Lightweight drainage footing forms

Abstract

This invention relates to the building and construction industry where footing forms are used for preparing the foundation of a structure such as a building. In one embodiment, this invention relates to footing forms for pouring concrete foundation, wherein the footing forms are cut from polymeric foams, such as expanded polystyrene (EPS). In another embodiment, the polymeric foam-based footing form have drainage built into it. In yet another embodiment, the footing form comprises grooves for attaching spacing inserts for dimensioning the footing forms. In a further embodiment, the footing form is prepared from GPS or graphite-infused polystyrene.

Description

[0001] PCT Specification

[0002] Docket No. 092457.000614 TITLE

[0003] Lightweight Drainage Footing Forms

[0004] CROSS REFERENCE TO RELATED APPLICATIONS

[0005] The present application hereby claims the benefit of the provisional patent application of the same title, U.S. Application No. 63 / 742,976, filed January 8, 2025, the disclosure of which is herein incorporated by reference in its entirety.

[0006] FIELD OF INVENTION

[0007] This invention relates to the building and construction industry where footing forms are used for preparing the foundation of a structure such as a building. In one embodiment, this invention relates to footing forms for pouring concrete foundation, wherein the footing forms are cut from polymeric foams, such as expanded polystyrene (EPS). In another embodiment, the polymeric foam-based footing form have drainage integrally built into it. In yet another embodiment, the footing form comprises grooves for attaching spacing inserts for dimensioning the footing forms. In a further embodiment, the footing form is prepared from GPS or graphite-infused polystyrene.

[0008] BACKGROUND

[0009] Generally, in buildings and other structural constructions, foundation footers are lumberbased and are formed using large planks, for example, 2 ft xl2 ft (or 2 ft x 10 ft or 2 ft x8 ft) pieces staked in the ground with a rebar suspended in the cavity. After the concrete is poured and cured, the footing forms must be removed.

[0010] In one example, next to the footer, a perforated PVC pipe is buried in gravel for foundation drainage. Similarly, a commercially available footing form product, Form -A- Drain® has a perforated PVC form to replace wooden lumber and includes drainage. But it also uses stakes and spacers and can replace the 2 ft X 10 ft lumber with 2 ft x 10 ft PVC drains. Driving and removing stakes is heavy labor, however. Similarly, footer forms can be challenging to remove from cured concrete. It takes additional time to clean spilled concrete off from the footer forms.

[0011] The present invention, among other things, addresses one or more of the above issues, by eliminating or reducing the use of stakes, for example. It also offers the advantage of leaving the footer forms in place within the foundation. In one embodiment, because the footer forms are made from a foam such as expanded polystyrene or EPS, they are

[0012] 092457.000614\4934-2261-8246.1PCT Specification

[0013] Docket No. 092457.000614 significantly lighter than the lumber-based structures. Moreover, the inventive footer form can be prepared with a wide base such that the forms can stand on their own during assembly.

[0014] The footer forms of the present invention, further delineated infra, also reduce the labor for forming the foundation and by allowing for a pre-installed drainage pipe or an integral drainage pipe. Stated differently, the present invention, in one of its embodiment, addresses the issues of lumber-based footing forms and the Form-A-Drain® system with significant labor savings.

[0015] SUMMARY OF THE INVENTION

[0016] In one embodiment, this invention relates to a first footing form system for preparing a foundation of a structure in the building and construction industry, wherein the footing form is prepared from at least one polymeric material.

[0017] In another embodiment, this invention relates to a first footing form system as recited above, wherein the polymeric material is a polymeric foam.

[0018] In yet another embodiment, this invention relates to a first footing form system as recited above, wherein the polymeric foam is a closed-cell foam, an open-celled foam, or a blend of the closed-cell and the open-celled foam.

[0019] In one embodiment, this invention relates to a first footing form system as recited above, wherein the polymeric foam is EPS, XPS, GPS, polyisocyanurate, polyurethane, or a combination thereof.

[0020] In another embodiment, this invention relates to a first footing form system as recited above, wherein the footing form further comprises at least one integrated drainage system.

[0021] In yet another embodiment, this invention relates to a first footing form system as recited above, wherein the integrated drainage system is a cylindrical pipe prepared within the polymeric foam of the footing form or is a drainage pipe different from the polymeric foam.

[0022] 2

[0023] 092457.000614\4934-2261-8246.1PCT Specification

[0024] Docket No. 092457.000614 In one embodiment, this invention relates to a first footing form system as recited above, further comprising a system for suspending rebars inside the footing form and comprising at least one rebar.

[0025] In another embodiment, this invention relates to a first footing form system as recited above, further comprising a spreader that maintains a form spacing and supports said at least one horizontal rebar.

