Multiple dimension beam, deck and column system

Abstract

A method, forming panel and system provide for monolithic pouring of concrete columns, beams and elevated decks. The forming panel may be variously sized and dimensioned to serve as a beam forming member or a column forming member, and includes a frame having at least one reinforcing member having a plurality of penetration indicators which are not in registry, at least initially, with any opening in a face plate of the form. The penetration indicators serve as markers and preferably guide templates for drilling openings at preselected locations in the face plate at corresponding to the indicators. The openings so drilled are part of coupler-receiving passages, whereby forms may be variously configured in different dimensions or arrangements. The forms may be configured to provide column form assemblies, beam form assemblies, or receive floor forms in a variety of configurations, and may be readily reconfigured and reused by plugging openings which are in currently undesired locations.

1 . A method for forming cast-in-place building structures of poured concrete material, comprising the steps of:
 providing a forming member including a concrete-engaging member having a rear surface and an opposite front surface adapted for engaging and forming poured concrete material, and a frame connected to the concrete-engaging member and extending rearwardly of the rear surface, said frame being configured and adapted for receiving couplers for connecting respective forming members in adjacency, the frame including at least one reinforcing member positioned along the rear surface, said reinforcing member having a plurality of penetration indicators at predetermined locations opposite and adjacent said concrete-engaging member;   utilizing said penetration indicators to create an opening in said concrete engaging member in registry with a selected one of said penetration indicators to provide a coupler passage extending through said concrete-engaging member and said reinforcing member of said frame;   providing couplers and attaching said forming member to other forming members utilizing said couplers to form a concrete-receiving form assembly defining a region corresponding to a desired configuration of a structural member of the building, at least one of said couplers extending through said passage including the opening created in the concrete engaging member from said front surface to said rear surface and through said reinforcing member at said penetration indicator;   pouring concrete into said region;   allowing the concrete to cure to a self-sustaining condition; and   removing the forming members of the form assembly.   
     
     
         2 . A method as set forth in  claim 1 , wherein said step of utilizing said penetration indicators to create an opening includes drilling through said concrete-engaging member. 
     
     
         3 . A method as set forth in  claim 2 , wherein said penetration indicators are holes in said reinforcing member, and including the steps of positioning a drill bit within the hole and drilling the openings in the concrete-engaging member in registry with the holes in the reinforcing member. 
     
     
         4 . A method as set forth in  claim 2 , including the step of inserting a plug into the opening after removing the forming members of the form assembly. 
     
     
         5 . A method as set forth in  claim 2 , wherein the penetration indicators are spaced at preselected, substantially evenly spaced intervals along the reinforcing member. 
     
     
         6 . A method as set forth in  claim 5 , wherein the concrete-engaging member includes a surrounding edge and the frame includes at least a pair of opposed, spaced apart rails positioned adjacent respective portions of the surrounding edge of the concrete-engaging member and wherein the rails have holes therein, and wherein the step of utilizing the penetration indicators to create an opening includes the step of selecting a penetration indicator corresponding to a desired hole in one of rails and wherein the step of drilling the opening through the concrete-engaging member causes the selected penetration indicator and the opening to be aligned with a selected one of said holes in the rails when said forming member is attached to the other forming members. 
     
