Column forming apparatus and methods

Abstract

A column forming apparatus wherein concrete is poured into a cavity of the apparatus to form a column for a wall. Embodiments include forming the column both off-site and on-site. Other embodiments include forming a columnless wall. In one embodiment of a column molding apparatus, first and second forming pieces and first and second blocking members can be used to form a column of predetermined shape with the blocking members leaving indentations in the formed column.

1 . A column forming apparatus for forming concrete columns, comprising:
 a mold apparatus having a first forming piece, a second forming piece, a first blockout piece, and a second blockout piece, wherein the said first and second forming pieces are engaged with the said first and second blockout pieces, said first and second forming piece being substantially parallel and said first and second blockout pieces being substantially parallel;   whereby a mixture can be poured into said mold apparatus to solidify and harden into a column structure of a predetermined shape with said two blockout pieces leaving indentations in the concrete column.   
   
   
       2 . The column forming apparatus of  claim 1 , further comprising external clamps placed at various locations whereby said clamps contain said forming pieces against the high pressures exerted by the poured liquid concrete used to form the columns. 
   
   
       3 . The column forming apparatus of  claim 1 , further comprising reinforcing means configured to be inserted into said mixture before said mixture is allowed to harden. 
   
   
       4 . The column forming apparatus of  claim 1 , further comprising a plug placed in the center of the mold, whereby a hole can be created through the center of the manufactured column so that said column can be secured to a footing with protruding rebar. 
   
   
       5 . The column forming apparatus of  claim 1 , further comprising a plurality of rebar pieces configured to be placed vertically within the mold and integrated into the finished column. 
   
   
       6 . The column forming apparatus of  claim 1 , wherein the bottom surface of the mold apparatus is supported on a surface of the mold apparatus is supported on a surface such as a rubber mat, hard ground, or solid concrete. 
   
   
       7 . The column forming apparatus of  claim 1 , further comprising a column cap. 
   
   
       8 . The column forming apparatus of  claim 7 , further comprising a removable eye-bolt configured to be installed at the top of said cap, whereby the cap can be lifted from the top. 
   
   
       9 . The column forming apparatus of  claim 7 , further comprising a steel loop configured to be installed at the bottom of said cap, whereby the cap can be lifted from the bottom. 
   
   
       10 . The column forming apparatus of  claim 4 , further comprising a column footing, comprising of an excavation filled with concrete. 
   
   
       11 . The column footing of  claim 10 , further comprising pieces of rebar protruding upward and configured to fit within the hole created by the plug. 
   
   
       12 . The column forming apparatus of  claim 1  wherein said first and second molding pieces, when assembled, provide a substantially cylindrical shape for the outside of said column forming apparatus. 
   
   
       13 . The column forming apparatus of  claim 2  wherein said external clamp comprise strap surrounding said first and second molding pieces. 
   
   
       14 . The column forming apparatus of  claim 12  wherein said first and second molding pieces are made out of foam. 
   
   
       15 . The column forming apparatus of  claim 14  wherein said foam is coated with a protective coating. 
   
   
       16 . The column forming apparatus of  claim 1  comprising liners substantially covering the inner forces of said first and second molding pieces. 
   
   
       17 . The column forming apparatus of  claim 16  wherein said liners substantially cover the interior exposed surface of said first and second molding pieces and provide a texture and shape for the column formed with the apparatus. 
   
   
       18 . The column forming apparatus of  claim 1  wherein said blockout pieces include members respectively engaging said first and second forming pieces for holding said pieces together. 
   
   
       19 . The column forming apparatus of  claim 16  wherein said liners have members respectively engaging said first and second forming pieces for holding said pieces together. 
   
   
       20 . The column forming apparatus for manufacturing concrete columns, comprising:
 a mold apparatus having a first side piece and a second side piece configured to form the poured concrete in a desired column shape; and   wall panels placed between said first side piece and second side piece,   whereby a column molded to the shapes of said wall panels can be constructed in situ as a part of a wall under construction.   
   
