Liner system for forming concrete panels

Abstract

A form for creating a pattern in uncured concrete during a casting process includes a support frame and a perforated reinforcing structure coupled adjacent to at least a portion of the support frame. The perforated reinforcing structure includes a plurality of apertures defined therein. A pliable liner is disposed at least partially within the plurality of apertures and at least partially about the perforated reinforcing structure adjacent the support structure. The pliable liner has a patterned surface formed thereon for creating a corresponding pattern in uncured concrete poured adjacent the form.

Description

BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates generally to a liner system for use in forming concrete panels used in concrete fences, walls and related structure. [0003] 2. Related Art [0004] Vertically oriented concrete panels have been used for a number of years in applications including concrete fences, sound walls, partitions, etc. Concrete panels are often poured and cured in a central manufacturing area and shipped as cured panels to job sites, where the panels can be assembled into a fence or similar structure. It is often desirable to apply a textured, decorative finish to such concrete panels to enhance the appearance of the panels. Decorative finishes such as pseudo-brick finishes, pseudo-rock wall finishes, etc., give the concrete panels a more aesthetically pleasing appearance, and in some cases, such as in sound wall applications, can increase the effectiveness of the concrete panels. [0005] One type of system develope...

AI Technical Summary

Benefits of technology

[0008] It has been recognized that it would be advantageous to develop forms for use in vertically forming concrete panels that include liner systems that are physically robust and that can withstand the severe environmental conditions involved in vertically forming concrete panels.

Problems solved by technology

While systems that pour concrete into vertical forms have been successful in creating decorative patterns on both sides of the vertical concrete panel, the forms used to create such panels have had several operational problems.

For example, the forms are quite expensive to make because they must be made of a material that i) won't adhere to the cured concrete, ii) won't deform to a great extent under the weight of uncured concrete, and iii) is sufficiently pliable so as to be easily removable from the pattern created in the cured concrete.

These environmental conditions have caused liners used in vertical concrete forms to prematurely degrade and / or become prematurely separated from adjacent supporting framework structure.

Consequently, the relatively expensive liners have had a relatively short useful life and it has been necessary to produce new forms on a relatively frequent basis.

Such problems have increased both the material costs associated with vertical pour systems, and with the number of labor hours necessary to maintain a constant fabrication cycle.

Images