Abstract:
A lightweight forming system and the method of using same that can be used to construct concrete columns of various external shapes. The system includes a reusable, flexible securement jacket that can be wrapped around a rigid concrete receiving component having a concrete receiving chamber into which the concrete is poured. 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:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    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. 
         [0003]    2. Discussion of the Prior Art 
         [0004]    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. 
         [0005]    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. 
         [0006]    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 Sonico 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. 
         [0007]    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. 
       SUMMARY OF THE INVENTION 
       [0008]    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. 
         [0009]    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. 
         [0010]    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. 
         [0011]    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. 
         [0012]    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. 
         [0013]    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 wooden columns supporting an overhead structure without the necessity of removing, or damaging the existing overhead structure. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIG. 1  is a generally perspective, foreshortened view of one form of the securement component of the concrete forming system of the invention. 
           [0015]      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. 
           [0016]      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. 
           [0017]      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 . 
           [0018]      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 . 
           [0019]      FIG. 6  is an enlarged cross-sectional view taken along lines  6 - 6  of  FIG. 5 . 
           [0020]      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. 
           [0021]      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. 
           [0022]      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. 
           [0023]      FIG. 10A  is a greatly enlarged, generally perspective view of the area designated as  10 A- 10 A in  FIG. 1 . 
           [0024]      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. 
           [0025]      FIG. 10C  is a view similar to  FIG. 10B  but showing the final step in the operation of the adjustable latch. 
       
    
    
     DESCRIPTION OF THE INVENTION 
       [0026]    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. 
         [0027]    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 . 
         [0028]    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. 
         [0029]    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. 
         [0030]    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. 
         [0031]    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. 
         [0032]    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”. 
         [0033]    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. 
         [0034]    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. 
         [0035]    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.    
         [0036]    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. 
         [0037]    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.