Patent Publication Number: US-5896714-A

Title: Insulating concrete form system

Description:
FIELD OF THE INVENTION 
     The present invention relates to concrete construction utilizing foam block forms, more specifically to improvements to the foam panels, panel spacing ties and the interaction of the ties with the foam panels. 
     BACKGROUND OF THE INVENTION 
     Insulating Concrete Form Systems (&#34;ICFS&#34;) are known which act as a form to contain the fluid concrete while it solidifies, and also provide insulation for the finished structure. ICFS utilise a plurality of individual units or blocks, assembled in an interlocking arrangement, to create the forms for the concrete walls Each block comprises a pair of foamed plastic panels, which are held together with a plurality of ties. 
     The ties are truss-like and comprise flange portions which reside within the foam panels and an intermediate web portion connecting the flange portions, thus securing and holding the panel portions. One such example is disclosed in U.S. Pat. No. 4,229,920 to Lount, issued Oct. 28, 1980 who teaches use of a block having a multi-component tie. 
     More contemporary ICFS designs have implemented ties having integral flanges and web portions. Examples of this construction include U.S. Pat. No. 5,390,459 to Mensen, U.S. Pat. No. 4,884,382 to Horobin and U.S. Pat. No. 4,731,968 to Obino. 
     Horobin teaches slide-in ties which have complementary flanges and &#34;T&#34; slots formed in the panels. Each slot extends from the top of the panel to a point just lower than the mid-point. Accordingly, both the tie and the flange portions of the tie are substantially less in height than the panel. The flange itself has an &#34;H&#34; profile in plan; the outer portion for engaging the panel&#39;s &#34;T&#34;-slot, and the inner portion for stabilizing the inner face of the panel. The tie&#39;s web comprises three horizontal tension members, joined together at the flanges. 
     Obino provides a tie similar to Horobin, but the flanges are moulded into the foam of the panel. Both the web and flanges are substantially shorter than the panels. The web structure is continuous; lacking any holes. 
     In Mensen, the tie is moulded into the panel with the flange located flush with the outside of the panel. The flange extends substantially the full height of the panel. In side view, the tie resembles an &#34;H&#34;, the horizontal dash representing the web portion being much narrower that the flanges. Diagonal gussets extend from the web&#39;s midpoint to points adjacent the distal ends of each flange. 
     These above designs result in non-optimal distribution of the hydrostatic stress of the fluid concrete across the narrow central web portion of the tie and in the upper and lower portions of the foam panels. In Horobin and Obino, the foam portion is completely unsupported by the tie at the panel&#39;s upper and lower ends. In Mensen, the tips of the flanges are inadequately supported by the gussets. The result is excessive deformation of the top and bottom portions of the foam panels when filled with concrete. This is especially apparent when high vertical concrete lifts (a full; 8&#39; high wall) are poured in a single stage. 
     Mensen, Horobin and Obino permit attachment of interior and exterior surface finishing materials such as drywall or siding to the vertically-oriented flange portions of the ties. Of these three designs, only Mensen provides a flange which extends substantially the full height of the panels and is visible from outside the block for ease of attaching fastening devices. 
     Conventional systems permit vertical misalignment such that the flanges of adjacent blocks are not always aligned vertically. This poses difficulties for installers who need to accurately locate the flanges when attaching finishing materials 
     Within the typical dimensions of building construction there is frequently the need for a half-height concrete form block to be used, for example, below and above window openings. Although some ICFS designs provide a custom block having a less-than-standard height, none of the existing designs permits a block to cut horizontally in half to create a &#34;half-height&#34; block which continues to provide independently structurally sound characteristics. 
     In summary, the blocks of conventional systems, as described above, have the following features in common: 
     a pair of substantially rectangular foamed plastic panels; 
     two or more ties which extend across the space between panels for securing the panels in opposing, parallel, and spaced orientation, the spacing forming a cavity therebetween for containing the fluid concrete while it solidifies; 
     the web portions of the ties being substantially less in height than the panels; and 
     means associated with the edges of the panels for engaging cooperating means on adjacent blocks in order to assemble the complete wall form system. 
     Disadvantages associated with the above systems include: 
     inadequate support of hydrostatic pressures; 
     deficient flange configuration, being either, 
     that they are too short to provide a convenient support upon which to mechanically fasten finishing materials as in Horobin and Obino, or 
     that they cause interruption of the integrity of the outer face of the panel, compromising adhesion of surface mount materials like stucco, as is the case in Mensen; and 
     permitting misalignment of flanges between vertically adjacent blocks, further complicating the mechanical fastening of the finishing materials. 
