bar holder assembly comprised of two reinforcement bar holders 220A and 220B.
Referring to FIGS. 2P-2R there is illustrated one example of an exemplary embodiment of how reinforcement bar holders 220, can be used to hold a vertical reinforcement bar 211 in position within a non-polystyrene insulating concrete forms 100A and 100B. FIG. 2P illustrates a reinforcement bar holder 220 shown above its intended final position which would be snapped to a horizontal reinforcement bar 211, within a non-polystyrene insulated concrete form 100. Referring to FIG. 2Q there is illustrated one example of two reinforcement bar holders 220A and 220B snapped together to form a vertical-to-horizontal reinforcement bar holder assembly within the non-polystyrene insulated concrete form 100. Referring to FIG. 2R there illustrated one example of a completed vertical-to-horizontal reinforcement bar holder assembly 220A-B, in final position snapped to a horizontal reinforcement bar 211, and snapped to a vertical reinforcement bar 213, within a non-polystyrene insulated concrete form 100.
In an exemplary embodiment, a system of securing non-polystyrene insulated concrete forms and positioning reinforcement bars during construction of a concrete structure can comprise at least one of a non-polystyrene insulated concrete form 100 and at least one of a fastening clip 200, the fastening clip 200 having a top member 204, the top member 204 further comprises at least one of a receptacle 203 integrally formed in the top member 204, the receptacle 203 locates, orientates, and fastens with at least one of a reinforcement bar holder 210, the fastening clip 200 holds together at least two of the non-polystyrene insulating concrete forms 100. A horizontal reinforcement bar holder 210, used in combination with the fastening clip 200, further comprises a first end and a second end, a saddle 212 disposed and integrally formed at the first end, a base 216 is integrally formed between the first end and second end, the base 216 comprising a plurality of removable extensions 201, a locator tab 218 is integrally formed at the second end, the locator tab 218 thickness and length are sized to fit into a slot 110 formed in a structural cross member of a non-polystyrene insulated concrete form 100, the locator tab 218 is shaped at the second end and has a plurality of gripping teeth 215 integrally formed therein which cause the horizontal reinforcement bar holder 210 to be friction-fit and retained within the slot 110, wherein the saddle 212 engages a horizontally orientated reinforcement bar 211, the locator tab 218 is inserted into the non-polystyrene insulating concrete form 100, the base 216 contacts the surface of the non-polystyrene insulating concrete form 100 creating a fixed distance between the non-polystyrene insulating concrete form 100 and the horizontally orientated reinforcement bar 211 and supporting the horizontally orientated reinforcement bar 211 in predetermined and precise location within horizontal cavities 109 of the non-polystyrene insulating concrete form 100.
In another exemplary embodiment, the fastening clip 200 further comprises at least two of a clamping leg 205 which are juxtaposed, wherein when the fastening clip 200 is applied to at least two of the non-polystyrene insulating concrete form 100 each of the clamping leg 205 grips at least one of the non-polystyrene insulating concrete form 100.
In another exemplary embodiment, the fastening clip 200 further comprises a top member 204, each of the clamping leg 205 are disposed at either end of the top member 204 and one end of the clamping leg 205 is formed integrally with the top member 204 the other end of the clamping leg 205 is a free end, each of the clamping leg 205 forms an acute angle to the longitudinal axis of the top member 204, the longitudinal axis being the axis which traverses the top member 204 between each of the clamping legs 205, wherein the distance between each of the clamping leg 205 measured between attach points with the top member 204 is greater than the distance measured between each of the free ends.
In another exemplary embodiment, each of the clamping leg 205 further comprises a foot 207 formed integrally with the free end, the foot 207 curving outwardly from the clamping leg 205 forming a widened aperture between each of the clamping leg 205.
In another exemplary embodiment, each of the clamping leg 205 are connected to one end of each of at least two of a lower cross member 206, the other end of each of the lower cross member 206 is integrally formed into an upper cross member 204, and each of the clamping leg 205 comprising a plurality of gripping teeth 209 integrally formed with and located on the interior surface of each of the clamping leg 205.
In another exemplary embodiment, a reinforcement bar holder 220 comprising a support saddle 222 integrally formed on one end which is orientated to support a reinforcement bar 211 and a connector 224 integrally formed on the other end, the connector 224 comprising a cross member 219 and at least two of a connector leg 223, one end of the connector leg 223 being integrally formed with the cross member 219 and the other end of the connector leg 224 comprising a foot 225, each of the foot 225 being orientated on the connector leg 224 to facilitate the reinforcement bar holder 220 fastening to a second reinforcement bar holder 220 or to the fastening clip 200, wherein the reinforcement bar holder 220 supports the reinforcement bar 211 or 213 in predetermined and precise locations within the non-polystyrene insulated concrete form 100.
