Abstract:
A lightweight forming system and the method of using same that can be used to construct concrete columns of various external shapes and sizes. The system includes a reusable, flexible securement jacket that can be wrapped around a concrete receiving component having a concrete receiving chamber into which the concrete is poured. Load is exerted on the concrete receiving component in a novel manner through the use of elongated load tubes that are affixed to the spaced apart edges of the securement jacket. A plurality of draw-latches of novel construction are affixed to the load tubes at vertically spaced apart locations and when closed by the workman function to forcefully pull the load tubes together to positively pre-load the concrete receiving component prior to pouring concrete. The securement jacket of the system can be quickly and easily removed as soon as the concrete has sufficiently cured and can then be immediately reused to pour another column. Following use, the securement jacket can be rolled into a tight bundle for transport and storage.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This is a Continuation In Part of U.S. application Ser. No. 11/977,255 filed Oct. 25, 2007 now abandoned. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable 
     INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC 
     Not applicable 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to a concrete forming apparatus and the method of using the same. More particularly, the invention concerns a concrete forming apparatus that is especially well suited for use in forming concrete support columns. 
     2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98 
     A common practice in the construction industry is to use specially constructed wooden forms, or alternatively, elongate paper fiber tubes to form concrete columns. The use of wooden forms is generally quite time consuming and cost ineffective. While the use of paper fiber tubes is more efficient than the use of wooden forms, these paper fiber tubes are typically very bulky and are quite cumbersome to handle and transport. Additionally, the tubes are quite expensive and can be used only once and then scrapped. Once the tube is in place and properly anchored, concrete is poured into the interior of the tube and allowed to harden so as to form a column. After the concrete has hardened, the tube is stripped away from the concrete column and discarded. 
     Obviously, the use of the paper fiber tubes produces a generally cylindrically shaped column with a relatively smooth outer surface. In order to use the conventional paper fiber tubes to produce other than a cylindrically shaped column, the Sonoco Company of Hartsville, S.C. has developed a concrete form that comprises a paper fiber tube having an elongate, square fiberboard insert that is locked in place with polystyrene. The use of these modified paper fiber tubes enables the formation of substantially rectangular-shaped columns. 
     The thrust of the present invention is to provide a novel, lightweight, forming system that includes a reusable, flexible jacket that can be secured about a selected Styrofoam shape into which the concrete is poured. By using Styrofoam shapes of various configurations, concrete columns of selected external shapes can readily be formed. 
     BRIEF SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a novel, lightweight forming system and the method of using same that can be used to construct concrete columns of various external shapes. 
     Another object of the invention is to provide a system of the aforementioned character which comprises a reusable, flexible securement jacket that can be wrapped around a Styrofoam shape into which the concrete is poured. 
     Another object of the invention is to provide a system as described in the preceding paragraph in which the load exerted on the Styrofoam shape by the poured concrete is distributed evenly throughout the entire surface of the securement jacket material. 
     More particularly, the load is carried solely by the tensile strength of the securement jacket material through the use of elongated load tubes that are affixed to the spaced apart edges of the securement jacket. A plurality of draw-latches of novel construction are affixed to the load tubes at vertically spaced apart locations and when closed by the workman function to forcefully pull the load tubes together to positively pre-load the Styrofoam shape prior to pouring concrete. Additionally, the vertical load tubes function to lift and position the securement jacket material smoothly and evenly about the Styrofoam shape until the draw-latches can be engaged. 
     With the forgoing in mind, it is a specific object of the invention to provide a method and apparatus as described in the preceding paragraphs, which unlike certain of the prior art structures, does not use bands, straps, hoops, ribs, walers or strong backs as load bearing members when pouring the concrete column. 
     Another object of the invention is to provide a system of a character described that comprises a one piece assembly with no loose parts. 
     Another object of the invention is to provide a system as described in the preceding paragraphs in which the securement jacket is provided in various lengths to accommodate various column heights. 
     Another object of the invention is to provide a system of the class described which requires no tools to accomplish the erection of the system. 
     Another object of the invention is to provide a method and apparatus of the character described in the preceding paragraphs in which the securement jacket of the apparatus can be quickly and easily removed as soon as the concrete has sufficiently cured and can be immediately reused to pour another column. 
     Another object of the invention is to provide a method and apparatus as described in which columns of any height can be formed by staggering the joints of the Styrofoam shape relative to the joints of the securement jacket. 
     Another object of the invention is to provide an apparatus of the class described that is easy-to-use, easy to store and easy to transport. More particularly, it is an object of the invention to provide a securement jacket of the character described that can be rolled into a tight bundle for transport and storage. 
