Abstract:
An accessory kit for reusable footing forms ( 1001, 1002 ) used in conjunction with insulated concrete forms or steel panel wall forms. The kit includes an inside corner mold ( 500 ) and an inside corner form ( 600 ) that attach to the footing forms ( 1001, 1002 ). The inside corner molds are secured by slotted fasteners ( 410, 440 ) that are adjustably positioned and fastened by wedge bolts ( 400 ). The kit also includes outside corner molds ( 100, 200 ) that is adjustable to accommodate a variety of final wall configurations. An adjustment lever ( 600 ) is provided to assist in positioning two abutting footing forms ( 1001 ).

Description:
FIELD OF THE INVENTION 
       [0001]    This invention relates generally to the field of cast in place construction techniques, and more particularly to reusable steel footing forms that act as a mold into which concrete or other structural material is poured. 
       BACKGROUND OF THE INVENTION 
       [0002]    Footings for buildings have been constructed from a wide range of materials including boulders, cobbles, crushed rock, and concrete. The purpose of the footing is to provide a wide base with sufficient strength to support the vertical walls that extend above each footing. Depending on soil types and climate, footings vary in size and composition to accommodate the desired building and conditions. 
         [0003]    Concrete footings have typically been poured to include imbedded reinforcing steel. Wooden planks and stakes are used to create a mold within which the concrete footing is formed. After the concrete has been cast and cured, the wood is removed, often resulting in destruction of the wood. Walls are then constructed on top of the footings. If concrete walls are to be poured on top of the cured footings, a second mold setup and concrete pour is required. 
         [0004]    Steel footing forms have been used to create concrete footings that permit walls and footings to be poured simultaneously. Numerous logistical problems are common with existing steel footing molds. Assembly is time consuming, and achieving the desired wall length can be problematic. Maintaining the desired dimension, shape and orientation requires that the construction crew perform numerous repetitive steps, consuming time and introducing the possibility for error. 
         [0005]    Existing devices utilize corner forming structures that were fastened with steel stakes or sometimes with threaded fasteners that eventually fail, thereby introducing errors and requiring greater skill on the part of the user. U.S. Pat. No. 6,332,599, entitled FOOTING FORMS FOR CONCRETE MONOLITH CONSTRUCTION, discloses the use of corner forms that are secured by long tie bolts placed inside of sleeves. 
       SUMMARY OF THE INVENTION 
       [0006]    The present invention is a reusable integrated footing and wall mold form. The invention is usable with both insulated concrete form construction and with concrete walls constructed with reusable wall panel forms. The invention includes an inside corner accessory that allows the present steel footing form to work with the traditional wall panel forms. The inside corner accessory seals off holes that otherwise allow liquid concrete to escape from the mold structure at the transition point between steel footing form and steel wall panel form, thereby permitting wall panel forms to be poured simultaneously with the steel formed footings. 
         [0007]    The present invention uses a method to join the various straight and corner steel footing mold parts that is compatible with existing wall panel form fasteners. All bolts used to connect steel footing form parts are secured with commonly available wedge bolts. The wedge bolts simplify the securing of footing forms when compared to threaded fasteners, and are adjustable to accommodate various wall thicknesses. Each bolt is contained within a small diameter tube that is cut to the width of and remains embedded in the cast concrete. The tube allows the bolt to be removed and reused. 
         [0008]    The present invention includes corner forms and related accessories that are assembled with convex head slotted bolts secured with wedge bolts. The convex head is cast into the concrete and is easily removed as the convex end offers almost no gripping surface and is only cast approximately one quarter of an inch into the concrete footing. The slotted bolts can be inserted through an array of holes that allow for exact bolt placement and the construction of any common wall thickness. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is a perspective view of outside corner forms and an inside corner form constructed according to the principles of the present invention attached to a reusable wall form; 
           [0010]      FIG. 2  is an end elevation of a cast concrete monolith produced by the reusable wall forms illustrated in  FIG. 1 ; 
           [0011]      FIG. 3  is a side elevation of a slotted shaft and wedge bolt as utilized by the wall forms depicted in  FIG. 2 ; 
           [0012]      FIG. 4  is an end elevation of a cast concrete monolith with an insulated concrete form in place; 
           [0013]      FIG. 5  is a perspective view of a first inside corner form constructed according to the principles of the present invention; 
           [0014]      FIG. 6  is a perspective view of a second inside corner form constructed according to the principles of the present invention; 
           [0015]      FIG. 7  is an exploded perspective view of an outside corner form constructed according to the principles of the present invention; 
           [0016]      FIG. 8  is a top plan view of a footing form constructed according to the principles of the present invention; 
           [0017]      FIG. 9  is a perspective view of a footing form adjustment lever constructed according to the principles of the present invention; and 
           [0018]      FIG. 10  is a perspective view of the footing form adjustment lever as illustrated in  FIG. 9  shown in an engaged relationship with two steel footing forms constructed according to the principles of the present invention. 
