Abstract:
An insulated concrete form panel assembly for constructing insulated concrete walls includes a frame comprising a plurality of steel studs and at least two cross member that connect the studs together. A pair of insulating panels are fastened to and span respective inner and outer opposing sides of the frame so as to define concrete receiving cavities between the panels and the studs. A brick ledge may be constructed by separating a laterally extending, generally rectangular elongated mid portion of the outer insulating panel from a remainder of the outer insulating panel. An upper edge of the mid portion is then moved a predetermined distance outward from the remainder of the outer insulating panel such that the mid portion is disposed in a desired position at an angle to the remainder of the outer insulating panel. The mid portion is then secured in the desired position relative to the frame.

Description:
TECHNICAL FIELD  
         [0001]    This invention relates to insulating concrete from (ICF) systems for constructing walls.  
         INVENTION BACKGROUND  
         [0002]    Insulating Concrete Form (ICF) systems are known for use in constructing exterior wall systems with high performance and environmentally friendly materials that have vastly improved the energy efficiency, air quality, durability and overall comfort of dwelling structures. The relatively high cost of constructing and using these forms, however, have limited their acceptance to the upper spectrum of the customer home market.  
           [0003]    One example of such a system is disclosed in U.S. Pat. No. 4,223,501 issued Sep. 23, 1980 to DeLozier (the DeLozier patent). The DeLozier patent discloses an insulated concrete wall form comprising a plurality of blocks arranged in stacked courses. Each block includes a pair in insulating panels in a spaced parallel disposition. The panels of each block are held together by vertically oriented steel panels. However, stacked courses of blocks are time-consuming to construct.  
           [0004]    Another known type of insulated concrete form system is disclosed in U.S. Pat. No. 5,809,725 issued Sep. 22, 1998 to Cretti (the Cretti patent). The Cretti patent discloses an insulated concrete wall panel form that includes a framework of interconnected wires holding two insulating panels in a spaced parallel disposition. Similarly, U.S. Pat. No. 5,852,907 issued Dec. 29, 1998 to Tobin et al., disclosed an insulated concrete wall panel form design that includes a framework of steel reinforcing rods and form ties that interlock parallel form panels. However, the interconnecting wires and rods are difficult and time consuming to assemble with insulating panels.  
           [0005]    U.S. Pat. No. 5,839,249 issued Nov. 24, 1998 to Roberts (the Roberts patent) disclosed vertically oriented interconnected steel studs that extend vertically through vertically oriented openings in stacked foam concrete form blocks in an insulated concrete wall panel structure. These vertically oriented studs are used to help vertically align the stack of foam blocks and are inserted through cylindrical cavities that are alternated with other cylindrical cavities into which concrete is poured.  
           [0006]    Both U.S. Pat. Nos. 4,033,544 and 6,085,476 disclose fabricating insulated concrete wall panel forms, transporting those frames to a work site, and connecting the panels together pouring concrete into them.  
           [0007]    What is needed is a simpler and quicker way to assemble insulating concrete wall forms at a job site.  
         INVENTION SUMMARY  
         [0008]    An insulated concrete form panel assembly is provided that includes a frame comprising a plurality of steel studs and at least two cross members that connect the studs together. A pair of insulating panels are fastened to and span respective inner and outer opposing sides of the frame so as to define concrete receiving cavities between the panels and the studs.  
           [0009]    A method of forming insulated concrete walls is provided that includes the steps of providing a plurality of steel studs and inner and outer insulating panels. A frame is formed by connecting a cross member between the steel studs. An insulated concrete form panel is then completed by attaching the inner and outer insulating panels to respective opposite inner and outer sides of the frame such that the panels generally span the inner and outer sides of the frame.  
           [0010]    According to another aspect of the invention the formation of the insulated concrete form panel may also include configuring the insulated concrete from panel to form a brick ledge when concrete is provided within the panel. Configuring the insulated concrete form panel to form a brick ledge includes at least partially separating a laterally extending, generally rectangular elongated mid portion of the outer insulating panel from a remainder of the outer insulating panel. An upper edge of the mid portion is then moved a predetermined distance outward from the remainder of the outer insulating panel such that the mid portion is disposed in a desired position at an angle to the remainder of the outer insulating panel. The mid portion is then secured in the desired position relative to the frame.  