     Another object of the invention is to provide a novel, lightweight forming system that is particularly useful in replacing existing wooden columns that are used to support an overhead structure with concrete columns of selected exterior design. 
     Another object of the invention is to provide a forming system and a method of using the system as described in the preceding paragraph which can be used to replace existing columns supporting an overhead structure without the necessity of removing, or damaging the existing overhead structure. 
    
    
     
       BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a generally perspective, foreshortened view of one form of the securement component of the concrete forming system of the invention. 
         FIG. 2  is a generally perspective view of a prior art overhead structure embodying a plurality of wooden vertical support members the character of which are replaced by concrete columns formed in accordance with one form of the method of the present invention. 
         FIG. 3  is a generally perspective, foreshortened view illustrating one step of one form of the method of the invention for replacing rotted wooden vertical support members with concrete columns using the concrete forming system of the present invention. 
         FIG. 4  is a generally perspective, foreshortened view illustrating the next step of one form of the method of the invention for replacing rotted wooden vertical support members wherein the Styrofoam insert component of the apparatus of the invention is positioned about the structure illustrated in  FIG. 3 . 
         FIG. 5  is a generally perspective, foreshortened view illustrating the next sequential step of one form of the method of the invention for replacing rotted wooden vertical support members wherein the securement component of the apparatus of the invention is positioned about the structure illustrated in  FIG. 4 . 
         FIG. 6  is an enlarged cross-sectional view taken along lines  6 - 6  of  FIG. 5 . 
         FIG. 7  is a cross-sectional view of an alternate form of column shape that can be produced in accordance with the method of the present invention. 
         FIG. 8  is a cross-sectional view of still another form of column shape that can be produced in accordance with the method of the present invention. 
         FIG. 9  is a cross-sectional view of yet another form of column shape that can be produced in accordance with the method of the present invention. 
         FIG. 10A  is a greatly enlarged, generally perspective view of the area designated as  10 A- 10 A in  FIG. 1 . 
         FIG. 10B  is a view similar to  FIG. 10A  but showing the next step in the operation of one of the adjustable latches of the invention. 
         FIG. 10C  is a view similar to  FIG. 10B  but showing the final step in the operation of the adjustable latch. 
         FIG. 11  is a generally perspective, foreshortened view of an alternate form of the securement component of another embodiment of the concrete forming system of the invention. 
         FIG. 11A  is a generally perspective view of one form of the draw latch connector member of the present invention. 
         FIG. 11B  is a generally perspective illustrative view showing the draw latch connector member interconnected with one of the draw tubes of the securement jacket assembly of the apparatus of the invention. 
         FIG. 11C  is a generally perspective illustrative view similar to  FIG. 11B , but showing the draw latch connector member moved into engagement with the other of the draw tubes of the securement jacket assembly of the apparatus of the invention. 
         FIG. 11D  a generally perspective illustrative view similar to  FIG. 11C , but showing the draw latch connector member moved into a closed position to draw the other of the draw tubes closer so as to positively pre-load the Styrofoam shape component of the apparatus of the invention prior to pouring concrete. 
         FIG. 12  is an enlarged cross-sectional view taken along lines  12 - 12  of  FIG. 11 . 
         FIG. 12A  is an enlarged, fragmentary cross-sectional view of the draw latch area of  FIG. 12 , but showing the draw latch connector member moved into a closed position to draw the spaced apart draw tube closer so as to positively pre-load the Styrofoam shape component of the apparatus of the invention prior to pouring concrete. 
         FIG. 13  is a cross-sectional view of an alternate form of column shape that can be produced in accordance with an alternate form of the method of the invention. 
         FIG. 14  is a cross-sectional view of still another form of column shape that can be produced in accordance with an alternate form of the method of the invention. 
         FIG. 15  is a cross-sectional view of still another form of column shape that can be produced in accordance with an alternate form of the method of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to the drawings and particularly to  FIGS. 1 ,  3 ,  4  and  5 , the various components of one form of the apparatus of the invention for constructing a concrete column are there shown. One of the most important and unique components of the apparatus is the novel securement component  14  the character of which it is shown in  FIG. 1  of the drawings. The details of the construction and operation of this important securement component will presently be described.  FIG. 6  of the drawings shows the securement component  14  of the concrete forming system of the invention encircling the equally important, rigid elongate member  16  of the invention. Member  16  has a concrete receiving chamber  16   a  that is here shown as being generally fluted in cross-section and within which an elongate metal reinforcing member  18  is centrally disposed. It is to be understood that the concrete receiving chamber can also be generally rectangular in cross-section ( FIG. 7 ), can be generally circular in cross-section ( FIG. 8 ) and can be generally octagonal in cross-section ( FIG. 9 ). It is apparent that the shape of the concrete receiving chamber dictates the shape of the outer surface of the concrete column that is to be formed in accordance with the method of the invention. 
