Abstract:
A concrete form system includes an outer form composed of a structural foam material and a protective skin material. The protective skin material is in contact with the structural foam material and may be chemically bonded such as by crosslinking with the structural foam material. Each of the structural foam material and protective skin material may include a polymeric material. The protective skin material forms an exposed outer surface of the outer form, obviating any need for additional protection from the elements or to be applied during the construction process. The outer form thermally insulates around the periphery of a poured concrete slab, and can be coupled with an inner form, each of the outer form and inner form being assembled in a predetermined relationship and sized so as to control the vertical elevation and thickness of a concrete slab and a foundation stem wall cast between the inner and outer forms. The concrete form system can be pre-assembled in accordance with appropriate dimensions in a workshop in preparation for pouring a concrete slab on a remote job site.

Description:
[0001]    This Application claims the benefit of U.S. Provisional Application No. 62/240,643 titled “Coated Concrete Form,” to Bryan White, filed Oct. 13, 2015, the entire disclosure of which is expressly incorporated by reference herein. 
     
    
     TECHNICAL FIELD 
       [0002]    The present disclosure relates generally to concrete forms and related concrete construction technology, and relates more particularly to a concrete form system having an outer form with a structural foam material and an outer protective skin material. 
       BACKGROUND 
       [0003]    Construction technology related to the pouring, forming, and curing of concrete to build foundation slabs, footers, and basement walls has advanced significantly over the years. While some of the basic materials and procedures for creating a concrete structure have been little changed for literally more than a thousand years, more recently highly sophisticated materials, science, and construction engineering have been applied to certain apparatuses, notably forms, used in pouring concrete. 
         [0004]    One known technique relates to the use of foam panels to contain concrete in its uncured, flowable state in a particular shape so that the concrete can retain that shape once cured. Foam panels have the advantage of being relatively lightweight and easy to handle, and can provide insulation about the periphery of the structure to be formed. Foam panels of known design have various shortcomings relative to certain applications. For instance, foam panels are typically removed once curing of the poured concrete is complete, leaving an unsightly and unfinished exterior surface that must be painted, obscured, or otherwise treated to produce a suitably aesthetically pleasing finish. 
       SUMMARY 
       [0005]    In one aspect, a concrete form system includes inner and outer forms coupled together via a plurality of connecting webs. The outer form includes a structural foam material forming an inner surface, facing the inner form, and structured to contact concrete poured into a space between the inner form and the outer form. The outer form further includes a protective skin material in contact with the structural foam material and forming an exposed outer surface of the outer form. 
         [0006]    In another aspect, a method of making a concrete form is disclosed. The method includes production of a substantially rectangular body having a plurality of peripheral edges extending about a first and a second body side of an outer concrete form from a structural foam material, applying a protective skin material in liquid form to the first body side such that the skin material adheres to the structural foam material on the first body side, and packaging the substantial rectangular body for shipping with the protective material adhered to the structural foam material located upon only the first body side. 
         [0007]    In still another aspect, a method of constructing a foundation is disclosed, the method including assembling a concrete form system such that an inner form and an outer form are supported in parallel spaced apart relation, positioning the concrete form system upon a footing, pouring uncured concrete into a space extending between the inner and outer forms such that upon curing the concrete forms a solid wall extending upwardly from the footing, and orienting the outer form during assembly and positioning such that an inner surface formed from a structural foam material of the outer form faces the space and is contacted by the poured concrete, and an opposite surface formed from a protective skin material of the outer form is exposed and faces outwardly of the foundation. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0008]      FIG. 1  is a top diagrammatic view of a concrete form system and a foundation system at one stage of construction, according to one embodiment; 
           [0009]      FIG. 2  is a sectioned side diagrammatic view of a concrete form system at one stage of construction, according to one embodiment; 
           [0010]      FIG. 3  is a detailed enlargement of a rectangular body, according to one embodiment; and 
           [0011]      FIG. 4  is a diagrammatic view of stages of making a form for use in a concrete form system, according to one embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0012]    Referring to  FIG. 1 , there is shown a concrete form system  20  according to one embodiment. Form system  20  may be part of a foundation system  10  including a footer  12  of poured and cured concrete within a trench in the ground. An aggregate  14  of any suitable kind can be placed adjacent to footer  12  to form a subgrade, upon which a poured concrete foundation  13 , typically in the form of a slab is to be poured. A cutout  19  of foundation  13  illustrates aggregate  14  underneath and adjacent to foundation  13 . It should be appreciated that foundation system  10  could be used for supporting a residential living structure, a light industrial installation, or even a bare concrete slab to serve as a parking lot, or for any other conceivable purpose. In a practical implementation strategy, plumbing pipes  18 , electrical service wires, or other installations may be located within or upon aggregate  14  and thus covered by concrete foundation  13  once formed. 
