Concrete form tie with connector for finishing panel

Abstract

 A tie (50) for connecting and maintaining first and second panels of a concrete formwork in a fixed, spaced relationship during a wall building process is provided. The tie (50) includes a first connector (52) connectable to the first panel; and a second connector (54) connectable to the second panel (20)and connectable to at least one third panel such that the at least one third panel is spaced from the concrete surface.

Description

[0001] The present invention relates to forms for concrete walls, and more particularly to ties for connecting and maintaining first and second panels of a concrete formwork in a fixed, spaced relationship during a wall building process.

[0002] Conventional formwork for forming walls from pourable building material such as concrete consist of two opposed, typically plywood walls connected by a rod, trusswork or other connecting structure. More recently, it has become desirable to use insulating material such as expandable polystyrene for the formwork, in order to provide thermal and acoustic insulation to the finished wall. In certain applications, particularly those where it is desired to inhibit the effects of "thermal inertia" of a concrete wall so as to employ the ability of the concrete to retain heat for temperature stabilization, it is desirable to employ formwork with insulated paneling on only one side. The other side, typically of plywood, may or may not be removed after full or at least partial curing of the concrete.

[0003] Various insulated formworks and related technologies have been considered. For example, U.S. Patent No. 5,845,445 to Blackbeard discloses an insulated concrete form with a plurality of plywood boards at an inside surface, and a plurality of insulating foam panels at an outside surface. The plywood boards and insulating foam panels are connected by a plurality of elongated vertically aligned connecting members for retaining the panels in a spaced apart parallel relationship during the wall building process. The connecting members are connected to the insulating panels, and ties are attached to respective connecting members and the plywood boards. Each tie has a conventional embossed end to engage into a latch clip on the plywood side. During de-forming, the plywood boards may be removed by removing the attachment between the ties and latch clips.

[0004] U.S. Patent no. 6,314,694 to Cooper et al. discloses a one-side insulated formwork that includes an insulating panel connectable to a removable panel by a connecting structure, which may provide permanent reinforcement embedded in the insulating panel. The removable panel is attached to the connecting structure using removable fasteners. The connecting structure maintains a fixed spaced relationship between the insulating panel and the removable panel, and according to embodiments disclosed includes rebar hooks for supporting rebar for embedding in the concrete. After the concrete has at least partially cured, the removable fasteners and removable panel are removed, leaving exposed and flush with the outer surface of the concrete wall a surface of the connecting structure suitable for flush connection of a finishing panel.

[0005] U.S. Patent No. 6,526,713 to Moore, Jr. discloses an insulated concrete structure for forming walls from a pourable building material such as concrete. Moore proposed connecting two panels of a formwork using a web structure, a portion of which is preferably embedded in an insulating one of the panels. After the concrete has at least partially cured, one of the panels being now adjacent to the formed wall, may be removed or remain as part of the structure.

[0006] Although the above references disclose insulated formwork of various configurations, improvements are desired. For example, none of the references discussed above consider the challenges of installing electrical and/or plumbing after or during the wall forming process. It is therefore an object of the present invention to provide a novel wall form, tie and method using the same for building walls from pourable building material, such as concrete.

[0007] According to an aspect, there is provided a tie for connecting and maintaining first and second panels of a concrete formwork in a fixed, spaced relationship during a wall building process, the tie comprising:

a first connector connectable to the first panel; and

a second connector connectable to the second panel and connectable to at least one third panel such that the at least one third panel is spaced from the concrete surface.

[0008] According to an embodiment, the second panel is made of plywood and the third panel is made of drywall. In some embodiments, the tie can be made of plastic.

[0009] According to an embodiment, an insulating wall form comprises the tie, a first panel made from an insulating material and connected to the first connector; and a second panel connected to the second connector.

[0010] The first connector may be embedded in the first panel and the second connector may be removably connected to the second panel.

