Patent Publication Number: US-6990774-B2

Title: System support assembly

Description:
This application claims priority from a Provisional Patent Application having Ser. No. 60/253,697, which was filed on Nov. 27, 2000. 

   BACKGROUND OF THE INVENTION 
   1. Field of Invention 
   This invention pertains to a system support assembly. More specifically the present invention relates to the art of methods and apparatuses for securing concrete forms used during construction of foundations. 
   2. Description of the Related Art 
   In the art of constructing buildings, foundations are poured. Normally, a wood structure form is used where a contractor places wood inside and outside a concrete split between them. Footers are poured first, which require mounting brackets, rebar and other supports ordinarily used in construction in order to put the foundation blocks on the footers and keep the foundation blocks from moving side to side. After the footers are poured and cured, the foundation walls are poured. 
   Currently existing in the art for foundation walls are insulated concrete forms (ICFs), which are commonly referred to as Polysteel, a registered trademark of Berrenberg Enterprises. Inc. d/b/a American Polysteel Forms of New Mexico, and described in U.S. Pat. No. 4,879,855. ICFs are comprised of two insulated side walls and are secured together with rebar. An opening is defined between the walls so that concrete can be poured therein. The ICFs are stacked like blocks and are usually secured with wood supports about the perimeter of the wall. Once the concrete is poured and cured, the ICFs stay in place, thus becoming a permanent component of the foundation. 
   While suited for their intended purposes, many disadvantages exist with the current system of stacking ICFs and pouring concrete therein when constructing a foundation for a structure. First, numerous supports are required about the perimeter of the foundation so that the walls do not move from side to side. Also, the footer must be poured before the wall is built with the ICFs. Further, only experienced contractors in the art of construction can successfully construct a foundation using ICFs. Traditional construction of the foundation requires proper placement of the supports around the perimeter of the foundation wall. Further, it takes an entire crew of construction workers to properly pour the concrete. Another disadvantage, which can occur when pouring concrete, is that the ICF wall may buckle due to the weight of the concrete. 
   Therefore, a need exists in the art for a system support assembly which provides for a monopour system, wherein the concrete for the footers and the foundation are poured at one time. Also a system is needed where only one or two people are needed to pour the foundation and footers for a structure so that labor costs are decreased. It is also desirous that the system be easy to use, such that a person with only a modicum amount of experience in construction can successfully pour a foundation and associated footers. 
   SUMMARY OF THE INVENTION 
   A system support assembly comprises a pair of substantially parallel footer forms, insulated concrete forms, footer form base saddles, a poly form saddle assembly and first and second vertical stabilizers. The footer form base saddle may be generally unshaped and is driven into the ground forming two substantially parallel areas. Each footer form is placed within the row formed by the footer form base saddles such that a cavity is defined therebetween which will ultimately form the footer of the foundation. The poly form saddle assembly comprises a poly form saddle and fasteners. The poly form saddle may also be generally u-shaped and is placed over both footer forms, thus straddling the same. The poly form saddle may then be secured with corresponding fasteners. The insulated concrete forms are placed side by side and are stacked upward, such that a wall is formed. A first poly form vertical stabilizer is placed over the wall and operatively connected to the footer form base saddle. More insulated concrete forms are stacked to complete the wall. The second poly form vertical stabilizer may then be placed, preferably laterally spaced from the first poly from vertical stabilizer. The second poly form vertical stabilizer is also operatively connected to the footer form base saddle. Then, the concrete is poured into the insulated concrete forms such that the foundation wall and footers are poured and cured at one time. 
   Additional features of the system support assembly include without limitation, an extension for the footer form base saddle, a stabilizer mounting strap which operatively connects to the wall and the second poly form vertical stabilizer, a rebar suspension cradle, and a strake saddle. 
   Accordingly, it an object of the present invention to provide a system support assembly for securing insulated concrete forms that allows for a monopour wall so that the footers and the foundation wall are poured substantially simultaneously. 
   Another object of the present invention is to provide a system support assembly that remains a permanent component of the cured foundation wall and footers. 
   Yet another object of the present invention is to provide a system support assembly that uses less material and labor than conventional systems and methods of foundation construction. 
   Further, another object of the present invention is to provide a system support assembly that is a water-proof structure since the footers and foundation wall are poured substantially simultaneously. 
