CA1286517C - Insulating non-removable type concrete wall forming structure and device and system for attaching wall coverings thereto - Google Patents

Abstract

ABSTRACT OF THE INVENTION
A synthetic plastic concrete wall tie comprising a pair of triangular truss sections disposed in end-to-end relation, an intermediate web section joining the truss sections at the apexes of triangles of the triangular truss sections, and T-shaped end sections at opposite ends of the tie with each end section being formed integral with its stem joined with the associated triangular truss section, the cross piece of each T-shaped end section comprising means for anchoring the tie to a slotted wall section when assembled therewith.
The tie is usable with modular foamed plastic concrete form structure having a pair of modular concrete forming panels. The panels are comprised of a series of modular concrete forming sections stacked on top on one another in secured assembly and also disposed in end-to-end relation. The panels are positioned in spaced opposed relation with vertically spaced rows of T-shaped tie slots in the opposed sections positioned in longitudinally spaced transversely aligned relation along the upper and lower edges and which slots are hidden from view when viewing outer surfaces of the stacked sections. The ties hold the sections in assembly when secured in the tie slots. Tie locator indicia is provided on outer surfaces of the sections for providing for blind sighting to enable fasteners to be screwed through a wall covering, the indicia, the section and the synthetic plastic ties to securely anchor an exterior wall covering to the form structure after concrete has been poured therein.

Description

iS~7 , AN INSULATING ~ON~ MOVABLE TYP~ CONCRET~
W~LL F~RMlNG ST1~UCTURE AND DEVICE AND SYSTEM
FOR ATTAC11lNG WAL COVERINC~ T-1 ~ackqrour1d of the Invention Field of the Invention The present invention relates to a new and im~roved synthetic plastie conerete forming system. The present inventior1 also concerns a new and improved synthetic plastic concrete wall tie for use in the concrete forming system.
Stili another part of the invention relates to a new and ilnproved system and method for affixing wall coverings to a modular synthetie plastic conerete forrn strueture.
Aeeording to eertain other features of my invention, my new and improved synthetie plastie eonerete wall tie has triangularly shaped openings provided in end-to-end disposed truss seetions whieh allow concrete to flow laterally throuc3h triangular truss openings as eoncrete is poured into the form so that the ties do not act as dams to impede lateral flow of concrete in the form.
According to still other features of my invention, I
have provided a new and improved synthetie plastic wall tie that has unique end formations which enable the wall tie to be easily attaciled with slotted form seetions where the slots e1xtend in rows alonc3 upper and lower edges of the form section.
Still other features of my invention are eoneerned with a new and ilnproved synthetic plastic wall tie comprised of 20'~ caleium carbonate filled polypropylene of suEficient thickness to allow attaehment screws to be threaded into opposite ends of the tie to anchor wall coverincJs to a poured ,:' ' '-' ~
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concrete wall structure.
According to other important features of my invention, I have provided a new and improved synthetic plastic concrete wall tie which is totally modular in that it can be used and mounted in slots in wall sections synthetic plastic concrete forms from either edge of the tie.
According to still other important features of my .invention, I have provided a new and improved synthetic E~lastic concrete wall tie having reinforc.ing rod locating 10 Eingers which assist in providing one or more pockets for a concrete reinforcing rod to minimize movernent of the -reinforcing rod as concrete is poured into the form.
In the past, it will be appreciated that different types of foamed plastic concrete forming systems have been ~ 15 used in industry and, in this connection, attention is drawn to U.S. Patent Nos. 3,552,076 and 3,788,020. These patents ~: relate generally to concrete forms formed from low density foamed plastic and polymeric Inaterial but where the forms do ;
not possess the improvements herein described and illustrated.
. SUMMARY OF '~HE INVENTION :
In a modular synthetic foamed plastic concrete form structurc, wherein thc improvement comprises a pair of i. modular concrete impervious forminy panels each comprised of a series oE modular concrete forming sections stacked on top on olle~ another and also clisposed in end-to-end relation, the .: !
sectiorls each having means on its upper and lower edges and its opposite vertical edges for interlocking the sections in stacked, end-to-end engagement with one another, the panels being positioned in spaced relation, vertically spaced rows , ..

