Abstract:
A forming panel and method for using the same in construction of self-sustaining concrete wall structures is provided wherein a flexible barrier element is provided along a margin on the forming panel for impeding the flow of water and fine particles of a concrete mix pour past the barrier element. The margin may be along the perimeter edge of the forming panel or along an opening interior to the perimeter of the forming panel. When located near the perimeter, the flexible barrier element may be positioned in a slot extending parallel to the margin and located in the frame. When located near an interior opening, the barrier element may be provided on a reinforcing member positioned around the opening or on a door which shifts to improve access through the opening during placement of forming ties or the like. The forming panel may be coupled with adjacent forming members to provide a wall system, and two wall systems may be connected by forming ties to provide a channel for receipt of a concrete pour therebetween.

Description:
RELATED APPLICATION 
   This application is a division of U.S. patent application Ser. No. 09/834,149 filed Apr. 12, 2001 now U.S. Pat. No. 6,655,650. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention broadly concerns a forming panel used in forming wall structures of hardenable concrete, whereby multiple panels may be placed in adjacency and in opposition for receiving and supporting the concrete pour therebetween. More particularly, it is concerned with a concrete forming panel which includes a flexible barrier positioned adjacent and preferably aligned with a margin on the forming panel such as a perimeter edge or on an interior edge to inhibit the flow of the concrete mix therepast. 
   2. Description of the Prior Art 
   The formation of building walls, foundations and other wall structures from poured concrete after curing is well known and the forms used for holding the concrete fall into two general categories. Forming walls may be made of site-built forms, typically of plywood, and are used only once before being discarded, or of reusable forming panels, typically of wood, steel or aluminum or combinations thereof, which panels may be fastened together and then removed from the hardened concrete wall for reuse. While these reusable forming panels are typically of a greater initial cost, their ability to be repeatedly used more than compensates for the initial expense. 
   The reusable forming panels typically have a face plate supported by a frame and are joined together in adjacency (essentially side-by-side or angled) to provide a form wall, and two form walls oppose one another to receive the concrete therebetween. Each forming panel may have a number of relieved areas along the side to receive tie bars for connecting the opposing form walls. Where the panels meet along their perimeters, small gaps are present, especially in the relieved areas not occupied by a tie bar. Moreover, the panels may have interior holes or openings which are penetrated interiorly of the perimeter of the forming panel by tie bars, rods or the like, and there are similar gaps between the tie bars and the surrounding forming panel. The concrete is mixed with water to make it flowable and ready to pour, the concrete mix typically including water, fine particles of mortar and sand, and aggregate such as gravel. In the gaps along the perimeter of the forming panels and where there are openings on the interior of the forming panel, water and fine particles of sand and mortar of the wet concrete will typically migrate from the concrete pour during curing. As a result, the appearance of the cured and hardened concrete opposite these gaps will be discolored, and will typically have significant raised ridges and be pitted rather than smooth as appears along the face of the forming panel. The large ridges and the pitted area along the face may affect not only the appearance but also the performance of the concrete wall over time. 
   SUMMARY OF THE INVENTION 
   These problems are significantly ameliorated by the concrete forming panel provided with a flexible barrier in accordance with the present invention. By the provision of a flexible barrier along and proximate to one or more margins in the forming panel which engage flowable concrete during curing, such as the face plate and frame, a substantial reduction in the loss of fine mortar particles and water is achieved. This results in a finished wall surface with substantial reduction of discoloration and pitting, even in the relieved tie bar passage area or interior openings. The flexible barrier serves as a gasket which yields for variations in the size of the gaps as well as permitting tie bars and other forming accessories to abut and pass thereby, and stands up to rugged use environments. Moreover, when the panel has an opening within the perimeter of the face plate and rails of the frame, by providing an interior margin provided with such a barrier within the perimeter of the forming panel, the forming panel hereof substantially reduces the problem of large ridges and pitting where tie bars and other forming hardware must pass through openings in the frame inside of the perimeter. An additional benefit is reduced seepage of moisture into and through the hardened wall structure. 
