Multifunctional Concrete Forming System

Abstract

The multifunctional concrete forming system is intended to provide users with innovative components that are designed to enhance the efficiency, stability, and precision of concrete slab construction using steel-ply forms. More specifically, the system provides metallic ledger plates and an adjustable knee brace configured to adjust and support the ledger plates during setup and concrete placement. The adjustable knee brace enables the ledger plates to be set level even when the supporting form is not perfectly plumb. In addition to angular adjustment, the adjustable knee brace mechanically ties adjoining ledger plates together, preventing relative vertical movement between the plates during concrete placement. Further, the system includes grade stake pockets, which stabilize steel-ply forms and hold them securely to the desired grade, and adjustable corner brackets, which provide flexibility and stability for non-standard slab dimensions. Together, these components offer a comprehensive solution for efficient, accurate, and sustainable slab construction.

Description

FIELD OF THE INVENTION

[0001] The present invention relates generally to concrete forming systems. More particularly, the present invention relates to reusable steel components used in forming monolithic concrete slabs having a lowered perimeter ledger.BACKGROUND OF THE INVENTION

[0002] Concrete slabs for buildings are commonly formed using removable concrete form systems. In many applications, including self-storage facilities and similar structures, a ledger is formed around the perimeter of the slab so that a building may sit lower than the interior slab surface, thereby reducing water intrusion under doors and improving drainage. Ledger plates are often rigidly attached to concrete forms. In practice, concrete forms are frequently not set perfectly plumb, due to site conditions, uneven subgrade, or time constraints. When a ledger plate is attached to a non-plumb form, the resulting ledger surface may be out of level, leading to inaccuracies in slab geometry and additional labor to correct the condition. Prior forming systems lack a practical mechanism to independently adjust the angular orientation of a ledger plate relative to the form once the form has been erected. Additionally, there are no existing systems that adequately prevent relative elevation change between adjoining ledger plates during concrete placement.

[0003] It is an objective of the present invention to provide users with a multifunctional concrete forming system that addresses these challenges by introducing metal ledger plates, a revolutionary alternative to traditional wood forms. According to the present invention, the ledger plates are reusable, precise, and designed to streamline the process of forming concrete ledgers. Unlike wood forms, which are single-use and prone to inaccuracies, ledger plates in the present invention provide a long-term, cost-effective solution that ensures a high-quality finish. By eliminating the need for disposable wood forms, this invention reduces material costs, minimizes environmental waste, and improves the precision of slab construction. Further the present invention comprises adjustable knee brace device that mechanically ties adjoining ledger plates together, thereby preventing relative vertical movement between the ledger plates during concrete placement. Additionally, the present invention includes grade stake pockets, which stabilize steel-ply forms and hold them securely to the desired grade, and adjustable corner brackets, which provide flexibility and stability for non-standard slab dimensions. Together, these components offer a comprehensive solution for efficient, accurate, and sustainable slab construction.SUMMARY OF THE INVENTION

[0004] The present invention is intended to provide users with innovative components that are designed to enhance the efficiency, stability, and precision of concrete slab construction using steel-ply forms. More specifically, the present invention provides a concrete forming system including ledger plates and an adjustable knee brace configured to adjust and support the ledger plates during setup and concrete placement. The adjustable knee brace allows bidirectional angular adjustment of approximately plus or minus 3-4 degrees, enabling the ledger plates to be set level even when the supporting form is not perfectly plumb. In addition to angular adjustment, the knee brace device mechanically ties adjoining ledger plates together, preventing relative vertical movement between the plates during concrete placement. Further, the present invention comprises grade stake pockets, which stabilize steel-ply forms and hold them securely to the desired grade, and adjustable corner brackets, which provide flexibility and stability for non-standard slab dimensions. Together, these components offer a comprehensive solution for efficient, accurate, and sustainable slab construction.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] FIG. 1 is a top-front-right perspective view of a preferred embodiment of the present invention.

[0006] FIG. 2 is a bottom-rear-right perspective view of the present invention.

[0007] FIG. 3 is a rear elevational view of the present invention.

[0008] FIG. 4 is a top-rear-left perspective view of the present invention.

[0009] FIG. 5 is a left-side elevational view of the present invention.

[0010] FIG. 6 is a detailed view of section 6 from FIG. 5.

[0011] FIG. 7 is a right-side elevational view of the present invention.DETAILED DESCRIPTION OF THE INVENTION

[0012] All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention.

