System for building a structure

A footing block system is provided for the foundation of a structure and includes a pair of elongated longitudinally extending opposed shells which define a cavity between them for the reception of concrete in slurry form. Each of the shells includes an upright portion having a base adapted to engage the subsurface and an integral transverse portion extending to a rim, the rims of the first and second shells being spaced apart and facing one another. Bridge members are engageable with the opposed shells for joining them a fixed distance apart, mutually interlocking members being provided on the shells and on the bridge members for slidable reception in a longitudinal direction while preventing substantial movement therebetween in a transverse direction. Wall forms are engageable with and supported on the transverse portions of the shells and define a second cavity for the reception of concrete in slurry form, the first and second cavities being in mutual communication. When the concrete hardens, a unified footing and wall structure results.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention relates generally to building construction and, more 
particularly, to a novel system for constructing the foundation and walls 
of a structure. 
2. Description of the Prior Art 
It has long been known to construct foundations and structures utilizing 
interlocking components. For example, in U.S. Pat. No. 1,340,656 issued 
May 18, 1920 to Hughes et al., an all-concrete mausoleum structure is 
disclosed which is provided with side walls, rear and front walls, 
respectively, built on a foundation formed with a longitudinally disposed 
groove. The lower construction is surmounted by a cap or roof member 
comprising a single slab or a plurality of slabs interlocked by means of 
tenons and cooperating slots. The roof member forms a locking device that 
ties the whole structure together. 
More recently, in U.S. Pat. No. 2,134,941 issued Nov. 1, 1938 to Guignon, 
Jr., building units are disclosed which are in the nature of a block 
formed of sheet metal and comprising two complementary halves that may be 
fitted together on the job and filled with insulating material. 
In U.S. Pat. No. 2,676,482 issued Apr. 27, 1954 to Wilson, a wall of 
reinforced spaced building blocks are disclosed which are constructed of 
cement, stone, tile, and the like. A ladder-shaped frame is utilized for 
interconnecting the building blocks. 
For many years, footings and walls constructed of concrete have customarily 
required a combination of metal and wooden forms which are erected in 
place after a proper excavation has been made. Thereafter, concrete is 
poured into the cavity defined by the form and allowed to harden. When the 
concrete is sufficiently hard, typically after a day or two, the forms are 
removed. Some parts of the forms can be re-used and other parts must be 
discarded. Also, the described activity is labor intensive. In short, 
current practice results in a substantial amount of waste, both time-wise 
and material-wise. 
Still more recently, with the advent of light weight plastic foam 
materials, a number of constructions have been suggested for use as 
external wall forms for receiving concrete having a slurry composition. 
The following U.S. patents all disclose block forms of such light weight 
plastic foam material, each with a tongue and groove construction for 
erecting concrete walls: U.S. Pat. No. 4,894,969 issued Jan. 23, 1990 to 
Horobin, U.S. Pat. No. 4,967,528 issued Nov. 06, 1990 to Doran, and U.S. 
Pat. No. 5,086,600 issued Feb. 11, 1992 to Holland et al. At the same 
time, there has been no recent improvement, known to the inventor, to the 
manner of constructing the footing on which the wall forms and resulting 
walls are supported. 
It was in light of the foregoing state of the prior art that the present 
invention was conceived and now has been reduced to practice. 
SUMMARY OF THE INVENTION 
The present invention relates to a footing block system which is provided 
for the foundation of a structure. The system comprises a pair of 
elongated longitudinally extending opposed shells which define a cavity 
between them for the reception of concrete in slurry form. Each of the 
shells includes an upright portion having a base adapted to engage the 
subsurface and an integral transverse portion extending to a rim, the rims 
of the first and second shells being spaced apart and facing one another. 
Bridge members are engageable with the opposed shells for joining them a 
fixed distance apart, mutually interlocking members being provided on the 
shells and on the bridge members for slidable reception in a longitudinal 
direction while preventing substantial movement therebetween in a 
transverse direction. Wall forms are engageable with and supported on the 
transverse portions of the shells and define a second cavity for the 
reception of concrete in slurry form, the first and second cavities being 
in mutual communication. When the concrete hardens, a unified footing and 
wall structure results. 
Accordingly, it is a primary object of the invention to provide a novel 
system for constructing the foundation of a structure. 
