Methods and apparatuses for shaping concrete slab-on-ground foundations

Abstract

A method and apparatus for improving the shape of the underside of ribbed concrete slab-on-ground foundations, the foundation having earthen pads and trenched ribs, that includes positioning one or more shoring panels adjacent to at least one of the earthen pads along at least part of one vertical side of a rib, wherein the shoring panels are made from expanded polystyrene treated with a termiticide, backfilling sand in the void between the shoring panels and the earthen pad, dragging a screed across the top portion of the shoring panels to smooth the backfilled sand over the earthen pads, and pouring concrete within a perimeter defined by outer forms and over the earthen pads, backfilled sand, shoring panels, and trenched ribs. The ability to cut and form the panels provides a wide range of structurally efficient cross-sectional shapes with the concrete not possible with traditional methods.

1 . A method for improving the shape of the underside of ribbed concrete slab-on-ground foundations comprising the steps of: 
 digging trenches in the ground to form one or more earthen pads with ribs;    positioning one or more shoring panels adjacent to at least one of said earthen pads along at least part of one vertical side of a rib;    backfilling sand in the void between said shoring panels and earthen pad;    providing an outer perimeter form around the exterior of the earthen pads; and    pouring concrete within the perimeter defined by the outer forms and over said earthen pads, backfilled sand, shoring panels, and trenched ribs.    
   
   
       2 . The method of  claim 1 , wherein said trenches are dug by hand.  
   
   
       3 . The method of  claim 1 , wherein said trenches are dug by a trenching machine.  
   
   
       4 . The method of  claim 1 , wherein said shoring panels are made from any rigid material capable of maintaining its stiffness long enough for the installation process, inspection, placement of concrete, and the initial curing or set of the concrete.  
   
   
       5 . The method of  claim 1 , wherein said shoring panels are made from a lightweight rigid foam.  
   
   
       6 . The method of  claim 1 , wherein said shoring panels are made from a high density foamed synthetic resin such as expanded polystyrene, extruded polystyrene foam, polyurethane foam, or a foamed phenolformadehyde or like resin.  
   
   
       7 . The method of  claim 1 , wherein said shoring panels are made from expanded polystyrene treated with a termiticide.  
   
   
       8 . The method of  claim 1 , wherein said backfilled sand comprises fine sand, trenching spoils, or loose fill.  
   
   
       9 . The method of  claim 1  further comprising the step of: 
 adding a vapor barrier over said earthen pads, backfilled sand, and shoring panels before the concrete is poured.    
   
   
       10 . The method of  claim 9 , wherein said vapor barrier is made from 6-mil or 12-mil thick polyethylene sheeting.  
   
   
       11 . The method of  claim 1  further comprising the step of: 
 supporting said shoring panels adjacent said earthen pads with a stake driven into the ground.    
   
   
       12 . The method of  claim 11 , wherein said stake comprises steel re-bar, wood, sheet metal, composite material, or plastic or rigid pipe.  
   
   
       13 . The method of  claim 1  further comprising the step of: 
 shaping said shoring panels to form an efficient cross-sectional profile or shape that will mold the concrete into various shapes.    
   
   
       14 . The method of  claim 13 , wherein said profile or shape comprises a “C” shape, “L” shape, “I” shape, “T” shape, “F” shape, convex shape, or concave shape.  
   
   
       15 . The method of  claim 1 , wherein two or more shoring panels are positioned adjacent to each other and are used to form virtually any angle from 0 to 360 degrees.  
   
   
       16 . The method of  claim 15  further comprising the step of: 
 connecting the corners of the adjacent shoring panels.    
   
   
       17 . The method of  claim 16 , wherein the step of connecting the corners of the adjacent shoring panels comprises 
 applying a band of adhesive fabric tape, metal banding, or plastic tape or banding to the shoring panels to prevent the corners from separating while retaining the loose fill of the earthen pad.    
   
   
       18 . The method of  claim 16 , wherein the step of connecting the corners of the adjacent shoring panels comprises 
 applying a metal strap, windstorm strap, or other material strap to the shoring panels to prevent the corners from separating while retaining the loose fill of the earthen pad.    
   
   
       19 . The method of  claim 18   wherein said strap has two ends, each end to be bent more or less the same distance in from each end as the thickness of the shoring panels at right angles in the same direction creating tabs; and    wherein said strap is then bent preferably in the middle at a slightly greater angle than that of the shoring panels creating a spring effect assisting the tabs into the material of the shoring panels thus holding the panels together.    
   
   
       20 . The method of  claim 16 , wherein the step of connecting the corners of the adjacent shoring panels comprises 
 cutting of “J” channel of a metal or other material on one vertical plane and one horizontal plane, leaving the remaining vertical plane intact, bending at this point to any angle, and placing over and or under the horizontal edges of said shoring panels to prevent the corners from separating while retaining the loose fill of the earthen pad.    
   
   
       21 . The method of  claim 1 , wherein a plurality of shoring panels are positioned adjacent to each other to surround one or more earthen pads.  
   
   
       22 . The method of  claim 21  further comprising the step of: 
 encircling the adjacent shoring panels with adhesive fabric tape, metal banding, or plastic tape or banding to prevent the corners from separating while retaining the loose fill of the earthen pad.    
   
   
       23 . The method of  claim 1  further comprising the step of: 
 placing a temporary or permanent spacer between the earthen side of a pad and the vertical face of a shoring panel adjacent another earthen pad.    
   
   
       24 . The method of  claim 23 , wherein said spacer comprises foam, wood, plastic blocks, bricks, or wire cages.  
   
   
       25 . The method of  claim 1  further comprising the step of: 
 placing a temporary or permanent spacer between the vertical face of a shoring panel adjacent one earthen pad and the vertical face of a shoring panel adjacent another earthen pad.    
   