[0013] In reference to FIG. 1 through FIG. 7, the present invention is a multifunctional concrete forming system. More specifically, the present invention comprises innovative components designed to enhance the efficiency, stability, and precision of concrete slab construction using steel-ply forms.

[0014] According to a preferred embodiment, the present invention comprises at least one concrete form 2, a plurality of ledger plates 4, and a knee brace device 6. Preferably, the plurality of ledger plates 4 is used for forming concrete ledgers on monolithic slabs. More specifically, the plurality of ledger plates 4 are durable, reusable attachments designed for use with any size steel-ply wall forms in the construction of monolithic concrete slabs. In the preferred embodiment, the plurality of ledger plates 4 is constructed from 3 / 16″ mild steel, wherein these plates streamline the process of forming a precise ledger around the slab's edge. As seen in FIG. 4, each of the plurality of ledger plates 4 comprises a plate body 8, a proximal end 10, a distal end 12, a plurality of fastener apertures 14, and a recessed edge 16. The plate body 8 forms the main surface of each of the plurality of ledger plates 4. The proximal end 10 is positioned opposite to the distal end 12 about a width of the plate body 8. In other words, the proximal end 10 is the edge of the ledger plate that is close to the concrete form, and the distal end 12 is the edge of the plate body 8 that is opposite to the proximal end 10. Thus, as seen in FIG. 1, the plurality of ledger plates 4 is detachably attached to the at least one concrete form 2, wherein the proximal end 10 of each of the plurality of ledger plates 4 is perimetrically aligned with an outer edge of the at least one concrete form 2. In order to attach the plurality of ledger plates 4 onto the at least one concrete form 2, the plurality of fastener apertures 14 traverses through the plate body 8 adjacent to the proximal end 10. To that end, a plurality of form fasteners may be provided, wherein the plurality of form fasteners is integrated between the at least one concrete form 2 and the plurality of fastener apertures 14. Preferably, the plurality of form fasteners includes opposed connection tabs and a removable pin. More specifically, the plurality of ledger plates 4 feature 2″ holes at the top, allowing construction crews to insert concrete vibrators through the holes. This ensures proper consolidation of the concrete and eliminates air pockets along the edge of the slab, resulting in a stronger and more durable finish. However, it should be noted that the plurality of fastener apertures 14 may be of any shape, size, etc. and the plurality of form fasteners may comprise any other fastening techniques, components, arrangement of components etc. that are known to one of ordinary skill in the art, as long as the intents of the present invention are not altered. As seen in FIG. 1 through FIG. 7, the plurality of ledger plates 4 is oriented in a direction normal to a height of the concrete form. In other words, the flat surface of the ledger plate is placed perpendicular to the height of the concrete form. Preferably, the plurality of ledger plates 4 is designed to work seamlessly with 12″, 14″, and 16″ steel-ply wall forms, making them versatile for a wide range of projects. However, the present invention may be used with any size steel-ply forms, as long as the intents of the present invention are not altered. The plurality of ledger plates 4 attaches to steel-ply wall forms using standard wedge bolts, ensuring stability and ease of installation. Furthermore, the plurality of ledger plates 4 can be removed before the concrete cures, enabling timely finishing and eliminating voids under the slab. Their reusability reduces material costs and environmental waste.

[0015] Continuing with the preferred embodiment, the recessed edge 16 is positioned along the distal end 12 of the plate body 8, and the recessed edge 16 is angularly offset from the plate body 8. This is so that the recessed edge 16 along the slab perimeter allows the building perimeter to sit 1.5 inches lower than the pad's height, effectively preventing water seepage. As seen in FIG. 2 and FIG. 4, the recessed edge 16 is oriented in a direction away from the at least one concrete form 2.

[0016] In the preferred embodiment, the knee brace device 6 is operatively coupled between the at least one concrete form 2 and two adjacent ledger plates, wherein the two adjacent ledger plates are from the plurality of ledger plates 4. In other words, the knee brace device 6 is configured to adjust and support the ledger plates during setup and concrete placement. Further, the knee brace device 6 is configured to selectively adjust an angular orientation of the proximal edge of the ledger plates relative to the concrete form. Further, the adjustable knee brace device 6 allows bidirectional angular adjustment of approximately plus or minus 3-4 degrees, enabling the ledger plates to be set level even when the supporting form is not perfectly plumb.

