Simplified non-polystyrene permanent insulating concrete form building system

Abstract

A simplified insulating concrete form building system comprised of forms made from wood chips or other organic fibers, embedded in a Portland cement matrix, molded and trimmed into various shapes and sizes. The forms are held in position within the wall by means of unique, simplified form geometry and an internal fastening clip which combine to improve alignment and stability of the wall prior to filling the forms with concrete. The simplified geometry reduces worker error in orienting the form correctly within the wall thereby reducing handling and corresponding fatigue. The form's smooth faces provide more compact palletized shipments of forms, thereby reducing cost and damage in shipment. Concrete reinforcement bars are held within forms using a system of reinforcement bar holders which enables the precise positioning of the reinforcement within the wall, thereby increasing speed and accuracy of construction as well as structural performance of the wall assembly.

1 . A system for securing non-polystyrene insulated concrete forms and positioning reinforcement bars during construction of a concrete structure, the system comprising:
 at least one of a non-polystyrene insulated concrete form; and   at least one of a fastening clip, the fastening clip having a top member, the top member further comprises at least one of a receptacle integrally formed in the top member, the receptacle locates, orientates, and fastens with at least one of a reinforcement bar holder, the fastening clip holds together at least two of the non-polystyrene insulating concrete form, the fastening clip further comprises at least two of a clamping leg which are juxtaposed, wherein when the fastening clip is applied to at least two of the non-polystyrene insulating concrete form each of the clamping leg grips at least one of the non-polystyrene insulating concrete form.   
     
     
         2 . The system in accordance with  claim 1 , wherein the fastening clip is reinforced nylon, polypropylene, or polyvinyl chloride. 
     
     
         3 . The system in accordance with  claim 1 , wherein each of the clamping leg disposed are at either end of the top member and one end of the clamping leg is formed integrally with the top member the other end of the clamping leg is a free end, each of the clamping leg forms an acute angle to the longitudinal axis of the top member, the longitudinal axis being the axis which traverses the top member between each of the clamping leg, wherein the distance between each of the clamping leg measured between attach points with the top member is greater than the distance measured between each of the free ends creating a friction fit with at least two of the non-polystyrene insulating form. 
     
     
         4 . The system in accordance with  claim 3 , wherein each of the clamping leg further comprises a foot formed integrally with the free end, the foot curving outwardly from the clamping leg forming a widened aperture between each of the clamping leg. 
     
     
         5 . The system in accordance with  claim 1 , wherein each of the clamping leg are connected to one end of each of at least two of a lower cross member, the other end of each of the lower cross member is integrally formed into an upper cross member, and each of the clamping leg comprising a plurality of gripping teeth integrally formed with and located on the interior surface of each of the clamping leg. 
     
     
         6 . The system in accordance with  claim 1 , further comprising:
 a horizontal reinforcement bar holder comprising a first end and a second end, a saddle disposed and integrally formed at the first end, the second end is attachable to the fastening clip, wherein the saddle engages a horizontally orientated reinforcement bar creating a fixed distance between the non-polystyrene insulating concrete form and the horizontally orientated reinforcement bar.   
     
     
         7 . The system in accordance with  claim 1 , further comprising:
 a reinforcement bar holder comprising a saddle integrally formed on one end which is orientated to support a reinforcement bar and a connector integrally formed on the other end, the connector comprising at least one of a cross member and at least two of a connector leg, one end of the connector leg being integrally formed with the cross member and the other end of the connector leg comprising a foot, each of the foot being orientated on the connector leg to facilitate the reinforcement bar holder fastening to a second reinforcement bar holder or to the fastening clip, wherein the reinforcement bar holder supports the reinforcement bar in predetermined and precise locations within the non-polystyrene insulated concrete form.   
     