[0011] According to another aspect, there is provided a method of making a concrete wall, comprising:

providing a first panel having an inward facing surface and an outward facing surface, the first panel made of insulating material;

providing a second panel having an inward facing surface and an outward facing surface;

connecting a first connector of a tie to the first panel and a second connector of the tie to the second panel, wherein the first and second connectors are separated by an intermediate portion with a length corresponding approximately to the thickness of the concrete wall thereby providing a fixed space between the first and second panels for receiving a charge of the concrete; and

attaching a third panel to the second connector to provide a fixed space between the concrete surface and the third panel.

[0012] In some embodiments, a charge of concrete may be provided into the fixed space between the first and second panels. The charge can be provided prior to attaching the third panel.

[0013] In some embodiments the first and second panels may be vertically stacked.

[0014] In some embodiments the first panel can be moulded and the first connector may be connected to the first panel during moulding.

[0015] In some embodiments the second connector may comprise a passageway and electrical cables and/or plumbing may be passed through the passageway prior to attaching the third panel.

[0016] The tie, formwork employing the same, and method for making a wall provide previously unrealized advantages because they permit the option of removal of the second panel after wall construction prior to attachment of the third panel, while permitting spacing between the third panel and the concrete surface and/or second panel for passing electrical wires and/or plumbing and the like. Thus, the electrical wires and/or plumbing may more easily be inspected and/or repaired than systems which involve embedding such utilities in the concrete wall itself.

[0017] Embodiments will now be described more fully with reference to the accompanying drawings in which:

Figure 1 is a perspective cutaway view of a formwork having first and second panels and a tie;

Figure 2 is a perspective cutaway view of an at least partially set concrete wall of Figure 1 with a second panel having been removed and a third panel being connected;

Figure 3 is a perspective view of an alternative tie embodiment;

Figure 4 is a side view of a formwork having first and second panels and the tie of Figure 3;

Figure 5 is a side view of the at least partially set concrete wall of Figure 4 with a second panel having been removed and a third panel connected;

Figure 6 is a perspective view of another alternative tie embodiment;

Figure 7 is a perspective cutaway view of a formwork having first and second panels and an alternative tie embodiment;

Figure 8A is a perspective view of a first connector and an intermediate portion of an alternative tie embedded in a first panel and connectable to a second panel;

Figures 8B and 8C are perspective views of the intermediate portion of the alternative tie of Figure 8A embedded in an at least partially set concrete wall and connectable to a third panel connection portion of the tie;

Figure 8D is a perspective view of the alternative tie of Figures 8A-8C being connected to a third panel;

Figure 8E is a top view of alternative ties as shown in Figures 8A-8D embedded in concrete and connected to a third panel;

Figure 9 is a perspective view of another alternative tie embodiment;

Figure 10 is a top view of the alternative tie embodiment of Figure 9 connected to first, second and third panels; and

Figure 11 is a top partial view of an alternative tie being connected to a second panel.

[0018] In the following description, embodiments of a tie for connecting and maintaining first and second panels of a formwork in a fixed, spaced relationship during a wall building process, and of a method of making a concrete wall are provided.

[0019] Figure 1 is a perspective cutaway view of a portion of a formwork according to an embodiment. The formwork has at least one first panel 10, at least one second panel 20 and at least one tie 50. The first panel 10 is an insulating panel made of polystyrene, and the second panel 20 is made of plywood.

[0020] The tie 50 includes a first connector 52, an intermediate portion 60, and a second connector 54. As can be seen, the first connector 52 is embedded in the first panel 10. The second connector 54 is shown connected to the second panel 20 at a second panel connection portion 56 by screws or other suitable removable fasteners. The second connector 54 is removable from the second panel 20 upon removal of the fasteners. The tie 50 maintains the first and second panels in a fixed spaced relationship thereby to provide space between the panels for receiving and holding a charge of poured concrete 40.

