WO1997032092A1

WO1997032092A1 - Method of erecting poured concrete walls

Info

Publication number: WO1997032092A1
Application number: PCT/CA1997/000136
Authority: WO
Inventors: Vittorio De Zen
Original assignee: Royal Building Systems CDN Ltd
Current assignee: Westlake Canada Inc
Priority date: 1996-02-29
Filing date: 1997-02-28
Publication date: 1997-09-04
Anticipated expiration: 1998-08-29
Also published as: AR005905A1; CA2170680A1; AU1762897A; ZA971577B; SA97170663A

Abstract

A method of erecting structural walls reinforced with encased concrete comprising assembling a plurality of hollow structurally stable interlocking thermosplastic wall forming components (4, 10, 11) into at least two interlocked hollow wall sections disposed one relative to the other such that they can be spanned by and will support a platform (19) placed on top thereof, said interlockedwall forming components (4, 10, 11) being open to the top of said wall sections and being in internal concrete flow communication with each other, spanning said wall sections with a platform (19)placed on top thereof, said platform providing access for the pouring of concrete into some of said interlocked wall forming components, then pouring concrete into some of said interlocked wall forming components to flow between said components.

Description

METHOD OF ERECTING POURED CONCRETE WALLS

FIELD OF THE INVENTION

This invention relates to improvements in the erection of poured concrete walls for houses or other building structures without the need to erect and dismantle access scaffolding presently required or dismantle any wall forms.

The invention also provides for the erection aforesaid of poured concrete walls which are insulated.

The invention further provides for the erection of poured concrete walls as aforesaid in which a concrete floor slab supported on the walls can be united therewith as part of the wall erection process.

BACKGROUND OF THE INVENTION

Conventionally poured concrete walls used, for example, as basement and other exterior walls for housing and other building structures involves the erection of suitable form work defining the wall shape, pouring concrete into the form work, and, when same is sufficiently set, removing the form work.

In my earlier PCT Application PCT/CA94/00274, 1 disclosed an arrangement of extruded thermoplastic components which can be interlocked together to form a wall structure for receiving concrete therein with internal communication provided between the interlocking components so that concrete poured therein can flow therebetween to provide a thermoplastic wall structure held in interlocked relation and converted to a permanent wall by the concrete confined therein.

In all previous cases, in order to carry out the pouring of the concrete, it has been necessary to provide access so that the workman can control the concrete pour from the top of the wall both for easier control and for safety so that they will not be working below the wall, as for instance at the bottom of a basement dug out, where they would be subject to injury on any wall collapse.

The present invention is directed to eliminate the need for such access scaffolding and any removable form work while enabling the workmen to control the pour safely from the top of the wall.

SUMMARY OF THE INVENTION

The invention of the present invention involves erecting a first stable concrete receiving wall section by interlockingly connecting a plurality of hollow thermoplastic interlocking wall components having internal concrete receiving compartments opening to the top of the wall section and being in full communication with each other substantially throughout said wall section, erecting at least a second wall section corresponding to said first wall section out of alignment with said first wall section in position to support with said first wall section a platform spanning said wall sections, placing a platform on top of and spanning said wall sections, said platform being formed with passage means providing access to at least certain of said concrete receiving compartments when placed on top of said wall sections, then pouring concrete through said passage means into said compartments to fill same.

The invention also provides for the erection of an insulated concrete wall as aforesaid through the use of wall forming components which incorporate insulation filled or receiving compartments as well as concrete receiving compartments, the insulation compartments being arranged so that with insulation therein they block heat transfer through the wall sections.

Still further according to the invention, the platform used to span or bridge the wall sections preferably comprises a floor panel in the form of a concrete slab and when the concrete is poured to fill the wall forming compartments, pouring is continued to fill the floor slab passages to unite the floor slab to the wall sections it spans.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a broken away perspective view illustrating the assembly of the hollow interlocking thermoplastic wall forming components into a corner section of an insulated basement wall.

Figure 2 is a view similar to Figure 1 but showing the wall forming components seated on the basement floor slab.

Figure 3 is a plan view looking down on the assembled wall forming components of Figure 2.

Figure 4 is a view similar to Figure 3 but showing a floor slab resting on top of the wall forming components with the floor slab having notches therein affording access to certain of the concrete receiving compartments.