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of 'r-shaped tie slots in the opposed sections positioned in longitudirlally spaced relation along the upper and lower ecl~es ancl which slots are hidden from view when viewing outer su.rEaces of the stacked sections, synthetic plastic ties each having opposite e~larged T-shaped tie ends retainingly engaged in said T-shaped tie slots securing the sections in .
oL~posed spaced relation, the outer surfaces of -the sections ..
having tie locator indicia thereon for enabling fasteners to be screwed through the panel into the synthetic plastic ties to securely anchor exterior wall finishing covering to the sections.
A synthetic plastic concrete wall tie comprising a air of triangular truss sections disposed in end-to-end ~ -.
relation, an intermediate web section joining the truss sections at the apexes of triangles of the triangular truss sec-tions, and T-shaped end sections at opposite ends of the ~.
tie with each end section being formed integral with its stem jointecl with the associated triangular truss section, the cross piece of each T-sllaped end section comprising means for anchoring the tle to a slotted wall section when assernbled therewith.
A rnethod of securing a wall covering to a conc:rete . .
wall structure, the steps oE forming synthetic plastic wall forming sections from a Eoamed plastie rnaterial with row~ of 2S tie slots at spaced int~rvals along upper and lower edges and with indicia Eormed on outer wall surEaces of the forming section so that -the inclicia and the slots are transversely ~ alicJned in pairs along the edges enabling the indicia to act : as a tell tale for the slots and wall ties, securing opposite ~ 30 ends of synthetic plastic concrete wall ties in the slots of .~
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the wall forming sections to provide a reinforced orm structure, securing transverse closure sections be-tween the wall forming sections tc) provide form closures, pourin~ -concrete in the thus formed concrete forming structure and immersing and hiding the ties in the concrete, screwing fasteners through a wall covering, the panel section into the wall tie using the indicia as a blind concrete tie locator for ali-~ning the screw with the hidden wall tie enabling the ~crew to be scre~wed into the tie to securely fasten the wall covering thereto.
BRIEF D:ESCRIPTION OF THE DRAWINGS
Fig. l is an enlarged fragmentary cross-sectional view of a modular foamed plastic concrete foxrn structure embodying important features of my invention;
Fig. 2 is an enlarged perspective view partially in section showing a concrete form structure with reinforcing rods mounted therein;
`~ Fig. 3 is an enlarged vertical section of a concrete filled modular synthetic plastic concrete form structure embodying still further features of my invention;
Fig. 4 is an enlarged perspective view of a wall tie like the tie shown in Figs. 2 and 3;
! Fig. 5 is an enlarged perspective view oE a modifi~d type of wall tie similar to the one shown in ~`ig. 4 with a reinEorcing rod being shown in dotted and full lines for being supported upon the tie;
Fig. 6 is an exploded fr~gmentclry vertical section o~ a modular synthetic plastic concrete form structure and illustrating the manner by which wall coverings can be attached thereto;
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Fig. 7 is an enlarged ~ra~mentary explodcd view o~ a modular synthetic plastic conceete form steucture similar to that shown in Fig. 6 only with the components being in a rnore advanced stage oE assembly;
Fi~ ~ is an enlargen fra~mentary vertical section through a concrete ~illed modular syn~hetic plastic concretc form str~cture ~urther showing how a wall coverin~ may be attached to the modular concrete Eorming sections;
Fig. 9 is an enlarged eragmentary section taken on line 9-9 looking in the direction indicated by the arrows as seen in Fig. ~; and Fig. 10 is an enlarged fragmentary horizontal section of a pair o panels connected in end-to-end relation.
DESCRIPTION OF THE P~EF~ED EMBODIMENTS
The reerence numeral 10, as seen in Fig. 1, designates generally a modular ~oamed plastic concrete ~orm structure. The struc~ure that is shown in Fig. 1 is also shown in my co-pendin9 application for patent entitled: "A
PE~M~NENT NON-~MOV~BL~ INSULATX~G TYPE CONC~ETE WA~ FORMING
STRUCTUR~", Serial No- 508,2~1 Eiled concurrently herewith, ~ he struc~ure 10 is comprised of a pair of modular concrete orming panels 11 and 12 which are spaced from one another and which when properly installed serve to act as a Eorm into which concrete may be poured. The panels are each comprised oE a series oE modular concrete forming sections 13 which are all identical to one another with certain exceptions, as hereafter described. These sec~ions are adapted to be cut and arranged so as to enable window -------------------------:, .
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openin~s 14 to be ea~ily constructed. Cooperable with the~anels 11 and 12 are end closure panels 15 which extend transversely ~etween the forming panels 11 and 12 and between the forming sections 13 so as to confine poured concre~e. It will further be seen that the window openings 14 are also provided with closure panels 16. All of the panels 11, 12, the sections 13, the closure panels or end pieces 15, the window panels 16 and curved corner panels 17 are comprised of foamed plastic preferably an expandible polystyrene. This material has been found to have unique insulating properties and strength so as to enable concrete walls to be better insulated to ilnpede transmission of heat through a formed wall as will be further described at another point herein.
In order to properly reinforce the concrete forming structure 10, I have developed a new and improved wall tie 1 which is comprised o~ 20% calcium carbonate filled polypropylene as a preferred embodiment.
My thermal wall system is a whole new concept in energy efficient building technology. The buildin~ block sections oE expanded polystyrene serve as a permanent form ~or concrete. This system of construction is for use where enercJy conservation is for use where energy conservation and ~peed o~ construction are irnportant.
Expanded polystyrene or EPS is a closed cell, rigid, lightweight cellular plastic, white in color, that i8 mol~ed into various shapes with steam and pressure. Thermal wall system panels are made of modified polystyrene. The density oE the panels range between 1.7 and 2Ø Typical physical properties of EPS insulation is given in Table 1 below. Like ' :