Another object of the invention is to provide such a system which can be 
easily used and employs readily available, and easily formable, materials 
and which results in minimal waste of materials. The primary material 
preferably employed for purposes of the invention is an expanded plastic 
such as polystyrene. 
A further object of the invention is to provide such a system which is 
economical from a standpoint of fabrication as well as from a standpoint 
of use. 
Still another object of the invention is to provide such a system which can 
be safely used and is environmentally inert. 
Yet another object of the invention is to provide such a system which 
utilizes components which are relatively compact, light in weight, 
portable, and which can be pre-assembled away from the job site, then 
finally assembled at the job site with minimal additional effort. 
Still a further object of the invention is to provide such a system which 
can enable persons having minimal experience to successfully fabricate 
structural foundations and without requiring the use of special tools. 
Yet another object of the invention is to provide for the construction of a 
foundation in a manner which assures integrity between footing and walls 
and thereby prevents penetration of radon into the resulting structure. 
Yet a further object of the invention is the provision of a system enabling 
the continuous pour of concrete for footing, walls, and concrete slab. 
Other and further features, advantages, and benefits of the invention will 
become apparent in the following description taken in conjunction with the 
following drawings. It is to be understood that the foregoing general 
description and the following detailed description are exemplary and 
explanatory but are not to be restrictive of the invention. The 
accompanying drawings which are incorporated in and constitute a part of 
this invention, illustrate some of the embodiments of the invention and, 
together with the description, serve to explain the principles of the 
invention in general terms. Like numbers refer to like parts throughout 
the disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
Turn now to the drawings and, initially, to FIG. 1 which generally 
illustrates an overall system 20 for fabricating the foundation of a 
structure, the system 20 comprising a footing block system 22, a wall form 
system 24, and a concrete slab 26. For purposes of this disclosure, 
concrete is considered to be a building material comprised of a mixture of 
cement, aggregate of sand and stones, and water which hardens to a strong 
state when the water evaporates. It is customary for the concrete to be 
poured in a "liquid" or slurry state which is a watery mixture of moderate 
viscosity. After a period of hours, the concrete hardens to an extent that 
it can bear substantial loads, but only after a much longer period of time 
does it cure to its maximum strength. For purposes of the present 
invention, other suitable materials which have a slurry consistency for 
introduction into a mold cavity and which harden to a structure-bearing 
capability are intended to be included by that term even though they may 
not be strictly within the usual definition of concrete. 
As is customary for the construction of any foundation, it is necessary to 
make an excavation at the building site having an appropriate depth and 
outer dimensions to accommodate a building to be constructed. A 
substantially level subsurface 28 is then prepared, at least in the manner 
of a trench defining the outer periphery of the intended foundation of the 
structure. The footing block system is then placed onto the subsurface 28 
in a manner to be described. 
The footing block system 22 is more clearly illustrated in FIGS. 2 and 3. 
It comprises a pair of opposed congruent but mirror-imaged elongated 
longitudinally extending opposed shells 30, 32, respectively, so 
positioned and spaced as to define an intermediate cavity 34. The shells 
30, 32 are preferably comprised of a lightweight plastic material, a 
particular example of which is expanded polystyrene. Such material has the 
capability of being 100% recyclable and itself can be made by utilizing up 
to approximately 25% recycled materials. Each shell includes an upright 
portion 36 having a base 38 adapted to engage the subsurface 28 and an 
integral transverse portion 40 extending to a rim 42. 
The rims 42 of the shells 30, 32 are spaced apart and face one another. 
This construction of an assembled system can most clearly be seen with 
reference to FIGS. 4, 5, and 6. 
A plurality of bridge members 44, preferably comprised of the same material 
as the shells 30, 32, are utilized by the system 22. They are engageable 
with the shells 30, 32 and serve to join them while holding them a fixed 
distance apart. Each bridge member includes a main body 46 and an integral 
pair of spaced apart upright support members 48, 50 which extend 
transversely of the main body 46 between a foot 52 engageable with the 
subsurface 28 and a shoulder 54 (FIG. 3) underlying an associated 
transverse portion 40 of one of the shells 30, 32. 