[0017] In order to accomplish the above-mentioned functionalities, the knee brace device 6 comprises a vertical tower 18, a turnbuckle 20, and a base connector 22. Preferably, the vertical tower 18 is made of steel and extends upward from the at least one concrete form 2 at a distance of approximately 10 inches. In order to provide the angular adjustment, the turnbuckle 20 is provided, which is a clevis-style turnbuckle 20 having a first clevis end, that is configured to attach to the aperture in the vertical steel tower using a removable pin or fastener. Adjustment of the turnbuckle 20 varies the effective length of the adjustable knee brace device 6, thereby causing a leading edge of the ledger plates to pivot upward or downward relative to the form. In addition to adjusting the angular orientation of the ledger plates, the adjustable knee brace device 6 mechanically ties the adjoining ledger plates together, preventing relative vertical movement between the plates and maintaining consistent elevation during concrete placement. To that end, the base connector 22 is laterally mounted onto an intersection between the two adjacent ledger plates, wherein the two adjacent ledger plates are from the plurality of ledger plates 4. Further, as seen in FIG. 4, the base connector 22 is positioned adjacent to the proximal end 10 of the two adjacent ledger plates, and the vertical tower 18 is centrally mounted onto the base connector 22. Further, the vertical tower 18 extends in a direction away from the at least one concrete form 2.

[0018] As seen in FIG. 1, each of the plurality of ledger plates 4 comprises a connection tab 24, wherein the connection tab 24 extends terminally between the recessed edge 16 and the plate body 8 of each of the plurality of ledger plates 4. In other words, each of the plurality of ledger plates 4 has a protrusion towards the end or seam of the plate. Further, the turnbuckle 20 is connected between the vertical tower 18 and the connection tab 24. As seen in FIG. 6, the knee brace device 6 comprises a bottom aperture 26, a top aperture 28, and at least one knee brace fastener 30, wherein the bottom aperture 26 and the top aperture 28 traverses through the vertical tower 18. Preferably, the vertical tower 18 includes an aperture near its upper end (the top aperture 28) having a diameter of approximately ⅜ inch, and the turnbuckle 20 is rotatably coupled between the top aperture 28 and the connection tab 24. In other words, the second clevis end of the turnbuckle 20 is configured to attach to two adjoining ledger plates at a seam between the ledger plates. Each ledger plate includes a connection tab 24 positioned adjacent the seam, the tabs being aligned such that a removable pin having a diameter of approximately ⅜ inch passes through both tabs and the clevis end of the turnbuckle 20. Furthermore, the at least one knee brace fastener 30 is integrated between the base connector 22 and the at least one concrete form 2 through the bottom aperture 26. This is so that, the knee brace device 6 resists relative vertical movement between adjoining ledger plates during concrete placement, wherein the adjoining ledger plates are from the plurality of ledger plates 4. Thus, the knee brace device 6 mechanically ties the adjoining ledger plates together, preventing relative vertical movement between the plates and maintaining consistent elevation during concrete placement. Additionally, the knee brace device 6 is lockable to maintain the angular orientation of the ledger plates during concrete placement. It should be noted that the knee brace device 6 may comprise any other fastening device, fastening technique, components, arrangement of components etc., that are known to one of ordinary skill in the art, as long as the intents of the present invention are not altered.

[0019] Continuing with the preferred embodiment, the present invention comprises adjustable corner brackets that are versatile attachments designed to enhance the flexibility and stability of concrete forms in slab construction. Accordingly, the present invention comprises a corner brace 32, wherein the corner brace 32 comprises a first brace panel 34, a second brace panel 36, a corner stake holder 38, and a plurality of corner fastener holes 40. Preferably, the corner brace 32 allows for precise adjustments to the length and width of the slab in increments of 0.25″, accommodating non-standard slab sizes. They also feature integrated grade stake brackets for added stability during the pour.

[0020] As seen in FIG. 4, the corner stake holder 38 is centrally mounted in an outside corner, along a connecting edge between the first brace panel 34 and the second brace panel 36. Preferably, the first brace panel 34 is normally offset from the second brace panel 36, or the first brace panel 34 is perpendicular to the second brace panel 36. The brackets enable fine-tuning of slab dimensions in 0.25″ increments, providing flexibility for various project specifications. The corner stake holder 38 or built-in stake pocket allows for the attachment of grade stakes, further stabilizing the formwork and maintaining accurate positioning.

