Modular Concrete Wall System

Abstract

Disclosed is a modular poured concrete wall system that addresses the needs not optimally met by the prior art, where inexpensive small light interlocking forms are quickly and readily assembled, to produce the desired aesthetically pleasing appearance of a brick wall system. The forms remain in place as part of the final structure and finished surface of the walls. Thus, a footer track assembly is affixed to a standard concrete footer or foundation. Then the modular forms are assembled upon the footer track, stacked together to produce the appearance of a brick wall. As each row or two of forms are assembled, the forms are filled with concrete. Following the concrete pour, additional forms are assembled on the top of the prior forms, to produce additional rows. By repeating this process, the full height of the wall can be quickly reached. The method may include steel rebar, such as for horizontal bond beams and for vertical strength. In an alternative embodiment, curved modular forms may be assembled to produce a circular column, where the exterior surface is finished as a decorative brick appearance.

1 . A modular form unit for casting concrete comprising:
 a) a rectangular surface,   b) single flanges at two adjacent edges of said rectangular surface and parallel to said rectangular surface, and   c) double flanges at two edges opposite to the said single flanges where said double flanges include means of interconnecting with single flanges of other modular form units of the same type,   
     whereby a plurality of said modular form units may be assembled with each other to create an assembled concrete form. 
   
   
       2 . A concrete wall system comprising:
 a) a plurality of said modular form units from  claim 1 ,   b) means for bracing said modular form units,   c) means for fixing and aligning said modular form units to a foundation, and   d) concrete poured and set within assembled modular forms,   
     whereby upon curing of the concrete the modular form units remain in place as part of the finished surface of the concrete wall. 
   
   
       3 . A method of building a concrete wall comprising the steps of
 a) aligning and securing footer track assemblies on concrete footers or foundations,   b) placing the said modular form units of  claim 1  upon the said footer track assemblies, where
 (1) the bottom flanges of the modular form units fit upon the upward edges of the footer track rails and 
 (2) the vertical single flanges of each modular form unit are inserted into the vertical double flanges of adjacent modular form units, 
   c) adding one or more additional rows of said modular form units to the top of the first row of said modular form units,   d) securing the top of the assembled forms by means of metal spreader struts, a jig, or tool,   e) fixing structural elements such as steel reinforcing bar or utility elements such as pipes or electrical conduit,   f) pouring concrete into the forms, which are tapped and manipulated to secure the flow of the concrete into all parts of the form,   g) assembly of the next one, two, or more rows after the concrete has been poured and settled into the forms from the prior rows, and   h) repetition of the process detailed herein until the desired height of the concrete wall is obtained   
     whereby the construction of the walls of the structure will be rapid, and thereby afford a significant savings in labor. 
   
   
       4 . The modular form unit of  claim 1  wherein the said rectangular surface comprises a raised surface of between ⅛ and ¾ inches above the said flanges to simulate a brick, whereby the finished wall exterior presents the appearance of a brick wall. 
   
   
       5 . The modular form unit of  claim 4  wherein said rectangular surface incorporates a textured finish whereby the finished appearance as the exterior of a brick wall or other aesthetically pleasing construction is improved. 
   
   
       6 . A curved modular form unit for casting concrete comprising:
 a) a curve rectangular surface,   b) single flanges at two adjacent edges of said curved rectangular surface and parallel to said curved rectangular surface, and   c) double flanges at two edges opposite to the said single flanges where said double flanges include means of interconnecting with single flanges of other modular form units of the same type,   
     whereby a plurality of said curved modular form units may be assembled with each other to create an assembled concrete form. 
   
   
       7 . A concrete column system comprising:
 a) a plurality of said curved modular form units from  claim 6 ,   b) means for bracing said modular form units,   c) means for fixing and aligning said modular form units to a foundation, and   d) concrete poured and set within assembled modular forms,   
     whereby upon curing of the concrete the curved modular form units remain in place as part of the finished surface of the concrete column. 
   
   
       8 . A method of building a concrete column comprising the steps of
 a) aligning and securing footer track assemblies on concrete footers or foundations,   b) placing the said curved modular form units of  claim 6  upon the said footer track assemblies, where
 (1) the bottom flanges of the curved modular form units fit upon the upward edges of the footer track rails and 
 (2) the vertical single flanges of each curved modular form unit are inserted into the vertical double flanges of adjacent modular form units, 
   c) adding one or more additional rows of said curved modular form units to the top of the first row of said modular form units,   d) securing the top of the assembled forms by means of metal spreader struts, a jig, or tool,   e) fixing structural elements such as steel reinforcing bar or utility elements such as pipes or electrical conduit,   f) pouring concrete into the assembled forms, which are tapped and manipulated to secure the flow of the concrete into all parts of the form,   g) assembly of the next one, two, or more rows after the concrete has been poured and settled into the forms from the prior rows, and   h) repetition of the process detailed herein until the desired height of the concrete column is obtained   
     whereby the construction of the columns will be rapid, and thereby afford a significant savings in labor. 
   
   
       9 . The curved modular form unit of  claim 6  wherein the said rectangular surface comprises a raised surface of between ⅛ and ¾ inches above the said flanges to simulate a brick, whereby the finished wall exterior presents the appearance of a brick wall. 
   
   
       10 . The curved modular form unit of  claim 9  wherein said rectangular surface incorporates a textured finish whereby the finished appearance as the exterior of a brick wall or other aesthetically pleasing construction is improved.