Patent Publication Number: US-2022228380-A1

Title: System and method for round column construction

Description:
TECHNICAL FIELD 
     This patent application relates generally to a concrete construction systems and methods, and more specifically, to systems and methods for constructing a concrete column using a round column form. 
     BACKGROUND 
     Residential and commercial construction typically involves creation of vertical members, such as columns. These vertical members may transfer loads from slabs and beams by compression. Such compression may cause the vertical members to transfer load ultimately to the soil below. In other words, these vertical members are what allow a building or structure to stand. Most building or structure failure is the result of poor column construction. 
     Reinforced concrete construction of columns may be an important type of concrete element in a building, especially a multi-story building. However, the design and formation of these vertical elements may vary greatly. Things like shape, length, location, and understanding of various forces must be considered in their construction. With all these considerations, most conventional approaches may be complex, costly, and cumbersome. 
     Thus, a simple, inexpensive, reliable, and scalable systems and techniques to prepare and construct one or more columns or other similar vertical members in any building or structure may be imperative. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       Features of the present disclosure are illustrated by way of example and not limited in the following Figure(s), in which like numerals indicate like elements, in which: 
         FIGS. 1A-1B  illustrate a side view of a round column form, according to an example; 
         FIGS. 2A-2C  illustrate various views of a brace for a round column form, according to an example; 
         FIGS. 3A-3B  illustrate applications of a round column form, according to an example; and 
         FIG. 4  illustrates a method of forming a concrete column using a column form, according to an example. 
     
    
    