   In greater detail, the forming panel with flexible barrier along one or more of its margins broadly includes a form configured to receive a pour of a flowable concrete mix in supporting relationship thereagainst, the forming panel in a face plate typically of aluminum and a frame also of aluminum or steel having at least one siderail. The frame typically includes parallel and spaced apart, opposed endrails, siderails in spaced relationship and extending parallel thereto, and crossbraces, end reinforcements and gusset plates. The rails have exposed edges and face plate edges, with elongated grooves provided in the rails (both endrails and siderails) on the exterior side thereof. Flexible barriers acting as gaskets, preferably of filaments such as brush strips, are received in the grooves to impede the migration of water and fine particles of the concrete mix therepast as the barriers engage opposing parts of the forming panel or adjacent forming panels. The brush fibers of the brush strips are preferably oriented at an angle toward the concrete-receiving surface of the face plate and extend beyond the outer surface of the frame, whereby when the barrier is engaged by another component of the forming panel, a tie bar, another forming panel or an opposing barrier, the brush fibers project toward the concrete mix in the pour and the face plate rather than away to minimize the amount of water and fine mortar and sand particles of the mix carried into the gap between forms. Alternately, or in addition to the flexible barrier positioned near the perimeter margin of the forming panel, openings within the face plate may have flexible barriers mounted in proximity. The openings within the face plate may be substantially covered by a shiftable door which may be hinged, so that when there is no need to pass a tie bar therethrough, the door may be sealed. On the other hand, opening the door greatly facilitates placement and coupling of a tie bar to the forming panel, and closing of the door still permits a tie bar to pass thereby. The flexible barrier may be provided on either the door or a reinforcing enclosure around the opening, or both. The door is preferably hingably mounted to the reinforcing enclosure and a closure member provided to hold the door closed. A narrow gap may be provided between the door and the face plate when the door is in a closed position, to thereby permit the tie bar to pass therethrough when the door is closed, the barrier element helping to seal the gap. 
   As a result, forms are provided which substantially reduce the amount of discoloration and pitting in the finished wall surface, minimize the formation of ridges of material migrating into the gaps between forms, and provide an improved finished concrete surface while remaining rugged in use. These and other advantages will be appreciated by those skilled in the art with reference to the drawings and description which follow. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a rear perspective view of a concrete forming panel in accordance with the present invention, showing the face plate and the frame, with a flexible barrier extending around the siderails and endrails of the frame parallel to and adjacent the perimeter of the forming panel; 
       FIG. 2  is an enlarged, fragmentary perspective view showing a siderail and face plate in section and a relieved area for the passage of a tie bar, with the flexible barrier shown in an exploded view; 
       FIG. 3  is an enlarged fragmentary horizontal sectional view through a sidewall and the face plate showing the orientation of the tips of the fibers of the flexible barrier oriented at an acute angle to the plane in which the face plate lies; 
       FIG. 4  is an enlarged, fragmentary vertical sectional view through a portion of the face plate and showing a coupler pin and wedge for holding together two forming panels in side by side relationship and with a tie bar shown in broken lines; 
       FIG. 5  is an enlarged, fragmentary cross-sectional view taken through line  5 — 5  of  FIG. 4 , showing the orientation of two opposed flexible barrier elements of adjacent forming panels extending into the gap therebetween; 
       FIG. 6  is an enlarged, fragmentary cross-sectional view taken through line  6 — 6  of  FIG. 4 , showing the orientation of the two opposed flexible barrier elements when compressed by a tie bar received in the relieved area and passing through the gap; 