The upright portion 36 of each of the shells 30, 32 has a longitudinally 
extending groove 56 (see FIG. 3) which is generally parallel with and 
spaced from the base 38. The groove 56 includes an enlarged channel 58 and 
opposed peninsulas 60, 62 adjacent the enlarged channel defining a reduced 
slot 64 therebetween. 
In turn, each of the bridge members 44 includes opposed tongues 66 which 
project from opposite ends of the main body 46 and are intended for 
interlocking slidable engagement with the longitudinally extending grooves 
56 in an associated shell 30, 32. The tongues 66 are shaped for 
interlocking slidable engagement with the grooves 56 and serve the purpose 
of joining the opposed shells 30, 32 while substantially preventing 
transverse relative movement between shells. To this end, each of the 
tongues 66 includes an enlarged head 68 and a reduced neck 70 connecting 
the head to the main body 46. The dimensions of the head 68 are slightly 
smaller than those of the enlarged channel 58 and the dimensions of the 
reduced neck 70 are slightly smaller than the spacing between, and other 
dimensions, of the peninsulas 60, 62 on the associated shells 30, 32. 
With continued reference to FIGS. 2, 3, 5, and 6, it is seen that each 
transverse portion 40 of the shells 30, 32 has an underlying surface 72 
(FIGS. 5 and 6) facing the cavity 34 and is formed with a longitudinally 
extending slot 74 therein. In cooperating fashion, each of the upright 
support members 48, 50 has an elongated rib 76 which is slidably 
engageable with an associated slot 74. The shoulders 54 on the upright 
support members 48, 50 are of such a height that with the ribs 76 engaged 
with their associated slots 74, downward forces applied on the transverse 
portions 40 will result in substantially no deflection thereof relative to 
the upright portions 36. 
Thus, when a bridge member 44 is slidably engaged with the shells 30, 32 
such that the tongues 66 are engaged with their associated grooves 56 and 
the ribs 76 are engaged with their associated slots 74, the shells 30, 32 
are held in a substantially rigid fashion a spaced distance apart and 
substantial vertical forces applied to the transverse portions 40 can be 
resisted. According to the invention, a plurality of the bridge members 44 
are located at spaced distances along the length of the shells 30, 32. 
Furthermore, the bridge members 44 are also positioned to serve as 
connections between adjoining shells 30, 32 when they are placed in end to 
end relationship. Specifically, as most clearly illustrated in FIG. 2, a 
bridge member 44 is partially engaged with one pair of shells 30, 32 and 
projects a sufficient distance beyond the ends of those shells to 
similarly engage an adjoining pair of shells. In this manner, bridge 
members 44 not only maintain separation and structural integrity to the 
shells 30, 32, but also serve as connectors between adjoining shell pairs. 
Turn now to FIG. 2 for a description of a corner unit 78 utilized with the 
footing block system 22. A significant benefit of the invention resides in 
the construction whereby the fewest possible components are required and 
used. Indeed, according to the footing block system 22 of the invention, 
only two separate components are necessary, namely shells 30, 32 and 
bridge members 44. As previously explained, the shells 30, 32 are 
identical, a shell 30 merely being a mirror image, or reverse, of a shell 
32. For purposes of a corner unit 78, the shells 30, 32 may be suitably 
cut, as by sawing, on a bias line 80 which is at a forty-five degree angle 
relative to a longitudinal edge 82, or surface, of the shells. The mating 
surfaces of the adjoining shells 30 are then joined. This may be 
accomplished by the use of duct tape 84 (FIG. 2), for example, or, 
preferably, by means of a suitable adhesive of the type which will not 
attack the composition of the shells. The inner track shells 32 will have 
to be shortened, as by sawing, so that a transverse joint line 86 (FIG. 7) 
of an "inner" shell 32 is lined with a transverse joint line 88 of an 
"outer" shell 30. In this manner, a subsequent set or pair, of shells 30, 
32 can be placed in position, then joined as by duct tape or by adhesive 
to its adjoining corner set. 
While the dimensions of the footing block system 22 are arbitrary, a 
typical set of such dimensions would have the uppermost surface of the 
shells 30, 32 be twelve inches above the subsurface 28, a total width 
defined by opposing shells 30, 32 of twenty-four inches, and the length of 
each shell being forty-eight inches. 