In another exemplary embodiment, at least one of a non-polystyrene insulated concrete form 100 and a fastening clip 200 having a top member 204, the top member 204 further comprises at least one of a receptacle 203 integrally formed in the top member 204, the fastening clip 200 holds together at least two of the non-polystyrene insulating concrete form 100. A reinforcement bar holder 220 having at least two of a parallel saddle leg 227 contoured and integrally formed to form a saddle 222 (also referred to as a second saddle 222) between the interior surfaces of the parallel saddle leg 227, the saddle 222 is orientated to support a reinforcement bar 211 and at least one of a connector 224 integrally formed on the other end, the connector 224 comprising a cross member 219 and at least two of a connector leg 224, one end of the connector leg 224 being integrally formed with the cross member 219 and the other end of the connector leg 224 comprising a foot 225, each of the foot 225 being orientated on the connector leg 224, the connector leg 224 either fastens with at least one of the receptacles 203 which locates, orientates, and fastens the reinforcement bar holder 220 with the top member 204 or fastens with a second reinforcement bar holder 220, wherein the reinforcement bar holder 220 supports the reinforcement bar 211 or 213 in predetermined and precise location within the non-polystyrene insulated concrete form 100.
Referring to FIG. 3 there is illustrated one example of a method of securing non-polystyrene insulated concrete forms and positioning reinforcement bars during construction of a concrete structure.
In block 1002, at least two of a non-polystyrene insulating concrete form 100 are aligned, the non-polystyrene insulating concrete form 100 having a double middle web integral slot 110.
In an exemplary embodiment of the present invention, non-polystyrene insulated concrete forms 100 are assembled together to create wall assemblies by dry-stacking (i.e., no mortar between forms) successive courses of a non-polystyrene insulated concrete forms one upon another, usually with the longer longitudinal dimension of the a non-polystyrene insulated concrete forms in alignment with the plane of the wall. The non-polystyrene insulated concrete forms may be stacked in either running bond (i.e., vertical joints between non-polystyrene insulated concrete forms staggered to align with mid-point of forms immediately above and below it) or stack bond (vertical joints between non-polystyrene insulated concrete forms aligned in each successive course).
To begin a wall assembly, two non-polystyrene insulated concrete forms such as straight non-polystyrene insulated concrete forms 100 are aligned end to end, aligning the non-polystyrene insulated concrete forms' horizontal bond beam cavities 109, as previously described. The method moves to block 1004.
In block 1004, at least two of the non-polystyrene insulating concrete forms 100 are secured with at least one of a fastening clip 200. In this regard, a fastening clip 200 clamps together the abutted end webs of the adjacent non-polystyrene insulated concrete forms. Successive non-polystyrene insulated concrete forms in course can be placed in like manner until the entire course of forms is completed. The different configurations of non-polystyrene insulated concrete forms, which include the straight, the corner, the end-of-wall, and other non-polystyrene insulated concrete form assemble are fastened in the same manner. The method moves to block 1006.
In block 1006, positioning at least one of a horizontal reinforcement bar holder 210 within certain of the double middle web integral slot 110, the horizontal reinforcement bar holder 210 having a saddle 212 for retaining a reinforcement bar 211. In this regard, once the first course's forms have been so aligned and interconnected with web fastening clips 200, the horizontal reinforcement bar holders 210 can be inserted at appropriate intervals along the length of the wall into the non-polystyrene insulated concrete forms' double middle web integral slots 110, within the non-polystyrene insulated concrete forms' horizontal bond beam cavity 109. The method moves to block 1008.
In block 1008, placing the reinforcement bar 211 into the saddle 212. In this regard, with the horizontal reinforcement holders 210 located in their corresponding double middle web integral slots 110, the horizontal reinforcement bar 211 may be snapped into the horizontal reinforcement bar holder saddle 212. The method moves to block 1010.
In block 1010, positioning at least one of a horizontal-to-vertical (pair of reinforcement bar holders 220 snapped together) reinforcement bar holder on the reinforcement bar 211, the horizontal-to-vertical reinforcement bar holder 220 having a second saddle 222 for retaining a second reinforcement bar 211 or 213. In this regard, with the horizontal reinforcement bars 211 in position, vertical reinforcement bars 213 may be located precisely where desired according to the particular wall's design by using vertical-to-horizontal reinforcement bar holder 220, as previously described. The method moves to block 1012.
In block 1012, placing the second reinforcement bar into the second saddle 222.