   
       26 . The method of  claim 25 , wherein said spacer comprises foam, wood, plastic blocks, bricks, or wire cages.  
   
   
       27 . The method of  claim 1  further comprising the step of: 
 dragging a screed across the top portion of the shoring panels to smooth the backfilled sand over the earthen pads.    
   
   
       28 . A method for improving the shape of the underside of ribbed concrete slab-on-ground foundations comprising the steps of: 
 digging trenches in the ground to form one or more earthen pads with ribs, wherein said trenches are dug by hand or by a trenching machine;    positioning one or more shoring panels adjacent to at least one of said earthen pads along at least part of one vertical side of a rib, wherein said shoring panels are made from expanded polystyrene treated with a termiticide;    shaping said shoring panels to form an efficient cross-sectional profile or shape that will mold the concrete into various shapes;    connecting the corners of the adjacent shoring panels;    supporting said shoring panels adjacent said earthen pads with a stake driven into the ground, wherein said stake comprises steel re-bar, wood, sheet metal, composite material, or plastic or rigid pipe;    backfilling sand in the void between said shoring panels and earthen pad, wherein said backfilled sand comprises fine sand, trenching spoils, or loose fill;    dragging a screed across the top portion of the shoring panels to smooth the backfilled sand over the earthen pads;    adding a vapor barrier over said earthen pads, backfilled sand, and shoring panels;    providing an outer perimeter form around the exterior of the earthen pads; and    pouring concrete within the perimeter defined by the outer forms and over said earthen pads, backfilled sand, shoring panels, vapor barrier, and trenched ribs.    
   
   
       29 . An apparatus for improving the shape of the underside of ribbed concrete slab-on-ground foundations, the foundation having earthen pads and trenched ribs, comprising: 
 one or more shoring panels placed adjacent to said pad along at least part of one vertical side of a rib.    
   
   
       30 . The apparatus of  claim 29 , wherein said shoring panels are made from any rigid material capable of maintaining its stiffness long enough for the installation process, inspection, placement of concrete, and the initial curing or set of the concrete.  
   
   
       31 . The apparatus of  claim 29 , wherein said shoring panels are made from a lightweight rigid foam.  
   
   
       32 . The apparatus of  claim 29 , wherein said shoring panels are made from a high density foamed synthetic resin such as expanded polystyrene, extruded polystyrene foam, polyurethane foam, or a foamed phenolformadehyde or like resin.  
   
   
       33 . The apparatus of  claim 29 , wherein said shoring panels are made from expanded polystyrene treated with a termiticide.  
   
   
       34 . The apparatus of  claim 29  further comprising: 
 sand backfilled in the void between said shoring panels and earthen pads.    
   
   
       35 . The apparatus of  claim 29  further comprising: 
 a stake driven into the ground to support said shoring panels.    
   
   
       36 . The apparatus of  claim 29 , wherein said shoring panels are shaped to form an efficient cross-sectional profile or shape that will mold the concrete into various shapes.  
   
   
       37 . The apparatus of  claim 36 , wherein said profile or shape comprises a “C” shape, “L” shape, “I” shape, “I” shape, “F” shape, convex shape, or concave shape.  
   
   
       38 . The apparatus of  claim 29  further comprising: 
 means for connecting the corners of the adjacent shoring panels.    
   
   
       39 . The apparatus of  claim 38  wherein said means for connecting the corners of the adjacent shoring panels comprises 
 a band of adhesive fabric tape, metal banding, or plastic tape or banding applied to the shoring panels to prevent the corners from separating while retaining the loose fill of the earthen pad.    
   
   
       40 . The apparatus of  claim 38  wherein said means for connecting the corners of the adjacent shoring panels comprises 
 a metal strap, windstorm strap, or other material strap applied to the shoring panels to prevent the corners from separating while retaining the loose fill of the earthen pad.    
   
   
       41 . The apparatus of  claim 38  wherein said means for connecting the corners of the adjacent shoring panels comprises 
 a metal or other material “J” channel cut on one vertical plane and one horizontal plane, leaving the remaining vertical plane intact, bending at this point to any angle, and placing over and or under the horizontal edges of said shoring panels to prevent the corners from separating while retaining the loose fill of the earthen pad.    
   
   
       42 . The apparatus of  claim 29  further comprising: 
 a temporary or permanent spacer placed between the earthen side of a pad and the vertical face of a shoring panel adjacent another earthen pad.    
   
   
       43 . An apparatus for improving the shape of the underside of ribbed concrete slab-on-ground foundations comprising: 
 a trenching machine for digging trenches in the ground to form one or more earthen pads with ribs;    one or more shoring panels positioned adjacent to at least one of said earthen pads along at least part of one vertical side of a rib, wherein said shoring panels are made from expanded polystyrene treated with a termiticide and are shaped to form an efficient cross-sectional profile or shape that will mold the concrete into various shapes;    means for connecting the corners of the adjacent shoring panels;    a stake driven into the ground to support said shoring panels adjacent said earthen pads, wherein said stake comprises steel re-bar, wood, sheet metal, composite material, or plastic or rigid pipe;    means for backfilling sand in the void between said shoring panels and earthen pad, wherein said backfilled sand comprises fine sand, trenching spoils, or loose fill;    a screed dragged across the top portion of the shoring panels to smooth the backfilled sand over the earthen pads;    a vapor barrier draped over said earthen pads, backfilled sand, and shoring panels;    an outer perimeter form provided around the exterior of the earthen pads; and    concrete poured within the perimeter defined by the outer forms and over said earthen pads, backfilled sand, shoring panels, vapor barrier, and trenched ribs.