     DETAILED DESCRIPTION 
     For simplicity and illustrative purposes, the present disclosure is described by referring mainly to examples and embodiments thereof. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be readily apparent, however, that the present disclosure may be practiced without limitation to these specific details. In other instances, some methods and structures readily understood by one of ordinary skill in the art have not been described in detail so as not to unnecessarily obscure the present disclosure. As used herein, the terms “a” and “an” are intended to denote at least one of a particular element, the term “includes” means includes but not limited to, the term “including” means including but not limited to, and the term “based on” means based at least in part on. 
     As described above, reinforced concrete construction of columns may be an important type of concrete element in a building, especially a multi-story building. However, the design and formation of these vertical elements may vary greatly. Things like shape, length, location, and understanding of various forces must be considered in their construction. With all these considerations, most conventional approaches may be complex, costly, and cumbersome. 
     There may be several stages involved in the construction of columns, especially concrete columns. These may include, but not limited to: (1) column layout; (2) column reinforcement; (3) column formwork; and (4) pouring concrete into column. Column layout may generally be a stage that is determined early on in the design process and may occur practically in field. Column layout, for example, may include drawing, marking, and/or using rope-line measurements to place and position various columns in accordance with architectural drawings or layouts. Pouring concrete may be a relatively simple stage, assuming column reinforcement and formwork are established and completed. Pouring concrete may generally involve mixing concrete (machine, ready-mix, or otherwise) and pumping the mixed concrete into the established concrete form. The systems and methods described herein may be directed generally to aspects of (2) column reinforcement and/or especially (3) column formwork. 
     The systems and methods, as described herein, may provide a two-piece column form that is innovative and novel, in some examples, the systems and methods described herein may provide round column construction using overlaid plywood with excellent surface durability and/or for mirror gloss finishes or other finish. In some examples, panel construction may include a three-part, high-density, overlay on hardwood, such as a poplar/birch mixed inner ply. In some examples, a two-step technique, which may involve bonding using an adhesive, such as phenolic glue, and laminated with paper (e.g., #100 film) on both sides may also be involved to provide round column form. 
     It should be appreciated that after hours of 95° C. high temperature pressurized with molded half round forms, half round columns may set and formed permanently. In some examples, edges may be trimmed, e.g., tongue and groove, and calibrated to fit the round column. 
     Benefits and advantages of the systems and methods described herein may include ease of use, installation, removal and/or transportation of elements. The column forms and associated elements for the systems and methods described herein may also be easily cut, designed with grooves or notches, which help ensure stable interconnections that prevent or reduce concrete leakage. In addition, the column forms and processing techniques described herein may generally incorporate plywood that is light-weight and easy to handle. In some examples, the column forms may be used in a stacking configuration, e.g., up to 30 feet without use of a crane or other similar machinery. These and other advantages will be apparent in the detailed description provided below. 
       FIGS. 1A-1B  illustrate a side view of a column form  100 , according to an example. As shown in  FIG. 1A , the column form  100  may be a round column form in a vertical position. In some examples, the column form  100  may be a two-piece round column form that is held together by at least one strap  120  and at least one brace element  200 . The column form  100  may also be supported by one or more kickers  130 . One or more plumbs  140  may also be used to help ensure the column is plumb or other similar vertical positioning.  FIG. 1B  illustrates the column form  100  of  FIG. 1A  without the kickers  130  or plumbs  140 . 
     In some examples, the column form  100  may be a two-piece round column form, having a first form  100 A and a second form  100 B, as shown in  FIG. 1B . The first form  100 A and the second form  100 B of the column form  100  may be positioned in an alternating fashion for greater scalability and column form construction, as described in more detail below. In some examples, the column form  100  may be constructed of any number of strong yet lightweight material. For example, the column form  100  may be made of high-density poplar or birch hardwood. In some examples, the polar/birch hardwood may be an inner ply with other components forming outer layers. Other materials may also be used, such as simulated wood, bamboo, engineered lumber or ply, composite wood, off strand board (OSB), or any other wood, wood-like, or pulp material. 
     In some examples, the column form  100  may be bonded with an adhesive, such as phenolic glue, with outer layers laminating the hardwood inner ply. The outer layers, for example, may be thin film paper, such as #100 film paper. It should be appreciated that high temperature exposure and pressurization (e.g., 95° C.), the column form  100  may be molded into half-round forms, which can then be set and permanently used for column formwork and related construction. 
     It should be appreciated that the edges of the column form  100  may be trimmed as necessary to help ensure proper shape, size, and/or dimension of the column form  100 . In some examples, the trimming of the edges may also involve providing a tongue-and-groove to ensure secure fit of the two half-pieces during column formwork stages of construction. 
     During column formwork, the one or more kickers  130  may be used. These kickers  130  may be used to help secure to column form  100  with a slab (or ground) below. The brace element  200  and straps  120  may also be used to help retain and hold the column form  100  together. It should be appreciated that the brace element  200  may be used at a predetermined distance from the top of the column form  100 , as shown. In some examples, this predetermined distance may be 12 inches from the top of the column form  100 . Details of the brace element  200  will be described in more detail with respect for  FIGS. 2A-2C . Altogether, the brace element  200 , the straps  120 , and kickers  130  may be used to hold the column form  100  in a desired vertical position for concrete filling. 
     The strap  130  may include a 2-inch (or other dimension) strap and a fastener. In some examples, the strap  130  may be made of steel, or other suitable material, such as a nylon, polyester, wood, rubber, string, or pliable material that can be used to perform a similar feature. In some examples, the fastener may be any type of buckle, latch, or other similar fastening or securing mechanism to keep the strap  130  in place. As shown in  FIGS. 1A-1B , the straps  130  and brace element  200  may be place strategically at certain points around the column form  100 . 
     Although the systems and methods described herein are directed to round column forms with typical dimensions, it should be appreciated that there may or may not be any limits on the size, shape, width, length, height, material, or other dimensions for the column form  100  and associated elements, such as the strap  120 , the kicker  130 , etc. That said, in some examples, a diameter of the column form  100  may be in the 12- to 72-inch range. In some examples, the length (or height) of the column form  100  may be in the 4 to 20 feet range. In some examples, the plywood thickness may be 9 to 18 mm or ⅜ to ¾ inch (for a column form  100  having a 12- to 30-inch diameter) or 22 to 35 mm or ⅞ to 1⅜ inch (for a column form  100  having a 32- to 72-inch diameter). Although the sizes and ranges listed herein may be customary sizes in commercial or multi-story construction, other various sizes, dimensions, ranges, shapes, or values may also be provided for the column form  100 . 
     It should be appreciated that a release be applied to the interior of the column form prior to each use. The release may be any release agent, such as any number or various of oils, jellies, or other agents. These may include, but not limited to castor oil, petroleum jelly, grease, wax, and/or other nonstick release agent. Application of the form release may help extend the number of uses of the column form  100  for column formwork and filling. In some examples, use of a release agent may extend the life of the life (number of uses) of the column form  100  by 50% or more. 
       FIGS. 2A-2C  illustrate various views of a brace element  200  for a column form  100 , according to an example. As shown in  FIG. 2A , the brace element  200  may include a bracing collar  210 , a bracing flange  220 , and a fastener (e.g., bolt)  230 . In some examples, it should be appreciated that the bracing collar  210  may be position approximately 12 inches (or other predetermined distance depending on an overall height of the desired concrete column or form) below the top of the column form  100 . 
       FIG. 2B  illustrates a top and bottom views of the brace element  200 . As shown, the brace element  200  may hold the first form  100 A and the second form  200 A of the two-piece column  100  together. In some examples, the bracing collar  210  may be made of steel (or other similar material) with a fastener (e.g., bolt)  230  connecting the brace element  200  at one or more brace junctures  240 , as shown. In some examples, the brace collar  210  may have alignment holes to help with alignment of the brace element  200 . It should be appreciated that in some examples, the first form  100 A and the second form  100 B of the column form may be fitted together with a tongue and groove type configuration  200 C, as shown.  FIG. 2C  illustrates a tongue and groove type configuration  200 C of the plywood used in the column form  100  with greater magnification. Although a tongue and groove type configuration  200 C is shown, it should be appreciated that any number of fastening designs may be used as well. These may include any male-to-female connection or configuration that uses any type of fitted form factor. 
       FIGS. 3A-3B  illustrate applications  300 A- 300 B of a round column form, according to an example. As shown in  FIG. 3A , two half-round columns  100 A and  100 B may be set to form watertight by tightening the steel straps set at matching intervals according to the diameter and height of columns, as described herein. As shown in  FIG. 3B , two half-round columns  100 A and  100 B may also be set to form watertight by tightening the steel straps set at different or alternating intervals according to the diameter and height of columns, as described herein. In this application, the first form  100 A and the second form  100 B may be positioned in an alternating fashion to provide greater scalability and column form construction. 
     In some examples, the lowermost or bottom (1 st ) strap may be placed at approximately ⅝″ from the floor/base. The height may vary, but the intention to provide a little space may simply be to avoid the concrete to adhere to the form, and to be ready for the next pour. It should be appreciated that the subsequent straps may be required to increase ⅓ quantity at the bottom portion, at every additional 10′ height of columns, as outlined in TABLE 1 below. 
                                 TABLE 1                       Column Diameter   Space On            (inches)   Center (o.c.)                          12″~16″   16″-24″ o.c.           18″~22″   12″-20″ o.c.           24″~28″   10″-18″ o.c.           30″~34″    8″-12″ o.c.           36″~42″    6″-10″ o.c.           44″~48″    3″-6″ o.c.           60″~72″    2″-3″ o.c.                        
This may help with weight and load of concrete being poured into the forms and to help retain uniformity throughout the entire column, no matter how tall it is. It should be appreciated that the term “on-center,” sometimes often abbreviated “OC” or “o.c.,”” may be used in construction drawings, architectural plans, and woodworking designs. The term may indicate a relative dimension, and in this case, may refer to a distance between a center of one framing member to a center of a next member. In other words, the aforementioned spacings (in o.c.) may refer to the spacing between straps.
 