     Despite attempts to solve various shortcomings of the conventional blocks, the applicant is not aware of a system which provides sufficient strength to competently support the hydrostatic head of a full-height wall of fresh concrete, and enables convenient attaching of finishing materials. 
     SUMMARY OF THE INVENTION 
     The apparatus of the present invention avoids the structural weaknesses associated with the ties of the prior art and increases the versatility of the ties and blocks. 
     Prior art ties are designed, in part, to accommodate poor concrete placement practice. Practised for many years, one characteristic of low quality concrete mixing and placement practice has been to pour concrete from a minimum number of locations and rely on lateral flow to distribute the concrete along the length of the forms. To facilitate this lateral flow, the concrete was often mixed with an excessively high water content, resulting in poor concrete quality. To further facilitate lateral concrete flow, it has also been traditional practise to minimise the height of the ties inside the forms so as to provide the least obstruction to flow along the form. As described above, this tie design results in a weaker ICFS block. 
     In contradistinction, It is known that concrete should be mixed with the minimum amount of water necessary for proper chemical hydration of the cement. This &#34;low-slump&#34; concrete, which does not readily flow, provides significantly higher ultimate strength and reduces shrinkage and cracking of foundations. Further, modern placement equipment enables vertical placement of concrete into the forms from many closely spaced locations, eliminating the reliance on lateral flow. 
     Accordingly, and contrary to the conventional wisdom, in a first embodiment of the invention, a novel ICFS block is provided having a tie which incorporates flanges which extend substantially the full height of the panels, and have a plurality of horizontal tensile web members which are distributed substantially along the full height of the flanges. The members uniformly resist horizontal forces generated by the fluid concrete acting on the foam panels. 
     Preferably at least two horizontal members are located above the web&#39;s midpoint and two below so as to produce two independently structurally sound half-height blocks if cut laterally in half. Sufficient open area is provided through the tie to permit lateral concrete flow to occur across the ties so as to form an integral concrete mass. 
     Complementary tongue and groove features are formed into the top, bottom and end edges of the panels to enable interlocking of adjacent blocks. 
     In a first broad aspect of the invention then, a concrete form block is provided comprising: 
     a pair of rectangular foam plastic panels having inner and outer faces, top and bottom and end edges; 
     at least two ties spaced longitudinally and parallel from each other, each of which extend perpendicularly between the inner faces of the panels so as to space the panels in opposing and parallel orientation, each tie having two opposed flange portions and a web portion extending therebetween, each flange portion forming a vertical stud which extends substantially the height of the panels and is moulded within each panel, the web portion comprising a plurality of horizontally extending members distributed substantially along the full height of the flanges, the web having a majority of its cross-sectional area comprising open space; and 
     interlocking means along the edges of the panels so that the block interlocks with other blocks when placed adjacent one another. 
     In a second aspect of the invention, the top edges of each panel are formed with additional transverse tongues at the location of each tie. Complementary transverse grooves are formed in the bottom edges. The transverse tongues and grooves cooperate to force vertically adjacent blocks to always interlock such that the flanges of their respective ties are aligned. The combination of the full height aligned flanges result in a substantially continuous flange for the attachment of finishing materials. Preferably, indicia are provided, seen from the outside of the panel, for locating the position of the flanges. 
     The flanges of the tie reside wholly within the body of the panel. The plurality of the tie&#39;s horizontal members extend from the flanges, which are located within the panel, and pass through the block&#39;s cavity. For a moulded-in embodiment, this arrangement imposes a difficult task upon the moulding process so as to prevent the escape (&#34;flash&#34;) of panel-forming foam from between the horizontal members and into the cavity. 
     Accordingly, in a third aspect of the invention, it is preferable to include an anti-flash member for forming a continuous barrier between all the members at the interface of the panel&#39;s inner face and the block&#39;s cavity. The anti-flash member comprises a light member which extends substantially the entire height of the tie, offset from the flange sufficiently so as to correspond with the inner face of the panel. The member is non-structural and merely strong enough to restrain flash. 