Subsequent courses are assembled in a similar manner. As the non-polystyrene insulated concrete forms in succeeding courses are stacked upon the non-polystyrene insulated concrete forms immediately beneath them, the non-polystyrene insulated concrete forms' self-aligning ribs 108 are seated in the corresponding self-aligning grooves 107 of the forms in the course immediately below. These ribs and grooves facilitate vertical positioning and alignment of the non-polystyrene insulated concrete forms in the plane of the wall and interlock the non-polystyrene insulated concrete forms in the vertical plane of the wall, further strengthening the wall prior to filling the non-polystyrene insulated concrete forms with concrete. All courses of non-polystyrene insulated concrete forms are placed in accordance with this same procedure of clamping adjacent forms together with fastening clamps 200 and precisely positioning horizontal reinforcement bars 211 and vertical reinforcement bars 213 by snapping them into their respective horizontal reinforcement bar holders 210 and/or 220. The method moves to block 1014.
In block 1014 non-polystyrene insulated concrete forms 100 are filled with concrete 112. The method is exited.
An advantage of the present invention is that a single basic non-polystyrene insulated concrete form can be used to provide straight, corner, end-of-wall, half forms and lintel forms which simplifies modular building planning by eliminating special corner forms and using a single dimensional module.
In addition, the smooth, non-articulated faces of the non-polystyrene insulated concrete form simplify the assembly of a wall by not requiring the construction worker to match male-female ends, thereby reducing assembly errors, unnecessary handling of and/or damage to the non-polystyrene insulated concrete forms and corresponding worker fatigue
Furthermore, by virtue of its smooth faces, there are no projections on the non-polystyrene insulated concrete form to interfere with a tight palletizing of the non-polystyrene insulated concrete forms 100 for shipment, thereby providing for a more compact shipment within the dimensional limits of the pallet. This results in less possibility of damage to the non-polystyrene insulated concrete forms 100 in loading, in transit and in unloading, thereby resulting in cost savings.
Another advantage of the present invention is that the fastening clip 200 used to clamp adjacent wall forms together enhances wall stability and alignment of non-polystyrene insulated concrete forms in the horizontal plane of the wall during construction prior to the wall forms being filled with concrete.
In addition, the non-polystyrene insulated concrete form's self-aligning ribs 108 and grooves 107 on the bottom and top of each non-polystyrene insulated concrete form enhance wall stability and alignment of non-polystyrene insulated concrete forms in the vertical plane of the wall during construction prior to the wall forms being filled with concrete.
Furthermore, the non-polystyrene insulated concrete form's double middle web 104 with its middle web integral slot 110 serves to provide for the precise location of horizontal reinforcement bar holders 210. The double middle web 104 with its middle web integral slot 110 also functions as a cutting guide whereby two half forms 100 may be realized by cutting through the form's 100 side walls in alignment with the slot.
An advantage in the present invention of the horizontal reinforcement bar holder 210 provides for a positive and precise location of single or multiple horizontal reinforcement bars 210 within the horizontal bond beam cavity 109 of the wall. This ensures the reinforcement bars 211 can be positioned according to the drawings and specifications of the construction project. This precise positioning of the horizontal reinforcement 211 better ensures a more complete structural performance of the reinforced concrete as a building element as well as the more complete envelopment of the reinforcement bars by the concrete since, with the present invention, the reinforcement bars 211 do not rest on the bottom of the horizontal bond beam cavity 109 as has been traditionally the case with other prior art concrete forms.
The vertical-to-horizontal reinforcement bar holder assembly provides for a positive and precise location of single or multiple vertical reinforcement bars 213 within the vertical cavities of the wall. This precise positioning of the vertical reinforcement 213 better ensures a more complete structural performance of the reinforced concrete as a building element as well as the more complete envelopment of the reinforcement bars 213 since, with the present invention, the reinforcement bars 213 are not inserted into the vertical cores after the concrete has filled the cores as has been traditionally the case with other prior art concrete forms.
Accordingly, it will be understood that those skilled in the art that the simplified non-polystyrene permanent insulating concrete form building system of this invention can be used to produce walls that are strong, more precise and simpler to build.
Although the description above contains much specificity, the specific items illustrated should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. For example, the non-polystyrene insulated concrete forms can be manufactured in differing sizes and have other shapes such as trapezoidal, circular, oval, triangular, etc.; the fastening clamp may be combined with reinforcement bar holders for transverse orientation of the forms when a super thick wall assembly may be required for locations of climatic extremes, etc.; the horizontal reinforcement holders 210 and/or 220 can have additional bar holder saddles for a single pair of support legs, etc.
Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.
While the preferred embodiment to the invention has been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first described.

