Abstract:
A wall forming system that uses a pair of panels in combination with a furring strip assembly and retainer The pair of panels are placed in spaced relation using the combination of the furring strip assembly and the retainer wherein the furring strip assembly holds the exterior of the panels while the retainer is disposed between the panels to hold them at a predetermined distance. By holding the panels at a predetermined distance concrete is poured within the cavity formed between the panels to create a wall.

Description:
CROSS REFERENCE TO A RELATED APPLICATION 
       [0001]    This application is based upon Applicants&#39; Provisional Applications Ser. Nos. 60/596,093 filed Aug. 31, 2005 and 60/767,207 filed Mar. 10, 2006. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    This invention is directed toward a wall forming system and more particularly a wall forming system that requires less concrete. 
         [0003]    Wall forming systems are well known in the art. Generally, a wall forming system has a pair of vertical panels that are held in spaced relation by a tie rail or furring strip assemblies. The space between these panels creates a generally uniform cavity where concrete is formed. The problem with such wall systems is that they require more concrete due to the cavity formed which adds to expense, and the amount of insulation provided by the panels is likewise limited. Excess concrete additionally increases fluid pressures that create blow outs, bowing and snaking of walls and ultimately contribute to poor quality of finished product of typical ICF systems. Therefore, a need exists in the art for an improved wall system. 
         [0004]    An object of this invention is to provide a wall system that requires less concrete. 
         [0005]    Another object of the present invention is to provide a wall system that provides greater insulation. 
         [0006]    A still further object of this invention is to provide a wall system that is easier to assemble. 
       BRIEF SUMMARY OF THE INVENTION 
       [0007]    A wall forming system having a pair of panels that are positioned in spaced relation from one another to form a cavity having a web section and a column section. There is at least one furring strip assembly secured to the pair of panels to hold the panels in spaced relation wherein the furring strip assemblies have retaining flanges with a web section that spans between the flanges. A retainer is then disposed within the furring strip assembly and within the cavity contacting the panels to hold the panels in place. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is an elevation view of a concrete structure formed within the wall forming system; 
           [0009]      FIG. 2  is a plan top view of a concrete structure formed within a wall forming system; 
           [0010]      FIG. 3  is a top plan view of a wall forming system; 
           [0011]      FIG. 4  is a plan side view of a furring assembly; 
           [0012]      FIG. 5  is a plan side view of panels of a wall forming system; 
           [0013]      FIG. 6  is a side plan view of a furring assembly; 
           [0014]      FIG. 7  is a top plan view of a corner of a wall forming system; 
           [0015]      FIG. 8  is a side plan view of a retainer for a wall forming system; and 
           [0016]      FIG. 9  is a top plan view of a wall forming system. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0017]    Referring to the  FIGS. 1-3 , the wall forming system  10  includes a pair of panels  12  having an outer surface  14  and an inner surface  16 . The panels have an outer section  18  that extends longitudinally the length of the outer surface  14  and an inner section  20  that extends inwardly from and has a length less than the outer section  18 . A channel or conduit  21  may be cut through the outer section  18  for receiving electrical wires and the like. Specifically the conduit  21  is pre-cut for ease of installation of the electrical wires or preferably cut on-sight. The panels  12  are made of a material having a relatively high insulating value. 
         [0018]    When assembled, two panels  12  are positioned in spaced relation where inner surfaces  16  face one another and form a cavity  22  having a web section  24  and a column section  26 . The cavity  22  receives poured concrete or other hardenable materials. When hardened, the hardenable materials form a wall structure. 
         [0019]    The panels  12  are held in position relative to one another, and relative to adjacent pairs of panels  12  by a furring assembly  28 . While the furring strip assembly  28  may have any shape, as shown in  FIGS. 4 and 6 , preferred is a strip  28  having retaining flanges  30  and one or more webs or connectors  32  that span the distance between the flanges  30 . The webs  32  may include one or more slots  34  to hold conventional reinforcing bars (not shown). Such reinforcing bars are provided to strengthen and increase the durability of the poured, cured, and hardened final wall structure. 
         [0020]    Cut out of the furring assembly  28  in alignment with conduit  21  is one or more openings  36 . The openings allow wires to extend from the conduit  21  of one panel  12  to the conduit  21  of an adjacent panel  12  through the opening  36 . 
         [0021]    Disposed within the connector  32  of the furring strip assembly  28  are a plurality of retaining slots  38 . One of the retaining slots may be offset in relation to the other slots so that the retainer  40  may be installed one way and is not reversible. The retaining slots  38  can be of any shape. A retainer  40  is inserted through slots  38  to hold panels  12  in place. Preferably a retainer is positioned at the top and bottom of the furring strip assembly. The retainer can be of many shapes (e.g.  FIGS. 3 ,  8 , etc.). In one embodiment ( FIG. 3 ) the retainer  40  has a longitudinal section  42  with supporting flanges  44  connected to the ends. The longitudinal section  42  has at least one vertical rebar holder  46  and the flanges  44  have generally arcuate ends  48  that engage inner surface  26 . The generally arcuate ends  48  allow for easy insertion of panels  12  and provide a spring type action to hold the panels in place. 