     As best seen in  FIG. 1  of the drawings, securement component  14  here comprises a reusable, flexible securement jacket  20  that includes a body portion  22  having lateral edges  22   a  and  22   b . Securement jacket  20  also includes connector means for interconnecting the lateral edges to secure the securement jacket in position about the rigid elongate member  16  in the manner shown in  FIG. 6 . As best seen in  FIG. 1 , the connector means here comprises a plurality of longitudinally spaced-apart connector straps  24  to which a plurality of conventional adjustable latches  24   a  are connected (see also  FIGS. 10A ,  10 B and  10 C). In the present form of the invention, the connector means also comprise a plurality of conventional latch engaging elements  24   b  that are also carried by the spaced-apart connector straps  24  (see  FIGS. 5 ,  10 A,  10 B and  10 C). The connector straps, the adjustable latches and the latch engaging elements are constructed and arranged so that the adjustable latches  24   a  are positioned proximate the lateral edge  22   a  of the flexible body portion  22  and the latch engaging elements  24   b  are positioned proximate the lateral edge  22   b  of the flexible body portion. Adjustable latches  24   a  as well as latch engaging elements  24   b  are readily commercially available from hardware stores and building supply outlets. As also shown in  FIG. 1 , reusable, flexible securement jacket  20  further includes plurality of circumferentially spaced-apart, generally longitudinally extending steel reinforcing straps  26  that are connected to body portion  22  in the manner shown in  FIG. 1 . 
     Securement jacket  20  can be constructed from various durable materials, such as canvas and like materials. Rigid elongate member  16 , which comprises first and second cooperating portions  16   a  and  16   b  (See  FIG. 6 ), can also be constructed from various materials, but preferably is constructed from a lightweight foam material such as Styrofoam. 
     Considering now one form of the method of the invention for constructing a vertically extending concrete column. In the simplest form of the method of the invention, the two halves  16   a  and  16   b  of the rigid elongate member  16  are joined together and disposed in a generally vertical orientation. This done, the securement component  14  is wrapped around the elongate member in the manner illustrated in  FIG. 6 . The assemblage thus formed takes the place of the elongate paper fiber tubes typically used in prior art concrete column forming methods. 
     With the securement component in position around the Styrofoam elongate member  16  in a manner so as to substantially prevent expansion of the rigid elongate member, the latches  24   a  are interconnected with the latch engaging elements  24   b  so as to secure together the lateral edges of the securement jacket in the manner illustrated in  FIGS. 10A ,  10 B and  10 C of the drawings. The latches and the latch engaging elements are constructed and arranged so that they effectively function to bring the securement jacket  20  into secure pressural engagement with the elongate member  16 . Next, the concrete is poured into the concrete receiving chamber  16   c  ( FIG. 6 ) formed interiorly of the elongate member  16 , and the flexible securement jacket is maintained in position about the rigid elongate member for a period of time sufficient to allow the concrete to set-up to form a hardened concrete column. 
     Once the concrete has set up, the latches  24   a  are manipulated so that the securement jacket can be removed from its position about the elongate member  16 . Once removed, the securement jacket can be rolled into a compact roll for transport and storage pending its next use. With the securement jacket removed from about the elongate member  16 , the two halves of the elongate member can be separated from the concrete column and appropriately stored for subsequent use. 
     Another form of the method of the present invention is illustrated in  FIGS. 2 ,  3 ,  4  and  5  of the drawings. This method involves the replacement with concrete columns of defective existing wooden columns, such as the columns “C” shown in  FIG. 2  of the drawings, that are used to support an overhead beam “B” of a structure such as the patio structure “P”. 