         [0013]    Referring now also to  FIG. 2 , there is shown a sectioned diagrammatic view of foundation system  10  and form system  20  along line  2 - 2  of  FIG. 1 . System  20  may include an inner form  22  having a first substantially rectangular body  24  with a top peripheral edge  26  and a bottom peripheral edge  28 . System  20  may also include an outer form  30  having a second substantially rectangular body  32  with a top peripheral edge  34  and a bottom peripheral edge  36 . A plurality of connecting webs  38  couple together inner form  22  and outer form  30  in spaced apart relation, with a space  48  extending therebetween. The coupling together of inner form  22  and outer form  30  is also such that rectangular bodies  24  and  32  are oriented parallel to one another at least in a practical implementation, and bottom peripheral edges  28  and  36  are positioned in a common plane or only modestly out of plane, for positioning system  20  upon footer  12 . In one implementation, the components of form system  20  can be assembled prior to placement upon footer  12 , either at a job site or even at a remote assembly facility. An alignment channel  40  extends along bottom peripheral edge  36 , and can be fastened by any suitable means such as an adhesive or fasteners to the concrete forming footer  12 . A fastening bolt  41  is shown as an illustrative example. In a practical implementation strategy, form system  20  may have the general shape of a polygon, extending about a plurality of sides of the foundation system  10 . Form system  20  can therefore contain and direct the flow of concrete  16  not yet in a cured state, filling space  48  to form a stem wall or the like that is positioned upon footer  12 . 
         [0014]    In  FIG. 2 , space  48  is shown filled part way with concrete  16 , which will typically be poured to fill space  48 , and flow or extend over the top of inner form  22  to make contact with aggregate  14 . Contact between portions of the poured concrete forming the stem wall and forming the slab is not visible in  FIG. 2  due to the section planes chosen. In some instances a gap or intervening layer of a different material could be positioned between the stem wall and slab portions. Inner form  22  may have a shorter height  27 , height  27  being the distance from footer  12  to top peripheral edge  26 , than height  35  of outer form  30 , height  35  the distance from footer  12  to top peripheral edge  34 . It can thus be appreciated that a horizontally extending foundation  13  once cured will be supported upon aggregate  14 , while a downwardly extending stem wall may be formed integrally with the foundation  13  and at least in certain instances extends peripherally about aggregate  14  at an outer edge of foundation system  10 , to contact footer  12  in between inner form  22  and outer form  30 . The relative height  27  of inner form  22  to height  35  of outer form  30  may facilitate the general shaping of the stem wall so as to allow concrete  16  to flow over inner form  22  and come into contact with aggregate  14  when poured into space  48 , or flow over inner form  22  in an opposite direction to fill space  48 . The difference between height  27  and height  35  may depend on a desired thickness of foundation  13 . As concrete  16  may flow over inner form  22  but not outer form  30 , height  35  may be at least the total of height  27  and the desired thickness of foundation  13 . For example, if the height  35  of outer form  30  is 4 feet and the desired thickness of foundation is 6 inches, the height  27  of inner form  30  may not be greater than 42 inches. Outer form  30  may be shaped so a kicker brace or the like  42  may receive top peripheral edge  34  and support the same during pouring of concrete into space  48 . An additional channel piece  52  may be provided as shown end-on in  FIG. 1  for positioning at a corner where adjacent panels of outer form  30  are adjoining, extending vertically from footer  12 . It can be seen that channel piece  52  can include channels generally extending in a parallel configuration but opening so as to define approximately a right angle to receive the rectangular bodies  32  of outer form  30  at the corner. An analogous channel can be provided for inner form  22  and is shown in  FIG. 1  via reference numeral  54 . 