[0021] The second connector 54 of the tie 50 also includes a third panel connection portion 58 that is spaced from the second panel connection portion 56 by virtue of the dimensions of the second connector 54 and the relative positions of the second and third panel connection portions 56, 58. More particularly, the second panel connection portion 56 and third panel connection portion 58 are spaced apart such that the third panel 30 when connected to the third panel connection portion 58 is spaced from the inside surface of the concrete wall 40. The use of this spacing is illustrated in Figure 2. Figure 2 is a perspective cutaway view of the at least partially set concrete wall 40 that was poured in Figure 1 with the second panel 20 having been removed. A third, or "finishing" panel 30 made of drywall is being connected to the third panel connection portion 58. With the second panel 20 having been removed, the third panel 30 connected to the third panel connection portion 58 is spaced from the inside surface of the concrete wall 40. Intermediate the second and third panel connection portions 56, 58 are passageways 62 through second connector 54. Passageways 62 are dimensioned to permit passage of electrical cables/wires 64 and/or plumbing (not shown) or other utilities being installed along the wall between the third panel 30 and the inside surface of the concrete wall 40.

[0022] Figure 3 is a perspective view of an alternative tie 50A. Tie 50A has a plurality of first connectors 52A and intermediate portions 60A connected to a second connector 54A. Second connector 54A includes a second panel connection portion 56A connectable to one or more second panels 20, and a plurality of third panel connection portions 58A connectable to at least one third panel 30. Passageways 62 pass from one side to the other of the second connector 54A.

[0023] Figure 4 is a side view of a formwork having first and second panels 10, 20 and the tie 50A of Figure 3 during pouring of concrete 40.

[0024] Figure 5 is a side view of the at least partially set concrete wall 40 of Figure 4 with the second panel 20 having been removed from second panel connection portion 56A, and a third panel connected to third panel connection portion 58A.

[0025] Figure 6 is a perspective view of another alternative tie 50B. Tie 50B has a single first connector 52B and intermediate portion 60B connected to a second connector 54B. Second connector 54B includes a second panel connection portion 56B connectable to one or more second panels 20, and a plurality of third panel connection portions 58B connectable to at least one third panel 30. Passageways 62 pass from one side to the other of the second connector 54B. Open-topped channels 63 also pass from one side to the other of the second connector 54B to ease installation of electrical cables/wire and/or plumbing or other utilities.

[0026] Figure 7 is a perspective cutaway view of a formwork having first and second panels 10, 20 and an alternative tie 50C. Tie 50C has a single first connector 52C and intermediate portion 60C. A second panel connection portion 56C is connected to intermediate portion 60C and is removably connected to second panel(s) 20. A third panel connection portion 58C is removably connectable to the second panel connection portion 56C once second panels 20 are removed after the concrete 40 has at least partially set. Connectability between second and third panel connection portions 56C and 58C is by virtue of the dimensions of an extension channel 57C in second panel connection portion 56C suitable for receiving in interference fit an extension protrusion 59C of third panel connection portion 58C.

[0027] Multiple ties 50C are stackable by virtue of mechanical interlock members. These mechanical interlock members include respective stacking protrusions 66C on the second panel connection portion 56C and the third panel connection portion 58C. The stacking protrusions 66C mate in interference fit with respective corresponding stacking channels (not shown) in adjacent second and third panel connection portions 56C, 58C of an adjacent tie 50C.

[0028] At the bottom of Figure 7, a third panel 30 is shown connected to the third panel connection portion 58C which is, in turn, connected to the second panel connection portion 56C.

[0029] Figure 8A is a perspective view of a first connector 52D and an intermediate portion 60D of an alternative tie 50D. First connector 52D is embedded in a first panel 10 and is connectable to a second panel 20. For ease of transport, intermediate portion includes arms 61 which can, due to their pivotability relative to first connector 52D, fold against the inside surface of the first panel 10 during transportation. Arms 61 can also fold towards each other and mate to form the intermediate portion 60D having a second panel connection portion 56D.

[0030] Figures 8B and 8C are perspective views of the intermediate portion 60D of the tie 50D of Figure 8A embedded in an at least partially set concrete wall 40 and connectable to a third panel connection portion 58D of the tie 50D. Third panel connection portion 58D is connected to a third panel(s) 30 after the concrete 40 has been poured and at least partially set and second panel(s) 20 have been removed from second panel connection portion 56D.

[0031] Figure 8D is a perspective view of the tie 50D of Figures 8A-8C being connected to a plurality of third panels 30, and having an electrical cable 64 passing through a passageway 62 of the third panel connection portion 58D.