[0026] In yet another embodiment, this invention relates to a first footing form system as recited above, further comprising an adjustable leveling system that can be adjusted in comparison to a second footing form system, wherein the second footing form system has the same characteristics of the first footing form system.

[0027] In one embodiment, this invention relates to a first footing form system and the second footing form system as recited above, wherein the two systems are held in dimensional stability through a fabric.

[0028] In another embodiment, this invention relates to a first footing form system and the second footing form system as recited above, wherein the fabric is a perforated fabric.

[0029] In yet another embodiment, this invention relates to a first footing form system and the second footing form system as recited above, wherein the fabric comprises polyester, felt, glass-fiber-reinforced composite fabric, Kevlar® or Nomex® type material or other plantbased materials such as jute fabric or a combination thereof.

[0030] In one embodiment, this invention relates to a method for preparing foundation comprising:

[0031] (i) providing at least one footing form system including a first footing form system wherein the first footing form is prepared from at least one polymeric material,

[0032] (ii) placing the footing forms in the trench, and

[0033] (iii) pouring concrete into the footing form cavity.

[0034] 3

[0035] 092457.000614\4934-2261-8246.1PCT Specification

[0036] Docket No. 092457.000614 In another embodiment, this invention relates to a method as recited above, wherein the polymeric material is a polymeric foam.

[0037] In yet another embodiment, this invention relates to a method as recited above, wherein the polymeric foam is a closed-cell foam, an open-celled foam, or a blend of the closedcell and the open-celled foam.

[0038] In one embodiment, this invention relates to a method as recited above, wherein the polymeric foam is EPS, XPS, GPS, polyisocyanurate, polyurethane, or a combination thereof.

[0039] In another embodiment, this invention relates to a method as recited above, wherein the footing form further comprises at least one integrated drainage system.

[0040] In yet another embodiment, this invention relates to a method as recited above, wherein the integrated drainage system is a cylindrical pipe prepared within the polymeric foam of the footing form or is a drainage pipe different from the polymeric foam.

[0041] In one embodiment, this invention relates to a method as recited above, further comprising a system for suspending rebars inside the footing form and comprising at least one rebar.

[0042] In another embodiment, this invention relates to a method as recited above, further comprising a spreader that maintains a form spacing and supports said at least one horizontal rebar.

[0043] In yet another embodiment, this invention relates to a method as recited above, further comprising an adjustable leveling system that can be adjusted in comparison to a second footing form system, wherein the second footing form system has the same characteristics of the first footing form system.

[0044] In one embodiment, this invention relates to a method as recited above, wherein the two systems are held in dimensional stability through a fabric.

[0045] 4

[0046] 092457.000614\4934-2261-8246.1PCT Specification

[0047] Docket No. 092457.000614

[0048] In another embodiment, this invention relates to a method as recited above, wherein the fabric is a perforated fabric.

[0049] In yet another embodiment, this invention relates to a method as recited above, wherein the fabric comprises polyester, felt, glass-fiber- reinfo reed composite fabric, Kevlar® or Nomex® type material or other plant-based materials such as jute fabric or a combination thereof.

[0050] BRIEF DESCRIPTION OF DRAWINGS FIG. 1 shows a typical footer form made from lumber being used at a construction site for preparing the foundation for a building.

[0051] FIG. 2 shows another footing form system currently in use also known as Forma-a-Drain® from Westlake.

[0052] FIG. 3 shows a first footing form and a second footing form that each is made from foam and has preferably a PVC drainage system installed within the footing form.

[0053] FIG. 3A shows a schematic of an individual footing form made from foam with carve-out for the drainage pipe and the temporary wood plank.

[0054] FIG. 4 shows an embodiment with more than one spreader, and more than one horizontal rebars.

[0055] FIG. 4A shows a closed-up view of another embodiment of FIG. 4, showing the integrated channel C and rebar clips.

[0056] FIG. 5 shows the concept of adjustable leveling between the first footing form and the second footing form.

[0057] FIG. 6 shows a conceptual representation of one embodiment of the present invention, wherein a reusable spreader cleat is used to dimensionally stabilize the footer forms and provides spacing.

[0058] FIG. 6A shows a picture of a footing form foam block and the drainage pipes that are to be installed.

[0059] FIG. 6B shows an assembled set of footing form foam blocks and drainage pipes inserted therein (see also FIG. 3A for perspective).

[0060] FIG. 6C shows concrete poured into an assembled foam block to demonstrate the concept.

[0061] 5

[0062] 092457.000614\4934-2261-8246.1PCT Specification

[0063] Docket No. 092457.000614 FIG. 7A shows two footing forms held in place using a fabric that is connected at the base of the footing forms.