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all organic materials, EPS is combustible and should not be ex~osed to flamc or othcr ignition sources.
TYPICAL I~HY~ICAL ~O~ OF k'PS

~P~Ilu~ Unll~ AS~ n~
1 û 1 25 I S 2 0 S Tru~l~nalCon~ucllv,ly al2SF Blul(m~ C;7701 023 022 021 020 ~f~,lol al40f (sq ~ Fl~n) CSI~ 024 0235 022 021 al 75f 026 ~255 024 023 Tnalmdl R~s,slance al 25f al I ,ncn 4 35 4 54 4 76 5 ~0s (H~ al 40f Inlci~ness -- 4 1, 4 25 4 SS 4 76 0 i~l 75r 3 f~S 3 92 4 1 1 4 35 ~un~Jln f'lOpL'lllL'S
Colllplc~slvu 10~ D~lolmdllon ps' D1~21 1~)14 1318 1521 .~$33 ~lu~u~l ` p~.l C2r~3 25 30 32 3r~ 40 50 ;S 75 Slh p5~ G~3 Iti 20 17 21 If J 22 23 27 ~n"~ ps, D732 If ~ 22 23 ~5 26 32 33 37 .ll Mo~lulus l~sl -- 2~0320 37(~410 4L~0S00 600~0 ,Aoaul~ ~ ol Elasllcny psl _ Ir~0 220 250 310 320 360 ~IDO
~o~Slul~ R~slslar-~
WV7 pclm-n C3SS 1~30 1 12f~ 0925 0615 2 0 bDsolpl,on ~vol ) pelc~nl C27~ ? S 2 S 2 U ~55 In~n Cap~lla~lv -- -- nune none none none CU~ IIICI~?I11 o~
- ItwlmJIE~pans~on Inl(ln~lF) D~6 0000035 0000035 OOW. . 0000035 __ _ _ _ mUr~l SL~I~IIC~ 7cmptlalule f Long l~lm 167 167 167 167 Illl~lnl.ll~nl 160 lflO IfJ0 180 :::
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The basic building components of my thermal wall ~.
~, 30 system are the two solid 2" panels 11 and 12 of polystyrene , . .
connected together with high impact plastic ~ies 18. q'he length of the tie 18 determines the width of the concrete wall. Each block or section 13 has castellations 20 along its top edge or surEace 21 and matching castellations along i.ts under edge 23 (Fig. 1). The blocks or sections 13 are pl~ced one on ~QP Of the other and pressed together using sin~ple hand pressure. The castellations Inesh together :. creatinCJ a aompletely smooth surace that is interlooked.
: The vertical ends of the block or section 13 are tongue 24 and groove 25 (Fig. 10) and interlock as well. The blocks or sections 13 are erected directly on top oE footings or on the floor slab, as design dictates. The footings must be level .
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iS~7 and ~lat. When placing concrete, particular care should be taken in the first lift to check the horizontal and vertical levels.
Each of the end closures 15 vertically extending S alternating hooked shaped ribs and grooves generally indicated at 26 which are shaped like and complimentary to hook shaped ribs 27 and hooked shaped grooves 28 (Fi~J. 8) to enable opposite ends of the end closures l5 to be slid into interlocked aSSelllbly with the opposed sections 13, 13. The -~
sections have the ribs ~7 and grooves 28 formed integral with ~
the associated section 13 and when set up, the ribs 27 and -the grooves 28 on the opposed panels 11 and 12 confront one another. ~
The ties 18 are adapted to coact with upper and ~ ;
lS lower rows of T-shaped slots 29 which are formed in each of the sections 13. The slot 29 opens on an inner side so that the T-shaped slots oppose one another when two sections 13-13 are placed in opposed relation such as is shown in Fig. 2.
The ties 18 are provided with T-shaped tie ends 30-30 which ~-have a configuration that matches the shape of the slots 29 so as to be slideably engageable together when assembled with the sections. 'l`he ties 18 when engaged with the opposed sections along their upper and lower edges provide a sturdy concrete form structure.
It will be note~ rom comparing Figs. ~ and 5 that there are two different types of ties and these ties have been identified as ties 18 and 18'. The ties 18 and 18' are essentially identical except that the tie 18' is a shorter tie and can be used where narrower concrete walls are to be ~o formed such as having a thickness of 8". The longer ties 18 .. ` , ~'~ ''' :' , , . . , . . :
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~~5~.7 are adapted to be uscd in the forrnation of concret~ walls haviny a thickness of 10". The length of the ties can be varied as re~luired. The ~ies 18 are similar in construction to the ties 18 and the differences will be pointed out hereafter.
With respect to the ties 18, each tie has an interrnediate or rnid-web section 31', and a pair of triangular truss sections 32 are disuosed on opposite ends of the mid-s~ction 31' in integral one piece assembly therewith.
~l~he intermediate web section 31' joins the truss sections at the apexes of triangles of the triangular truss sections. As stated, the triangular truss sections 32 and 33 define triangular truss openings 34 and 35. It is these openings that have been created to enable concre-te to flow freely ~ -through the ties in an unimpeded manner so that the ties will not act as dams to confine the flow of liquid concreee in the molds or forms as the concrete is poured.
The triangular truss sections 32 and 33 terminate in end truss portions 36 and 37 which in turn merge into the ~l~-shaped tie ends 30-30. Each of the tie ends includes a . , .
cross piece portion 30a and a stem portion 30b. The truss ~ections are further defined by truss legs 3~, 39, qO and 41 which are all preferably oE a diameter oE approximately 3/16".
ZS 'I'he ties l8 are also provided with upstanding Einc~ers 42-42 with a pair of the Eingers being mounted on each edge of the tie and more particularly are joined to adjacent truss legs. The ~ingers 42 coact with the truss legs so as to form V shaped notches 43 for receiving ~ 30 reinforcing rods 44. It has been found tha~ where the ties ''~ `