   
       21 . The column forming apparatus of  claim 12 , wherein the said side pieces are placed on both sides of the ends of juxtaposed positioned wall panels so that the ends of the panels extend into the mold and shape the sides of the column. 
   
   
       22 . The column forming apparatus of  claim 12 , further comprising pieces of cardboard or other sturdy material that are folded around the ends of said panels. 
   
   
       23 . The column forming apparatus of  claim 12 , further comprising clamps or braces on the side pieces to hold said side pieces together during the pouring and curing of the concrete. 
   
   
       24 . The column forming apparatus of  claim 12 , further comprising a free-standing panel support system for holding wall panels in place, comprising:
 a diagonal member that is staked into the ground at one end and supports the wall vertically;   an L-shaped piece that fits snuggly against the side of the wall and is bent so that it extends under the wall panel and to the other side; and   a turn-buckle apparatus that attaches said diagonal member to said L-shaped piece so that the position of the wall panel can be easily adjusted.   
   
   
       25 . The column forming apparatus of  claim 12 , further comprising a column cap. 
   
   
       26 . The column forming apparatus of  claim 17 , further comprising a removable eye-bolt configured to be installed at the top of said cap, whereby the cap can be lifted from the top. 
   
   
       27 . The column forming apparatus of  claim 17 , further comprising a steel loop configured to be installed at the bottom of said cap, whereby the cap can be lifted from the bottom. 
   
   
       28 . A method of manufacturing concrete columns, comprising:
 positioning a mold apparatus having a first forming piece, a second forming piece, a first blockout piece and a second blockout piece wherein the said first and second forming pieces are attached to the said first and second blockout pieces, said first and second forming pieces being substantially parallel and said first and second blockout pieces being substantially parallel, said two blockout pieces leave vertical recesses in the concrete column into which ends of wall panels can fit;   introducing solidifying mixture into molding compartment;   allowing said solidifying mixture to cure or harden to form a column; and   removing said column from said mold apparatus after said solidifying mixture has sufficiently cured or hardened.   
   
   
       29 . The method of  claim 20 , wherein mold pieces are held together by external clamps placed at various locations in order to contain said blockout pieces and side pieces against the high pressures exerted by the poured liquid concrete used to form the columns. 
   
   
       30 . The method of  claim 20 , wherein a plug placed in the center of the mold. 
   
   
       31 . The method of  claim 20 , wherein a steel rebar a mesh kit in order to provide the column of added strength. 
   
   
       32 . The method of  claim 23 , wherein the rebar pieces are placed vertically within the mold and become integrated into the finished column. 
   
   
       33 . The method of  claim 20 , wherein the bottom surface of the mold apparatus is supported on a surface such as a rubber mat, hard ground, or solid concrete. 
   
   
       34 . A method of forming concrete columns, comprising:
 positioning between pre-fabricated wall panels a mold apparatus having a first side piece, a second side piece, wherein said first and second side pieces being substantially parallel;   positioning said wall panels so that the ends of the panels extend into the mold and shape the sides of the column;   introducing solidifying mixture into molding compartment in said mold apparatus;   allowing said solidifying mixture to cure or harden to form said column; and   removing said column from said mold apparatus after said solidifying mixture has sufficiently cured or hardened,   whereby columns molded to the shapes of said wall panels can be constricted in situ as a part of wall under construction.   
   
   
       35 . The method of  claim 26 , further comprising placing reinforcing mechanism in the molding compartment before the introduction of solidifying mixture. 
   
   
       36 . The method of  claim 27 , wherein said reinforcing mechanism comprises of four pieces of long rebar. 
   
   
       37 . The method of  claim 26 , further comprising of means to tighten said mold apparatus around said wall panels. 
   
   
       38 . The method of  claim 29 , wherein the tightening means comprises of external clamps. 
   
   
       39 . The method of  claim 26 , further comprising support mechanisms on both sides of the wall panels. 
   