   Still yet, another object of the present invention is to provide a system support assembly that is easy to use. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention may take physical form in certain parts and arrangement of parts, a preferred embodiment of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof and wherein: 
       FIG. 1  is a perspective view of the present invention. 
       FIG. 2  is another perspective view of the present invention. 
       FIG. 2A  is an exploded view of the present invention. 
       FIG. 2B  is a front elevational view of one of the vertical stabilizers of the present invention. 
       FIG. 3  is a cross sectional view of the present invention. 
       FIG. 3A  is a side view of the stabilizer mounting strap. 
       FIG. 4  is a perspective view of the strake saddle. 
       FIG. 5  is front view of the rebar suspension cradle. 
       FIG. 6  is a side view of the rebar suspension cradle. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Turning to  FIGS. 1-3 , a system support assembly  10  is shown. Generally, the system support assembly comprises footer means, such as a pair of footer forms  11 , insulated concrete forms (ICF)  13 , footer form base saddles  22 , a poly form saddle assembly  14  and first and second vertical stabilizers  26   a ,  26   b . Although, the present invention is described to be used with ICFs, any other structure utilizing block-like units may take advantage of the system support assembly  10 , including without limitation, brick laying or other concrete forms. The footer form base saddle  22  may be generally u-shaped and is driven into the ground forming two substantially parallel areas. Each footer form  11  is placed within the footer form base saddles  22  such that a cavity is defined therebetween which will ultimately form the footer of the foundation. The poly form saddle assembly  14  comprises a poly form saddle  12  and fasteners  16 ,  17 ,  18 . The poly form saddle  12  may also be generally u-shaped and is placed over both footer forms  11 , thus straddling the same. The poly form saddle  12  may then be secured with corresponding fasteners  16 ,  17 ,  18 . The ICFs  13  are placed side by side and are stacked upward, such that a wall  19  is formed. A first poly form vertical stabilizer  26   a  is placed over the wall  19  and secured to operatively connected to the footer form base saddle  22 . More ICFs  13  are stacked to complete the wall  19 . The second poly form vertical stabilizer  26   b  may then be placed, preferably laterally spaced from the first poly form vertical stabilizer  26   a . The second poly from vertical stabilizer  26   b  is also operatively connected to the footer form base saddle  22 . Then, the concrete is poured into the ICFs such that the foundation wall  19  and footers are poured and cured at one time. 
   With reference to  FIGS. 1 ,  2 ,  2 A and  2 B, the poly form saddle assembly  14  comprises the poly form saddle  12 , a poly form slide bracket  20 , a poly form slide bracket bolt  16 , and a flat washer  17  and nut  18 . The poly form saddle  12  straddles the footer forms  11  and supports the wall  19 . The poly form slide bracket bolt  16  holds together the ply for the slide bracket  20 , which allows the wall  19  to be moved for a more correct and true wall  19 . Normally, footer forms  11  have a tendency to move approximately ½ inch to 1 inch. The slide bracket  20  allows the movement of the wall  19  so that the wall  19  can be more true. This bolt  16  fastens the poly form saddle assembly  14  together. The poly form slide bracket bolt  16  also functions as a cradle for the rebar  15  in the footer. Supporting the rebar  15  in the footer is very important during construction of the foundation because the rebar  15  cannot lay on the ground or contact the sides of the footer. 
   Traditionally, when a footer is poured, the footer forms are positioned and then the concrete for the footer is poured. Once the concrete begins to cure, the rebar  15  is laid on the top, and it slowly sinks. It is vital that the rebar  15  not sink to the bottom because the added strength the rebar provides would be lost. In the present invention, the footer forms  11  are positioned as is the rest of the system support assembly  10  in one building stage. Since the present invention utilizes a monopour system, the poly form slide bracket bolt  16  is needed to support the rebar  15  and prevent it from sinking to the bottom of the footer. Further, it is desirous that the poly form slide bracket bolt  16  be able to move in the slots so that perfect alignment is achieved. 
   With continuing reference to  FIG. 2A , the flat washer  17 , nut  18 , and the poly form slide bracket  20  form the poly form slide bracket assembly  14 . Although a bracket bolt, a flat washer and nut are the preferred, any type of fasteners may be used with sound engineering judgment. The slide bracket  20  has pins in the bracket that actually penetrate the ICF  13  so that the ICF  13  cannot lift. The slide bracket  20  holds the ICF  13  against the footer, giving it stability. These are pins that go into a dolly to hold it tight. 