[0032] Figure 8E is a top view of a plurality of ties 50D as shown in Figures 8A-8D embedded in the concrete wall 40, and connected to third panels 30.

[0033] Figure 9 is a perspective view of another alternative tie 50E. The tie 50E has an intermediate portion 60E between its first connector 52E and its second panel connection portion 56E, that is adjustable in length as shown in Figure 9. Third panel connection portion 58E mates with second panel connection portion 56E after the concrete 40 has been poured and has at least partially set and second panels 20 have been disconnected from the second panel connection portion 56E. Third panel connection portion 58E mates with second panel connection portion 56E by virtue of an interference fit between an extension channel 57E in second panel connection portion 56E and an extension protrusion 59E on third panel connection portion 58E.

[0034] It can be seen in Figure 9 that depending on the desired configuration of formwork, second panels 20 can occlude the extension channel 57E, requiring their removal prior to connection of the third panel connection portion 58E. Alternatively, if it is desired to keep second panels 20 while connecting third panels 30, then they may be attached to the second panel connection portion 56E so as not to occlude the extension channel 57E. In this way, the third panel connection portion 58E may be connected to the second panel connection portion 56E while second panels 20 remain connected to second panel connection portion 56E.

[0035] Figure 10 is a top view of the alternative tie 50E of Figure 9 connected to first, second and third panels 10, 20, 30.

[0036] Figure 11 is a top partial view of an intermediate portion 60F and a second connector 54F of an alternative tie. Adjacent third panel connection portion 58F of second connector 54F are flaps 55F pivotably connected to the second connector 54F. Flaps 55F are at least a portion of the height of the third panel connection portion 58F (i.e. extend into the page in Figure 11). Other means of pivotably connecting flaps 55F to second connector 54F may be used. Flaps 55F pivot away from second panels 20 in order to permit insertion of spacer boards S against second panels 20 and second connector 54F. Once the spacer boards S are in place as shown in Figure 11, flaps 55F are pivoted back against the spacer boards and at least one respective fastener F is passed through flap 55F into the respective spacer board S. The spacer board S is thereby held against a respective second panel 20 and maintains the fixed formwork during pouring of the concrete 40. Upon at least partial setting of the concrete, the fasteners F, spacer boards S and second panels 20 may be removed, and a third panel 30 then connected to the third panel connection portion 58F of the second connector 54. It will be understood that an embodiment employing such flaps may be used without spacer boards where at least a part of second panel 20 is thick enough to interact with the flaps suitably to permit second panel to be held in place by the flaps as described.

[0037] In order to make a wall from pourable building material such as concrete, a first panel made of an insulating material is provided. The first panel has an inward facing surface facing towards the interior of the building, and an outward facing surface facing towards the exterior of the building. A second panel, also having an inward facing surface and an outward facing surface, and preferably of plywood, is also provided. The first connector of the tie is connected to the first panel. It will be understood that this may be done upon manufacture of the first panel where the insulating material is expandable polystyrene or the like such that the first connector is thereby embedded in the panel during moulding. The second connector of the tie is then connected to the second panel using fasteners such as screws and/or some alternative or combined mechanical connection. When the first and second panels are connected to the tie as described, the first and second connectors are separated by an intermediate portion with a length corresponding approximately to the thickness of a wall being made. A fixed space between the first and second panels for receiving a charge of the concrete is thereby provided. A charge of concrete is then provided into the fixed space between the first and second panels. The electrical cable and/or plumbing may be passed through passageways 62 prior to connection of the third panel, preferably made of drywall.

[0038] It will be understood that, in some embodiments, the third panel may be connected prior to pouring of the concrete into the fixed space between the second and third panels. If electrical cable and/or plumbing are required, then this of course is installed prior to connection of the third panels. In some cases, the second panels would remain part of the finished wall, albeit hidden from view inside the building by the third panels. Furthermore, the second panels may remain part of the finished wall whether or not the third panels were connected prior to or after pouring of the concrete. This is left to the preference of the builder, and the suitability of the second panel remaining part of the wall. Indeed, some described embodiments of ties described herein require removal of the second panel prior to connection of the third panel, and some do not.