     Following removal of one of the effective existing wooden columns, the first step in this alternate method of the invention is to affix to the overhead beam a first pair of spaced-apart “L” brackets  32  (see  FIG. 3 ). This done a second pair of spaced-apart “L” brackets  34  are affixed to the concrete slab “S” at a location directly beneath the spaced-apart brackets  32 . Next, a metal reinforcing member  36  is positioned within the brackets  32  and  34  and beneath the beam “B” in the manner illustrated in  FIG. 3  of the drawings. As indicated in  FIG. 3 , metal reinforcing member  36 , is provided with upper and lower through bores  38  and  40  respectively that are located so as to align with bolt receiving apertures  42  and  44  respectively formed in brackets  32  and  34 . An upper bolt  46 , which is receivable through apertures  42  formed in upper brackets  32  and through upper bore  38  formed in reinforcing member  36 , functions to secure the reinforcing member to the upper brackets. In similar fashion, a lower bolt  48 , which is receivable through apertures  44  formed in lower brackets  34  and through lower bore  40  formed in reinforcing member  36 , functions to secure the reinforcing member to the lower brackets. 
     Once the bolts  46  and  48  have been appropriately secured to brackets  32  and  34 , the next step in this latest form of the method of the invention is to place the two halves  16   a  hand  16   b  of the Styrofoam support member  16  about the assemblage shown in  FIG. 3  and comprising the reinforcing member  36  and the brackets  32  and  34  (see  FIG. 4 ). This done, the securement component  14  is wrapped around the elongate member in the manner illustrated in  FIG. 5 . As before, the assemblage thus formed takes the place of the elongate paper fiber tubes typically used in prior art concrete column forming methods. 
     With the securement component in the circumscribing position around the Styrofoam elongate member  16  so as to substantially prevent expansion of the rigid elongate member, the latches  24   a  are interconnected with the latch engaging elements  24   b  in the manner illustrated in  FIGS. 10A ,  10 B and  10 C of the drawings so that the securement jacket  20  is brought into secure pressural engagement with the elongate member  16 . Next, the concrete can be poured into the concrete receiving chamber  16   c  ( FIG. 6 ) formed interiorly of the elongate member  16  and allowed to set up in a normal fashion. If necessary, a metal guide shoot (not shown) can be used to guide the concrete into the concrete receiving chamber  16   c.    
     Once the concrete has set up, the latches  24   a  are manipulated so that the securement jacket can be removed from its position about the elongate member  16 . Once removed, the securement jacket can be rolled into a compact roll for transport and storage pending its next use. With the securement jacket removed from about the elongate member  16 , the two halves of the elongate member can be separated from the concrete column and appropriately stored for subsequent use. 
     Referring now to  FIGS. 11 through 12A , the various components of an alternate form of the apparatus of the invention for constructing a concrete column are there shown. This latest embodiment of the invention is similar in many respects to that illustrated in  FIGS. 1 through 10  of the drawings and like numerals are used in  FIGS. 11 through 12A  to identify like components. As in the earlier described embodiments, an important and quite unique component of this latest form of the apparatus is the novel securement component  52  the character of which is shown in  FIG. 11  of the drawings. As in the earlier described embodiment of the invention, this important component encircles the elongate Styrofoam assembly  53  of the invention ( FIG. 12 ). Assembly  53 , which comprises two halves  53   a  and  53   b , is substantially identical in construction and operation to the elongate Styrofoam assembly previously described and is provided with a concrete receiving chamber  53   c  that is here shown as being generally fluted in cross-section. Centrally disposed within the concrete receiving chamber is an elongate metal reinforcing member  18  that is also substantially identical in construction and operation to that previously described. It is to be understood that the concrete receiving chamber  53   c  can be of various configurations including being generally rectangular in cross-section, being generally circular in cross-section and being generally octagonal in cross-section. 
     As indicated in  FIG. 11  of the drawings, securement component  52  here comprises a reusable, flexible securement jacket  56  that includes a body portion  58  having spaced apart lateral edges  58   a  and  58   b . As best seen in  FIGS. 12 and 12A , lateral edges  58   a  and  58   b  cooperate with body portion  58  to form longitudinally extending draw tube receiving connector segments  60  and  62  that each telescopically receives an elongated, tubular shaped draw tube. More particularly, connector segment  60  telescopically receives a first elongated draw tube  64 , while connector segment  62  telescopically receives a second elongated draw tube  66  ( FIG. 12A ). 
     Securement jacket  52  can be constructed from various durable materials, such as a polyvinylchloride coated, high tenacity polyester and like polymer materials. Assembly  53 , can also be constructed from various materials, but preferably is constructed from a rigid, lightweight foam material such as Styrofoam. 
     Securement jacket  52  also includes novel connector means for releasably connecting together the lateral edges of the securement jacket so as to secure the securement jacket in position about the elongate assembly  53  in the manner shown in  FIG. 12  of the drawings. 
     As best seen in  FIGS. 11 through 12A , the connector means of this latest form of the invention comprises a plurality of longitudinally spaced-apart adjustable draw latches  68  that function to releasably interconnect the draw tubes  64  and  66 . 