Figure 5 is a broken away perspective view of a perimeter wall showing two parallel side walls joined by an end wall formed by the interlocking wall forming components of Figures 1 to 3 and showing a floor slab about to be lowered down to span and rest on the top of the side walls, the floor slab having notches giving access to certain of the concrete receiving compartments of the wall forming components.

Figure 6 is an enlarged broken away perspective view showing a portion of the floor slab about to rest on the underlying wall portion with one of its notches registering with the concrete receiving compartment of the box connector.

Figure 7 is a broken away perspective view showing a corner section of the wall formed by the interlocked wall forming components with the floor slab supported thereon to form a working platform from which to control the pouring of concrete into the concrete receiving compartments of the wall forming components.

Figure 8 is a broken away perspective view illustrating a section of a wall formed with wall forming components that, in addition to having concrete receiving compartments, also have insulation receiving compartments in communication with each other and showing a floor slab resting on top thereof forming a working platform from which to control the introduction of concrete into the concrete receiving compartments and as well the introduction of foamed insulation material into the insulation receiving compartments through an access notch in the floor slab.

DETAILED DESCRIPTION ACCORDING TO THE PREFERRED EMBODIMENTS OF THE PRESENT INVENTION

The invention is particularly described in relation to the erection of a concrete reinforced insulated basement wall, although it will be appreciated that the invention is equally applicable to concrete reinforced above ground perimeter walls, and to spaced concrete reinforced wall sections which can be bridged by a floor or other platform spanning therebetween.

It will be understood however that the invention is equally applicable to the erection of concrete reinforced walls which need not be insulated.

With reference to Figures 1 to 3 directed to the erection of a concrete reinforced insulated basement wall, a concrete floor slab 1 is poured in the basement excavation 2 with reinforcing rods 3 embedded in the concrete.

In place of conventional form work, a wall of interlocking wall forming components in the form of hollow thermoplastic extrusions is assembled on the floor slab 1. These wall forming components comprise hollow panel members 4, box connectors 10 and corner members 11 of rectilinear cross section extruded from a thermoplastic material, preferably a poly vinyl chloride (PVC) with suitable fillers or reinforcing agents such as calcium chloride to provide the components with the requisite structural strength and stiffness to contain a charge of concrete when same is introduced therein.

As illustrated the panel 4 has 3 internal concrete receiving compartments 5 and three insulation receiving compartments 6 filled with insulation material 7 such as fiber glass or the like.

The panels 4 are provided with locking grooves 8 to be interlockingly engaged by locking fingers 9 of box connectors 10 or corner members 11.

The box connectors 10 like the panels 4 have a concrete receiving compartment 12 and an insulation receiving compartment 13 filled with insulation 14.

The corner member 11 has a concrete receiving compartment 15 and insulation receiving compartments 16 filled with insulation 17.

The walls of the concrete receiving compartments 5, 12 and 15 of the panels, box connectors and corner members 4, 10 and 11 respectively are cored to provide flow passages 18 which, when the wall forming components 4, 10 and 11 are assembled into interlocked relationship to form the desired wall configuration, will be in registration so that concrete introduced, for instance, into the box connectors 10 can flow through the flow passages 18 into the wall formed by the wall forming components, comprising in addition to the box connectors 10, the panels 4, and corner members 11, to fill their respective concrete receiving compartments.

Because of the structural integrity of the wall forming components 4, 10 and 11 themselves and because of their mutual support from their interreaction by being interlocked together, these components provide a stable wall structure capable of supporting a work platform or floor slab placed on top thereof. As shown in Figure 1 , the wall forming components are assembled by sliding one relative to the other with the locking fingers 9 engaging in the locking grooves 8 and they are sleeved down on to the reinforcing rods 3 which project up into the interior thereof.

Upon assembling the interlocking wall forming components 4, 10 and 11 to complete a wall or sections of a wall which can be bridged by a support platform spanned therebetween, a platform 19 is placed on top thereof as illustrated in Figures 5 and 6. This platform 19 is in the form of a floor slab having a plurality of notches 20 formed in three of the edges thereof. The platform or floor slab 19 is adapted to span between the spaced side walls 21 of the wall formation shown in Figure 5 and rest on top thereof with the notches 20 in the side edges 22 of the floor slab preferably registering with the concrete receiving compartments 12 of the box connectors 10 whereby they provide access to these box connector concrete receiving compartments 12 for the pouring of concrete therein.