It will be appreciated that the footing block system 24 may be cut, then 
assembled, on site, or such cutting and assembly may be performed off 
site, as dictated by individual job circumstances. The footing block 
system is easily transportable to the job site due to light weight and its 
relatively compact size. 
The wall form system 24 intended for use in combination with the footing 
block system 22 will now be described. As seen especially in FIGS. 1, 2, 
5, and 6, the wall form system 24 is generally depicted as a monolithic 
concrete-block form 110 having a substantially elongated body structure 
defined by oppositely disposed side walls 112 and 114, end wall designated 
generally at 116, and bridge 118. The block form 110 is used exclusively 
in corner constructions. A slightly different block form 110A is used at 
all other locations in conjunction with the block form 110. The block form 
110A differs only in having bridges 118 at both ends. 
Side walls 112 and 114, end wall 116, and bridge 118 together define a 
box-like structure which is made from an expandable polystyrene or like 
synthetic material having an elongated body cavity, indicated generally at 
124. The body cavity is further defined by a plurality of cell sections 
125 (FIG. 4) which are provided between successive pairs of a plurality of 
transverse strut members 126. The strut members 126 together with end wall 
116 and bridge 118, serve to separate and provide the necessary support 
for the side walls 112, 114. 
Interlocking means are also provided, whereby the concrete-block forms are 
readily stackable, one on top of the other in an interlocking 
relationship, without the need for mortar or any other binder prior to 
pouring concrete within the body cavities. Generally, viewing FIG. 3, 
interlocking means indicated at 130 comprise an elongated rail 134 formed 
along the upper longitudinal edge of each side wall and end wall alike. 
That is, each end wall 116 includes an interlocking cross rail member 136. 
The oppositely disposed rail members 134 and 136 are further formed with 
lateral locking arm members 138 which effectively define sockets 140. 
In order to form a positive interlocking arrangement, the lower 
longitudinal edges of each block form 110, 110A are formed with 
corresponding longitudinal channels 142 (better seen in FIG. 3). Channel 
142 extends the full length of each side wall 112 and 114. Channel 142 is 
provided with a plurality of laterally extending, equally-spaced channels 
146 that define post members 145. Accordingly, when forms 110, 110A are 
stacked, rails 134 are positioned in channels 142, and locking arm members 
138 are engaged with lateral channels 146. It should be noted that the 
interengaging surfaces or walls of the rails 134, locking arm members 138, 
sockets 140, and channels 142 are preferably formed with an inward taper 
from top to bottom thereof for ease of their initial engagement and for 
their retention in the engaged condition. 
Consider now the overall system 20, viewing especially FIGS. 2 and 3, in 
which the block forms 110, 110A are suitably mounted on the shells 30, 32. 
Extending along an upper surface of the transverse portions 40 of each of 
the shells 30, 32 is an elongated longitudinally extending connection 
ridge 150 positioned parallel to the rim 42 and defined by a pair of 
longitudinally extending connection slots 152, 154. With the shells 30, 32 
supported on the subsurface 28 in juxtaposed position, as illustrated in 
FIGS. 2 and 3, and joined by the bridge members 44 in the manner earlier 
described, a row of the block forms 110 is then appropriately mounted onto 
associated shells 30, 32. To this end, a block form 110 is lowered into 
position in the direction of arrows 156 (FIGS. 2 and 3) until the post 
members 145 are slideably received within the connection slots 152, 154. 
Simultaneously, a connection ridge 150 from each shell is slideably 
received in an associated channel 142 of an associated block form 110. The 
block forms 110 are placed in end to end relationship continuing along the 
entire course defined by the shells 30, 32 of the footing block system 22. 
At a corner location, viewing FIG. 2, one of the block forms 110 has an end 
wall 116 which is fully closed. When block form 110A is positioned in 
engaging relationship with the block form 110 adjacent end wall 116, 
suitable cutouts 156, 157 in the side wall 114 of the block form 110 must 
be made. These cutouts are indicated by dashed lines in FIG. 2 and enable 
the ease of flow of concrete in the slurry form in a manner to be 
described. It will usually be necessary to cut a last block form 110, 110A 
to proper length to complete a course for one wall of the foundation. 