         [0015]    Outer form  30  may include a structural foam material  50  that forms an inner surface  44  of substantially rectangular body  32 , faces inner form  22  and is thus structured to contact concrete  16  poured into space  48 . Structural foam material  50  may be a one-piece body and is to be understood as structural in that it does not collapse under its own weight, at least when shaped and dimensioned according to generally analogous building products. For instance, outer form  30  might be from about 3 feet wide or tall to about 6 feet wide or tall, from about 2 feet long to about 16 feet long, and from about ½ inch thick to about 12 inches thick. It will be appreciated that the width and length and thickness of body  32  will typically be chosen based upon the intended service application, and accordingly relatively shorter or narrower forms constructed according to the present disclosure might be relatively thinner, whereas relatively taller or wider forms might be relatively thicker. Specific examples of suitable materials for constructing outer form  30  are further discussed herein. 
         [0016]    Referring also to  FIG. 3 , there is shown a detailed enlargement of a portion of outer form  30  in greater detail. Outer form  30  further includes a protective skin material  56  in contact with structural foam material  50 . In  FIG. 2 , protective skin material  56  is peeled back from structural foam material  50  to illustrate the relatively greater flexibility of material  56  versus material  50 . In the present embodiment, protective skin material  56  may be in contact with only one side of structural foam material  50 , with inner surface  44  remaining free of protective skin material  56  allowing inner surface  44  to contact concrete  16  freely. Inner surface  44  may therefore be in fluid contact with uncured concrete  16  allowing concrete  16  to flow into any voids or pores  60  in structural foam material  50 . The ability of uncured concrete  16  to fluidly contact inner surface  44  without any barrier such as a polymeric coating or other material allows concrete  16  to form a relatively stronger mechanical bond with structural foam material  50  when curing, providing structural rigidity to form system  20 , and may increase durability and longevity of system  20 . In some embodiments, there may additionally be a chemical bond between concrete  16  and structural foam material  50 . A strong bond between outer form  30  and concrete  16 , especially where an outer surface  46  may be textured to have visual or stylistic characteristics as will be discussed further herein, may have certain advantages as will be appreciated by those with skill in the art. 
         [0017]    Protective skin material  56  forms the exposed outer surface  46  of outer form  30  located opposite inner surface  44 . In a practical implementation strategy, rectangular body  32  may consist essentially of structural foam material  50  and protective skin material  56 , although certain additives such as fire retardants, anti-fungals, colorants, pesticides, or still other materials might be part of rectangular body  32 . The outer surface  46  formed by protective skin material  56  may be substantially smooth in many instances, and smoother than inner surface  44 , but can also be roughened or textured in others. In  FIG. 3 , indentations or slots  59  are shown in a regular and alternating arrangement with protrusions  57 , a structure that might be seen where a faux brick or stone finish is formed on skin  56 . It is contemplated that material  56  might be applied, as further discussed herein, and textured via mechanical indentation means or another technique prior to completing curing, although the present disclosure is not thereby limited. Thus, embodiments are contemplated where a wood grain, a stone grain, a brick pattern, or still other visually and aesthetically observable properties are present. Top peripheral edge  34  and bottom peripheral edge  36  may be formed of structural foam material  50 . Since surface  44  will typically be formed of the structural foam material, the only protective skin material used may be the protective skin material that is applied to one side only of body  32 . 
         [0018]    It is also contemplated that structural foam material  50  may include a foamed polymeric material, and protective skin material  56  may include a continuous polymeric material adhered to the foamed polymeric material. Further still, the continuous polymeric material may be chemically bonded to the foamed polymeric material. Examples of suitable continuous polymeric materials are certain materials commonly applied by plural component spray, and including a polyurethane, a polyurea, an epoxy, or a hybrid of any of these. Foamed polymeric material comprising material  50  may include a polyisocyanate, polyurethane, or polystyrene, for example. Inner form  22  may be any suitable material desirably but not necessarily having some resistance to degradation over time. The material of which inner form  22  is made will typically be different than the material of which outer form  30  is made, and could include any polymeric material suitable for permanent installation in ground contact conditions. 