       FIG. 7  is an enlarged, fragmentary cross-sectional view similar to  FIG. 6 , showing the relieved area adapted to receive the tie bar as in  FIG. 6 , but in the condition when a tie bar is not placed therethrough, with the flexible barrier elements engaging one another in the gap; 
       FIG. 8  is a rear elevational view of another aspect of the forming panel of  FIG. 1 , showing the portion of the forming panel which is provided with an opening in the face plate interior to the perimeter of the face plate and the side rails and end rails of the frame and having a reinforcing enclosure around the opening and a door for substantially closing the opening; 
       FIG. 9  is an enlarged, fragmentary cross-sectional view taken along line  9 — 9  of  FIG. 8 , showing two opposed forming panels of opposite forming walls positioned and connected by a tie bar for receiving flowable concrete in the channel therebetween, one of the panels being shown in plan, and the tie bar passing between the forming panels through the opening and a barrier element in both the enclosure and the door of the forming panels; 
       FIG. 10  is an enlarged, fragmentary elevational view in partial cross-section along line  10 — 10  of  FIG. 9 , showing the combination pin fastener and door retainer in a first position holding the door closed and passing through a hole in the tie bar; and 
       FIG. 11  is an enlarged, fragmentary elevational view in partial cross-section as in  FIG. 10 , but with the combination pin fastener and door retainer retracted and retained in a second position where the hinged door is open to facilitate insertion of the tie bar or removal of the forming panel. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Referring now to the drawing, a concrete forming panel  10  in accordance with the present invention broadly includes a face plate  12  typically of aluminum and a frame  14  mounted along the perimeter  15  of the forming panel  10 , also preferably primarily of aluminum by welds  17 . As used herein, “aluminum” refers to aluminum alloys, such as, for example, ASTM 6061 T-6 alloy, and the face plate, and a typical thickness of aluminum sheeting used as a face plate  12  would be about 0.125 inch. The frame  14  preferably includes a pair of elongated endrails  16  and  18  and a pair of opposed siderails  20  and  22 , which in the illustrated embodiment the siderails are shown parallel to each other and perpendicular to the endrails, although it may be appreciated that it is possible for the forming panel to be in various geometries and have arcuate edges. A typical endrail or siderail of aluminum has a thickness of about ⅜ inch. The frame may include cross-braces  24 , and end braces, gusset plates at the corners, and steel bushing plates or reinforcements to reinforce holes  26  spaced along the siderails  20  and  22  which receive therethrough coupler pins  28  secured by wedges as shown in  FIGS. 4 ,  5  and  6 , with such steel reinforcing members positioned adjacent the holes  26  for wear resistance. The face plate  12  lies in a plane and is shown flat and smooth, although textured surface face plates  12  may be used as well. 
   A barrier element  30  of flexible material such as rubber or more preferably brush strips  32  of nylon fibers or bristles  34  secured by metal retaining clips  36  is received in longitudinally extending slots  38  in the siderails  20  and  22  and the endrails  16  and  18 . The slots  38  are located more proximate the face plate edge  40  of the siderails and endrails than the back side exposed edge  42  of the siderails and endrails. The siderails and endrails each have an outer surface  44  and an inner surface  46 , the slots  38  being in communication with the outer surface  44  as shown in  FIGS. 2 and 3 . The slots  38  are most preferably provided at an acute angle φ relative to the face plate  12  so that the bristles  34  extend forwardly toward the face plate edge  40  of the siderails and endrails. The bristles  34  are also of a sufficient length relative to the depth of the slots  38  that they project beyond the outer surface  44 . The slots  38  are preferably positioned in a thickened region  48  of the siderails and endrails as shown in  FIG. 3  in order to avoid weakening of the siderails and endrails. 