[0064] FIG. 7B shows the fabric may be fastened to the foam mechanically or through an adhesive. FIGS. 7C and 7D show the fabric may be wrapped around or fastened the drainage pipes in the first footing form and the second footing form.

[0065] DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0066] Before the present compositions, articles, devices, and / or methods are disclosed and described, it is to be understood that the aspects described below are not limited to specific methods as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. As used in the specification and in the claims, the term "comprising" may include the embodiments "consisting of" and "consisting essentially of."

[0067] Disclosed are materials, compositions, and components that can be used for, can be used in conjunction with, can be used in preparation for, or are products of the disclosed method and compositions. These and other materials are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, and the like of these materials are disclosed that while specific reference of each various individual and collective combinations and permutation of these compounds cannot be explicitly disclosed, each is specifically contemplated and described herein. Thus, if a class of adhesives A, B, and C are disclosed as well as a class of additives D, E, and F and an example of a combination A-D is disclosed, then even if each is not individually recited, each is individually and collectively contemplated. Thus, in this example, each of the combinations A-E, A-F, B-D, B-E, B-F, C-D, C-E, and C-F are specifically contemplated and should be considered disclosed from disclosure of A, B, and C; D, E, and F; and the example combination A-D. Likewise, any subset or combination of these is also specifically contemplated and disclosed. Thus, for example, the sub-group of A-E, B-F, and C-E are specifically contemplated and should be considered disclosed from disclosure of A, B, and C; D, E, and F; and the example combination A-D. This concept applies to all aspects of this disclosure including, but not limited to, compositions, and steps in methods of making and using the disclosed compositions. Thus, if there are a variety of additional steps that can be performed it is understood that each of these additional steps can be performed with any specific embodiment or combination of embodiments of the disclosed methods, and that each such combination is specifically contemplated and should be considered disclosed.

[0068] Unless expressly stated otherwise, it is not intended that any method outlined herein be construed as requiring that its steps be performed in a particular order. Accordingly, where 6

[0069] 092457.000614\4934-2261-8246.1PCT Specification

[0070] Docket No. 092457.000614 a method claim does not expressly recite an order to be followed by its steps, or where neither the claims nor the descriptions specifically state that the steps are to be limited to a precise sequence, it should not be inferred that a specific order is intended or required. This holds for any possible non-express basis for interpretation, including, but not limited to: logical flow or arrangement of steps; interpretations derived from the grammatical organization, syntax, or punctuation; and the quantity or variety of embodiments detailed in the specification. The description of the invention should not be read as mandating a fixed sequence of steps, unless such a requirement is articulated explicitly.

[0071] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. In case of conflict, the present specification, including definitions, will control. Except where expressly noted, trademarks are shown in upper case.

[0072] Unless stated otherwise, all percentages, parts, ratios, a., are by weight. Ranges can be expressed herein as from "about" one particular value, and / or to "about" another particular value. When such a range is expressed, another aspect includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. It is also understood that there are a number of values disclosed herein, and that each value is also herein disclosed as "about" that particular value in addition to the value itself. For example, if the value "10" is disclosed, then "about 10" is also disclosed. It is also understood that each unit between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

[0073] Unless stated otherwise, pressures expressed in psi units would be gauge, and pressures expressed in kPa units would be absolute. Pressure differences, however, are expressed as absolute (for example, pressure 1 is 25 psi higher than pressure 2).

[0074] When an amount, concentration, or other value or parameter is given as a range, or a list of upper and lower values, this is to be understood as specifically disclosing all ranges formed from any pair of any upper and lower range limits, regardless of whether ranges are separately disclosed. Where a range of numerical values is recited herein, unless otherwise stated, the range is intended to include the endpoints thereof, and all integers and fractions within the range. It is not intended that the scope of the present disclosure be limited to the specific values recited when defining a range.

[0075] When the term "about" is used, it is used to mean a certain effect or result can be obtained within a certain tolerance, and the skilled person knows how to obtain the tolerance. When

[0076] 7

[0077] 092457.000614\4934-2261-8246.1PCT Specification Docket No. 092457.000614 the term "about" is used in describing a value or an endpoint of a range, the disclosure should be understood to include the specific value or endpoint referred to.

[0078] As used herein, the terms "comprises," "comprising," "includes," "including," "has," "having" or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but can include other elements not expressly listed or inherent to such process, method, article, or apparatus.

[0079] The transitional phrase "consisting of" excludes any element, step, or ingredient not specified in the claim, closing the claim to the inclusion of materials other than those recited except for impurities ordinarily associated therewith. When the phrase "consists of" appears in a clause of the body of a claim, rather than immediately following the preamble, it limits only the element set forth in that clause; other elements are not excluded from the claim as a whole.