           [0011]    This method and apparatus reduces labor costs and construction time, and can be installed at a cost low enough to serve the middle marker and affordable market.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]    [0012]FIG. 1 is a respective cutaway view of au insulated wall panel constructed according the invention and partially filed with concrete;  
         [0013]    [0013]FIG. 2 is a cross-sectional side view of an insulated wall panel constructed according to the invention;  
         [0014]    [0014]FIG. 3 is a partially cut-away cross-sectional side view of an insulated wall panel constructed according to the invention and including a brick ledge for supporting finishing materials such as brick or stone above ground level;  
         [0015]    [0015]FIG. 4 is a front view of a brick ledge tie shown in FIG. 3;  
         [0016]    [0016]FIG. 5 is a side view of brick ledge tie of FIG. 4; and  
         [0017]    [0017]FIG. 6 is a top view of a brick ledge tie of FIG. 4. 
     
    
       [0018]    I intend this description to illustrate certain embodiments of the invention rather than to limit the invention. Therefore I have used descriptive words rather that limiting words. Obviously, it&#39;s possible to modify this invention from what the description teaches. One may practice the invention other than as described.  
       DETAILED DESCRIPTION  
       [0019]    An insulated concrete  46  wall construction assembly constructed according to the invention is shown at  10  in the drawings. The assembly  10  includes a series of 18 gauge steel studs  12  oriented vertically and parallel to one another spaced approximately 10 inches apart on center. The studs  12  are held in place relative to one another by 20 gauge steel angle strip cross members  14 ,  16 ,  18 ,  20  to form a frame or framework  21 . Two top angle strips  40   14 ,  16  are fastened across the studs  12  at opposite sides of upper ends of the studs  12  and two bottom angle strips  40   18 ,  20  are fastened across the studs  12  at opposite side of respective bottom ends of the studs  12 .  
         [0020]    The studs  12  are standard construction well known in the art and are formed from rolled steel. As best shown in FIG. 2, each stud  12  has a c-shaped cross-section and is formed to include an elongated main panel  22  and a pair of opposing flanges  24 ,  26  that extend integrally and perpendicularly from along the length of the main panel  22  and provide stiffness to the studs. Inwardly directed elongated lips  28 ,  30  extend perpendicularly and integrally inward from along outer edges of each of the flanges  24 , 26 . The main panels  36 ,  38   22  of the studs  12  are in a facing relationship to one another, i.e., studs  12  are aligned such that side surfaces of the main panels  36 ,  38   22  face one another. The studs  12  may be of whatever length is necessary for a given wall application.  
         [0021]    Each stud  12  also includes a plurality of apertures  32  typically spaced two feet apart along the length of each stud  12 . The apertures  32  of each adjacent stud  12  line up horizontally to accommodate the passage of a horizontal steel-reinforcing rod  34 . A length of grade 60-⅜ inch steel reinforcing rod  34  extends horizontally through each set of corresponding apertures  32  in the adjacent studs  12 .  
         [0022]    An inner sheet or panel  36  of commercially available insulating foam is fastened to a front or inner side of the framework  21  of steel studs  12  and a corresponding outer sheet or panel  38  of insulating foam is fastened to an opposite back or outer side of the framework  21  such that the two sheets  36 ,  38  of insulating foam are disposed parallel to one another. Each sheet of foam is preferably two-inch thick sheet of extruded polystyrene. Sheets of extruded polystyrene are readily available from a number of sources such as the Dow Chemical Company. The panel  36  could also be plywood, PVC foam plastic, oriented strand board, or other suitable material.  
         [0023]    As best shown in FIG. 1, the foam panels  36 ,  38  are secured to opposites of the framework  21  using approximately two inch wide furring strips  40  and a plurality of fasteners  42  such as approximately three inch long deck screws. Deck screws are then preferred fasteners  42  as they are readily available in large quantities and easy to install using standard self-loading power drill. The screw fasteners  42  are spaced approximately ten inches on center along each furring strip  40  and the furring strips  40  are oriented vertically against outer surfaces of each of the insulating foam panels  36 ,  38  in alignment with side surfaces of each of the studs in the framework  21 . The fasteners  42  pass through furring strips  40 , the insulated foam panels  36 ,  38  and then into flanges  26 ,  28  at the sides of the studs  12 . As such, the furring strips  40  distribute the loading of the fasteners  42  along vertical portions of the foam panels  36 ,  38  sandwiching the foam panels  36 ,  38  between the furring strips  40  and the flange portions  26 ,  28  of the studs  12 .  