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are constructed so as to be provided with the fingers 42 defining the notches 43 that the concrete rods 44 can be more fixedly located at the point in time when the liquid concrete is poured into the form so that the reinforcing rods will not bounce and move as the concrete C is poured thereon.
The shorter tie 18' differs from the tie 18 in that it is only L)rovided with a single pair oE upstanding fingers 45 and these fingers extend above and below tie mid-section 47 as shown in Fig. 5. The fingers 45 and the mid-section 47 coact together to define notches on opposite sides of the fingers so that when the concrete rods 44 are engaged in the notches, the rods can be more positively fixed relative to the ties so that the rods will not laterally shift when concrete is poured thereon.
According to other important features of my invention, I have provided embossed I-shaped indicia 50 as seen in Fig. 6. The embossed I-shaped indicia 50 are vertically spaced in rows on an outer face adjacent to upper and lower edges of each section 13 in transverse alignment with the T-shaped slots 29 that open on the opposite surface or face of the section 13. The ernbossed I-shaped indicia 50 have an upstanding portlon 58 that is in transverse alignment with a stem portion 29a of the notch 29 (Fig. 6).
The embossed I-shaped indicia 50 is provided on both sides of the section and opposite each row of the T-shaped slots and the spacing of the embossed I-shaped indicia may be varied as required. This spacing of the indicia may be of the order of every 6" along the lencJth of the section.
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' -' ' . ' ' ' ` ' The embossed I-shaped indicia 50 serve as a "tell tale" or as a "blind slot locator" to enable furring strips 51 to be attached by screws 52 (Fig. 7-9) in such a way that the screws can be screwed directly in~o the ties 18 and, more particularly, throu~h the T-shaped ends of the tie and into the stem portion 30b oE ~he T-shaped end 30 of the tie to firmly anchor the furring strip 51 to the section 13.
Thereafter, a wall covering 53 can be suitably attached to the Eurring strips 51 by additional screw fasteners as indicated at 54 in Fig. 3.
The ties 18 and 18 otherwise identified as the long tie 18 and the short tie 18 are preferably constructed having the following approximated dimensionsO

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Length Height Thickness Width of Stem of Tie of Tie of Flat End of T-shaPed End Long Tie 11" 2-3/16" 3/16" 1-5/16"
Short Tie9" 2-3/16" 3/16" 1-1/4"
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Width of Intermediate Length Diameter 'I'russ Sectionof E'inqer of Finqer Lon~ Tie1-13/16" 5/8" 3/16"
Short Tie 1-1/4" 5/8" 3/16"

Length of I.enqth o~ Diam~ter of Vertical Diagonal Diagonal ; 25 T,russ Le~ Truss Leqs Truss Leqs Lonq ~ie1-3/4" 3-1/16" 3/16"
Short ~l`ie 1-3/4" 2-3/8" 3/16"
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The ties 18 have been tested and have been found to have the following approximated test characteristics:

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.' ~1 2~36~;~7 TEST STUDY OF
CALCIUM CARBONATE FILLE~
POLYPROPYLENE TIES