[0080] The transitional phrase "consisting essentially of" limits the scope of a claim to the specified materials or steps and those that do not materially affect the basic and novel charac-teristic(s) of the claimed invention. A "consisting essentially of" claim occupies a middle ground between closed claims that are written in a "consisting of" format and fully open claims that are drafted in a "comprising" format. Optional additives as defined herein, at a level that is appropriate for such additives, and minor impurities are not excluded from a composition by the term "consisting essentially of."

[0081] Further, unless expressly stated to the contrary, "or” and "and / or" refers to an inclusive and not to an exclusive. For example, a condition A or B, or A and / or B, is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0082] The use of "a" or "an" to describe the various elements and components herein is merely for convenience and to give a general sense of the disclosure. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise. As used in the specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0083] The term "predominant portion" or "predominantly," as used herein, unless otherwise defined herein, means greater than 50% of the referenced material. If not specified, the percent is on a molar basis when reference is made to a molecule (such as hydrogen and ethylene), and otherwise is on a weight basis (such as for additive content).

[0084] The term "substantial portion" or "substantially," as used herein, unless otherwise defined, means all or almost all or the vast majority, as would be understood by the person of 8

[0085] 092457.000614\4934-2261-8246.1PCT Specification

[0086] Docket No. 092457.000614 ordinary skill in the context used. It is intended to take into account some reasonable variance from 100% that would ordinarily occur in industrial-scale or commercial-scale situations.

[0087] All parts, percentages and ratios used herein are expressed by weight unless otherwise specified.

[0088] In this specification and in the claims which follow, reference will be made to a number of terms which shall be defined herein.

[0089] "Optional" or "optionally" means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where the event or circumstance occurs and instances where it does not.

[0090] While aspects of the present invention can be described and claimed in a particular statutory class, such as the system statutory class, this is for convenience only and one of skill in the art will understand that each aspect of the present invention can be described and claimed in any statutory class. Unless otherwise expressly stated, it is in no way intended that any method or aspect set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not specifically state in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that an order be inferred, in any respect. This holds for any possible nonexpress basis for interpretation, including matters of logic with respect to arrangement of steps or operational flow, plain meaning derived from grammatical organization or punctuation, or the number or type of aspects described in the specification. Throughout this application, various publications are referenced. The disclosures of these publications in their entireties are hereby incorporated by reference into this application in order to more fully describe the state of the art to which they pertain. The references disclosed are also individually and specifically incorporated by reference herein for the material contained in them that is discussed in the sentence in which the reference is relied upon. Nothing herein is to be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Further, the dates of publication provided herein may be different from the actual publication dates, which can require independent confirmation. In the context of the present description, all publications, patent applications, patents and other references mentioned herein, if not otherwise indicated, are explicitly incorporated by reference herein in their entirety for all purposes as if fully set forth.

[0091] Illustrative Embodiments

[0092] The following describes exemplary embodiments of the present invention in the building construction context, which pertains to footing forms suitable for use in the foundation of 9

[0093] 092457.000614\4934-2261-8246.1PCT Specification

[0094] Docket No. 092457.000614 residential and commercial buildings and other structures. As discussed previously, the present invention allows for labor savings.

[0095] In the present disclosure footing forms are alternatively addressed as footer forms, foundation footers, basement foundation footers, and footers.

[0096] In one embodiment, this invention relates to a first footing form system for preparing a foundation of a structure in the building and construction industry, wherein the footing form is prepared from at least one polymeric material. The footing form is preferably made of foam, and more preferably expanded polystyrene. The footing form has either a drain-pipe installed in a specific slot for such drain-pipes, or the slot is formed in such manner that a cylindrical structure carved out within the footing form acts as a drain-pipe. Stated differently, the drain-pipe is integral to the foam-based footing form. Because the footing form is lightweight, it can be retained within the foundation after the concrete is poured. As a result, there is no need for stakes, which are required in a lumber based footing forms.

[0097] In a preferred embodiment of the invention, EPS, XPS, or GPS are used to construct the footing forms. In yet another embodiment, the dimensional spacing of the footing forms is accomplished by a spreader or by a fabric at the base of the footing forms. In a preferred embodiment, the spreader further supports rebars that are used to strengthen the concrete.

[0098] Varying embodiment of the invention are described in context of Figs. 1-7C, infra.

[0099] Illustrative Embodiment— FIG. 1

[0100] Fig. 1 shows a typical footer form made from lumber being used at a construction site for preparing the foundation for a building. Wood planks of 2 X 10 dimensions are used in the footer form configuration for subsequent concrete pouring. The planks are separated by spacers and vertical stakes are provided for support. The forms are removed once the concrete is poured. Forms have to be cleaned during or after pour for their easier removal. After the concrete is poured and forms are removed, PVC drainage is installed.