The notches 20 in the floor panel 19 on the edge 23 of the floor panel are adapted to register with the concrete receiving compartments 12 of the box connectors 10 of the end wall 24 of the wall formation of Figure 5.

It will be understood that the platform or floor slab 19 supported on top of the wall formation or wall sections formed by the interlocked wall forming components 4, 10 and 11 is adapted to serve as a work platform from which workmen on top of the wall formation or wall segments can operate in the pouring of the concrete via hopper H into the concrete receiving compartments 5, 12 and 15 as illustrated in Figure 7.

Because of the intercommunication through passages 18 between the concrete receiving compartments of the wall forming components 4, 10 and 11 , concrete introduced preferably into the box connectors compartments 12 through the platform notches 20 can flow and spread to fill the concrete receiving compartments 5 and 15 respectively of the panels 4 and corner members 11 as well as the concrete receiving compartment 12 of the box connector 10. As illustrated in Figure 7, reinforcing rods 25 can be inserted through the passages 18 to provide interior reinforcement of the concrete in the concrete receiving compartments of the wall forming members and the concrete will also embed the reinforcing rods 3 of the floor slab 1.

By continuing the concrete pour through the notches 20 of the floor slab until the notches are filled with concrete, the floor slab can be integrally locked with the supporting wall formation, it being understood that the open sides of the notches will be closed during this stage of the concrete pouring.

In this way the complete wall can be formed and covered by a complete floor made up of a plurality of abutting floor slabs 19 without the need for workmen to be working from a position below the top of the wall and without the need to provide access scaffolding to support workmen adjacent the top of the wall to direct concrete during the pouring of the wall. As a result the method of the invention provides an important safety factor and eliminates the need for access scaffolding and the time, cost and labour required to erect and dismantle same.

In the embodiment of the invention illustrated in Figures 1 to 7, there is provided a fully insulated basement wall reinforced with encased concrete with the wall forming components 4, 10 and 11 forming a permanent integral part of the wall. These wall forming components provide ascetic smooth surfaces while isolating the concrete of the wall from water and moisture penetration to provide a fully insulated thoroughly dry basement.

It will be appreciated that the invention is equally applicable to above ground walls where, for instance, the wall of the subsequent floor above the ground floor can be erected in the same manner with wall forming components 4, 10 and 11 mounted on the assembled floor slabs 19 forming the ground floor on top of the basement walls. Where desired the wall forming components of an above ground wall erected from components corresponding to components 4, 10 and 11 may have such components provided with protective coating such as a coextruded protective skin. In the illustrations in Figures 1 to 7, the wall forming components 4, 10 and 11 have their insulation receiving compartments 6, 13 and 16 filled with insulation at the time of their assembly into interlocked wall forming relation. Figure 8 illustrates an alternative arrangement in which the box connector 10' not only has its concrete receiving compartment 12' in communication with the concrete receiving compartments of its adjoining interlocked components, eg. compartments 51 of panel 4' through passages 18', but also has its insulation receiving compartment 13' in communication with the insulation receiving compartments of its adjoining interlocked components, eg. compartments 61 of panel 4' through passage 26.

With this arrangement when the floor slab or platform 19' is placed on top of a wall structure employing box connectors 10' and wall panels 4', the notches of the platform 19' will provide access to both the concrete compartments 12' and insulation receiving compartments 13' of the box connectors 10' so that not only can concrete be introduced into the assembled wall through the concrete discharge nozzle 27 but the notches 20' allow insulation to be foamed into the insulation receiving compartments 12' and 13' through the discharge nozzle 28.

It will be appreciated that the width and height of the walls which can be formed according to the method of the present invention can be selected as desired by changing the dimensions of the extruded wall forming components 4, 10 and 11, and further such wall forming components can be extruded without having the insulation receiving compartments 6, 13 and 16 if desired.

It is understood that other variations in detail may be made without departing from the scope of the invention as set out the appended claims.

Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A method of erecting structural walls reinforced with encased concrete comprising assembling a plurality of hollow structurally stable interlocking thermoplastic wall forming components into at least two interlocked hollow wall sections disposed one relative to the other such that they can be spanned by and will support a platform placed on top thereof, said interlocked wall forming components being open to the top of said wall sections and being in internal concrete flow communication with each other, spanning said wall sections with a platform placed on top thereof, said platform providing access for the pouring of concrete into some of said interlocked wall forming components, then pouring concrete into said some of said interlocked wall forming components to flow between said components.