   As shown in  FIG. 2A , the footer form base saddle  22  is illustrated. The footer form base saddles  22  are driven into the ground for the footer forms  11  to rest in and that makes the wall  19  level. The footer form base saddles  22  are preliminarily utilized to level the wall  19 . Once the footer form base saddles  22  are driven into the ground, a leveler a laser or other similar means is used to obtain a straight line. If the ground is loose due to sand or other conditions such that the footer form base saddle  22  would sink, the extension  24  may be used. The extension  24  is attached to the rod of the footer form base saddle through a coupling means, best seen in FIG.  2 . Once the extension  24  is attached to the footer form base saddle  22 , the footer form base saddle  22  is driven farther down into the ground to provide the system support assembly  10  with increased stability. 
   The coupling means of the extension  24  has an opening on one side large enough for the rod of the footer form base saddle  22  to fit securely. This open end may be threaded or preferably, ribbed for securing the rod therein. Using the rib provides a very tight fit when the coupling means and rod are driven together. Ribbing allows for the coupling means and rod to be knolled so that when they are driven together they would be not removable. This second side of the coupling means is either welded or permanently attached to the rod of the extension, although this is not required. It is preferable to have one opening in the coupling means. The rod of the footer form base saddle  22  and the extension  24  is approximately twelve inches, although any length can be used. 
     FIG. 3  shows that the footer form base saddles  22  support one footer form  11 , wherein the poly form saddle  12  straddles both footer forms  11  at the same time. It is preferred that that the footer form base saddles  22  be spaced apart approximately four feet. Anyone using the present invention may adjust this spacing accordingly to suit their needs. 
   The footer form base saddles  22  also may comprise slots. These slots are for receiving the poly form vertical stabilizer  26 . In the preferred embodiment of the present invention, the poly form vertical stabilizer are in two different sizes, 48 inches and 96 inches. Once three rows of ICFs  13  are positioned, the first vertical stabilizer  26   a  may be secured. This keeps the wall  19  from moving side to side at the 48 inch elevation. 
   With reference to  FIG. 2A , pins are shown on the poly form slide bracket  20 . The pins may be integral pieces of the slide bracket  20 . The slide bracket  20  and pins may be constructed with a strip of steel. The pins provide strength. Since the ICFs  13  are made out of a poly like material, some crushing may occur at the bottom from the weight of the structure. The pins actually tie into the ICFs  13 . 
   In another embodiment of the present invention, a channel is utilized, which may be constructed from light weight steel. For example, angle iron could be used instead of the pins. This would also enable the ICF  13  to rest on the channel. 
   With reference to  FIG. 3 , the stabilizer mounting strap  28  has two portions. One portion operatively connects to the ICF  13 , and the second portion is slightly angled from the first and operatively connects to the poly form vertical stabilizer  26 .  FIG. 3  shows that the stabilizer mounting strap is generally used on the second poly form vertical stabilizer  26   b.    
   The poly form vertical stabilizers  26  eliminate the ability for the ICF to pull and twist by its own compression in the wall  19 , because its knotted right into the steel. This eliminates whalers and 2×4 supports that are utilized along the perimeter of the wall. When filling the ICFs with concrete, the center section can bow in and out. The poly form vertical stabilizers  26  eliminate that bowing because of the placement of the stabilizers  26  within the poured concrete. It is preferred that the first and second vertical stabilizers  26   a ,  26   b  be laterally spaced from one another and each be placed approximately in four foot intervals about the wall  19 . The interval could be lengthened to eight foot sections or even six feet or twelve feet. Any spaced interval may be used to prevent the wall  19  from buckling. Further, the poly form vertical stabilizers are preferably made of steel, namely band steel. Any light-weight material that is easy to cut may be utilized. Once the concrete has cured, the stabilizer mounting straps  28  and vertical stabilizers  26  may be removed. Thus, once the process is complete, the only clean-up required is snipping off the vertical stabilizers  26  and removing the stabilizer mounting straps  28 . When working with foundation, time is a large cost factor. Moving 2×4&#39;s and restocking, getting them out, pulling nails, etc., takes a tremendous amount of time. By eliminating these supports and utilizing the present invention, clean up is quicker and easier and, thus, more cost effective. 