     
         7 . A method of forming differently configured cast-in-place beam or column concrete structural members for buildings comprising the steps of:
 providing a plurality of forming members each including a concrete-engaging member having a rear surface and an opposite front surface adapted for engaging and forming poured concrete material, and a frame connected to the concrete-engaging member and extending rearwardly of the rear surface, said frame being configured and adapted for receiving couplers for connecting respective forming members in adjacency, the frame including at least one reinforcing member positioned along the rear surface, said plurality of reinforcing members each having a plurality of penetration indicators at predetermined locations opposite and adjacent said concrete-engaging member;   utilizing said penetration indicators to create first openings in said concrete engaging members in registry with a selected first one of said penetration indicators to provide first coupler passages extending through the concrete-engaging members and the reinforcing members of the frames;   providing couplers and attaching said forming members to adjacent other forming members utilizing said couplers to form a first concrete-receiving form assembly defining a region corresponding to a first desired beam or column configuration, at least some of said couplers extending through said first passages including the first openings created in the concrete engaging members from said front surface to said rear surface and through said reinforcing member at said first one of said penetration indicators;   pouring concrete into said region;   allowing the concrete to cure to a self-sustaining condition;   removing the forming members of the first form assembly;   plugging at least temporarily, at least some of the openings in the concrete-engaging members of at least some of the forming members;   utilizing said penetration indicators to create second openings in at least some of said concrete engaging members in registry with a selected second one of said penetration indicators to provide second coupler passages extending through the concrete-engaging members and the reinforcing members of the frames;   attaching said forming members to adjacent other forming members utilizing said couplers to form a second concrete-receiving form assembly differently arranged and configured from said first concrete-receiving form assembly and defining a second region corresponding to a second desired beam or column configuration, at least some of said couplers extending through said second passages including the second openings created in the concrete engaging members from said front surface to said rear surface and through said reinforcing member at said selected second one of said penetration indicators;   pouring concrete into said second region;   allowing the concrete in said second to cure to a self-sustaining condition; and   removing the forming members of the second form assembly.   
     
     
         8 . A method as set forth in  claim 7 , wherein a first set of said first concrete-receiving form assembly is configured as a column form assembly defining a first region having a substantially upright long axis, and including the step of providing a plurality of said first sets and fluidically connecting the first sets. 
     
     
         9 . A method as set forth in  claim 8 , wherein a second set of said first concrete-receiving form assemblies are configured as a beam form assembly having a second region presenting a substantially horizontal long axis, and including the step of connecting said plurality of second sets of first concrete-receiving form assemblies to said second set of said first concrete-receiving walls systems whereby concrete poured into said first regions is in fluidic communication with concrete poured into said second region. 
     
     
         10 . A method as set forth in  claim 9 , wherein the forming members in said second set of said first concrete-receiving form assemblies include ledger forms having an extension adapted for coupling a floor form thereto, and including the steps of:
 providing a plurality of floor forms;   coupling respective ones of said floor forms to the extensions of corresponding ones of said ledger forms to form a deck forming system positioned adjacent said second set; and   flowing the poured concrete onto the deck forming system to form an elevated deck, whereby concrete on said deck forming system is in fluidic communication with said first and second regions.   
     
     
         11 . A method as set forth in  claim 9 , wherein a third set of said first concrete-receiving form assemblies are configured as a second beam form assembly having a third region presenting a substantially horizontal long axis, and including the steps of attaching the forming members of said third set in a different configuration than said second set whereby said third region has a different cross-sectional configuration than a cross-sectional configuration of said second set, and connecting said third set of first concrete-receiving form assemblies to said second set and said first set of said first concrete-receiving walls systems whereby concrete poured into said first regions is in fluidic communication with concrete poured into both said second region and said third region. 
     
     
         12 . A system for forming beams and columns of poured-in-place concrete for a building, comprising:
 a plurality of forming panels each having a face plate presenting a front side for receiving concrete thereagainst and a back side opposite to the front side and a surrounding edge, and a frame coupled to the face plate and presenting at least first and second spaced-apart rails each having a width and positioned adjacent the surrounding edge and extending rearwardly from said rear side, said frame including a reinforcing member positioned adjacent to said rear side, said reinforcing member including a plurality of holes selectively positioned on said reinforcing member opposite a portion of said face plate, said portion of said face plate including at least one opening aligned in registry with a corresponding one of said holes to define a passage located between said rails which is sized and positioned to receive a coupler therethrough;   a first set of couplers operatively connecting a first set of said forming panels to present a first column-forming wall structure substantially enclosing a concrete-receiving volume, at least one of said first set of couplers extending through a selected one of said passages of one of said first set of forming panels to and through a hole in a rail of another of said first set of forming panels;   a second set of couplers operatively connecting a second set of said forming panels to said first set of forming panels whereby said second set of forming panels; and   a third set of couplers operatively connecting said second set of panels to form a first beam-forming wall structure wherein at least some of said second set of panels are opposed, spaced-apart, substantially upright beam ledger forms and some of said second set of panels are substantially horizontal sill plate forms which are connected by ones of said third set of couplers extending through a selected one of said passages of one of said beam ledger forms of said second set of forming panels to and through a hole in a rail of a corresponding one of said sill plate forms whereby said first beam-forming wall structure defines a concrete-receiving channel,   said first beam-forming wall structure being arranged and operatively coupled to said first column-forming wall structure whereby concrete received in said concrete-receiving channel fluidically communicates with concrete received in said concrete-receiving volume of said first column-forming wall structure.   
     