   The siderails  20  and  22  are not of constant thickness along their longitudinal length, but rather their outer surface  44  is provided with longitudinally spaced, laterally extending relieved areas  50  adjacent unrelieved areas  51 , the relieved areas  50  providing passages for tie bars  52  to be placed thereon and in the gaps between adjacent forming panels  10  as shown in  FIGS. 6 and 7 . The tie bars  52  are used to separate and hold at a predetermined distance an opposite forming wall of other forming members in order to provide a channel  126  therebetween for receipt of a pour of flowable concrete  54  therein. An adjacent relief  56  is also provided in the face plate  12  (see  FIG. 2 ). As may be seen in comparing  FIG. 5  showing two adjacent forming panels  10  in side-by-side relationship in cross-section taken through the siderails  20  and  22  of adjacent forming panels  10  with  FIG. 6  taken in cross-section through the siderails  20  and  22  and the tie bar  52 , the depth of the slots  38  are slightly less in the vicinity of the relieved areas  50  so that the tips of the barrier element fibers are substantially linear thus equidistant in a direction perpendicular from the outer surface  44  at the unrelieved areas  51  and exposing slightly more of the barrier element fibers in the relieved areas  50  than the unrelieved areas. Because the slots  38  are oriented on an axis that is at an acute angle φ relative to the plane in which the face sheet  12  lies, the resulting forward angled orientation of the bristles  34  toward the face plate  12 , the engagement of opposed flexible barriers  30  with a tie bar  52  or with the barrier element  30  of an adjacent forming panel  10  causes the bristles  34  to slightly bend in a forward direction as shown in  FIGS. 5 and 6 . This in turn enhances the performance of the barrier element  30  by providing both a greater density of concentration of the bristles  34  where they interengage and also extending them forwardly to reduce the region into which water and particles from the concrete pour may migrate and lessen the extent of any ridge which may be formed as the concrete flows in to the gap  58  between the adjacent forms  10 . As shown in  FIG. 7 , the bristles  34  of the barrier elements  30  are particularly helpful where there is no tie bar  52  positioned in a relieved area  50 , which would otherwise present an even wider opening between the adjacent forming panels  10 . The barrier elements  30  are preferably mounted all around the forming panel  10  on each of the rails in an orientation parallel to and closely adjacent the perimeter of the face plate  12 . 
   FIGS.  1  and  8 – 11  illustrate an alternate embodiment where, in addition or as an alternative to the flexible barrier element  30  provided in the frame  14  around the perimeter of the forming panel  10 , an opening  60  is provided in the face plate  12  inside the frame  14  and thus interiorly of the perimeter. A closure and support element  61  is attached to the face plate  12  adjacent the opening, shown as a reinforcing enclosure  62  of aluminum which surrounds and thus reinforces the opening and is attached to the face plate  12  or the cross members by welding, fasteners or the like. The enclosure  62  includes a base  64  which mounts to the face plate  12  by welding or the like to support and reinforce the face plate  12  surrounding the opening  60  and two spaced-apart gates  66  and  68 , each having a respective passage  70  and  72  therethrough. A reinforcing rod  74  of hard steel, such as ASTM 228-93 wire, is received in a groove  76  adjacent the passages  70  and  72  and the deformation of the aluminum alloy caused by drilling the passages serves to pinch or hold the rod  74  in place. The reinforcing rod  74  helps to resist wear on the gates  66  and  68  and prevent enlargement of the passages. The base  64  may include a slot  78  adjacent to and facing the opening for receipt of a flexible barrier element  30  therein. Again, the flexible barrier elements may be rubber or more preferably brush strips  32  of nylon bristles  34  held by metal clips. 
   A hinge  80  is provided on the base  64  for pivotally mounting a door  82 . As illustrated by  FIG. 9 , the door  82  may swing between a first position substantially but not completely closing the opening  60  and a second position which is open. The door  82  includes a head  84  and an insert  86  which fits within the opening  60 . The head  84  presents a lip  88  which engages the base  64  and has a reinforcing rod  74  received in a groove  90  therein. The head  84  is sized to provide a slot  92  between the head  84  and the base  64  to permit passage of a tie bar  52 . 
   The door  82  is held closed by closure mechanism  94 . The closure mechanism  94  is mounted on arm welded to the face plate  12  or to a cross-brace  24  of frame  14 . The closure mechanism  94  includes a housing  96 , a pin  98  shiftably received in the housing  96 , and a catch  100 . As illustrated in  FIGS. 10 and 11 , the pin  98  is biased toward the gate  66  by a coil spring  102  received within the housing. The pin  98  includes a shank  104  slidable within the housing  96 , a narrowed neck  106 , and a nose  108  which is rounded at its tip. Both the nose  108  and the shank  104  have a greater diameter than the diameter of the neck  106 . The catch  100  includes a bar  110  which is mounted by a hinge  112  for toggling on pivot mount  114 . The bar  110  has a first end  116  which is engaged on its underside by a spring  118  extending from the housing  96  and a second end  119  which has a cradle  120  which includes an arcuate web  122  sized to receive the neck  106  but not the shank  104  therein. Thus, the spring  118  biases the cradle  120  toward the pin  98 . 