     Turning particularly to  FIGS. 11A ,  11 B,  11 C and  11 D it can be seen that each of the adjustable draw latches  68  comprises a hub portion  70  that is rotatably connected to the first draw tube  64 , an elongated body portion  72  that is pivotally connected to the leg  70   a  of the hub portion and a curved latch portion  74  that is engagable with the second draw tube  66 . As indicated in  FIGS. 11 ,  11 B,  11 C and  11 D, the lateral edges of the securement jacket are provided with spaced apart openings  75  to accommodate the plurality of longitudinally spaced-apart adjustable draw latches  68 . 
     As illustrated in  FIGS. 11B and 11C , by lifting on the finger engaging portion  77  of the draw latch, the hub portion  70  will be caused to rotate relative to the first draw tube  64  from the first position shown in  FIG. 11B , wherein the latch portion  74  is spaced apart from second draw tube  66 , to the second position shown in  FIG. 11C  wherein the latch portion  74  has moved into engagement with draw tube  66 . From the second position shown in  FIG. 11C , by pressing downwardly on the finger engaging portion  77  of the draw latch as indicated by the arrow  79 , hub portion  70  will be caused to rotate relative to hub portion  70  toward the third position shown in  FIG. 11D  wherein the draw latch has acted upon the draw tubes in a manner to urge them to draw closer together. 
     As indicated by the arrows  81  in  FIG. 11 , as the draw latches act upon the draw tubes to urge them to draw closer together, a uniform load is placed upon the body portion  58  of the securement jacket, which, in turn, uniformly pre-loads the elongate Styrofoam assembly  53 . Due to the novel construction and positioning of the draw tubes, the load imposed on the securement jacket is uniquely distributed evenly throughout the entire surface of the jacket material. Additionally, draw tubes  64  and  66  serve to help lift and position the jacket material smoothly and evenly around the elongate Styrofoam assembly  53  until the draw-latches can be engaged. 
     Considering now the form of the method of the invention for constructing a vertically extending concrete column using the novel flexible securement jacket  52 . First the two halves of the elongate assembly  53  are joined together and disposed in a generally vertical orientation. This done, the securement jacket  52  is wrapped around the assembly  53  in the manner illustrated in  FIG. 12 . With the securement jacket in position around the Styrofoam assembly, the adjustable draw latches  68  are operated in the manner previously described to draw together the draw tubes of the securement jacket in the manner illustrated in  FIGS. 11D and 12A  of the drawings. With the elongate assembly  53  thusly preloaded, the concrete “C” is poured into the concrete receiving chamber  53   c  ( FIG. 12 ), and the flexible securement jacket is maintained in position about the assembly  53  for a period of time sufficient to allow the concrete to set-up to form a hardened concrete column. 
     Once the concrete has set up, the latches  68  are manipulated so that the securement jacket can be removed from its position about the assembly  53 . Once removed, the securement jacket can be rolled into a compact roll for transport and storage pending its next use. With the securement jacket removed from about the assembly  53 , the two halves of the assembly can be separated from the concrete column and appropriately relocated or stored for subsequent use. 
     In another form of the method of the invention for replacing a wooden post disposed between a supporting base and an overhead structure with a concrete column, the first step comprises removing the wooden post. Next, a structural support is positioned between the supporting base and the overhead structure. This done, a metal reinforcing member is positioned between the supporting base and the overhead structure. Next, the elongated assembly  53  is positioned around the metal reinforcing member in a manner such that said metal reinforcing member is disposed generally centrally of the concrete receiving chamber  53   c . With the elongated assembly  53  thusly in position, the flexible securement jacket  52  is placed around the elongate assembly and the draw latches are operated to draw together the draw tubes. This action will cause the securement jacket  52  to uniformly compress the assembly  53  in a manner to substantially prevent expansion of the assembly upon pouring concrete into the concrete receiving chamber  53   c.    
     With the securement jacket  52  thusly in position, the concrete is poured into the concrete receiving chamber  53  and the flexible securement jacket is maintained in position about the assembly  53  for a period of time sufficient to allow the concrete to set-up to form a hardened concrete column. Finally, the flexible securement jacket is removed from about the assembly  53  and the assembly  53  is removed from about the hardened concrete column. 
     Having now described the invention in detail in accordance with the requirements of the patent statutes, those skilled in this art will have no difficulty in making changes and modifications in the individual parts or their relative assembly in order to meet specific requirements or conditions. Such changes and modifications may be made without departing from the scope and spirit of the invention, as set forth in the following claims.