           [0019]      FIG. 11  is a perspective view of the inside corner form for insulated concrete forms and the outside corner form with an insulated concrete form resting on them. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0020]      FIG. 1  illustrates outside corner forms  100 ,  200 , and  300  attached to footing forms  1001 ,  1002 . The footing forms  1001 ,  1002  are substantially identical to the type illustrated and described in the previously mentioned U.S. Pat. No. 6,332,599. Outside corner forms  100  and  200  perform the function of closing the footing forms so concrete may be poured without leakage. The corner forms also perform a second function of anchoring building corners within necessary close tolerances to achieve building accuracy. Form  100  and  200  are identical except for the placement of holes  145 ,  170 ,  245 ,  270  and the presence or absence of tabs  155 . When  100  and  200  are connected to one another at edges  105  and  205 , tabs  155  overlap onto surfaces  210 ,  220 ,  230  so holes  145  and  170  line up with holes  245  and  270  and are fastened with convex bolt  440 . Outside corners may be built to make 45, 90 or other degrees 
         [0021]    As seen in  FIG. 7 , each of the outside corner forms  100  and  200  includes a base vertical extension,  110  and  210  respectively, upon which a standard lumber such as a 2×4  160 ,  260  may be attached. Lumber  160 ,  260  provide an anchor point on forms  100  and  200  to which stakes or other such devices can be attached with screws or nails to hold forms  100  and  200  at a desired level and position with respect to the ground surface. A simple linear bend which may be formed by a common metal brake tool forms the junctions  115  and  215  between vertical extensions  110 ,  210  and the sloping side walls  120 ,  220 . The slope angle  225  reduces concrete volume, allows for easy removal from cast concrete and must match the angle  1007  of the forms  1001 ,  1002  for easy, seamless assembly. 
         [0022]    The sloping side walls  120 ,  220  terminate by means of a simple lineal bend  180 ,  280  located at the upper vertical extension  130 ,  230  which is approximately at the exterior edge  940 ,  945  of the wall panel forms  910 ,  915 . The forms  910 ,  915  may be forms such as the Symons™ wall panel forms manufactured by the Dayton Superior Corporation 7777 Washington Village Dr., Suite 130, Dayton, Ohio 45459. The wall panel forms  910 ,  915  remain in place only until contained liquid concrete  930  hardens around reinforcement steel  920  to form wall  950 . The exterior edge  940 ,  945  of wall panel form  910 ,  915  lands approximately in line with the exterior edge  805 ,  810  of a common insulated concrete form  801 ,  802  which remains in place with the concrete wall. Support ledges  150 ,  250  consisting of lineal bends  185 ,  285  serve to support vertically extending wall panel forms  910 ,  915  or insulated concrete forms  801 ,  802 . Short vertical lips  140 ,  240  extend above ledges  150 ,  250  approximately one inch to hold the wall panel forms  910 ,  915  or insulated concrete forms  801 ,  802  in place on the ledges  150 ,  250 . Between wall panel forms  910  and  915  as well as between corner forms  100 ,  200  and opposing sides of straight forms  1001 ,  1002 , there is a space  1050  which will in the preferred embodiment be filled with concrete  930 , reinforcement steel  920  or other suitable construction materials. 