         [0024]    The steel stud framework  21 , foam panel  36 ,  38 , furring strips  40 , and associated fasteners  42  make up an insulating concrete form panel (ICFP)  44  and a form that can be transported to a building site fastened together with other insulating concrete form panels  36 ,  38  interlaced with steel reinforcing rod  34  and filled with concrete  46  as will be described below. Each ICFP is configured to rest upon a standard poured concrete footing  48  straddling the 2×3 keyway that is formed into and runs along the centerline of a standard concrete  46  footing  48 .  
         [0025]    As shown in FIG. 3, a brick ledge  50  can be formed to extend laterally from the outer surface of an ICFP  44 . The brick ledge  50  is approximately two feet high and angles outward and upward at an approximate 15-degree angle such that a top edge  52  of an outwardly extended portion  54  of the outer panel  38  is spaced approximately 4- {fraction (1/2)} from the outer surface of the outer foam panel 38. The outwardly angled portion 54 of the foam panel is held in place by a plurality of brick ledge ties 56 as shown in FIGS 4-6.    
         [0026]    Each brick ledge tie  56  is formed from a length of number nine gauge steel wire and is bent to include generally U-shaped anchor portion  58  shaped to form an interference with a stud  12  when oriented horizontally within an interior surface  60  of a stud  12  between the inner and outer flanges  24 ,  26  of the stud  12  as shown in FIGS. 3 and 6. As shown in FIGS. 5 and 6, an arm portion  62  of each brick ledge tie  56  extends from the anchor portion  58  horizontally to the top outer edge of  52  of the outwardly angles portion  54  of the outer insulator panel  38 .  
         [0027]    Each brick ledge tie  56  also includes a retainer portion  64  that extends from an outer end of the arm portion  62  and is configured to grasp the upper edge  52  of the outwardly angles foam panel portion  54 . The retainer portion  64 , as best shown in FIG. 4, is bent into a generally square shape to help distribute loads exerted by the brick ledge tie  56  on the upper edge  52  of the outwardly angled foam panel portion  54  once concrete  46  has been introduced into the ICFP  44 . As shown in FIG. 5, the retainer portion  64  of the brick ledge tie  56  is angled to match the orientation of the outwardly angles portion  54  of the outer foam panel  38 . As shown in FIG. 6, the retainer portion  64  of the brick ledge tie  56  is shaped to closely match the contours of the inner wall  60  of the steel stud  12 . As best shown in FIG. 6, the retainer portion  64  is also shaped to bend or wrap around the outer lip  30  extending from the outer flange  26  of a stud  12  and then to merge into the arm position  62  and extend laterally outward in the general direction of the top edge  52  of the outwardly angled foam panel section  54 .  
         [0028]    In practice, insulated concrete wall  46  can be constructed according to the present invention by first constructing the framework  21  of steel studs  12 . The framework  21  is constructed by first inserting a pair of the angle strips  14 ,  18  into parallel spaced-apart slots formed in the flat topped surface of a table. The slots are formed into the table so that the angle strips  14 ,  18  are held in parallel spaced-apart orientation at a distance generally equal to a desired height of the wall to be constructed. The studs  12  are then laid parallel to one another such that the extend horizontally across the two angle strips  14 ,  18  with downward-facing ones of their flanges  24  resting on top of the two angle strips  14 ,  18 . The studs are then attached to the angle strips  14 ,  18  using sheet metal screws driven through the downward-facing flange portion  24  of each stud  12  and into the angle strips  14 ,  18 .  
         [0029]    The remaining two angle strips  16 ,  20  are then placed on the upward-facing flange portions  26  of the studs  12  opposite the two angle strips  14 ,  18  that have already been fastened to the studs  12 . The remaining angle strips  16 ,  20  are then fastened to the studs  12  in a like manner.  
         [0030]    A foam panel  36  having a length and a width generally matching the corresponding length and width of the now completed framework  21  of steel studs  12 , is then placed on the framework  21 . The panel  36  is oriented such that upper and lower edges of the foam panel are retained by upwardly extending portions  70 ,  72  of each of the most recently fastened angle strips  16 ,  20 . Furring strips  40  are then placed on the foam panel  36  in alignment with each of the steel studs  12  and are fastened in place as described above. The entire partially-completed panel is then flipped over and a second foam panel  38  of generally like dimensions is similarly affixed to the newly upturned side of the framework  21 .  