     The tie can be used, without modification, in both a moulded-in or a slide-in tie configuration. Moulded-in tie blocks provide the advantage of avoiding work-site assembly, but are more expensive to ship than are the collapsible, more compact slide-in tie blocks. For a slide-in embodiment, the same tie is utilized as described above, incorporating the full panel-height flanges, full panel height web with two or more horizontal members distributed both above and below the web&#39;s mid-point. The panels are formed with &#34;T&#34;-shaped slots amenable to accept the flanges of the ties. As above, complementary transverse tongue and grooves are formed in the respective top and bottom edges of the panels to force the flanges in vertically adjacent blocks to always align. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a single block which incorporates features of the first embodiment of the present invention, including a mould-in tie and inter-block interlocking tongue and grooves; 
     FIGS. 2a, 2b, 2c and 2d are top, front, bottom and end orthographic views respectively of the block of FIG. 1; 
     FIG. 3 is a perspective view of a tie of the block of FIG. 1; 
     FIG. 4 is a perspective view of a corner block also incorporating moulded-in ties; 
     FIG. 5 is a perspective view of a single block which incorporates features of an embodiment of the present invention which uses slide-in ties; 
     FIG. 6 is a partial perspective view taken along lines VI--VI of the block of FIG. 5, illustrating a &#34;T&#34;-slot for a slide-in tie; and 
     FIG. 7 is a perspective view of a plurality of blocks, of either embodiment, assembled for illustration of the vertical alignment of flanges. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Having reference to FIG. 1, one block 1 of an Insulating Concrete Form System (&#34;ICFS&#34;) is shown. A plurality of blocks 1 are laid adjacent each other, longitudinally end-to-end and vertically row-by-row (FIG. 7). For strength, each successive row has the ends of each block offset from the ends of the blocks in the adjacent rows. 
     In conventional and the novel systems, each block 1 comprises two rectangular foam panels 2 typically formed of expanded polystyrene. Each panel 2 has an outer face 16 and an inner face 17. Two or more ties 3 (six shown) extend transversely between the panel&#39;s inner faces 17 to locate the panels 2 in parallel opposed and spaced relation to each other. The ties 3 are spaced longitudinally and parallel to each other along the panels 2. 
     Having reference to FIGS. 2a through 3, each tie 3 comprises two laterally opposed flange portions 4 and a web portion 5 extending therebetween. Typically a tie is a unitary plastic structure of high density polyethylene or polypropylene. 
     Each flange 4 engages one of the opposed panels 2 and prevents lateral movement relative to the opposed panel 2. 
     Flanges 4 also serve as a structure to which finishing materials may be secured. Shown in exploded view in FIG. 2a, sheeting material 6 is attached to the flanges 4 with mechanical fasteners 7. 
     Thus far, the description of the block of a ICFS is also descriptive of the prior art systems. 
     In a first embodiment of the present invention, a novel ICF System is provided in which novel ties 3 and complementary panels 2 are formed in a moulded-in configuration. The same tie 3 (FIG. 3) is also amenable to a slide-in application as disclosed in a further embodiment discussed later. 
     Tie 3 has a web portion 5 and opposing flange portions 4. The flange 4 forms a &#34;T&#34;-shape in section. The outermost portion the &#34;T&#34; 8 lies parallel to the plane of the panels 2. 
     The height of each flange 4 is substantially equal to the full height of the panels 2. As shown in FIG. 7, when the ties 3 are aligned with the ties 3 of blocks 1 in adjacent rows, the full-height flanges 4 form a nearly continuous structure 15 upon which to attach and support finishing materials, such as drywall or siding. 
     The flanges 4 are structurally maintained in a spaced apart and parallel relation by the tie&#39;s web 5. The web 5 comprises a plurality of members 9 extending horizontally between flanges 4. The horizontal members 9 are distributed vertically between the flange&#39;s top 10 and bottom 11. At least two members 9 (3 are shown) are located above the mid-point M of the web, and at least two members 9 (3 shown) below. Should the ICFS block be cut laterally in half, at least two horizontal members 9 remain above the cut and at least two members 9 will remain below the cut, thereby providing independent and structurally sound half-blocks (not shown). 
     Diagonal members 12 in the web provide torsional stiffness. 
     The overall cross-section of the horizontal members 9 is sized to withstand hydrostatic pressure of fluid concrete pressing laterally outwardly on the inner faces 17 of the panels 2 without causing excessive panel deflection. Using six plastic ties 3, spaced along a 11/3&#39; high×4&#39; long panel, and wherein each tie 3 has six horizontal members 9 which are about 0.25&#34; high×0.20&#34; in section, the block&#39;s panels 2 can withstand a pressure of a height of eight feet of concrete poured at once. 
     The plurality of members 9 extending between flanges poses a challenge during the moulding process. Along a plane where the inner face 17 of the panel 2 forms, the tie 3 comprises an alternating pattern of members 9 and space 13. For properly forming foam panels, the moulding equipment must successfully restrain the flow of foam (&#34;flash&#34;) about each member 9 to limit its escape. 