     In an example, the systems and methods may follow column specifications as outlined below in TABLE 2. 
     
       
         
           
               
               
               
               
               
             
               
                   
                 TABLE 2 
               
               
                   
                   
               
               
                   
                   
                   
                 Approx. Weight  
                 Approx. Volume  
               
               
                   
                 Column 
                 Length 
                 Per Lineal Ft.  
                 of Concrete  
               
               
                   
                 Diameter 
                 Up To 
                 (Half Round) 
                 Per Lineal Ft. 
               
               
                   
                   
               
             
            
               
                   
                 12″ 
                 30′ 
                 2.55 lbs 
                  0.8 cu-ft 
               
               
                   
                 14″ 
                 30′ 
                  2.9 lbs 
                  1.0 cu-ft 
               
               
                   
                 16″ 
                 30′ 
                  3.2 lbs 
                  1.4 cu-ft 
               
               
                   
                 18″ 
                 30′ 
                  3.3 lbs 
                  1.8 cu-ft 
               
               
                   
                 20″ 
                 30′ 
                 3.75 lbs 
                  2.2 cu-ft 
               
               
                   
                 22″ 
                 30′ 
                 4.35 lbs 
                  2.6 cu-ft 
               
               
                   
                 24″ 
                 30′ 
                   6 lbs 
                  3.1 cu-ft 
               
               
                   
                 26″ 
                 30′ 
                  6.6 lbs 
                  3.6 cu-ft 
               
               
                   
                 28″ 
                 30′ 
                  7.2 lbs 
                  4.2 cu-ft 
               
               
                   
                 30″ 
                 30′ 
                  7.8 lbs 
                  4.9 cu-ft 
               
               
                   
                 32″ 
                 30′ 
                  8.3 lbs 
                  5.5 cu-ft 
               
               
                   
                 34″ 
                 30′ 
                  8.9 lbs 
                  6.3 cu-ft 
               
               
                   
                 36″ 
                 30′ 
                  9.5 lbs 
                  7.0 cu-ft 
               
               
                   
                 38″ 
                 30′ 
                 10.1 lbs 
                  7.9 cu-ft 
               
               
                   
                 40″ 
                 30′ 
                 10.7 lbs 
                  8.7 cu-ft 
               
               
                   
                 42″ 
                 30′ 
                 11.3 lbs 
                  9.6 cu-ft 
               
               
                   
                 44″ 
                 30′ 
                 11.9 lbs 
                 10.6 cu-ft 
               
               
                   
                 46″ 
                 30′ 
                 12.5 lbs 
                 11.5 cu-ft 
               
               
                   
                 48″ 
                 30′ 
                 13.1 lbs 
                 12.6 cu-ft 
               
               
                   
                   
               
            
           
         
       
     
     In some examples, there may be recommendations for approximate maximum rate of pouring of concrete into the column form, as shown in the specifications outlined below in TABLE 3. 
     