     
         13 . A system as set forth in  claim 12 , further including a plurality of floor forms, wherein said floor forms are coupled to said ledger forms in elevated relationship to said first column-forming wall structure. 
     
     
         14 . A system as set forth in  claim 12 , further including a plurality of box corner forms coupled to and interconnecting said first beam-forming wall structure to said first column-forming wall structure, whereby said box corner forms include first and second elongated walls, said first and second elongated walls being oriented in substantially perpendicular relationship to each other, each of said elongated walls having a wall width greater than the rail width, and a connecting flange connected to and extending substantially perpendicular to a respective one of said elongated walls and substantially parallel and opposite to the other of said elongated walls, each of said connecting flanges having at least one hole therein sized and configured for receiving a coupler therethrough. 
     
     
         15 . A forming system as set forth in  claim 14 , wherein said ledger form includes a rearwardly projecting extension having a dimension, said dimension being substantially the same as the width of said elongated wall. 
     
     
         16 . A forming system as set forth in  claim 12 , wherein said reinforcing member extends substantially between said rails and said plurality of holes in said reinforcing members are positioned at evenly spaced intervals therebetween, at least some of said holes being located adjacent an imperforate portion of said face plate whereby said at least some of said holes are not in registry with an opening in said face plate. 
     
     
         17 . A forming system as set forth in  claim 12 , wherein said reinforcing member is positioned in substantially perpendicular alignment to said rails and wherein said plurality of holes in the reinforcing member are in lateral alignment with a hole in the rail and oriented such the axes of the holes in the reinforcing member are substantially co-planar with but oriented perpendicular to the holes in the rails. 
     
     
         18 . A forming panel for receiving thereagainst pourable cementatious material for forming a building member comprising:
 a face plate having a surrounding edge, a front side adapted for receiving poured cementatious material thereagainst and a rear side;   a frame coupled to said face plate and extending rearwardly therefrom, said frame including at least first and second rails spaced apart connected to said face plate proximate the surrounding edge,   wherein said frame further includes at least one reinforcing member extending along said rear side of said face plate between said first and second rails, said reinforcing member having a multiplicity of penetration indicators spaced at preselected locations along said reinforcing member, said penetration indicators being positioned adjacent an imperforate portion of said face plate and configured a hole may be created in said imperforate portion of said face plate in registry with said penetration indicator for receiving therethrough coupling members for coupling the forming panel to an adjacent forming panel.   
     
     
         19 . A forming panel as set forth in  claim 18 , wherein said penetration indicators include holes in said reinforcing member positioned at common spacing intervals in substantially lateral alignment along said reinforcing member. 
     
     
         20 . A forming panel as set forth in  claim 19 , wherein said reinforcing member includes an elongated slot and a U-shaped collar received in said slot having a backing positioned adjacent one of said rails, said backing including a hole positioned in registry with a corresponding hole in the rail. 
     
     
         21 . A method of connecting forming members for forming concrete structures comprising the steps of:
 providing a first forming member having a face plate having an opening therein to provide a coupler passage and a rearwardly extending frame including a channel having an elongated rearwardly open slot;   providing a second forming member having a face plate and a rearwardly extending frame including at least one siderail having a hole therethrough;   positioning the first forming member substantially perpendicular to the second forming member with the face plate of the first forming member oriented adjacent to the side rail of the second forming member and the opening in the face plate in alignment with the hole in the siderail;   inserting a coupler through the passage and the hole; and   threadably connecting the coupler to one of the first and second forming members.   
     
     
         22 . A method as set forth in  claim 21 , wherein the channel includes elonged ribs extending into the slot, and including the steps of providing an externally threaded bushing, threading the bushing onto the channel, and passing the coupler through the bushing. 
     
     
         23 . A method as set forth in  claim 21 , wherein the coupler is threaded, and including the steps of providing a nut complementally configured to threadably receive the coupler and threadably connecting the coupler to the nut.