         [0019]    It can also be seen from  FIG. 3  that an interface  58  resides between material  50  and material  56 . Material  50  may contain voids or pores  60 , commonly associated with a cellular foam material. It will be seen at interface  58  that certain of the voids or pores  60  may be open such that material  56  intrudes therein. It will thus be appreciated that some degree of mechanical interlocking between material  50  and material  56  may occur. As will be further discussed herein, material  56  is applied in the form of a liquid or liquids, thus imparting the tendency for flow of the liquid into any voids or pores in material  50  and interlocking with the same upon curing. Depending upon the materials selected which will typically and by necessity be chemically compatible, polymer crosslinking between material  56  and material  50  may occur. Those skilled in the art will appreciate the cure time and/or hardening time of foamed polymeric materials, and in particular extruded foam polymeric materials, can be such that application of material  56  in plural component liquid form can be timed to enable some chemical bonding between the materials  50  and  56 , and even making available some flexibility in the extent to which chemical bonding is sought. In other words, while it is contemplated that prefabricated and fully cured and/or hardened foamed polymeric materials can be sprayed with plural component coatings according to the present disclosure, in many instances the plural component polymeric material coatings can be sprayed onto the foamed polymeric material prior to completion of curing and/or hardening, in some instances substantially prior to completion of curing and/or hardening and in others when curing and/or hardening of the foamed polymeric material is substantially completed. Desirable properties relating to the manner in which materials  50  and  56  interact and stick together can be empirically determined. 
         [0020]    Referring now to  FIG. 4 , there is shown an example a production assembly  100  for producing rectangular bodies  24 ,  32  having a protective skin material  56  that can be used in constructing foundation system  10  or form system  20  according to the present disclosure. Process flow in the production assembly generally flows from an extruder  64  to a sprayer  72  and then to a cutter  68  as demonstrated by process flow arrows in  FIG. 4 . A texturing device (not shown) could also be part of production assembly  100 , and positioned so as to form texturing as contemplated herein on skin  56 , potentially while soft and/or prior to completing curing. Raw material of conventional type can be fed into a hopper  62 , and then heated and processed to a foamed or foamy state in extruder  64 . Extruder  64  will generate an extrusion in the form of a foam body  66  that can be cut via cutter  68  to a desired dimension, foam body  66  having a first body side  67  and a second body side  69 . For example, according to the present disclosure, cutter  68  may be configured to cut foam body  66  for use as rectangular body  24  and/or rectangular body  32 . In some embodiments, foam body  66  may be formed of structural foam material  50 . It can be seen from the process flow of  FIG. 4  that cutter  68  will typically be employed after application of plural component spray  70 . In other words, given a relatively fast cure time commonly on the order of no more than several minutes for many plural component sprays, cutting of the extruded foam body with adhered skin material will typically occur after the skin material has been applied. Plural component spray  70  includes relatively fast-curing liquids, which, when applied to foam body  66  will cure rapidly, forming protective skin material  56 . As discussed herein, plural component spray  70  may chemically bond to foam body  66  when curing. Sprayer  72  may be structured so as to spray plural component spray  70  on first body side  67  of foam body  66  while leaving second body side  69  free of plural component spray  70 . An optional cutter  74  is shown, however, that might be additionally or alternatively used to cut foam body  66  prior to application of the plural component spray  70 . With the plural component spray  70  applied only upon first body side  67  of the extruded foam body  66 , resulting in a coated foam body  76 . Once cut to length coated foam body  76  can be packaged for shipping. While embodiments are contemplated where a number of packaged panels will be strapped to a pallet or the like  78 , it will be appreciated that no limitation to the manner of packaging is contemplated herein, and in some instances no packaging at all could be used without departing from the full and fair scope of the present disclosure. From the foregoing description and that to follow, it will be apparent the present disclosure provides solutions to various shortcomings in known systems. On the one hand, the present disclosure provides for a finished exterior and protective surface of the form system. Physical damage, soiling and UV damage to the insulating foam is avoided. Those skilled in the art will be familiar with the relatively long periods of time that can occur between various stages of construction. Seasonal breaks and long periods of bad weather can leave insulating concrete forms exposed and likely to deteriorate if some protection is not provided. A separate crew in addition to the concrete contractor is often retained to install some sort of protective shielding exterior to the concrete forms. In some housing developments, some homes may be finished and ready for showing to prospective buyers while others are in various states of construction. Exposed foam board and the like can be considered unsightly, especially where splashed with mud, torn, dented, or otherwise degraded. The present disclosure overcomes these and other shortcomings of standard approaches. 
         [0021]    The present description is for illustrative purposes only, and should not be construed to narrow the breadth of the present disclosure in any way. Thus, those skilled in the art will appreciate that various modifications might be made to the presently disclosed embodiments without departing from the full and fair scope and spirit of the present disclosure. For instance, while certain practical implementation strategies are disclosed herein relative to specific material compositions, it will be appreciated that the present disclosure is not strictly limited as such and other possible combinations and mixtures of materials will be apparent to those skilled in the art. Other aspects, features and advantages will be apparent upon an examination of the attached drawings and appended claims.