Forming apparatus for concrete floors, ceilings and walls

A reusable low maintenance forming system for forming concrete floors, ceilings and walls with joists thereunder utilizes concrete displacement form pans supported by a temporary framework and floor. A plurality of alignment channels are arranged in parallel series of elongate aligned rows and are adapted to alignably receive and support the flanges of parallel and adjacent form pans. A plurality of joist bottomed wedges are arranged in parallel series of aligned rows and adapted to fit within the alignment channels as to abut and seal against the lower free ends of the form pans afterwhich uncured concrete may be placed over the system.

BACKGROUND OF THE INVENTION 
This invention generally relates to concrete floors and ceilings typified 
by having parallel ribs, beams or joists integrally formed thereunder. 
More particularly, this invention relates to a new and improved forming 
system for creating concrete floors and ceilings as described. 
Various types of support framework and form pan structures are known for 
supporting and shaping various types of concrete slab structures such as 
flooring and ceiling or roof decks. Several such form pan structures and 
support frameworks are disclosed in the following U.S. Pat. Nos.: 
2,206,939; 3,807,681; 4,003,542; 4,170,338; 4,243,200; and 4,659,057. 
The problems with these known pan form systems are multiple. Extensive time 
is needed in setting the forms up on the false framework or temporary 
decking. The pan forms are extremely difficult in removing from the cured 
concrete requiring extensive chiseling and prying which results in a 
blemished underside appearance of the ceiling or flooring. Also, the abuse 
that the form pans are subjected to in their removal from the cured 
concrete required extensive maintenance to maintain the trueness of the 
flanges of the pans. 
There is a need for a forming system for concrete floors and ceilings that 
will work efficiently, economically, rapidly, will form attractive and 
high quality concrete floor and roof deck constructions, will require 
minimal maintenance to the form pans, and will readily adapt to be used 
with any of a variety of system support framework means. 
SUMMARY OF THE INVENTION 
A reusable low maintenance forming system for forming concrete floors, 
ceilings and walls with joists thereunder utilizes concrete displacement 
form pans supported by a temporary framework and floor. A plurality of 
alignment channels are arranged in parallel series of elongate aligned 
rows and are adapted to alignably receive and support the flanges of 
parallel and adjacent form pans. A plurality of joist bottomed wedges are 
arranged in parallel series of aligned rows and adapted to fit within the 
alignment channels as to abut and seal against the lower free ends of the 
form pans afterwhich uncured concrete may be placed over the system. 
A principal object and advantage of the present invention is that the new 
and improved forming system advantageously creates efficient, economical, 
rapid, attractive, accurate, and high quality concrete floors, roof decks 
and wall structures. 
Another object and advantage of the present invention includes the improved 
appearance of ceilings and the underside of roof decks constructed with 
this system. 
Another object and advantage of the present invention is that the system is 
easily removed after the concrete has set without the necessity of 
chiseling or prying, which is highly destructive to the pan forms. 
Another object and advantage of the present invention is that it is usable 
with any framing means, including various support framework, temporary 
decking, false framework and flying false framework. 
Another object and advantage of the present invention is that it is usable 
with existing flange forms or form pans and further eliminates the need 
for internal bracing within the pans. 
Another object and advantage of the system is that it easily sets up in 
inclimate weather which is typical of construction sites. 
Another object and advantage of the present invention is that it is usable 
with floor and ceiling framework typically used in a bay surrounded by 
four columns together with flying false framework support. 
Another object and advantage of the present invention is that the system 
minimizes the maintenance typically required of the flange portions of the 
form pans and therefore prolongs the life of the form pans with minimal 
damage. 
Yet another object and advantage of the present invention is that the 
components are suitably made of pultruded structural fiberglass or 
reinforced plastic which is corrosion proof, resilient, nonbendable and 
not affected by the corrosive effects of curing concrete and weather.