[0039] Depending particularly upon the required height of the concrete wall being built, first and second panels may be vertically stacked upon each other to provide a formwork having a suitable height.

[0040] Embodiments of ties have been shown for use in construction environments in which a second panel is desired to be disconnected from the tie prior to connection of a third panel, and also in which the second panel may remain while a third panel is being connected.

[0041] While embodiments have been shown whereby ties are stacked using a mechanical interlock mechanism, other configurations are possible. For example, second connectors of two adjacent ties may cooperate with each other to connect to second and/or third panels without interlocking. In such an embodiment, two second connectors of two ties may have second panel connection portions that do not mechanically interlock or even touch, but align to both receive a common second panel. In other or complementary embodiments, the first portion of a tie may span the entire height of a first panel, while intermediate portions and/or second portions do not. Various combinations and modifications within the scope of the invention are possible.

[0042] While embodiments have been shown that have the third panel spaced from the second panel, it will be understood that second panels may be provided that are dimensioned and configured with respect to a tie so that there is little or no space between the third and second panels. It will be understood that in such embodiments, the second panel is intended to be disconnected from the formwork prior to connection of a third panel, such that the third panel is in fact spaced from the concrete wall surface thereby permitting passage of electrical cables/plumbing and the like between the third panel and the concrete wall surface.

[0043] Although embodiments have been described, those of skill in the art will appreciate that variations and modifications may be made without departing from the scope thereof as defined by the appended claims.

Claims

1. A tie (50) for connecting and maintaining first (10) and second (20) panels of a concrete formwork in a fixed, spaced relationship during a wall building process, the tie (50) comprising:

a first connector (52) connectable to the first panel (10); and

a second connector (54) connectable to the second panel (20) and connectable to at least one third panel such that the at least one third panel is spaced from the concrete surface.

2. The tie (50) of claim 1, wherein the second connector (54) is removably connectable to the second panel (20) or the at least one third panel.

3. The tie (50) of claim 1, wherein the first connector (52) is embeddable in the first panel (10).

4. The tie (50) of claim 4, wherein the first panel (10) is made of insulating material.

5. The tie (50) of claim 1, wherein the second connector (54) comprises a second panel connection portion and a third panel connection portion (58).

6. The tie (50) of claim 5, wherein the third panel connection portion (58) is removably connectable to the second panel connection portion.

7. The tie (50) of claim 5, wherein the second connector (54) comprises at least one passageway between the concrete surface and the third panel, for supporting an electrical cable and/or plumbing.

8. The tie (50) of claim 7, wherein at least one of the at least one passageway is an open-topped passageway.

9. The tie (50) of claim 1, wherein the second connector (54) is dimensioned to cooperate with or be coupled with a second connector (54) of at least one other tie.

10. The tie (50) of claim 9, wherein the second connector (54) comprises a mechanical interlock mechanism for coupling with the second connector (54) of the at least one other tie.

11. The tie (50) of claim 1, comprising at least one flap pivotably connected to the second connector (54) for connecting the second connector (54) to a second panel.

12. The tie (50) of claim 1, wherein the first connector (52) and second connector (54) are linked by an intermediate portion, the intermediate portion removably connectable to the first connector.

13. The tie (50) of claim 12, wherein the intermediate portion is removably connectable to the second connector.

14. An insulating wall form comprising:

the tie (50) of one of claims 1 to 13;

a first panel (10) made from an insulating material and connected to the first connector(52) ; and

a second panel (20)connected to the second connector (54).

15. A method of making a concrete wall, comprising:

providing a first panel (10) having an inward facing surface and an outward facing surface, the first panel (10) made of insulating material;

providing a second panel (20) having an inward facing surface and an outward facing surface;

connecting a first connector (52) of a tie (50) to the first panel (10) and a second connector (54) of the tie (50) to the second panel (20), wherein the first and second connectors (52,54) are separated by an intermediate portion with a length corresponding approximately to the thickness of the concrete wall thereby providing a fixed space between the first and second panels (10,20) for receiving a charge of the concrete; and

attaching a third panel to the second connector (54) to provide a fixed space between the concrete surface and the third panel.

Drawing