2. A method as claimed in Claim 1 in which said at least two interlocked hollow wall sections are disposed in spaced parallel relation.

3. A method as claimed in Claim 1 in which said at least two interlocked hollow wall sections form a corner.

4. A method as claimed in Claim 1, 2 or 3 in which said interlocking thermoplastic wall forming components are poly vinyl chloride extrusions.

5. A method as claimed in any of the preceding claims in which reinforcing bars are introduced into said wall forming components at their time of assembly into said at least two interlocking hollow wall sections.

6. A method as claimed in any of the preceding claims in which said platform comprises a floor slab to be supported by said wall sections.

7. A method as claimed in any of the preceding claims in which said wall forming components incorporate insulating material in position to block heat transfer through the wall sections.

8. A method as claimed in any of the preceding claims in which said wall forming components have compartments to receive foamed insulation which are open to the top of said wall sections and are in internal communication and said platform provides access for the introduction of insulating foaming material into some of said compartments, then introducing insulating foaming material into said some of said compartments to flow into the compartments in communication therewith.

9. A method of erecting concrete reinforced wall structures having at least two wall sections disposed the one relative to the other whereby they can be bridged by a span of platform placed on the top thereof, said method comprising forming each so disposed wall sections by assembling a plurality of hollow interlocking structurally stable extruded thermoplastic wall forming components into an interlocked wall form for each so disposed wall section, said hollow interlocked wall forming components having concrete receiving compartments open to the top of said wall form and in communication with each other for the flow of concrete therebetween, supporting a platform adapted to span between said section wall forms on the top of said section wall forms, said platform being formed to provide access to some of said concrete receiving compartments, then pouring concrete into said concrete receiving compartments to which said platform provides access to fill said compartments with concrete.

10. A method as claimed in Claim 9 in which said wall forming components also include compartments for receiving insulation material positioned to block heat transfer through walls formed by pouring concrete into said concrete receiving compartments.

11. A method as claimed in Claim 9 or 10 in which said platform is a floor slab.

12. A method according to any of the preceding claims in which said wall forms are hollow rectilinear poly vinyl chloride extrusions.

13. A method of erecting a concrete reinforced building perimeter wall such as a basement wall or the like on a support floor, comprising erecting a perimeter wall of hollow interlocking extruded thermoplastic wall forming components assembled in interlocked relation on said support floor, said components having concrete receiving compartments extending from said support floor to the top of said perimeter wall, said concrete receiving compartments being in internal concrete flow communication within said wall, lowering a floor section on top of said perimeter wall to span across sections thereof, said floor section being notched to provide access to some of said concrete receiving compartments, then, while utilizing said floor section as a work platform, pouring concrete into said concrete receiving compartments to which access is provided by said notched floor section to flow between said compartments.

14. A method as claimed in Claim 13 in which said floor section is concrete, and concrete is poured to fill the notches of said notched floor section to unite said floor section to said wall.

15. A method as claimed in Claims 13 or 14 comprising embedding upstanding reinforcing rods in said support floor and sleeving at least of some of said wall form components over said reinforcing rods to be embedded in concrete poured into said compartments.

16. A method as claimed in Claims 13, 14 and 15 in which said wall forming components have insulation receiving compartments filled with insulation positioned to block heat transfer through said perimeter wall.

17. A method as claimed in Claims 13, 14, 15 or 16 in which said wall forming components have insulation receiving compartments extending from the said support floor to the top of said perimeter wall said insulation receiving compartments being in internal flow communication within said wall, said notched floor section providing access to some of said insulation receiving compartments, and foaming an insulation material into said some insulation receiving compartments to flow between said insulation receiving compartments.

18. A method of forming a basement wall on a concrete base or the like comprising erecting a wall of hollow interlocking extruded thermoplastic components, said components being open to the top of the wall and having internal wall arrangements to provide a plurality of concrete receiving compartments bordered on at least one side of said wall by a plurality of insulation receiving compartments, said concrete receiving compartments being in communication throughout said wall and said insulation receiving compartments having insulation material mounted therein, placing a floor slab on top of said wall, said floor slab being formed to provide access to selected ones of said concrete receiving compartments, then pouring concrete from said floor slab into said selected ones of said concrete receiving compartments to fill said concrete receiving compartments.