AS~MIPP6020LPP6~30 PF~PERIY UNIT MET~OD120~)~30 Tensile Strength at 73F psi D6384,0003,500 ~longation at ~reak ~ D638 80 70 Flexural Strength at 73F psiD790 4,800 4,950 Flexural Mbdulus (tangent) psi x 105 ~790 2.6 2.9 S
Plexural Modulus ~1% Secant) psi x 10 2.4 2.6 Izod Impact at 73F Notched (1/2" x 1/8" bar) ft/Lb~ m.D256(1~ .75 .8 Izod Impact at 73F Unnotched ~1/2" x 1/8" kar) ft-Lb/in. D256 12 15 Gardner Impact in-Lb. --- 20 30 ~eat Deflection l~mperature, 66 psi F D648210 220 Specific Gravity --- D7921.05 1.14 ~ardness, Shore "D" --- D224072 73 Melt Flcw g/10 min.D1238(2) 4-6 4-6 Mineral Cantent ~ (3)20 30 ~old Shrinkage in/in --- .012 .011 ~ : ' ~1) Method A
(2) Condition L"L
25 (3) Buxn-out at 850F
Mbld Shrinkage i8 int~nded as a guid cnly, . as specific shrink~ge is a~fec~ed by part design, m~ld design, and m~lding ccnditions.
The values listed herein are to be used as ~ 30 guides, not a~ specificaticn lImit~.
.~ Determination o~ product suitability in any given applicatian is the respcnsibility of the user .

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My thermal wall structure introduces a new building product made of expandable polystyrene which serves as a permanent form for concrete construc-tion. This products main advantages are its speed of erection and the very high thermal insulation properties attained (R-Value of 2~+).
Similar products have been used extensively in Switzerland, Belgium, France, Germany, Venezuela, Australia and now the United States. It has been in use for nearly 20 years.
It is a simple building system: Ilollow blocks made of LO Expandable Polystyrene, with a flame retardant additive, are erected by means of toothed tops and grooved bottoms as is ; known in the art. Plastic ties hold the sides together and the length of the tie determines the width of the cavity or wall, the blocks are interlocked both horizontally and vertically.
Once erected, concrete is poured into the cavity of the wall creating an insulated load bearing structure.
My thermal wall building blocks or sections 13 are composed of panels of EPS (~xpandible Polystyrene) that are 2"
; thick, 12" high and 40" or 20" long. The density is nearly twice that of conventional insulation board. ~ whole range of exterior finishes can be applied. Scores of elastomeric coatings and stucco finishes may be used as well as siding or paneling. Interiors are finished with drywall, plaster, tile or in any other traditional manner.
My thermal wall structure is an advanced system of construction for use where energy conservation (by reduction of thermal transmission) and speed of construction (reduced labor costs) are important.
The inherent low thermal fluctuations ensure that . '. . .

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the risk of cracking of any external rendering and internal plaster-work are non-existent. The maximum possible expansion is 0.2 mm/m.
~ xcellent noise and impact sound reduction is also an important advantage of the Thermal Wall Sys-tem. Remembering that a diEference of 10 dB almost halves the volume of noise.
350 Ka/m2 Thermal Wall 250 mm is at 49 dB.
Expandable Polystyrene does not rot and when used properly in building construction it is not subject to any other kind of deterioration while in service.
Panels of Expandable Polystyrene are 2" thick, 12"
high and 40" or 20" long. The horizontally spaced rows of "t"
or T-shaped slots 29 are disposed along the top and bottom of each section. T-shaped ends 30-30 of the ties 18 are inserted into the slots 29. These ties 18 hold the sections 13 and the panels 11 and 12 together and also determine the width of the wall. Each blocks or sections 13 have the castellations 20 along its top surface and matching castellations along the underside as previously described. The blocks 13 are placed one on top of the other and pressed together using simple pressure the castellations mesh together creating a completely smooth surface and solid structure. The blocks are erected directly on top of footings or on a floor slab, as design :
dictates. The footin~s must be as level and 1at as possible.
When pouring concrete, particular care should be taken in the first three feet poured to check the horizontal and vertical levels, this is most important, as small errors an~ variations in the early levels will be greatly increased in height. The lightness of the blocks or sections 13 and the flexibility of . . ,~; :, , ....
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them means erection can be both fast and simple.
~;`or corners, windows, door openings an~l t-junctions a special made "endpiece" is also made of expandable polystyrene and is inserted into the end of the block. It slides into the block and acts as a bulkhead for concrete.
It is held in place by surface corrugations on the insides of the block uanels.
90 corners are formed by interlocking blocks perpendicular to one another and inserting endpieces to bulkhead the concrete. With a 10 inch wall rounded corners are available by use of my specially made corner block or section 17.
Thermal wall blocks or sections 13 can be cut quickly and easily with any conventional hand saw. Sanding i5 down the edge with a coarse abrasive block ensures a smooth tight fit.
The blocks or sections 13 are stacked to the desired height of 8 to 10 foot and are filled with regular concrete by means of a concrete truck and chute or with a concrete pumU. A super plasticizer additive is recommended to aid in 10wability of the concrete rnix without detriment to the strength of the concrete. The concrete should be placed in "li~ts" or layers of ~ Eoot, at a rate oE 8 to 10 foot per hour.
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Electric & Plumbinq Water supply lines and conduit for electric can be easily cut into the 2" thickness of the thermal wall, after the concrete has been ~oured. They are then covered with ; drywall or plaster. Pipes of greater diameter than 2", such as waste water pipes, should be placed in the wall cavity ,~, : ' , ~, .
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~f~ 17 before the concrete is poured. Completely surrounded by concrete and thermal wall polystyrene, the pipe will be insulated and insensitive to frost even if the building is unheated.
The use of thermal wall blocks or sections 13 in construction makes possible the type of energy-efficient construction that is necessary today (and will be even more so in the future jud~lng frorn the ever-increasing energy c~t~).
EPS (Expandable Polystyrene) panels 11 and 12 are connected together with the plastic ties 18 to form building - blocks. These blocks interlock horizontally and vertically and are stacked one upon another to a desired height and filled with concrete.
The blocks remain in place after the concrete has been poured and provides the structure with an R-Value of 20.
R-Value means the resistance to hea-t loss and the R
systeln is a way of rating insulation effectiveness: the higher the R-Value the greater the resistance provicled against heat and cold. ;~-T.W.S. blocks are formed from ARCO - "Dylite", a fire retardant EPS, and will not support combustion.
'rhere are no lilllits to the types of wall coverings, botil interior and exterior that may be applied. Generally the exterior is of ~ cemeticious inish and the interior is ~lastered or drywalled. Panels may be glued or screwed.
SOME OF THE ADVANTAGES:
~` 1. Rated R-20~ : Stretches Energy Dollars.
2. Concrete cures under ideal conditions, down to -10 degrees C and use of the sections 13 operates to extend ` ~' ' ' ' :, . .