Claims

1. A system for securing non-polystyrene insulated concrete forms and positioning reinforcement bars during construction of a concrete structure, the system comprising:

at least one of a non-polystyrene insulated concrete form; and

at least one of a fastening clip, the fastening clip having a top member, the top member further comprises at least one of a receptacle integrally formed in the top member, the receptacle locates, orientates, and fastens with at least one of a reinforcement bar holder, the fastening clip holds together at least two of the non-polystyrene insulating concrete form, the fastening clip further comprises at least two of a clamping leg which are juxtaposed, wherein when the fastening clip is applied to at least two of the non-polystyrene insulating concrete form each of the clamping leg grips at least one of the non-polystyrene insulating concrete form.

2. The system in accordance with claim 1, wherein the fastening clip is reinforced nylon, polypropylene, or polyvinyl chloride.

3. The system in accordance with claim 1, wherein each of the clamping leg disposed are at either end of the top member and one end of the clamping leg is formed integrally with the top member the other end of the clamping leg is a free end, each of the clamping leg forms an acute angle to the longitudinal axis of the top member, the longitudinal axis being the axis which traverses the top member between each of the clamping leg, wherein the distance between each of the clamping leg measured between attach points with the top member is greater than the distance measured between each of the free ends creating a friction fit with at least two of the non-polystyrene insulating form.

4. The system in accordance with claim 3, wherein each of the clamping leg further comprises a foot formed integrally with the free end, the foot curving outwardly from the clamping leg forming a widened aperture between each of the clamping leg.

5. The system in accordance with claim 1, wherein each of the clamping leg are connected to one end of each of at least two of a lower cross member, the other end of each of the lower cross member is integrally formed into an upper cross member, and each of the clamping leg comprising a plurality of gripping teeth integrally formed with and located on the interior surface of each of the clamping leg.

6. The system in accordance with claim 1, further comprising:

a horizontal reinforcement bar holder comprising a first end and a second end, a saddle disposed and integrally formed at the first end, the second end is attachable to the fastening clip, wherein the saddle engages a horizontally orientated reinforcement bar creating a fixed distance between the non-polystyrene insulating concrete form and the horizontally orientated reinforcement bar.

7. The system in accordance with claim 1, further comprising:

a reinforcement bar holder comprising a saddle integrally formed on one end which is orientated to support a reinforcement bar and a connector integrally formed on the other end, the connector comprising at least one of a cross member and at least two of a connector leg, one end of the connector leg being integrally formed with the cross member and the other end of the connector leg comprising a foot, each of the foot being orientated on the connector leg to facilitate the reinforcement bar holder fastening to a second reinforcement bar holder or to the fastening clip, wherein the reinforcement bar holder supports the reinforcement bar in predetermined and precise locations within the non-polystyrene insulated concrete form.