[0101] Illustrative Embodiment— FIG. 2

[0102] Fig. 2 shows another footing form system currently in use also known as Forma-a-Drain® from Westlake. As shown in the figure, the system has a perforated PVC form to replace wooden lumber and includes drainage. It also uses stakes and spacers and replaces the 2 X 10 lumber with 2 x 10 PVC drains. It has the PVC pipe in the stone with a fabric

[0103] 10

[0104] 092457.000614\4934-2261-8246.1PCT Specification

[0105] Docket No. 092457.000614 wrapped around it. Sand or similar fill keeps the landscape fabric clean. The PVC pipe is also inn the concrete as shown.

[0106] Illustrative Embodiment— FIGS. 3

[0107] Fig. 3 shows one of the embodiments of the present invention. It shows a first footing form and a second footing form that each is made from foam and has preferably a PVC drainage system installed within the footing form. This allows for a footing form that does not need to be removed after the pouring of the concrete. In this embodiment, gravel backfill is used to support forms during concrete pour, and as a result, stakes for support are not required. The figure also shows three horizontal rebars that reinforce the footer and are attached to a spreader that helps maintain spacing and support the horizontal rebars. This embodiment allows for significant labor savings. In one embodiment, more than one rebar is used. In another embodiment no rebar is used. In yet another embodiment, up to ten rebars are used for reinforcement purposes. In yet another embodiment, more than one drainage pipes are installed in the first and / or the second footing form. Fig. 3A shows a schematic of an individual footing form made from foam with carve-out for the drainage pipe and the temporary wood plank. (See Fig. 4A.)

[0108] Illustrative Embodiment— FIGS. 4

[0109] Fig. 4 shows another embodiment of the present invention. Fig.4 adds to the embodiment shown in Fig.3 Here, the foam cutting layout is also provided that minimizes waste. In addition, this embodiment includes more than one spreader, and more than one horizontal rebars. The rebars are suspended from the spreaders and into the concrete through the use of rebar hanger or bailing wire. In this embodiment, optionally included are channels in the foam, which have for example a 2 X 4 lumber installed in the channel. The lumber planks are reusable.

[0110] Fig. 4A shows a closed-up view of another embodiment of Fig. 4, wherein the integrated channel C and rebar clips are shown. The figure also shows a 2X4 wood plank temporarily inserted for straightening and supporting the footing form foam. Also shown is a drainage pipe carried by the form. The spreaders maintain form spacing and also support the horizontal rebar / s.

[0111] Illustrative Embodiment— FIG. 5

[0112] 11

[0113] 092457.000614\4934-2261-8246.1PCT Specification

[0114] Docket No. 092457.000614 Fig. 5 shows the concept of adjustable leveling between the first footing form and the second footing form. This allows for creating adjustable height footing form to accommodate slight variations in the height of excavated base. In one embodiment, during installation of the footing form, a spike is pushed through the side wall when level footing height is achieved, or some spray foam is used for solid lock.

[0115] Illustrative Embodiment— FIGS. 6

[0116] Fig. 6 shows a conceptual representation of one embodiment of the present invention. In this concept, a reusable spreader cleat is used to dimensionally stabilize the footer forms and provides spacing. A wire is slotted into cuts in the foam to provide tension and support one or more rebars. The foam, as described previously has an integrally included drain. Washers or swage stops are used to stop the movement of the foam footer forms during pour.

[0117] Fig. 6A shows a picture of a footing form foam block and the drainage pipes that are to be installed. Fig. 6B shows an assembled set of footing form foam blocks and drainage pipes inserted therein (see also Fig. 3A for perspective). Fig. 6C shows concrete poured into an assembled foam block to demonstrate the concept.

[0118] Illustrative Embodiment— FIGS. 7As

[0119] As shown in Fig. 7A, two footing forms are held in place using a fabric that is connected at the base of the footing forms. In this embodiment, the spreader is optional. As shown in Fig. 7B, the fabric may be fastened to the foam mechanically or through an adhesive. As shown in Fig. 7C and 7D, the fabric may be wrapped around or fastened the drainage pipes in the first footing form and the second footing form. The fabric will assist with holding the footing forms together during the pouring of the concrete. In one embodiment, the fabric is perforated such that the poured concrete can make contact with the soil beneath to strengthen the foundation. In one embodiment, the fabric is polyester, felt, glass-fiber-reinforced composite fabric, Kevlar® or Nomex® type material or other plantbased materials such as jute fabric.