       
         
           
               
             
               
                 TABLE 3 
               
               
                   
               
               
                 Approx. Maximum Rate of Pour 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                   
                 At 90° F. 
                 20 feet per hour 
               
               
                   
                 At 80° F. 
                 18 feet per hour 
               
               
                   
                 At 70° F. 
                 16 feet per hour 
               
               
                   
                 At 60° F. 
                 14 feet per hour 
               
               
                   
                 At 50° F. 
                 11 feet per hour 
               
               
                   
                 At 40° F. 
                  9 feet per hour 
               
               
                   
                   
               
            
           
         
       
     
       FIG. 4  illustrates a method  400  for using the column form, according to an example. The method  400  is provided by way of example, as there may be a variety of ways to carry out the method described herein. Although the method  400  is primarily described as being performed using the column form  100  as shown in  FIG. 1 , the method  400  may be executed or otherwise performed by other systems or apparatuses, or a combination of systems and apparatuses. Each block shown in  FIG. 4  may further represent one or more processes, methods, or subroutines, and one or more of the blocks may include machine-readable instructions stored on a non-transitory computer-readable medium and executed by a processor or other type of processing circuit (in any number of devices or related machinery) to perform one or more operations described herein. 
     At  410 , apply a release agent to an inner layer of a column form. In some examples, the column form may be a two-piece column form, as described herein. In some examples, the release agent may be any number of oils, jellies, or other agents, as described herein. 
     At  420 , fasten at least one fastener around the column form. In some examples, the at least one fastener may help fit the two pieces of the column form, in accordance with examples described herein. The fastener, in some examples, may be a system of at least one brace and/or at least one strap made of various materials described herein. The fastener system may also include any number of kickers (e.g., attached to the brace) to provide stability to the column form. In some examples, the two-piece column form may be fastened in any by the at least one strap in an alternative 
     At  430 , a concrete mixture may be poured into the concrete form to form a concrete column. As described herein, pouring concrete may generally involve mixing concrete (machine, ready-mix, or otherwise) and pumping the mixed concrete into the concrete form. It should be appreciated that any number of concrete mixtures may be used depending on specific application or use. For example, these may include various concrete mix/liquid/aggregate ratios. Fine, medium, or coarse aggregates may be used depending on application or use as well. 
     In some examples, paper linings (e.g., spiral paper tubes) may be used to help form concrete columns, piers, and/or footings. These paper linings may be customizable. For example, they may have 6″ to 60″ diameters and be configured for cut-to-length sizing using any number of basic cutting tools. In some examples, the paper linings may be made of recycled paperboard and include rain-resistant technology to keep rain or other source of moisture from impacting any concrete pour. Use of paper linings may minimize or eliminate need for cleaning, reassembly, or return freight costs. It may also provide setting and pouring multiple columns in a short timespan or overlapping time spans. 
     At  440 , unfasten the at least one fastener to remove the column form. This may be done once the concrete mixture has sufficiently dried or cured. In some examples, depending on the concrete mixture, this may take a relatively short time with little manual labor. For example, it may take 2 people approximately 6-8 hours to provide the formwork and concrete pour. 
     It should be appreciated that the systems and methods described herein may provide any number of technical advantages. These may include ease of use, installation, removal and/or transportation of elements. The column forms and associated elements for the systems and methods described herein may also be easily cut, designed with grooves or notches, which help ensure stable interconnections that prevent or reduce concrete leakage. In addition, the column forms and processing techniques described herein may generally incorporate plywood that is light-weight and easy to handle. In some examples, the column forms may be used in a stacking configuration, e.g., up to 30 feet without use of a crane or other similar machinery. Accordingly, the column forms described herein may provide reduced construction time, greater consistency in quality column construction, reproducibility and scalability, and less required man-power, all of which may translate to higher construction efficiencies, reliability, strength, and manageability. 
     What has been described and illustrated herein are examples of the disclosure along with some variations. The terms, descriptions, and figures used herein are set forth by way of illustration only and are not meant as limitations. Many variations are possible within the scope of the disclosure, which is intended to be defined by the following claims—and their equivalents—in which all terms are meant in their broadest reasonable sense unless otherwise indicated.