[0021] Furthermore, in order to integrate and secure fastening elements, the plurality of fastener holes traverses normally through the first brace panel 34, the second brace panel 36, and the corner stake holder 38. Any kind of fastener such as screws, nuts, bolts, etc. may be used for securing the corner brace 32 to the concrete form. Thus, wherein the at least one concrete form 2 comprises two adjoining concrete forms that are normally aligned with respect to each other, the corner brace 32 is connected along an intersection of the two adjoining concrete forms. Additionally, the corner brace 32 is designed for long-term use, offering a reliable solution for construction crews.

[0022] Continuing with the preferred embodiment the present invention comprises a plurality of stake-holder-devices 42, wherein the plurality of stake-holder-devices 42 is distributed along a length of the at least one concrete form 2. The plurality of stake-holder-devices 42 are innovative attachments designed to adapt steel-ply wall forms for use in slab construction. Made from durable mild steel, these pockets attach securely to the forms using wedge bolts, providing essential stability by preventing tipping and ensuring the forms remain at the desired grade during concrete pouring. Accordingly, each of the plurality of stake-holder-devices 42 comprises a stake holder 44, a stake panel 46, and a plurality of stake holder fastener holes 48. Preferably, the stake panel 46 is connected through a jam bolt, which clamps the stake pocket / stake holder 44 to the concrete stake, securely holding the form to the desired grade and eliminating movement during the pour. Further, the plurality of stake holder fastener holes 48 traverses normally through the stake panel 46 and the stake holder 44, for enabling additional fasteners that secure the stake holder 44 tightly to the concrete form without movement. Thus, the stake holder 44 device serves as secure anchor points for stakes, keeping the forms stable and level during the pour.

[0023] Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.

Claims

1. A multifunctional concrete forming system comprising:at least one concrete form;a plurality of ledger plates;a knee brace device;each of the plurality of ledger plates comprising a plate body, a proximal end, a distal end, a plurality of fastener apertures, and a recessed edge;the proximal end being positioned opposite to the distal end about a width of the plate body;the plurality of ledger plates being detachably attached to the at least one concrete form, wherein the proximal end of each of the plurality of ledger plates is perimetrically aligned with an outer edge of the at least one concrete form;the plurality of fastener apertures traversing through the plate body adjacent to the proximal end;the plurality of ledger plates being oriented in a direction normal to a height of the concrete form;the recessed edge being positioned along the distal end of the plate body;the recessed edge being angularly offset from the plate body; andthe knee brace device being operatively coupled between the at least one concrete form and two adjacent ledger plates, wherein the two adjacent ledger plates are from the plurality of ledger plates, and wherein the knee brace system is configured to selectively adjust an angular orientation of the proximal edge of the ledger plates relative to the concrete form.

2. The multifunctional concrete forming system of claim 1 further comprising:the knee brace device comprising a vertical tower, a turnbuckle, and a base connector;each of the plurality of ledger plates comprising a connection tab;the vertical tower being centrally mounted onto the base connector;the base connector being laterally mounted onto an intersection between the two adjacent ledger plates, wherein the two adjacent ledger plates are from the plurality of ledger plates;the base connector being positioned adjacent to the proximal end of the two adjacent ledger plates;the connection tab extending terminally between the recessed edge and the plate body of each of the plurality of ledger plates; andthe turnbuckle being connected between the vertical tower and the connection tab.

3. The multifunctional concrete forming system of claim 2 further comprising:the knee brace device comprising a bottom aperture, a top aperture, and a plurality of knee brace fasteners;the bottom aperture and the top aperture traversing through the vertical tower;the turnbuckle being rotatably coupled between the top aperture and the connection tab;the plurality of knee brace fasteners being integrated between the base connector and the at least one concrete form through the bottom aperture.

4. The multifunctional concrete forming system of claim 2, wherein the knee brace provides bidirectional angular adjustment of approximately plus or minus 3 to 4 degrees.

5. The multifunctional concrete forming system of claim 2, wherein the vertical tower extends in a direction away from the at least one concrete form.

6. The multifunctional concrete forming system of claim 2, wherein the knee brace device is lockable to maintain the angular orientation of the ledger plates during concrete placement.

7. The multifunctional concrete forming system of claim 1, wherein the recessed edge being oriented in a direction away from the at least one concrete form.

