Concrete wall forming system using fabric

Abstract

A wall form assembly comprising a substantially rigid surface to maintain the form assembly in a predetermined orientation and at least one flexible fabric surface spaced from the rigid surface. The rigid surface and flexible fabric surface are interconnected by a plurality of flexible links to define a container with side walls to receive a flowable and settable wall forming material. The wall form assembly offers the advantages of being significantly lighter, less labour intensive and less expensive than existing formworks. The wall form assembly permits efficient waterproofing and insulation of the constructed wall.

We claim;  
     
         1 . A wall form assembly comprising: 
 a substantially rigid surface to maintain the form assembly in a pre-determined orientation;    at least one flexible, fabric surface spaced from the rigid surface to define a container with side walls; and    a plurality of flexible links extending between the side walls of the container to position the at least one flexible, fabric surface with respect to the rigid surface.    
     
     
         2 . A wall form assembly as claimed in  claim 1  in which the at least one flexible, fabric surface is a woven material and each of the flexible links comprises a tie extending from the material.  
     
     
         3 . A wall form assembly as claimed in  claim 2  in which each tie comprises a loop of material.  
     
     
         4 . A wall form assembly as claimed in  claim 2  in which each tie comprises a drop stitch of the warp or weft of the woven material.  
     
     
         5 . A wall form assembly as claimed in  claim 3  in which each loop is anchored to the substantially rigid surface.  
     
     
         6 . A wall form assembly as claimed in  claim 5  in which each loop is anchored to the substantially rigid surface by a hook member mounted to said surface.  
     
     
         7 . A wall form assembly as claimed in  claim 5  in which each loop is anchored to the substantially rigid surface by gluing to said surface.  
     
     
         8 . A wall form assembly as claimed in  claim 1  in which the substantially rigid surface is formed from panels of plywood.  
     
     
         9 . A,wall form assembly as claimed in  claim 1  in which the substantially rigid surface is formed from panels of rigid insulation material.  
     
     
         10 . A wall form assembly as claimed in  claim 9  in which the rigid insulation material is extruded polystyrene (XPS).  
     
     
         11 . A wall form assembly as claimed in  claim 9  in which the rigid insulation material is expanded polystyrene (EPS).  
     
     
         12 . A wall form assembly as claimed in  claim 1  in which the at least one flexible, fabric surface is formed from a plurality of fabric sheets with each sheet being joined to an adjacent sheet by a fastener.  
     
     
         13 . A wall form assembly as claimed in  claim 12  in which the fastener comprises a zipper.  
     
     
         14 . A wall form assembly as claimed in  claim 1  in which the at least one flexible, fabric surface is impermeable to water.  
     
     
         15 . A wall form assembly as claimed in  claim 14  in which the flexible, fabric surface is rendered impermeable to water by a waterproof coating.  
     
     
         16 . A wall form assembly as claimed in  claim 15  including a water drainage layer adjacent the waterproof coating.  
     
     
         17 . A wall form assembly as claimed in  claim 1  in which the plurality of flexible links extend between the side walls of the container in a regular pattern on about 3 inch centers.  
     
     
         18 . A wall form assembly as claimed in  claim 1  in which the substantially rigid surface defines one side wall of the container and a single flexible fabric surface defines the other side wall of the container.  
     
     
         19 . A wall form assembly as claimed in  claim 1  in which an outer substantially rigid surface defines one side wall of the container, an intermediate rigid surface defines a middle layer, and an outer flexible fabric surface defines the other side wall of the container.  
     
     
         20 . A wall form assembly as claimed in  claim 19  in which the intermediate rigid surface is a rigid insulation panel.  
     
     
         21 . A wall form assembly as claimed in  claim 19  in which the flexible links extend between the outer substantially rigid surface and the outer flexible fabric surface through openings formed in the intermediate rigid surface.  
     
     
         22 . A wall form assembly as claimed in  claim 1  in which a first outer flexible fabric surface defines one side wall of the container, an intermediate rigid surface defines a middle layer and a second outer flexible fabric surface defines the other side wall of the container.  
     
     
         23 . A wall form assembly as claimed in  claim 22  in which the intermediate rigid surface is a rigid insulation panel.  
     