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the building season.
3. By usin(J the sections 13 in block form, heating and air conditioning costs can be reduced by 50%.

4. The sections 13 and the formed blocks are fire ~;
retardant and will not support combustion.

5. Sound Proof.

6. Water ~epell.lnt.

7. Mold and mildew resistant and rot proof.

8. The sections 13 have no food value and ins~cts cannot digest it.

9. The sections 13 are versatile and can be used ; both above and below,grade for residential, multi-family an~
con~ercial construction, as well as high-rise construction.

10. My forms are lightweight and the interlocking procedures enable increased productivity with less construction time.

11. The sections and the formed blocks are air tight and voids and air filtration are virtually eliminated. , 12. Wall thickness may vary from 6, 8 or 10" based on length of ties.

13. The rounded corner sections allow Eor increased , , clesign possibilities with no additional ~raming costs.

14. There is a complete absence of cracking of internal and ~xternal Einishes and maximum possible expansion ; 25 is 0.2 mm/m.

15. U~e of my concrete forlns enable a quicker return on Investment Dollar~.
' LIMITATIONS
(a) Loading: ,~
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~ 30 Thermal wall panels should not be installed under ;'`

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surfaces subject to lleavy point loading; the E.P.S. does not add structual integrity to the wall; it simply insulates i~.
(b) Solvents:
E.P.S. including thermal wall uanels can not be exposed to L~etroleum-based solvents fuels or coal tar L~roducts and their vapors.
(c) Ultraviolet DecJredation:
Prolonged exposure to ~unlite (~ltraviolet rays) will cause E.P.S. rnaterial to discolor and a dustiny of the surface will occur. Wall panels must be covered to prevent degredation.
(d) Flarnmability:
- The E.P.S. material used in forming thermal wall panels has a flame retardant additive but it should be considered combustable when directly exposed to a constant source of flame. It should not be installed near an open flame or other source of ignition. Current model buildin~

code requirements should be met for adequate protection.
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Claims (20)

1. In a modular formed plastic concrete form structure, wherein the improvement comprises a pair of modular concrete forming panels each comprised of a series of modular concrete forming sections stacked on top on one another and also disposed in end-to-end relation, the sections each having means on its upper and lower edges and its opposite vertical edges for interlocking the sections in stacked, end-to-end engagement with one another, the panels being positioned in spaced opposed relation, spaced T-shaped tie slots in the opposed sections and which slots are hidden from view when viewing outer surfaces of the stacked forming sections, tie located indicia on outer surfaces of the forming sections for providing blind sighting means to enable screws to be screwed through a wall covering, the indicia, the forming section and into the synthetic plastic ties to securely anchor an exterior wall finishing covering to the forming sections, synthetic plastic wall ties for use with concrete forms, the wall having a pair of T-shaped end sections including a tie stem having a sufficient thickness for receiving an end of a screw in threaded engagement therewith, the T-shaped end sections having parallel cross pieces at opposite ends of the tie secured to said modular concrete forming sections, the tie cross pieces having outer tie faces positioned generally at right angles to a plane through the length of the wall tie enabling said screw to be screwed through into the associated tie stem for attaching a wall covering thereto.

2. The form structure of claim 1 further characterized by concrete rod locator means being provided along a top edge of the tie defining a pair of side-by-side V-shaped notches for receiving concrete tie rods to resist movement of the concrete tie rods as concrete is poured thereon, the wall tie having a thickness approximately 3/16".