   The present invention also may comprise a strake saddle  30 , which is best seen in  FIGS. 3 and 4 . A strake, as used herein, is a brace or a tie that is of undescribed proportion that goes from one end of the structure to the other. For the purposes of the system support assembly  10 , it allows a walker, when you are pouring concrete, to walk this board around the distance of the wall  19  to pour the concrete into this wall  19 . This is advantageous because the wall is likely to be eight feet high, and a person cannot easily pour concrete over their head. This allows someone to stand on the wall  19  and to work the concrete down into the wall  19 . The strake saddle  30  extends down either side of the ICF  19  approximately 9½″ with a 2×10 plank to sit on it. Placement of the strake saddles  30  would be to the discretion of the workers. The planks should be 2×10&#39;s, and may be placed on either side of the strake saddle  30 . Angle supports extend from the edge of the planks and secures to an ICF  13 . As shown in  FIG. 4 , three angle supports are utilized per strake. Again, any amount of angle supports may be used. The angle supports extend approximately 12 inches from the top of the wall  19  to the ICF  13 . 
   The strake saddle  30  may be one piece of sheet steel. Openings are formed therein to save weight and to provide an opening to poor the cement. Once the monopour is complete, the strake saddle  30  is removed by removing the boards pulling of the main body portion of the strake saddle  30 . 
   The rebar suspension cradle  40  is shown in  FIGS. 5 and 6 . The rebar  15  is positioned in the center of the ICF  13 . The assembly currently used to build the wall  19  does not allow the rebar  15  to be suspended in the center. To suspend the rebar  15 , it must be tied together. Currently, during set-up, portions of the rebar  15  protrude from the ICF  13 . Two rebar need to be tied with wire. In order to keep the rebar  15  suspended, it is tied in approximately four sections at a time. However, this problem is solved with the present invention. The rebar suspension cradles may be positioned every eight feet. The rebar suspension cradle is a piece of steel, and it does not have to be heavy steel. It could be strap that is stamped out with three locking curves on it, best seen in FIG.  6 . The locking curves would interlock to the framework that is already provided by the ICF  13  to allow the suspension of the rebar  15  therein. The step of tying rebar  15  together is eliminated. The rebar suspension cradle  40  is positioned at the end of each ICF, a piece of rebar  15  is placed therein, and then the next row of ICFs  13  is put in place. These cradles  40  allow the rod to be held in place during the monopour.  FIG. 5  shows triangular shaped holes in the rebar suspension cradle  40 . Any shape may be used that is chosen in accordance with sound engineering judgment. 
   To use the present invention, a suitable trench is dug for the foundation and footer. The foundation is squared corner-to-corner. Next, the poly form base saddles  22  are positioned. One line of the base saddles  22  are set. The footer form base saddles  22  are set from the center line of the ICFs  13 . Once the saddle line is driven, the string (not shown) is positioned. Each saddle  22 , is driven into the ground, and then each footer form  11  is intalled, which is already known in the art. Of course, the extensions  24  may need to be attached to each saddle  22  if the ground is too soft. 
   After both sides of the footer forms  11  are installed, the poly form saddle  12  is mounted over the footer forms  11 . The poly form saddle assembly  14  may be preassembled or it may be assembled as needed. The next step is to position the poly form side bracket bolt  16 , flat washer  17 , the nut  18 , and the slide bracket  20  on the saddles  22  on one side. The rebar  15  is then cradled in the poly form slide bracket bolts  16 . Two rebar for the lower quarter goes onto the bolts  16 . The rebar sits on these bolts  16 —one on each side of the poly form saddle  12 . 
   Next, one row of ICFs  13  are positioned on top of the poly form saddle assembly  14 . The ICFs  13  then should be aligned. Then, the line for the wall  19  is pulled to ensure the wall  19  is correctly positioned on the poly form saddle  12 . The bolts  16  are tightened to secure the slide brackets  20  to the ICF  13 . In summary at this juncture, one string line is set on one side of the wall  19  and the poly form saddle assembly  14  is secured to that one side. Then, one or two rows of ICFs  13  are positioned, meaning as close as possible to the tightened side. The other side of the poly form saddle assembly  14 , which is loose, is slid against the ICF  13  and then tightened for a snug fit. 