[0120] The fabric advantageously facilitates the dimensional stability of the EPS blocks and allows for better structural retention of the poured concrete, which is initially non-solid. In the case of the single fabric attached to two forms, it holds the base of the two forms together dimensionally. In the case of the split fabric attached to two separate forms, the forms are free to be dimensioned any distance from one another. As uncured concrete is poured into the cavity it presses the fabric against the ground creating a frictional force that resists

[0121] 12

[0122] 092457.000614\4934-2261-8246.1PCT Specification Docket No. 092457.000614 the lateral movement of the fabric. The width of the fabric will need to be engineered to provide sufficient force such that combined with cleats at the top of the form, it will exceed the pressure of concrete pressing against the walls.

[0123] In one embodiment, the fabric in between the foam or EPS blocks comprises perforations. Such perforations allow for the poured concrete to make contact with supporting surface below the fabric. Such contact and eventual adhesion helps form a stronger foundational connection to the supporting surface, for example, the soil, sand, or gravel underneath the EPS block and the fabric itself. The perforations range from 0.1 mm to 50 mm. These perforations can be uniformly distributed across the surface of the fabric or can be non-uniformly distributed across the surface. In another embodiment, the perforations can be uniformly sized, non-uniformly sized, non-uniformly sized in a particular pattern, or non-uniformly sized in a random fashion. Stated differently, the size range of the perforations is selected from any one of the following numbers, as well as a number within a range defined by any two numbers below, including the endpoints of such range, as measured in mm:

[0124] 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, . . .2.0, 3.0, 4.0, 5.0, 6.0, 7.0, 8.0, 9.0, 10.0,. . .20.0. . .30.0, . . , 40.0, . . and 50.0.

[0125] In one embodiment, the present invention addresses the above issues, by eliminating or reducing the use of stakes. It also offers the advantage of keeping the footer forms in the foundation without removing them. In one embodiment, because it is made from a foam such as expanded polystyrene or EPS, it is significantly lighter than the lumber-based footing forms.

[0126] It should also be noted that in one embodiment, the inventive object has a wide base so that the forms can stand on their own during assembly. In one embodiment, the block may be dimensioned using back fill materials or using wire, tape, or other cordage.

[0127] In one embodiment of the present invention, the footing form block comprises preassembled PVC drainage combining two labor steps. In another embodiment, the footing forms may have custom fasteners / spread bars for holding rebar and dimensioning the footers. In yet another embodiment, the footing forms have may have channels cut to accept lumber, for example, a 2 ft x 4 ft lumber to assist in truing / straightening the forms. Dimensions may allow for easy transitioning to traditional lumber forms for geometries and grades not possible with the footing forms of the present invention.

[0128] In one embodiment, the footing forms have such geometry that limits waste material in the hot-wire cutting. Footing forms may have a leveling mechanism cut into the foam.

[0129] 13

[0130] 092457.000614\4934-2261-8246.1PCT Specification Docket No. 092457.000614 The footing forms of the present invention are preferably used for residential construction. In yet another embodiment, the footing forms are used for non-residential construction, including commercial, industrial, and public works.

[0131] Polymeric Foam for Footing Forms

[0132] The polymeric foam material used in the present invention includes extruded polystyrene foam, see for example, W02018098570A1. In one embodiment, the foams are made of extruded polystyrene, expanded polystyrene, polyethylene, polypropylene, or polyurethane. They are useful industrial products because of their excellent heat-insulating, cushioning and other properties. These foams have found acceptance over the years in such applications as thermal insulation and cushioning as well as raw material for the fabrication of various shaped articles. The preparation of thermoplastic foams by extruding a heat-plastified mixture of a thermoplastic resin and a blowing agent is well known in the art and is described in U.S. Pat. Nos. 2,740,157; 3,067,147; 3,413,387; 3,413,388; 3,431,163; 3,431,164; 3,954,929 and 3,966,381 and Canadian Pat. No. 451,864. Similarly, various methods of preparing open or close-celled expanded polystyrene and other thermoplastic resins are described in art such as U.S. Pat. Nos. 3,243,485; 3,922,328; 4,399,086; 5049328; 5,271,886; and 7,358,280; U.S. Pat. App. Pub. Nos. US20020117769, US20130266766; and EPO patents EP0242191A2 and EP1995273A2. All art cited in this document is incorporated by reference as if fully set forth herein. In still further aspects, the foam can comprise polyisocyanurate or a blend or combination of a polyisocyanurate and polyurethane foam.

[0133] The foam can comprise extruded foam, expanded foam, or a combination thereof. As one of ordinary skill in the art will appreciate, extruded foams can be prepared by melting a suitable polymer material, incorporating a blowing agent to yield a foamed gel, and extruding the foamed gel through a die to form the desired foam layer. Expanded foams can be prepared by subsequent expansion of beads containing a blowing agent, wherein the expanded beads are molded at the time of expansion to form the desired foam layer. The foam can have any desired density. For example, the foam can have a density of at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or even at least about 20 pounds per cubic feet (pcf) according to ASTM D1622. In further aspects, the foam can have a density in the range of about 1 pcf to about 20 pcf. In still further aspects, the foam density can be any desired value within any range derived from any of the above exemplified values, including, for example, a density in the range from about 2 to about 5 pcf, or from about 1 to about 10 pcf.