DETAILED SPECIFICATION 
The present invention comprises a new forming system 70 for concrete floors 
and roof decks 10 typically having parallel ribs, beams or joists 12 
thereunder and joist bottoms or bases 14. The new forming system 70 
generally includes a support framework 46, alignment channels 74, flange 
forms 18 and joist bottom wedges 94 or 112. 
To appreciate the invention, one must have an understanding of prior art 
forming systems 16 shown in FIGS. 1 through 6. Such systems 16 typically 
include flange forms, form pans or displacement forms 18 that are 
reusable, stackable, interchangeable, and often made of fourteen gauge 
steel that is commonly 1/16 of an inch thick. The form pans 18 are twelve 
to twenty inches high and commonly three feet long. However, pans 18 may 
vary in dimension to accommodate particular individual engineering 
requirements. The flange forms 18 have a top wall 20 and depending side 
walls 22 terminating in lower free ends 24. The side walls 22 have an 
inside 26 and an outside 28. Extending outwardly from the free ends 26 are 
support flanges 30 that are typically one to one and one half inch in 
width. The four corners of the forms 18 at flanges 30 commonly have 
apertures 32 where through nails 34 may be driven into the support 
framework 46 described below. The forms 18 have open ends 36 which permit 
overlap of the forms to adjust the length of the particular aligned pan 
row 42. End form pans or caps 38 are often used to terminate the formwork 
structure. Often internal reinforcement bracing 40 is utilized within the 
forms 18 to assure that they do not cave inwardly under the force of the 
placed concrete 60. 
The parallel series 44 of elongate aligned rows 42 of flange forms 18 are 
supported by a support framework 46 which often may be referred to as a 
temporary decking or framing falsework. Such framework 46 typically has 
adjustable support posts 48 and supporting cross beams 50 which further 
support a false deck or floor 52 commonly made of lumber or plywood to 
securely receive nails 34. Once the support framework 46 is positioned, 
chalk lines 54 are snapped and the flange forms 18 are aligned and secured 
to the plywood floor 52. Thereafter, concrete 60 is placed over the 
structure as to be illustratively four to six inches thick over the top 
wall 20 of the forms 18. 
Specifically referring to FIGS. 4 and 5, the placed concrete 60 has a 
tendency to creep into the space 62 between the false plywood floor 52 and 
the flanges 30 of the forms 18 thereby forming beads or globs 64 of 
concrete. After the concrete has cured and the support framework 46 has 
been removed, it is necessary for the workmen to chisel and pry at arrow C 
to reach the support flanges 30 of the flange forms 18 and to pull them 
out of the cured concrete. This effort results in both an uneven joist 
base 66 as well as damage and required maintenance to the flange forms 18, 
particularly the support flanges 30. 
Referring to FIGS. 7 through 13, the unique forming system 70 of the 
present invention may be appreciated. Once the support framework 46 is set 
up, chalk lines 72 are snapped. Thereafter, alignment channels, troughs or 
boxes 74 are aligned onto the floor 52 with respect to the chalk lines or 
tape measurements 72 which desirably may be used, such as in inclimate 
weather. The channels 74 are illustratively six inches wide and 1/8 inch 
thick and may be constructed of a variety of material but have been found 
to work well out of formed metal, reinforced plastic or pultruded 
structural fiberglass, such as that made by Advance Fiber Products of 
120-6th Avenue Southeast, Winnebago, Minn. 56098. However, engineering 
demands may vary the dimensions and materials. 
The alignment channels 74 appropriately have a base 76 with apertures 78 
therethrough which permits securement of the alignment channel 74 to the 
floor 52 suitably by nails 34. Thereafter, the channels 74 alignably 
receive the flanges 30 of pans 18. Slots 80 are also provided in the 
alignment channel 74 as they are alignable with the joist bottom wedges 94 
as will be appreciated below. The channels 74 have reinforced corners 82 
from which outwardly and upwardly extends support shoulders or flanges 84 
which appropriately may be one and three eighths inch in height 
illustratively. Additionally, tall reinforcement shoulders 86 may be 
provided that are four to six inches in height, illustratively, thereby 
replacing the necessity of internal reinforcement bracing 40. The 
alignment channels 74 appropriately have open ends 88 which permit an 
arrangement of parallel series 92 of aligned rows 90 of channels 74 in an 
overlapping, abutting or jointable arrangement. Channels 74 may also be 
substituted by L-shaped brackets 95 as will obviously be appreciated. 
Joist bottom wedges 94 are shown in FIGS. 10 through 12 and appropriately 
are contoured or M-shaped and approximately six inches in width for 
illustration purposes. The wedges 94 also may be made of the pultruded 
structural fiberglass for noncorrosion and strength purposes. The wedges 
94 have flat, intermediate or central portions 96 with inclined walls 98 
terminating in peaks 100 which engage the outside 28 of pan side walls 22. 
Extending downward from peaks 100 are depending feet 102. Along the 
inclined walls 98 appropriately are parallel apertures 104 which are 
alignable with the slots 80 of the alignment channels and will permit the 
securement of the wedges 94 within the alignment channels 74 suitably by 
nails. 
The joist bottom wedges 94 are intended to be arranged in parallel series 
108 of elongate aligned rows 106 in jointable arrangement and adapted to 
fit within one row 90 of the alignment channels 74 afterwhich they are 
secured suitably by nails so that the peaks 100 engage the outside 28 of 
pan side walls 22. As the concrete 60 is placed into the system 70, the 
concrete force, represented by arrow F, permits the joist bottom wedges 94 
to expand outwardly under the weight of the uncured concrete as to further 
create a tighter seal 110 between the wedge 94 and the form pans 18 
adjacent the lower free ends 24. 
FIGS. 11 and 12 show an alternate structure of the joist bottom wedge 112 
made of the fiberglass material preferably. The wedge 112 has a U-shaped 
structure with a flat, intermediate or central portion 114. The inclined 
walls 116 are appropriately constructed with a radius, such as 17/8 inch 
illustratively, terminating at peaks 118. The radius dimension is suitably 
determined by the required rebar coverages and particular structural 
design of reinforcement steel in concrete. Extending downward from peaks 
118 are depending feet 120. Parallel apertures 122 are along the inclined 
walls 116 and are suitably alignable with the slots 80 of the alignment 
channels 74 for securing this embodiment of the wedge 112 to the channels 
74 as is appreciated above. 
Similarly, as placed concrete 60 is placed into the system 70, the concrete 
force, shown by arrow F, creates a seal 126 between the peak 118 and feet 
120 and the pan side walls 22 adjacent the lower free ends 24. 
Referring to FIG. 13, the newly created concrete floor or ceiling has an 
even or smooth base, 111 or 128 respectively, depending on which wedge 94 
or 112 was used by the worker. What is most important, the removal of the 
support frame structure 46 easily permits the removal of the floor 52, 
alignment channels 74, form pans 18 and the wedges 94 or 112 
simultaneously. By this arrangement, the new forming system 70 readily 
permits itself to be used with flying support framework requiring further 
minimal worker's time in setting up and removing the flange forms and 
further in maintaining the forms. 
The newly created concrete structure 10 may additionally be oriented 
vertically to form a wall structure. 
The present invention may be embodied in other specific forms without 
departing from the spirit of essential attributes thereof; therefore, the 
illustrated embodiment should be considered in all respects as 
illustrative and not restrictive, reference being made to the appended 
claims rather than to the foregoing description to indicate the scope of 
the invention.