   In use, the forming panel  10 , shown individually in  FIG. 1 , is coupled to adjacent forming members, such as another forming panel  10  as shown in  FIGS. 5 ,  6  and  7 , to provide one forming wall  122 , and another forming wall  124  is positioned opposite as shown in  FIG. 9  so that a channel  126  for receiving flowable concrete  54  is therebetween. Tie bars  52  are placed in at least some of the relieved areas  50 , though typically not all of them and extend through the channel to connect the forming walls  122  and  124  when connected to the forming panels by pins  28 . Adjacent forming panels are connected by pins  28  held in place by wedges as shown in  FIGS. 4 ,  5 ,  6  and  7 , with these pins  28  passing through holes in the tie bars  52  to hold them in position. The tie bars extend across and through the channel  126  for connecting the opposing forming walls  122  and  124 , whereby after the concrete  54  cures, the tie bars  52  remain embedded in the concrete wall structure formed thereby. 
   In addition, door  82  may swing open to facilitate positioning of a tie bar  52  through the opening  60  in opposing forming panels  10 . The pin  98  is first retracted against the coil spring  102  and the catch is released whereby the web  122  of the cradle  120  rests around the neck  106  and against the shank  104  to hold the pin  98  in a retracted position. The tie bar  52  is then aligned to lie closely adjacent the gate  66 , whereupon the door may be closed to substantially block the opening  60 . With the door closed, the operator presses on the first end  116  of the catch  100  to release the spring loaded pin  98 . The pin  98  then passes through the hole of the tie bar  52  and through the gate  66  to both hold the door  82  in the closed position and secure the forming panel  10  to the tie bar  52 . Thereafter, dry concrete mixed with water may be poured into the channel  126 , which after a suitable curing period, hardens. The barrier elements  30  substantially inhibit the flow of water and fine particles of mortar, sand and the like from the concrete  54  while it cures. The barrier elements  30  along the side rail and end rail edges oppose one another as shown in  FIG. 5  to inhibit substantial flowing of material without inhibiting the performance or coupling ability of the forming panels. The bristles  34  yield when engaged by tie bars  52  or the frame  14  and being separate, resist tearing, while providing a substantial barrier to the flow of water and fine particles from the concrete. The flexible barrier elements are especially beneficial in resisting flow of water and fine particles both when a tie bar  52  is present in a relieved area  50  or, even more importantly, when a tie bar  52  is not used in a relieved area as shown in  FIG. 7 . When an opening  60  is provided in the forming panel interiorly of the perimeter provided by the frame, the door  82  is able to swing open to ease the placement of the tie bar. After the tie bar  52  is in place, the door may be closed to inhibit the flow of concrete or the water and fine particles thereof through the opening  60 . The flexible barrier elements  30  in the base  64  and the door  82  further limit the migration of water and fine particles through the slot  92 . The first end  116  of the bar  110  is depressed to release the cradle, whereupon the coil spring  102  pushes the pin  98  through the gate  66  so that the nose of the pin  98  rests against the head of the door  82  to hold the door in a closed position. 
   After the concrete  54  cures and hardens, the forming panels  10  may be readily removed for reuse by removing the wedges from the coupler pins  28  and pulling the coupler pins through the holes  26  in the rails. The pin  98  is retracted so that the cradle engages the neck of the pin  98  to permit opening of the door  82 . This also disengages the pin  98  from the tie bar  52 , permitting the forming panels  10  to be removed. The barrier elements  30  substantially limit the migration of water and fine particles from the concrete  54  as it hardens and thus inhibits the formation of substantial ridges opposite the gaps between forming panels. A smoother surface of the resulting wall with substantially less pitting results from the use of the barrier elements both around the perimeter edge of the forming panels  10  and at any interior openings. 
   Although preferred forms of the invention have been described above, it is to be recognized that such disclosure is by way of illustration only, and should not be utilized in a limiting sense in interpreting the scope of the present invention. Obvious modifications to the exemplary embodiments, as hereinabove set forth, could be readily made by those skilled in the art without departing from the spirit of the present invention. 
   The inventor hereby states his intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of his invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention as set out in the following claims.