[0134] 14

[0135] 092457.000614\4934-2261-8246.1PCT Specification

[0136] Docket No. 092457.000614 The foam can be either closed cell or open cell. Open cell foam is more likely to let water vapor condense inside the cells. In further exemplary aspect, the foam is closed cell. In a further aspect, the foam is greater than about 50, 60, 70, 80, or even greater than about 90% closed-cell according to ASTM D2856.

[0137] Since water can negatively impact thermal performance, the foam preferably exhibits limited or substantially no water absorption. For example, the foam exhibits a water absorption of less than about 10, 9, 8, 7, 6, 5, 4, 3, 2, or even less than about 1% according to ASTM C209. In a further aspect, the foam exhibits a water absorption of less than about 10, 9, 8, 7, 6, 5, 4, 3, 2, or even less than about 1% according to ASTM C2842. In a still further aspect, the foam can exhibit a water absorption in the range of about 10 to about 0%. In a yet further aspect, the water absorption can be any desired value within any range derived from any of the above exemplified values, including, for example, a water absorption in the range from about 0 to about 5%, or from about 1 to about 3.5%.

[0138] Moreover, the foam layer can have any desired water vapor permeance (or transmission) value. For example, the water vapor permeance can be about 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, or even about 0 perms according to ASTM E96. In a further aspect, the water vapor permeance can be in the range of about 0 to about 20 perms. In a still further aspect, the water vapor permeance can be any desired value within any range derived from any of the above exemplified values, including, for example, a water vapor permeance in the range from about 0 to about 2 perms, or from about 1 to about 5 perms. In other aspects, one or more optional additives can also be incorporated into or otherwise applied to the foam. Exemplary and non-limiting additives can include flame retardants, colorants, ultraviolet absorbers, textured coatings, and the like as well as any combinations thereof.

[0139] The foam pieces can be secured to each other, for example, by fasteners such as metal or plastic fasteners, or any conventionally used adhesive material known in the art to be compatible for use with foam. For example, according to non-limiting aspects of the invention, the adhesive can be selected from a phenol-formaldehyde resin, hot-melt adhesive, polyvinyl acetate (PVA) resin, or any combination thereof. In still a further aspect, the adhesive can be isocyanate-based.

[0140] The foam disclosed herein can exhibit comparable physical strength and durability over wood planks. Thus, in one aspect, the inventive foam footing forms can exhibit enhanced structural strength and dimensional stability when compared to a conventional or reference footing forms when exposed to substantially the same environmental and / or physical forces under substantially similar conditions.

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[0142] 092457.000614\4934-2261-8246.1PCT Specification

[0143] Docket No. 092457.000614 To that end, the foam can have a dimensional stability of about less than 5, 4, 3, 2, or even less than about 1% according to ASTM D2126. In a further aspect, the dimensional stability is preferably about less than 2%. The foam can also have any desired compressive strength. For example, the foam can have a desired compressive strength of at least about 1, 5, 10, 15, 20, 25, 30, 35, 40 pounds per square inch (psi) according to ASTM D1621. In a further aspect, the compressive strength can be in the range of about 1 to about 40 psi. In a still further aspect, the compressive strength can be any desired value within any range derived from any of the above exemplified values, including, for example, a compressive strength in the range from about 15 to about 30 psi, or from about 20 to about 25 psi. Likewise, the foam can have any desired tensile strength. For example, the foam can have a tensile strength of greater than about 300, 400, 500, 600, 700, 800, 900, 1000, 1500, 2000 pounds per cubic foot (pcf) according to ASTM D1623. In a further aspect, the tensile strength can be in the range of about 300 to about 2000 pcf. In a still further aspect, the tensile strength can be any desired value within any range derived from any of the above exemplified values, including, for example, a tensile strength in the range from about 500 to about 1000 pcf, or from about 600 to about 800 pcf.

[0144] It should be noted that all references cited above, and otherwise, in this specification are incorporated in this specification as if they were fully set forth herein.

[0145] In one embodiment, the foam is expanded Polystyrene (EPS), Extruded Polystyrene (XPS), Graphite Polystyrene (GPS), or polyisocyanurate foam.