         [0023]    Holes  145  and  170  are located on tabs  155  bent at a desired angle, usually ninety degrees, to fasten corner form  100  to corner form  200  through holes  245 ,  270  using convex head slot bolt  440 . Convex head slot bolt  440  is held in place using an industry standard wedge bolt  400  commonly used to secure wall panel forms. Sets of holes  135 ,  235  secure corner forms  100 ,  200  to straight forms  1001 ,  1002 . Holes for fastening corner forms may be designed round, square or rectangular so fastening can be accomplished with a variety of slotted bolts or wedge bolts. Several holes are provided to accommodate various common wall thicknesses such as 6 inch or 8 inch, as well as to accommodate the widths of various insulated concrete forms  801 ,  802  currently for sale in lumber and construction stores. 
         [0024]      FIG. 5  illustrates inside corner form  500  for use with insulated concrete forms  801 ,  802 . Corner form  500  is comprised of two mirror image identical parts  580 ,  590  joined by overlapping tabs  540  typically spot welded together. Base vertical extensions  510 ,  515  which form the wider portion  960  of the resulting concrete footing  900  are joined at a simple linear bend  570 ,  575  to sloping side walls  520 ,  525 . The slope angle  585  must match the angle of straight forms  1001 ,  1002  for easy, seamless assembly. Sloping side walls  520 ,  525  terminate at approximately the exterior faces  805 ,  810  of insulated concrete forms  801 ,  802  where a linear bend  522  leads to upper vertical extensions  530 ,  535 . Extending perpendicular to the face of  530  and  535  at point  1060  aligned with straight form  1001 ,  1002  ledges are tabs  550 ,  560 . The tabs  550 ,  560  serve to prevent concrete from leaking through the straight form ledge channel  1060  when the walls  950  and footings  900  are filled with concrete. Significant volumes of low viscosity concrete may leak thru holes approximately ¼″ or larger if not blocked off or plugged by some material or device such as  550 ,  560 . 
         [0025]    Holes  542 ,  545  are placed to provide a maximum strength connection to straight form  1001 ,  1002 . Inside corner form  500  is secured to straight forms using convex head slot bolt  440 . Convex head slot bolt  440  is held in place using an industry standard wedge bolt  400  commonly used to secure wall panel forms. 
         [0026]      FIG. 6  illustrates inside corner form  300  for use with wall panel forms  910 ,  915 . Corner form  300  is comprised of two mirror image identical parts  360 ,  370  joined by overlapping tabs  350  that are typically spot welded together. Base vertical extensions  305 ,  315  which form the wider portion  960  of the resulting concrete footing  900  are joined at a simple linear bend  312 ,  317  to sloping side walls  320 ,  325 . The slope angle  322  must match the angle  1007  of  1001 ,  1002  for easy, seamless assembly. Sloping side walls  320 ,  325  terminate approximately at the exterior faces  940 ,  945  of wall panel forms  910 ,  915  where a simple lineal bend  323 ,  327  leads to upper vertical extension  330 ,  335 . Upper vertical extension  330 ,  335  ends at a linear bend  352 ,  357  leading to horizontal ledges  340 ,  343  which serve to support the wall panel forms  910 ,  915  as well as contain concrete that would otherwise leak at this point  1008 . 
         [0027]    Holes  305 ,  345  are placed to provide a maximum strength connection to straight form  1001 ,  1002 . Inside corner form  300  is secured to straight forms  1001 ,  1002  using convex head slot bolt  440 . Convex head slot bolt  440  is held in place using an industry standard wedge bolt  400  commonly used to secure wall panel forms in the concrete construction industry. Inside corners may be manufactured to make 90, 45 or other degree corners if desired. 
         [0028]      FIG. 3  illustrates the preferred embodiment of slotted bolts  410 ,  440  that serve to fasten footing forms  1001  and  1002  securely together. Slotted bolt  410  is a long rod typically made of steel that slides through straight footing forms  1001 ,  1002  and associated spacer tubes  1003 . Sets of holes  415  allow for variation in the width  1004  of the footings by placing pin  405  in desired hole. Slot  420  on the other end of bolt  410  provides a fastening point to secure the bolt tightly in place by placing industry standard wedge bolt  400  into slot  420  and pressing the bolt  400  tightly against upper and lower vertical sections  1032 ,  1033  of straight forms  1001 ,  1002 . After the concrete in the footings  900  and walls  950  has hardened, the wedge bolts  400  are easily tapped out of the slotted bolts  410  with a hammer and the slotted bolts subsequently tapped out of the straight footing forms  1001 ,  1002  for later reuse. 