Being comprised of an expanded plastic material, this is not a difficult 
task although it should be carefully performed. As with the shells 30, 32, 
it is desirable to use a suitable adhesive to bond together adjoining 
block forms after they are all in position on the footing block system 22. 
After a first level of the block forms 110, 110A has been positioned on the 
footing block system 22, additional levels of the block forms are to be 
added in the manner indicated in FIGS. 1, 5, and 6, preferably staggered 
in the manner of bricks so that a joint between one pair of block forms on 
one level will not be coincident with a joint between an adjoining pair of 
block forms on the next succeeding level. The number of levels of block 
forms 110, 110A to complete a wall form system 24 is arbitrarily chosen 
according to the depth of the excavation and the height of the wall 
desired above ground level. When an uppermost course of the block forms 
110 has been completed, the excavation may be backfilled carefully to 
assure no harm to the footing block system 22 and to the wall form system 
24. Concrete in its slurry form is then poured into the overall system 20. 
Alternatively, the pour of concrete may be performed first and only after 
it achieves a sufficiently hardened condition would backfill be 
accomplished. 
It will be appreciated that in all instances, reinforcement for the 
resulting concrete structure must be provided. In this regard, with 
respect to the footing block system 22, longitudinally extending troughs 
158 are formed on an upper surface of the main body 46 of each bridge 
member 44 immediately adjacent the upright support members 48, 50. 
Elongated reinforcing bars 160 are placed on the longitudinal troughs 158 
of successive bridge members 44 for the entire length of the footing block 
system 22. Additionally, reinforcing bars 160 are positioned horizontally 
on the upper surfaces of the strut members 126 and bridge members 118 for 
each level of the block forms 110, 110A. Concrete in its slurry form is 
then poured into and through the top row of block forms 110, 110A until 
the cavity 34 for each set of shells 30, 32 is completely filled. 
Thereafter, the pour of concrete continues until all the layers of block 
forms 110, 110A are filled with concrete. 
At some suitable time during the pour of the concrete, reinforcing bars 162 
must be added to the system 20. The reinforcing bars 162 may be similar to 
the reinforcing bars 160. Their placement may be at any desired time 
during the pour of the concrete. It may be, for example, that they would 
be inserted through the uppermost course of the block forms 110, 110A when 
there had been a sufficient pour of concrete to assure that they would 
retain a substantially upright position when left unattended following 
their insertion. Thus, it may be desirable to place the reinforcing bars 
162 generally within each cell section 125 of the wall form system 24. 
This construction is particularly well seen in FIGS. 4, 5, 6, and 8. 
In certain instances, it may be desirable to form a concrete slab 26 close 
to ground level, as seen in FIG. 1. To this end, in keeping with the 
invention, it is possible to form the footing block system 22, the wall 
form system 24, and the concrete slab 26 all during the same pour of 
concrete. In this instance, the interior region of the excavation, that 
is, the excavation defined as lying within the confines of the footing 
block system 22 and the wall form system 24 will have been backfilled 
prior to the pour of the concrete slurry, and graded, to provide a 
subsurface 164 for the concrete slab. As seen in FIG. 6, suitable wire 
mesh is placed just above the subsurface 164 prior to pouring the concrete 
slurry and may extend into the body cavity 124 of each block form 110, 
110A. The pour of concrete then proceeds. When the level of the pour will 
have reached, then exceeds, the level of the subsurface 164, it continues 
until the slab 26 will have been created to the desired depth. 
In this manner, the major components of a footing block system 22, the wall 
form system 24, and the concrete slab 26 can all be formed at a single 
time resulting in maximum integrity of the final structure. 
The footing block system 22 and the wall form system 24 remain in place on 
a permanent basis. These provide for a built-in insulation factor of R-18, 
or better. The expanded plastic material of the systems 22, 24 also cause 
a longer curing time for the concrete, thereby creating a stronger 
structure. Of course, it will also be appreciated that the form blocks 
110, 110A can be so formed as to provide for windows and doors in 
predetermined locations prior to pouring the concrete. Such an expedient 
provides still a further savings of time and effort in the construction of 
a foundation. 
While preferred embodiments of the invention have been disclosed in detail, 
it should be understood by those skilled in the art that various other 
modifications may be made to the illustrated embodiments without departing 
from the scope of the invention as described in the specification and 
defined in the appended claims.