     Accordingly, thin flatbar-like anti-flash members 14 extend the height of the web 5 and with their cross-sectional plane lying parallel to the flanges 4. The anti-flash members 14 bridge the open space 13 between members 9 so as to form a continuous barrier. The anti-flash members 14 are non-structural and merely block foam from escaping during the moulding process. The anti-flash members are spaced sufficiently inwardly from each of the flanges so as to cooperate, with moulding equipment and align with the inner face 17 of the panel 2. Typically, for a panel thickness of 21/2&#34;, the flange 4 is inset about 3/8&#34; from the outer face of the foam panel, and the anti-flash 14 members are spaced about 21/8&#34; from the flanges. 
     Once moulded-in, the ties 3 and panels 2 form a unitary block 1 of an ICFS. 
     Tongue 20 and grooves 21 are provided at the block&#39;s two ends 28,29 to interlock panels 2 together and prevent transverse misalignment. A one end 28 of the block 1, the two ends of the panels 2 have opposing interlocking means 20,21; in other words, the end of one panel forms a tongue 20 and the end of the other forms a groove 21. In this way, full blocks 1 are not restricted to one mode of abutment with adjacent blocks. 
     Longitudinally extending tongues 22 protrude upwardly from the top edge 24 of both panels 2. The tongues 22 avoid collecting moisture and ice prior to assembly. Corresponding longitudinal grooves 23 are formed in the bottom edges 25 of the panels for interlocking with the top edge tongues 22 of a lower row of blocks 1. 
     At each longitudinal location of a tie 3, one or more short tongues 26 extend transversely from the top tongue 22. These short tongues 26 correspond with short transverse grooves 27 in the block&#39;s bottom edge 25. The short tongue 26 and grooves 27 cooperate to longitudinally locate the blocks of one row so that their ties 3 must align vertically with the ties 3 in the adjacent upper and lower rows. 
     The short tongue and grooves 26,27 extend to the outer face 16 of each panel 2 and thus visibly indicate the location of each tie 3 (FIG. 1). The tongue and grooves 26,27 are arranged as corresponding pairs. Preferably, two tongue 26,26 and grooves 27,27 are placed in closely-spaced arrangement. As shown in FIGS. 2a and 4, the two tongues and grooves of a corresponding pair 26,27 are approximately arranged or straddle the dimensional periphery of the tie 3. 
     Alternatively, indicia lines or embossing is applied to the panel&#39;s outer face 16 to visibly indicate the location of the tie 3. As shown on FIGS. 4 and 7, indicia lines delineate the continuous structure 15 on vertically adjacent blocks 1. Further, the indicia can delineate the dimensional extent of the flange 4. Best shown in FIG. 4, the indicia is formed using an embossing or bas relief formed into the outer face 16 of the panel 2. 
     As shown in FIG. 4, the invention is equally well applied to a corner block 28. 
     Moulded-in tie blocks provide the advantage of avoiding work-site assembly. Unfortunately, such blocks are more expensive to fabricate and occupy more space and are therefore more costly to ship to remote construction sites. 
     Accordingly, in a second embodiment and having reference to FIG. 5, it is desirable to provide block 30 which uses panels 31 and ties 3 which can be unassembled to form a more compact shipping unit. 
     Panels 31 are moulded without ties 3. A plurality of &#34;T&#34;-type slots 32 are formed in the panels 31. One &#34;T&#34; slot 32 is provided for each tie 3. The ties 3 are identical with those described for the first embodiment. Each slot 32 extends from the top edge 33 of the panel 31 to a point 34 adjacent the bottom edge 35 of the panel so as to accommodate the height of the tie&#39;s web 5. 
     Referring to FIG. 6, the outermost portion 36 of each &#34;T&#34; slot 32 is aligned longitudinally with the panel 31. The stem 37 of the &#34;T&#34; extends to the inner face of the panel 31. 
     The outermost portion 8 of the tie&#39;s flanges 4 (FIG. 3) slide into each &#34;T&#34; slot. The depth of the &#34;T&#34; slot 32 in the body of the panel 31 is coordinated with the tie&#39;s flange 4 and anti-flash member 14 so that the anti-flash members 14 do not substantially interfere with the panel 31 itself. 
     The use of a single tie 3 is preferable for both moulded-in and the modular slide-in tie embodiments. The single tie design is cost effective due to both the economies of scale in manufacturing a dual-purpose tie and due to reduced inventory costs. 
     The advantages achieved by the novel tie and panel system include: 
     the substantially full height web permits use of a plurality of horizontal web members distributed over the height of the flanges for strengthening the flanges against hydrostatic pressures; 
     full height flanges provide ample area for the attachment of finishing materials; 
     the forced alignment of flanges across successive rows of blocks ensures ease locating the flanges and installing finishing materials; 
     provision of two or more horizontal members above and two or more below the tie mid-point permits a block to be cut in half for increased versatility in assembly; and 
     the same tie can be used in both a moulded-in and a slide-in application.