3. The form structure of claim 1 further characterized by the tie being comprised of 20% calcium carbonate filled polypropylene and having a length of 11", a width of 3/16", and a height of 2-3/16".

4. The form structure of claim 1 wherein the tie is comprised of 20% calcium carbonate filled polypropylene and having a length of 9", a width of 3/16", and a height of 2-3/16".

5. The form structure of claim 1 wherein the tie locator indicia being comprised of longitudinally extending rows of I-shaped embossments extending along upper and lower edges of each section.

6. The form structure of claim 1 further characterized by the tie locator indicia comprising longitudinally extending rows of I-shaped embossments extending along upper and lower edges of each section, each embossment being transversely aligned with one of the slots.

7. An a modular foamed plastic concrete form structure, wherein the improvement comprises a pair of modular concrete forming panels each comprised of a series of modular concrete forming section stacked on top on one another and also disposed in end-to-end relation, the sections each having means on its upper and lower edges and its opposite vertical edges for interlocking the sections in stacked, end-to-end engagement with one another, the panels being positioned in spaced opposed relation, vertically spaced rows of T-shaped tie slots in the opposed sections positioned in longitudinally space aligned relation along the upper and lower edges and which slots are hidden from view when viewing outer surfaces of the stacked sections, tie locator indicia on outer surfaces of the sections for providing blind sighting means to enable fasteners to be screwed through a wall covering, the indicia, the section and into the synthetic plastic ties to securely anchor an exterior wall finishing covering to the sections, and synthetic plastic concrete load bearing wall ties each comprised of one piece and having T-shaped opposite ends engageable in said T-shaped tie slots, the T-shaped opposite ends being separated from one another by a pair of triangularly shaped truss sections positioned in end-to-end relation.

8. The form structure of claim 7 further characterized by the triangular truss sections each having triangularly shaped openings to allow concrete to flow laterally therethrough in an unimpeded manner.

9. The form structure of claim 7 further characterized by the tie being of a modular construction and being reversibly installable with concrete wall sections with either of its spaced horizontal edges being on top of the other edge.

10. A synthetic plastic concrete one piece load bearing form tie comprising a pair of triangular truss sections disposed in end-to-end relation, the truss sections each defining triangular truss openings of sufficient size to permit concrete to flow laterally therethrough, an intermediate web section joining the truss sections at the apexes of triangles of the triangular truss sections, and end attaching means at opposite ends of the tie formed integral with opposite ends of the tie, said attaching means a concrete form when assembled therewith, the truss sections each having a T-shaped end section at its outer end comprising means for anchoring the tie to a slotted wall section when assembled therewith, and with a cross piece on each T-shaped end section being modular and disposed in parallel relation to the cross piece at the opposite end of the form tie, the end attaching means comprising a generally T-shaped tie end and having cross piece and stem portions positioned at right angles to one another, the cross piece portion providing a flat face positioned at right angles to a plane through said tie for engagement by a screw, the stem portion being at right angles to said flat face and being of sufficient thickness to provide an anchor for receiving a screw into its interior thus enabling an article to be attached by a screw in assembly with the T-shaped tie end.

11. In a modular foamed plastic concrete form structure, wherein the improvement comprises a pair of modular concrete forming panels each comprised of a series of modular concrete forming sections stacked on top on one another and also disposed in end-to-end relation, the sections each having means on its upper and lower edges and its opposite vertical edges for interlocking the sections in stacked, end-to-end engagement with one another, the panels being positioned in spaced opposed relation, vertically spaced rows of T-shaped tie slots in the opposed sections positioned in longitudinally spaced aligned relation along the upper and lower edges and which slots are hidden from view when viewing outer surfaces of the stacked sections, tie locator indicia on outer surfaces of the sections for providing blind sighting means to enable fasteners to be screwed through a wall covering, the indicia, the section and into the synthetic plastic ties to securely anchor an exterior wall finishing covering to the sections, and synthetic plastic concrete load bearing wall ties each comprised of one piece and having T-shaped opposite ends engageable in said T-shaped tie slots, the T-shaped opposite ends being separated from one another by a pair of triangularly shaped truss sections positioned in end-to-end relation to the tie locator indicia being I-shaped in configuration.

12. The form structure of claim 11 further characterized by the tie locator indicia comprising longitudinally extending rows of I-shaped embossments extending along upper and lower edges of each section.

13. The form structure of claim 11 further characterized by the tie locator indicia comprising longitudinally extending rows of I-shaped embossments extending along upper and lower edges of each section, each embossment being transversely aligned with one of the slots.

14. A one piece synthetic plastic load bearing form tie comprising a pair of triangular truss sections disposed in end-to-end relation, an intermediate web section joining the truss sections, and only one T-shaped end section at each end of the tie with each end section being formed integral with its stem joined with the associated triangular truss section, a cross piece of each T-shaped end section comprising means for anchoring the tie to a slotted wall section when assembled therewith and with the cross pieces on each form tie being modular and disposed in parallel relation to one another load bearing form, modular V-shaped notches provided thereon along upper and lower surfaces providing locator means for enabling reinforcing rods to be carried in the turned up notches so that movement of the concrete reinforcing rods can be minimized as concrete is poured into the concrete form structure having one or more of the concrete reinforcing rods mounted therein.