   
       40 . The method of  claim 31 , wherein said support mechanism comprises:
 a diagonal member that is staked into the ground at one end and supports the wall vertically;   an L-shaped piece that fits snuggly against the side of the wall and is bent so that it extends under the wall panel and to the other side; and   a turn-buckle apparatus that attaches said diagonal member to said L-shaped piece so that the position of the wall panel can be easily adjusted.   
   
   
       41 . A columnless wall, comprising:
 a first wall panel and a second wall panel;   a continuous trench beneath said wall panels wherein said trench is filled with concrete;   a plurality of support means that secures said wall panels to said continuous concrete-filled trench.   
   
   
       42 . The wall of  claim 33 , wherein said support means comprise of four pieces of rebar embedded vertically each said wall panel. 
   
   
       43 . The wall of  claim 33 , wherein said support means comprise of two larger pieces of rebar embedded vertically each said wall panel. 
   
   
       44 . The wall of  claim 33 , wherein said support means are attached to said trench by the use of threaded fittings having one end attached to a piece of threaded rebar and other end exposed at the bottom of a said wall panel. 
   
   
       45 . The wall of  claim 33 , further comprising means of holding said wall panels in proper position columnless wall construction. 
   
   
       46 . The wall of  claim 37 , wherein said means comprises of:
 a diagonal member that is staked into the ground at one end and supports the wall vertically;   an L-shaped piece that fits snuggly against the side of the wall and is bent so that it extends under the wall panel and to the other side; and   a turn-buckle apparatus that attaches said diagonal member to said L-shaped piece so that the position of the wall panel can be easily adjusted.   
   
   
       47 . A columnless wall, comprising wall panels where each wall panel is configured to have a molded tongue at one end and a corresponding molded groove at other end, whereby panels can be joined together by placing together two said wall panels and inserting the molded tongue if one said wall panel with the molded groove of another said wall panel. 
   
   
       48 . A columnless wall, comprising wall panels joined together by the use of a plate spanning cross the joint between juxtaposed said wall panels. 
   
   
       49 . The wall of  claim 40 , further comprising a groove having dimensions larger than said plate is cut into the top of said juxtaposed wall panels, whereby the plate can be laid in the grooves of juxtaposed panels and covered with adhesive mortar to both permanently secure and hide said plate and also to protect said plate from rusting. 
   
   
       50 . A method of joining wall panels together without the use if a column, comprising:
 providing said wall panels;   molding a tongue structure and a corresponding groove structure in each said wall panel;   positioning the said wall pieces together; and   inserting the molded tongue of one said wall panel with the molded groove of another said wall panel.   
   
   
       51 . A method of joining wall panels together without the use of a column comprising:
 providing said wall panels; and   placing a plate spanning cross the joint between juxtaposed said wall panels.   
   
   
       52 . The method of  claim 43 , further comprising molding a groove having dimensions larger than said plate is cut into the top of said juxtaposed wall panels, whereby the plate can be laid in the grooves of juxtaposed panels and covered with adhesive mortar to both permanently secure and hide said plate and also to protect said plate from rusting. 
   
   
       53 . A method of forming columnless wall, comprising:
 inserting vertical pipes into the ground with a predetermined spacing between said pipes; and   fabricating wall panels to have profiles adapted to the shape of said pipes spaced at the said predetermined spacing between pipes, whereby each wall panel would have at least a plurality of profiles to fit around the pipes so that the wall panels can be held in position after said panels are lowered onto said vertical pipes.   
   
   
       54 . The method of  claim 45 , further comprising a jig to precisely measure the spacing between said pipes. 
   
   
       55 . The method of  claim 46 , wherein the jig is a long angle iron whose length is determined by the length of a pre-cast concrete panel wall section. 
   
   
       56 . A pre-cast wall erosion control system, comprising:
 a continuous line of concrete configures to prevent the erosion of the dirt beneath wall sections; and   column footings configured to be constructed higher than the line of concrete so that wall panels do not touch the continuous line of concrete and a space is left between said panels and said line of concrete to allow for expansion of said wall panels.