[0146] Expanded Polystyrene, more commonly referred to as EPS, is a closed cell made commonly with of 98% trapped air and only 2% plastic. In one embodiment, this invention relates to a flat board, a contoured shape, or a combination of flat and contoured shaped EPS. Extruded Polystyrene, referred to as XPS, is a closed cell product commonly used in remodeling and new construction applications. In one embodiment, this invention relates to a flat board, a contoured shape, or a combination of flat and contoured shaped XPS. Graphite polystyrene, or GPS, is made from Neopor beads, patented, and manufactured by BASF. Neopor gives GPS a dark gray appearance. In one embodiment, this invention relates to a flat board, a contoured shape, or a combination of flat and contoured shaped GPS.

[0147] Polyisocyanurate foam may include closed-cell polyisocyanurate (polyiso) foam. This is described, for example, in U.S. Patent No. 10829939B2, which is incorporated by reference herein.

[0148] Overall, the present invention allows for a significant reduction in labor and overall cost savings. It allows for an integration of drainage and that the footing forms can stay in the foundation.

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[0150] 092457.000614\4934-2261-8246.1

Claims

PCT SpecificationDocket No. 092457.000614 CLAIMS1. A first footing form system for preparing a foundation of a structure in the building and construction industry, wherein the footing form is prepared from at least one polymeric material.

2. The first footing form system as recited in Claim 1, wherein the polymeric material is a polymeric foam.

3. The first footing form system as recited in Claim 2, wherein the polymeric foam is a closed-cell foam, an open-celled foam, or a blend of the closed-cell and the open- celled foam.

4. The first footing form system as recited in Claims 2 or 3, wherein the polymeric foam is EPS, XPS, GPS, polyisocyanurate, polyurethane, or a combination thereof.

5. The first footing form system as recited in Claims 1-4, wherein the footing form further comprises at least one integrated drainage system.

6. The first footing form system as recited in Claim 5, wherein the integrated drainage system is a cylindrical pipe prepared within the polymeric foam of the footing form or is a drainage pipe different from the polymeric foam.

7. The first footing form system as recited in Claims 1-6, further comprising a system for suspending rebars inside the footing form and comprising at least one rebar.

8. The first footing form system as recited in Claim 7, further comprising a spreader that maintains a form spacing and supports said at least one horizontal rebar.

9. The first footing form system as recited in Claims 1-8, further comprising an adjustable leveling system that can be adjusted in comparison to a second footing form system, wherein the second footing form system has the same characteristics of the first footing form system.17092457.000614\4934-2261-8246.1PCT SpecificationDocket No. 092457.00061410. The first footing form system and the second footing form system as recited in Claim 9, wherein the two systems are held in dimensional stability through a fabric.

11. The first footing form system and the second footing form system as recited in Claim 10, wherein the fabric is a perforated fabric.

12. The first footing form system and the second footing form system as recited in Claims 10-11, wherein the fabric comprises polyester, felt, glass-fiber-reinforced composite fabric, Kevlar® or Nomex® type material or other plant-based materials such as jute fabric or a combination thereof.

13. A method for preparing foundation comprising:(i) providing at least one footing form system including a first footing form system wherein the first footing form is prepared from at least one polymeric material,(ii) placing the footing forms in the trench, and(iii) pouring concrete into the footing form cavity.

14. The method as recited in Claim 12, wherein the polymeric material is a polymeric foam.

15. The method as recited in Claim 14, wherein the polymeric foam is a closed-cell foam, an open-celled foam, or a blend of the closed-cell and the open-celled foam.

16. The method as recited in Claims 14 or 15, wherein the polymeric foam is EPS, XPS, GPS, polyisocyanurate, polyurethane, or a combination thereof.

17. The method as recited in Claims 12-16, wherein the footing form further comprises at least one integrated drainage system.18092457.000614\4934-2261-8246.1PCT SpecificationDocket No. 092457.000614 18. The method as recited in Claim 17, wherein the integrated drainage system is a cylindrical pipe prepared within the polymeric foam of the footing form or is a drainage pipe different from the polymeric foam.

19. The method as recited in Claims 12-18, further comprising a system for suspending rebars inside the footing form and comprising at least one rebar.

20. The method as recited in Claim 19, further comprising a spreader that maintains a form spacing and supports said at least one horizontal rebar.

21. The method as recited in Claims 12-20, further comprising an adjustable leveling system that can be adjusted in comparison to a second footing form system, wherein the second footing form system has the same characteristics of the first footing form system.

22. The method as recited in Claim 21, wherein the two systems are held in dimensional stability through a fabric.

23. The method as recited in Claim 22, wherein the fabric is a perforated fabric.

24. The method as recited in Claims 22-23, wherein the fabric comprises polyester, felt, glass-fiber-reinforced composite fabric, Kevlar® or Nomex® type material or other plant-based materials such as jute fabric or a combination thereof.19092457.000614\4934-2261-8246.1

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