8. The system in accordance with claim 1, further comprising:

a horizontal reinforcement bar holder, used in combination with the fastening clip, comprising a first end and a second end, a saddle disposed and integrally formed at the first end, a base is integrally formed between the first end and second end, the base comprising a plurality of removable extensions, a locator tab is integrally formed at the second end, wherein the saddle engages a horizontally orientated reinforcement bar, the locator tab is inserted into a non-polystyrene insulating concrete form, the base contacts the surface of the non-polystyrene insulating concrete form creating a fixed distance between the non-polystyrene insulating concrete form and the horizontally orientated reinforcement bar and supporting the horizontally orientated reinforcement bar in predetermined and precise location within horizontal cavities of the non-polystyrene insulating concrete form.

9. A system for securing non-polystyrene insulated concrete forms and positioning reinforcement bars during construction of a concrete structure, the system comprising:

at least one of a non-polystyrene insulated concrete form;

at least one of a fastening clip, the fastening clip having a top member, the top member further comprises at least one of a receptacle integrally formed in the top member, the receptacle locates, orientates, and fastens with at least one of a reinforcement bar holder, the fastening clip holds together at least two of the non-polystyrene insulating concrete form; and

a horizontal reinforcement bar holder, used in combination with the fastening clip, further comprises a first end and a second end, a saddle disposed and integrally formed at the first end, a base is integrally formed between the first end and second end, the base comprising a plurality of removable extensions, a locator tab is integrally formed at the second end, the locator tab thickness and length are sized to fit into a slot formed in a structural cross member of a non-polystyrene insulated concrete form, the locator tab is shaped at the second end and has a plurality of gripping teeth integrally formed therein which cause the horizontal reinforcement bar holder to be friction fit and retained within the slot, wherein the saddle engages a horizontally orientated reinforcement bar, the locator tab is inserted into the non-polystyrene insulating concrete form, the base contacts the surface of the non-polystyrene insulating concrete form creating a fixed distance between the non-polystyrene insulating concrete form and the horizontally orientated reinforcement bar and supporting the horizontally orientated reinforcement bar in predetermined and precise location within horizontal cavities of the non-polystyrene insulating concrete form.

10. The system in accordance with claim 9, wherein the fastening clip further comprises at least two of a clamping leg which are juxtaposed, wherein when the fastening clip is applied to at least two of the non-polystyrene insulating concrete form each of the clamping leg grips at least one of the non-polystyrene insulating concrete form.

11. The system in accordance with claim 10, wherein the fastening clip further comprises a top member, each of the clamping leg are disposed at either end of the top member and one end of the clamping leg is formed integrally with the top member the other end of the clamping leg is a free end, each of the clamping leg forms an acute angle to the longitudinal axis of the top member, the longitudinal axis being the axis which traverses the top member between each of the clamping legs, wherein the distance between each of the clamping leg measured between attach points with the top member is greater than the distance measured between each of the free ends.

12. The system in accordance with claim 11, wherein each of the clamping leg further comprises a foot formed integrally with the free end, the foot curving outwardly from the clamping leg forming a widened aperture between each of the clamping leg.

13. The system in accordance with claim 10, wherein each of the clamping leg are connected to one end of each of at least two of a lower cross member, the other end of each of the lower cross member is integrally formed into an upper cross member, and each of the clamping leg comprising a plurality of gripping teeth integrally formed with and located on the interior surface of each of the clamping leg.

14. The system in accordance with claim 9, further comprising:

a reinforcement bar holder comprising a support saddle integrally formed on one end which is orientated to support a reinforcement bar and a connector integrally formed on the other end, the connector comprising at least one of a cross member and at least two of a connector leg, one end of the connector leg being integrally formed with the cross member and the other end of the connector leg comprising a foot, each of the foot being orientated on the connector leg to facilitate the reinforcement bar holder fastening to a second reinforcement bar holder or to the fastening clip, wherein the reinforcement bar holder supports the reinforcement bar in predetermined and precise locations within the non-polystyrene insulated concrete form.