15. A one piece synthetic plastic load bearing form tie comprising a pair of triangular truss sections disposed in end-to-end relation, an intermediate web section joining the truss sections, and only one T-shaped end section at each end of the tie with each end section being formed integral with its stem joined with the associated triangular truss section, a cross piece of each T-shaped end section comprising means for anchoring the tie to a slotted wall section when assembled therewith and with the cross pieces on each form tie being modular and disposed in parallel relation to one another load bearing form, concrete tie locator means being provided along upper and lower edes of the tie so that the concrete locator means on its topside edge can restrict movement of the concrete tie as concrete is poured thereon, said locator means including at least one upstanding finger-like projection molded integral with the tie.

16. A one piece synthetic plastic load bearing form tie comprising a pair of triangular truss sections disposed in end-to-end relation, an intermediate web section joining the truss sections, and only one T-shaped end section at each end of the tie with each end section being formed integral with its stem joined with the associated triangular truss section, a cross piece of each T-shaped end section comprising means for anchoring the tie to a slotted wall section when assembled therewith and with the cross pieces on each form tie being modular and disposed in parallel relation to one another load bearing form, concrete tie locator means being provided along at least one edge of the tie to restrict movement of the concrete tie as concrete is poured thereon, said locator means including a pair of upstanding finger-like projections molded integral with the tie and extending upwardly from said one edge.

17. A one piece synthetic plastic load bearing form tie comprising a pair of triangular truss sections disposed in end-to-end relation, an intermediate web section joining the truss sections, only one T-shaped end section at each end of the tie with each end section being formed integral with its stem joined with the associated triangular truss section, a cross piece of each T-shaped end section comprising means for anchoring the tie to a slotted wall section when assembled therewith and with the cross pieces on each form tie being modular and disposed in parallel relation to one another load bearing form, concrete tie locator means being provided along upper and lower edges of the tie so that the concrete tie locator means on its topside edge can restrict movement of the concrete tie as concrete is poured thereon, said locator means on each edge comprising at least two upstanding longitudinally spaced finger-like projections molded integral with the tie.

18. A synthetic plastic concrete form tie comprising a pair of triangular truss sections disposed in end-to-end relation, the truss sections each defining triangular truss openings of sufficient size to permit concrete to flow laterally therethrough, an intermediate web section joining the truss sections at the apexes of triangles of the triangular truss sections, end attaching means at opposite ends of the tie formed integral with opposite ends of the tie, said attaching means at each end being for anchoring the tie to opposed wall section of a concrete form when assmebled therewith, and modular V-shaped notches provided thereon along upper and lower surfaces providing locator means for enabling reinforcing rods to be carried in the turned up notches so that movement of the concrete reinforcing rods can be minimized as concrete is poured into the concrete form structure having one or more of the concrete reinforcing rods mounted therein.

19. A synthetic plastic concrete form tie comprising a pair of triangular truss sections disposed in end-to-end relation, the truss sections each defining triangular truss openings of sufficient size to permit concrete to flow laterally therethrough, an intermediate web section joining the truss sections at the apexes of triangles of the triangular truss sections, end attaching means at opposite end of the tie formed integral with opposite ends of the tie, said attaching means at each end being for anchoring the tie to opposed wall section of a concrete form when assembled therewith, modular V-shaped notches provided thereon along upper and lower surfaces providing locator means for enabling reinforcing rods to be carried in the turned up notches so that movement of the concrete reinforcing rods can be minimized as concrete is poured into the concrete form structure having one or more of the concrete reinforcing rods mounted therein, concrete tie locator means being provided along a top edge of the tie defining a V-shaped notch for receiving a concrete tie rod to resist movement of the concrete tie rod as concrete is poured thereon.

20. A method of securing a wall covering to a concrete wall structure, the steps of forming synthetic plastic wall forming sections from a foamed plastic material with rows of tie slots at spaced intervals along upper and lower edges and with indicia formed on outer wall surfaces of the forming section so that the indicia and the slots are transversely aligned in pairs along the edges enabling the indicia to act as a tell tale for the slots and wall ties, securing opposite ends of synthetic plastic concrete wall ties in the slots of the wall forming sections to provide a reinforced form structure, securing transverse closure sections between the wall forming sections to provide form closures, pouring concrete in the thus formed concrete forming structure and immersing and hiding the ties in the concrete, screwing fasteners through a wall covering, the panel section into the wall tie using the indicia as a blind concrete tie locator for aligning the screw with the hidden wall tie enabling the screw to be screwed into the tie to securely fasten the wall covering thereto.