8. The multifunctional concrete forming system of claim 1, wherein the knee brace device resists relative vertical movement between adjoining ledger plates during concrete placement, wherein the adjoining ledger plates are from the plurality of ledger plates.

9. The multifunctional concrete forming system of claim 1 comprising:a corner brace;the corner brace comprising a first brace panel, a second brace panel, a corner stake holder, and a plurality of corner fastener holes;the corner stake holder being centrally mounted in an outside corner, along a connecting edge between the first brace panel and the second brace panel;the first brace panel being normally offset from the second brace panel;the plurality of fastener holes traversing normally through the first brace panel, the second brace panel, and the corner stake holder.

10. The multifunctional concrete forming system of claim 9 comprising:wherein the at least one concrete form comprises two adjoining concrete forms that are normally aligned with respect to each other;the corner brace is connected along an intersection of the two adjoining concrete forms.

11. The multifunctional concrete forming system of claim 1 comprising:a plurality of stake-holder-devices;each of the plurality of stake-holder-devices comprising a stake holder, a stake panel, and a plurality of stake holder fastener holes;the stake panel being terminally connected to the stake holder;the plurality of stake holder fastener holes traversing normally through the stake panel and the stake holder.

12. The multifunctional concrete forming system of claim 11, wherein the plurality of stake holder devices is distributed along a length of the at least one concrete form.

13. A multifunctional concrete forming system comprising:at least one concrete form;a plurality of ledger plates;a knee brace device;each of the plurality of ledger plates comprising a plate body, a proximal end, a distal end, a plurality of fastener apertures, a recessed edge, and a connection tab;the knee brace device comprising a vertical tower, a turnbuckle, and a base connector;the proximal end being positioned opposite to the distal end about a width of the plate body;the plurality of ledger plates being detachably attached to the at least one concrete form, wherein the proximal end of each of the plurality of ledger plates is perimetrically aligned with an outer edge of the at least one concrete form;the plurality of fastener apertures traversing through the plate body adjacent to the proximal end;the plurality of ledger plates being oriented in a direction normal to a height of the concrete form;the recessed edge being positioned along the distal end of the plate body;the recessed edge being angularly offset from the plate body;the vertical tower being centrally mounted onto the base connector;the base connector being laterally mounted onto an intersection between the two adjacent ledger plates, wherein the two adjacent ledger plates are from the plurality of ledger plates;the base connector being positioned adjacent to the proximal end of the two adjacent ledger plates;the connection tab extending terminally between the recessed edge and the plate body of each of the plurality of ledger plates;the turnbuckle being connected between the vertical tower and the connection tab; andthe knee brace device being operatively coupled between the at least one concrete form and two adjacent ledger plates, wherein the two adjacent ledger plates are from the plurality of ledger plates, and wherein the knee brace system is configured to selectively adjust an angular orientation of the proximal edge of the ledger plates relative to the concrete form.

14. The multifunctional concrete forming system of claim 13 further comprising:the knee brace device comprising a bottom aperture, a top aperture, and a plurality of knee brace fasteners;the bottom aperture and the top aperture traversing through the vertical tower;the turnbuckle being rotatably coupled between the top aperture and the connection tab;the plurality of knee brace fasteners being integrated between the base connector and the at least one concrete form through the bottom aperture.

15. The multifunctional concrete forming system of claim 13, wherein the knee brace provides bidirectional angular adjustment of approximately plus or minus 3-4 degrees.

16. The multifunctional concrete forming system of claim 13, wherein the vertical tower extends in a direction away from the at least one concrete form.

17. The multifunctional concrete forming system of claim 13, wherein the knee brace device is lockable to maintain the angular orientation of the ledger plates during concrete placement.

18. The multifunctional concrete forming system of claim 13 comprising:a corner brace;the corner brace comprising a first brace panel, a second brace panel, a corner stake holder, and a plurality of corner fastener holes;the corner stake holder being centrally mounted in an outside corner, along a connecting edge between the first brace panel and the second brace panel;the first brace panel being normally offset from the second brace panel;the plurality of fastener holes traversing normally through the first brace panel, the second brace panel, and the corner stake holder.

19. The multifunctional concrete forming system of claim 13 comprising:a plurality of stake-holder-devices;each of the plurality of stake-holder-devices comprising a stake holder, a stake panel, and a plurality of stake holder fastener holes;the stake panel being terminally connected to the stake holder;the plurality of stake holder fastener holes traversing normally through the stake panel and the stake holder.

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