     
         24 . A wall form assembly as claimed in  claim 22  in which the flexible links extend between the first and second outer flexible fabric surfaces through openings formed in the intermediate rigid surface.  
     
     
         25 . A wall form assembly as claimed in  claim 23  in which the intermediate rigid surface is spaced substantially equidistantly from the first and second outer flexible fabric surfaces.  
     
     
         26 . A wall form assembly as claimed in  claim 23  in which the intermediate rigid surface is positioned to contact one of the first and second outer flexible fabric surfaces.  
     
     
         27 . A wall form assembly as claimed in  claim 1  including a corner tensioning member installable at changes in direction of the wall form assembly.  
     
     
         28 . A wall form assembly as claimed in  claim 27  in which the corner tensioning member comprises a mounting bracket positionable against the rigid surface between the side walls of the container adjacent a corner region, the mounting bracket including a protruding flange that extends into the corner region for attachment to the flexible fabric surface to support and maintain tension of the fabric surface through the change in direction in the wall form assembly.  
     
     
         29 . A wall form assembly as claimed in  claim 28  in which protruding flange is formed with a plurality of openings therethrough.  
     
     
         30 . A wall form assembly comprising: 
 a substantially rigid surface to maintain the form assembly in a pre-determined orientation;    at least one flexible, fabric surface spaced from the rigid surface to define a cavity therebetween; and    a plurality of flexible links extending between the flexible, fabric surface and the substantially rigid surface to position the fabric surface with respect to the rigid surface.    
     
     
         31 . A method for constructing a wall comprising the steps of: 
 connecting together a substantially rigid surface and at least one spaced flexible, fabric surface by a plurality of flexible links to define a container with side walls, the rigid surface acting to maintain the flexible, fabric surface in a desired configuration; and    supplying a flowable and settable wall material to substantially fill the container to form a wall when the wall material has set.    
     
     
         32 . The method of  claim 31  in which the substantially rigid surface is positioned to define one side wall of the container and a single flexible fabric surface is positioned to define the other side wall of the container.  
     
     
         33 . The method of  claim 31  in which an outer substantially rigid surface is positioned to define one side wall of the container, an intermediate rigid surface is positioned to define a middle layer, and an outer flexible fabric surface is positioned to define the other side wall of the container.  
     
     
         34 . The method of  claim 33  in which the intermediate rigid surface is a rigid insulation panel.  
     
     
         35 . The method of  claim 33  in which the flexible links extend between the outer substantially rigid surface and the outer flexible fabric surface through openings formed in the intermediate rigid surface.  
     
     
         36 . The method of  claim 31  in which a first outer flexible fabric surface is positioned to define one side wall of the container, an intermediate rigid surface is positioned to define a middle layer and a second outer flexible fabric surface is positioned to define the other side wall of the container.  
     
     
         37 . The method of  claim 36  in which the intermediate rigid surface is a rigid insulation panel.  
     
     
         38 . The method of  claim 36  in which the flexible links extend between the first and second outer flexible fabric surfaces through openings formed in the intermediate rigid surface.  
     
     
         39 . The method of  claim 31  including the additional step of installing a corner tensioning member at changes in direction of the wall form assembly.  
     
     
         40 . The method of  claim 39  in which the corner tensioning member is a mounting bracket positionable against the rigid surface between the side walls of the container adjacent a corner region, the mounting bracket including a protruding flange that extends into the corner region for attachment to the flexible fabric surface to support and maintain tension of the fabric surface through the change in direction in the wall form assembly.  
     
     
         41 . A wall form assembly comprising: 
 a structural surface to maintain the form assembly in a pre-determined orientation;    at least one flexible membrane interconnected with the structural surface by a plurality of flexible links to position the at least one flexible membrane with respect to the structural surface to define a space therebetween to receive a flowable and settable material.    
     
     
         42 . A wall form assembly as claimed in  claim 41  in which the structural surface is a rigid surface.  
     
     
         43 . A wall form assembly as claimed in  claim 42  in which the rigid surface is formed from panels of rigid insulation.  
     
     
         44 . A wall form assembly as claimed in  claim 41  in which the at least one flexible membrane is a flexible material able to resist tensile forces.  
     
     
         45 . A wall form assembly as claimed in  claim 41  in which the at least one flexible membrane is a woven fabric material and each of the flexible links comprises a tie woven into the material.