         [0022]    In another embodiment ( FIG. 8 ) the retainer  40  has a longitudinal section  42  with supporting flanges  44  and having first and second vertical rebar holders  46   a  and  46   b.  The flanges  44  have flange sections  49  that extend outwardly from the longitudinal section  42  to ends  48   a  that extend in an opposite direction to the flange sections  49 . The flanges  44  are flexible and fit through retaining slots  38 . Further, the flange sections  49  have angled longitudinal prongs  49   b  that hold the panels  12  in place. 
         [0023]    Alternatively, the furring strip assembly  28  is received in grooves  41  cut within the panels  14  as shown by example in  FIG. 9  so that the outer surface  18  of panel  14  more readily receives stucco or EISS material. 
         [0024]    To assemble, the ends  48 ,  48   a  of flanges  44  of the retainer  40  are inserted through retaining slots  38  and frictionally held in place. The outer section  18  of the panel is then inserted between flange  30  and  44 . The arcuate shape facilitates insertion of the panel  12 . Vertical and horizontal rebar (not shown) are added as needed to holders  46 ,  46   a,    46   b  and  34  respectively. Concrete is then poured into cavity  22  and allowed to harden. 
         [0025]    In an alternative embodiment, as shown in  FIG. 5 , the inner section  20  of the panel  12  is spaced from the top edge  50  of the panel  12  to form a shelf  52  that defines a beam  54 . Preferably, the shelf has a tapered or angled surface  56  that extends from the panel  12  toward the cavity  22 . The tapered surface  56  facilitates flow of a hardening material from the beam  54  to the web section  24 . 
         [0026]    Also, the furring strip assembly  28 , alternatively, has a plurality of slots  34  for receiving reinforcement bars. By having a plurality of slots  34 , flexibility is provided to place horizontal reinforcement bars such that they do not intersect with vertical reinforcement bars. This is particularly a problem with above grade construction where vertical rebar is typically centered. 
         [0027]    To further assist with this problem, a retainer  40  having multiple vertical rebar holders  46 (A &amp; B) is used. Such a retainer  40  allows for use below grade (off-set rebar holder  46 B) which provides a gain of approximately 50% in strength, and above grade (centered rebar holder  46 A). To better secure the retainer to the furring strip assembly  28  a locking device  57  such as a spring clip extends transversely from the longitudinal section  42 , preferably from the point where the vertical rebar holders  46 A and B intersect. The spring clip (not shown) is inserted through a retaining slot  38  and expands outwardly to engage the connector  32  holding the retainer in place. In another embodiment, the locking device  57  ( FIG. 8 ) is a pin that is offset to insure that the pin  57  is installed in the correct position. Accordingly, rebar will not be installed in the wrong location in a below grade application where rebar is installed on the opposite sides of the lateral forces (opposite backfill). The furring strip assembly  28  and retainers  40  are used with conventional straight panels or with panels  12  having an inner section  20  that forms a web section  24  and/or a beam  54 . 
         [0028]    The wall forming system  10  also has a corner section  58  shown in  FIG. 7 . The corner section has an outer panel  60  and an inner panel  62 . The outer panel  60  and inner panel  62  both have an outer section  64  and an inner section  66 , with the inner sections  66  facing one another. In one embodiment, the inner section  66  is spaced from the top edge  50  of the panels  60  and  62  to form a shelf  52  that defines an area for a beam  54 . The shelf  52  may have an angled surface  56  to facilitate flow of hardening material. 
         [0029]    The inner and outer panels  60  and  62  are held in place by furring strip assemblies  28  that are transverse to one another. In most situations the furring strip assemblies  28  are at a 45° angle in relation to one another, but, depending upon the construction specifications, other angles are contemplated. 
         [0030]    Positioned between the outer panel  60  and the furring strip assembly  28 , is a support member  68 . The support member  68  surrounds the outer surface  16  of outer panel  60  to provide support, as well as a surface upon which materials, including exterior finish materials such as aluminum siding or the like, may be mounted. The support member  68  is made of any rigid material such as polycarbonate, wood, or metal, and may be formed as a single piece or in multiple pieces. 
         [0031]    The corner section may be pre-made, or modified to be bent to any angle on job sites using templates for particular specifications which is helpful when the corner angle is not standard. 
         [0032]    Thus, a system  10  is provided that reduces the amount of needed concrete, increases the amount of insulation provided and is easy to assemble. This reduced concrete causes a decrease in fluid pressures thus minimizing blow outs, bowing and snaking of walls. Thus, the system creates a high quality concrete wall that is straighter, taller, and more easily made with a user friendly system than previous concrete walls. Therefore, at the very least, all of the stated objectives have been met. 
         [0033]    It will be appreciated by those skilled in the art that other various modifications could be made to the device without the parting from the spirit in scope of this invention. All such modifications and changes fall within the scope of the claims and are intended to be covered thereby.