15. A system for securing non-polystyrene insulated concrete forms and positioning reinforcement bars during construction of a concrete structure, the system comprising:

at least one of a non-polystyrene insulated concrete form;

a fastening clip having a top member, the top member further comprises at least one of a receptacle integrally formed in the top member, the fastening clip holds together at least two of the non-polystyrene insulating concrete form; and

a reinforcement bar holder having at least two of a parallel leg contoured and integrally formed to form a saddle between the interior surfaces of the parallel leg, the saddle is orientated to support a reinforcement bar and a connector integrally formed on the other end, the connector comprising at least one of a cross member and at least two of a connector leg, one end of the connector leg being integrally formed with the cross member and the other end of the connector leg comprising a foot, each of the foot being orientated on the connector leg, the connector leg either fastens with at least one of the receptacles which locates, orientates, and fastens the reinforcement bar holder with the top member or fastens with a second reinforcement bar holder, wherein the reinforcement bar holder supports the reinforcement bar in predetermined and precise location within the non-polystyrene insulated concrete form.

16. The system in accordance with claim 15, wherein the fastening clip further comprises at least two of a clamping leg which are juxtaposed, wherein when the fastening clip is applied to at least two of the non-polystyrene insulating concrete form each of the clamping leg grips at least one of the non-polystyrene insulating concrete form minimizing slippage and separation.

17. The system in accordance with claim 16, wherein the fastening clip further comprises a top member, each of the clamping leg are disposed at either end of the top member and one end of the clamping leg is formed integrally with the top member the other end of the clamping leg is a free end, each of the clamping leg form an acute angle to the longitudinal axis of the top member, wherein the distance between each of the clamping leg attach points with the top member is greater than the distance between each of the free end.

18. The system in accordance with claim 17, wherein each of the clamping leg further comprises a foot integrally formed with the free end, the foot curving outwardly from the clamping leg forming a widened aperture between each of the clamping leg.

19. The system in accordance with claim 15, further comprising:

a horizontal reinforcement bar holder comprising a first end and a second end, a support saddle disposed and integrally formed at the first end, the second end is attachable to the fastening clip, wherein the support saddle engages a horizontally orientated reinforcement bar creating a fixed distance between the non-polystyrene insulating concrete form and the horizontally orientated reinforcement bar.

20. The system in accordance with claim 15, further comprising:

a horizontal reinforcement bar holder, used in combination with the fastening clip, comprising a first end and a second end, a support saddle disposed and integrally formed at the first end, a base is integrally formed between the first end and second end, the base comprising a plurality of removable extensions, a locator tab is integrally formed at the second end, wherein the support saddle engages a horizontally orientated reinforcement bar, the locator tab is inserted into a non-polystyrene insulating concrete form, the base contacts the surface of the non-polystyrene insulating concrete form creating a fixed distance between the non-polystyrene insulating concrete form and the horizontally orientated reinforcement bar and supporting the horizontally orientated reinforcement bar in predetermined and precise location within horizontal cavities of the non-polystyrene insulating concrete form.

21. A method of securing non-polystyrene insulated concrete forms and positioning reinforcement bars during construction of a concrete structure, the method comprising:

aligning at least two of a non-polystyrene insulating concrete form, the non-polystyrene insulating concrete form having a double middle web integral slot;

securing at least two of the non-polystyrene insulating concrete form with at least one of a fastening clip;

positioning at least one of a horizontal reinforcement bar holder within certain of the double middle web integral slot, the horizontal reinforcement bar holder having a saddle for retaining a reinforcement bar;

placing the reinforcement bar into the saddle;

positioning at least one of a horizontal-to-vertical reinforcement bar holder on the reinforcement bar, the horizontal-to-vertical reinforcement bar holder having a second saddle for retaining a second reinforcement bar;

placing the second reinforcement bar into the second saddle; and

filling the non-polystyrene insulating concrete form with concrete.