         [0031]    If a brick ledge such as the brick ledge shown at  50  in FIG. 3, is to be formed in the panel, when the outer foam panel  38  is laid down it is laid down in three separate horizontally oriented pieces  74 ,  76 ,  78 . The three pieces are cut so as to completely cover the exposed outer side of the framework  21 . A middle or mid section  76  of the three sections is cut two feet in vertical width and has a horizontal length that generally extends a full width of the ICFP. The middle section  76  will eventually serve as an angled outer insulating wall  76  of a brick ledge  50 . To leave the middle section  76  free to rotate outward at a later point during wall construction, the furring strips  40  are cut and attached to leave the two foot wide horizontal section of wall exposed. After the furring strips  40  are attached as described above, and additional furring strip  80  is fastened along a bottom edge of the two-foot wide section, perpendicular to the other furring strip  40 . In addition, at horizontally-spaced points approximately vertically midway along the center portion of the foam panel, roofing screws  82  are driven through the foam and into the steel studs  12  beneath to secure the middle foam panel section during transport.  
         [0032]    The now completed ICFPs  44  have then transported in this foam to a job site by loading them onto a truck or other suitable conveyance. In the case of ICFPs  44  having a brick ledge  50 s, the two-inch wide foam panel section  54  preferably remain secured until the ICFPS  44  have been unloaded at the job site and erected.  
         [0033]    At the job site, each of the ICFPs  44  is placed on a standard footing  48  straddling a standard three inch wide by two inch deep keyway that is generally formed along the approximate centerline of a concrete  46  footing  48  as shown in FIGS.  1 - 3 . A lower end of each ICFP  44  is open to allow concrete  46  poured in a top end of each ICFP  44  to flow into the keyway and lock the ICFPs  44  in position relative to the footing  48 .  
         [0034]    As each successive ICFP  44  is put into place, lengths of steel reinforcing rod  34  are inserted through the apertures  32  in the steel studs such that the reinforcing rod  34 s are disposed horizontally to one another and perpendicular to the studs  12 . Adjacent panels  36 ,  38  are fastened together edge-to-edge with short lengths of furring strips  40  that are screwed into the existing vertical furring strips  40  of the adjacent ICFPs  44 .  
         [0035]    At this point, any ICFPs  44  that are configured to form brick ledges  50  are set up for this purpose. To set up an ICFP to from a brick ledge  50 , the roofing screws  82  securing the mid panel section  54  are backed out until mid panel section  54  forms an approximate 15 degree with remainder of the outer surface of the outer foam panel  38 . At this point, the brick ledge ties  56  are installed by inserting the anchor portions  58  of each brick ledge tie  56  into one of the interior contours formed by the flanges  24 ,  26  and lips  28 ,  30  of each of the steel studs  12 . The retainer portions  64  of each of the brick ledge ties  56  are then slipped over the top edge  52  of the mid panel section  54 .  
         [0036]    At this point, any gaps in or between the foam panel sections are filled with expanding foam adhesive. Concrete  46  is then pumped into cavities formed between the studs  12  and the foam panels  36 ,  38 . In panels  36 ,  38  prepared to form brick ledges  50 , the concrete  46  also flows outward against the outwardly angled foam panel portions to form a brick ledge  50 . Standard methods for insuring there are no voids in the concrete  46  are then employed to include the use of a vibrator submerged into the concrete  46 .  
         [0037]    Constructed in this manner, the brick ledge  50  provides a high degree of sheer force resistance to vertical loads placed on the brick ledge  50 . The approximate two foot vertical height of the brick ledge  50  and the shallow 15-degree outward angle provides at two foot high concrete cross-section that supports the brick ledge  50  against downwardly-applied vertical sheer forces. This construction obviates the need to suspend steel reinforcing rod  34 s within the brick ledge  50  structure and also eliminates the time intensive task of installing such reinforcing rods.  
         [0038]    Once the ICFPs  44  have been erected and joined to one another, a water proofing membrane is sprayed on the outer surface of the ICFPs  44  and along the interface or joint between the ICFPs  44  and the footing  48 . The waterproofing membrane may be any one of a number of suitable such materials as are well known in the art and may be applied by any one of a number of known suitable means. A drain mat is preferably affixed over the membrane to protect the membrane from damage that can be caused by backfilling.  
         [0039]    I intend the above description to illustrate embodiments of the present invention by using descriptive rather than limiting words. Obviously, there are many ways that one might modify these embodiments while remaining within the scope of the claims. In other words, there are many other ways that one may practice the present invention without exceeding the scope of the claims.