         [0029]    Convex head slotted bolt  440  serves to secure outside corners  100 ,  200  together as well as to secure outside corners  100 ,  200  and inside corners  300 ,  500  to straight forms  1001 ,  1002 . Convex head slotted bolt  440  is placed through holes  145 ,  170 ,  245 ,  270 ,  305 ,  345 ,  135 ,  235  on corner forms  100 ,  200 ,  300 ,  500  and or straight forms  1001 ,  1002  to create desired footing configuration. Wedge bolt  400  is then placed in slot  430  and wedged tightly against the adjacent face  110 ,  130 ,  210 ,  230 ,  310 ,  330 ,  315 ,  335 ,  510 ,  530 ,  515 ,  535 , and  1032  of the footing form. A hammer may be used to pound in wedge bolt  400  farther and increase compression for a more ridged connection. The convex surface  435  is always placed inside the footing form because the smooth surface does not bond substantially with the cast concrete. The convex head can easily be removed from the concrete with a simple tap from a hammer cracking the minor bond allowing the removal of all corner form pieces. Conversely, the slot  430  of the slotted bolt  440  should always be placed to the outside of footing form corners for easy assembly and removal of wedge bolt  400 . Placing slot  430  to the inside where concrete is poured would permanently cement slotted bolt  440  into the footing and make removal of footing forms impossible. Slotted bolt  410 ,  440  may be manufactured as flat, square, or round shafts if desired. 
         [0030]      FIG. 9  illustrates the preferred embodiment of footing form adjustment Lever  600  which serves as a leverage tool to lengthen or shorten footing form assemblages. Lower lever arm  620  is formed as a ridged shaft approximately two feet in length with several attachment channels  630  welded in place perpendicular to the length of lower lever arm  620  along the bottom side  655  for attachment to footing form spacer  1003 . Lower lever arm  620  terminates at lower hinge  625  where a hole for receiving hinge pin  650  is drilled in the slightly thicker material of lower hinge  625  to allow rotation of hinge pin  650  while maintaining the strength of the tool  600  as is expected from common construction working tools over time and experiencing normal wear. 
         [0031]    Handle hinge  645  also joins to the hinge pin  650 . The handle hinge  645  is similar to the lower hinge  625 . Handle hinge  645  is joined to lever arm handle  605  which serves to provide leverage to the user of footing form adjustment lever  600  for adjusting the length of previously arranged footing forms. Lever  600  also serves a second purpose of pulling together or apart footing form sections during assembly. Lever arm handle  605  is approximately 3 feet long and sufficiently ridged so as to not bend or break when repeated full force is applied to move the weight of assembled footing forms  1001  where the frictional force produced by steel on steel and steel on earth interactions is present. 
         [0032]    Lever arm handle  605  extends upwardly from handle hinge  645  approximately one fourth of the length of handle  605  to horse shoe grip  615  with opposing grip edges which serve to engage adjacent footing form spacer  1003  for pulling together or pushing apart the adjacent forms  1001 ,  1002 . The friction force caused by the abutment of the adjoining forms  1001  requires the additional leverage of footing form adjustment lever  600  to make working with reusable steel footing forms practical and desirable. At the top of lever arm handle is handle grip  640  where a grip material that is comfortable for the hand to grasp is placed to enhance the tool ergonomically. 
         [0033]      FIG. 10  illustrates footing form adjustment lever  600  engaged with two adjacent steel footing forms  1001  with the attachment channel  630  engaging one spacer  1003  while the horse shoe grip  615  is engaged with another spacer  1003  of an adjoining footing form section  1001 . The lever  600  is positioned to pull or push on the two adjoining footing forms  1001 . Pulling on the handle  605  of the lever  600  will pull the two forms  1001  together by forcing one of the forms  1001  to slide over the top of the other form  1001  at the junction  1005  until the desired position is achieved. Pushing on the handle  605  of the lever  600  in the position illustrated will push the two footing form sections apart and make the total length of the abutting forms  1001  longer.