   After both sides are secured, then a third section of ICFs  13  is positioned. Once three rows of ICFs  13  are positioned, first poly form vertical stabilizers  26   a  are installed. The first poly form vertical stabilizers  26   a  are placed over the ICFs, down to each side of the saddle  22  and received into the side slots of the saddle  22 . A bolt tightens the poly form vertical stabilizers  26   a  in place. 
   Every time a row of ICFs are positioned, a rebar suspension cradle  40  should also be operatively connected thereto. Of course the rebar  15  could be tied instead. However, it is preferred that one rebar suspension cradle be attached to the ICFs  13  for every row of block in approximately eight foot intervals 
   Additional rebar is placed within the ICFs in a downward position, i.e., going straight down in each one of the ICFs  13  as the concrete is being poured. Utilizing the present invention serves at least three purposes with regards to the rebar  15 . First, as the rebar is positioned during the monopour, air is removed from the concrete. Second, as previously mentioned, it also eliminates the step of tying the rebar in suspension. Third, this additional rebar  15  adds additional structure to the ICFs  13 . 
   As previously mentioned, once three rows of ICFs  13  are in place, the poly form vertical stabilizers  26   a  are positioned. The vertical stabilizers  26  are attached to the wall  19  through the stabilizer mounting strap  28  that goes down along the ICF  13 . The mounting strap  28  should be mounted on the ICF  13  by screws, so that the vertical stabilizer  26  can be attached to it. This can be achieved in a number of ways. 
   One method would be to mount the stabilizer mounting strap  28  onto the ICF  13 . Then, the vertical stabilizer  26   a  is placed over top of stabilizer mounting strap  28 , and attach the two straps  26   a ,  28  together. The bottom side of the vertical stabilizer strap  26  is operatively connected to the saddle  22 . Wall  19  construction continues with the ICFs  13 , providing concrete isn&#39;t poured at that point. Although concrete can be poured at this level, it is not recommended because the rebar  15  then would be fastened into the concrete. In other words the remaining ICFs  13  would need to be lifted over the vertically positioned rebar  15 . 
   Once every ICF  13  section is positioned with the rebar suspension cradles  40 . up to the top row of ICFs  13 , which should be 96 inches, another poly form vertical stabilizer  26   b  is mounted. As previously stated, the stabilizers  26   a ,  26   b  are staggered, usually every 8 feet. In other words, in a length of a wall  19 , of sixteen feet, two of the 48 inch poly form vertical stabilizers  26   a , and two of the 96 inch poly form vertical stabilizers  26   b  would be staggered, so that one strap is suspending or holding the middle of the wall  19  while the second strap is suspending or holding the top of the wall  19 . 
   Once the top stabilizers  26   b  are all secured to the wall  19 , then the strake saddles  30  are positioned. The strake saddles  30  are positioned down over the wall and then the strake boards (2×10s) are laid. Once the strake boards are set on the saddle  30 , the concrete may be poured. Of course the strake saddles  30  could be anchored through the angle supports. 
   Once the concrete is poured and cured, then the strake boards and strake saddle  30  are removed. The vertical stabilizers are cut and discarded. The user can save the stabilizer mounting straps  28  if he or she so desires. Finally, construction for the rest of the structure can continue. 
   The footer form base saddles  22  should be made out of ⅛″ strap steel minimum. The vertical stabilizers  26  can be made of steel as thin as the straps they use for binding, such as those used for pallet straps. The thickness should be such that it can be cut with wire cutters, but not so thin that it will stretch. A recommended thickness could be approximately 1/16″ or thinner. Further, these vertical stabilizers  26  could be approximately one inch in width. The bolts, may be ⅜″ bolts minimum. 
   The pins on the rods of the footer saddles  22  should be about ½″ or any size which would permit their expansion into the earth and out far enough that they have structure to them and so they cannot move readily back and forth. And, of course, the bushing, or the coupling that puts the two of those together would be the ⅛ inch wall thickness. 
   The preferred embodiments have been described, hereinabove. It will be apparent to those skilled in the art that the above methods may incorporate changes and modifications without departing from the general scope of this invention. It is intended to include all such modifications and alterations in so far as they come within the scope of the appended claims or the equivalents thereof.