     
         8 . The system in accordance with  claim 1 , further comprising:
 a horizontal reinforcement bar holder, used in combination with the fastening clip, comprising a first end and a second end, a saddle disposed and integrally formed at the first end, a base is integrally formed between the first end and second end, the base comprising a plurality of removable extensions, a locator tab is integrally formed at the second end, wherein the saddle engages a horizontally orientated reinforcement bar, the locator tab is inserted into a non-polystyrene insulating concrete form, the base contacts the surface of the non-polystyrene insulating concrete form creating a fixed distance between the non-polystyrene insulating concrete form and the horizontally orientated reinforcement bar and supporting the horizontally orientated reinforcement bar in predetermined and precise location within horizontal cavities of the non-polystyrene insulating concrete form.   
     
     
         9 . A system for securing non-polystyrene insulated concrete forms and positioning reinforcement bars during construction of a concrete structure, the system comprising:
 at least one of a non-polystyrene insulated concrete form;   at least one of a fastening clip, the fastening clip having a top member, the top member further comprises at least one of a receptacle integrally formed in the top member, the receptacle locates, orientates, and fastens with at least one of a reinforcement bar holder, the fastening clip holds together at least two of the non-polystyrene insulating concrete form; and   a horizontal reinforcement bar holder, used in combination with the fastening clip, further comprises a first end and a second end, a saddle disposed and integrally formed at the first end, a base is integrally formed between the first end and second end, the base comprising a plurality of removable extensions, a locator tab is integrally formed at the second end, the locator tab thickness and length are sized to fit into a slot formed in a structural cross member of a non-polystyrene insulated concrete form, the locator tab is shaped at the second end and has a plurality of gripping teeth integrally formed therein which cause the horizontal reinforcement bar holder to be friction fit and retained within the slot, wherein the saddle engages a horizontally orientated reinforcement bar, the locator tab is inserted into the non-polystyrene insulating concrete form, the base contacts the surface of the non-polystyrene insulating concrete form creating a fixed distance between the non-polystyrene insulating concrete form and the horizontally orientated reinforcement bar and supporting the horizontally orientated reinforcement bar in predetermined and precise location within horizontal cavities of the non-polystyrene insulating concrete form.   
     
     
         10 . The system in accordance with  claim 9 , wherein the fastening clip further comprises at least two of a clamping leg which are juxtaposed, wherein when the fastening clip is applied to at least two of the non-polystyrene insulating concrete form each of the clamping leg grips at least one of the non-polystyrene insulating concrete form. 
     
     
         11 . The system in accordance with  claim 10 , wherein the fastening clip further comprises a top member, each of the clamping leg are disposed at either end of the top member and one end of the clamping leg is formed integrally with the top member the other end of the clamping leg is a free end, each of the clamping leg forms an acute angle to the longitudinal axis of the top member, the longitudinal axis being the axis which traverses the top member between each of the clamping legs, wherein the distance between each of the clamping leg measured between attach points with the top member is greater than the distance measured between each of the free ends. 
     
     
         12 . The system in accordance with  claim 11 , wherein each of the clamping leg further comprises a foot formed integrally with the free end, the foot curving outwardly from the clamping leg forming a widened aperture between each of the clamping leg. 
     
     
         13 . The system in accordance with  claim 10 , wherein each of the clamping leg are connected to one end of each of at least two of a lower cross member, the other end of each of the lower cross member is integrally formed into an upper cross member, and each of the clamping leg comprising a plurality of gripping teeth integrally formed with and located on the interior surface of each of the clamping leg. 
     
     
         14 . The system in accordance with  claim 9 , further comprising:
 a reinforcement bar holder comprising a support saddle integrally formed on one end which is orientated to support a reinforcement bar and a connector integrally formed on the other end, the connector comprising at least one of a cross member and at least two of a connector leg, one end of the connector leg being integrally formed with the cross member and the other end of the connector leg comprising a foot, each of the foot being orientated on the connector leg to facilitate the reinforcement bar holder fastening to a second reinforcement bar holder or to the fastening clip, wherein the reinforcement bar holder supports the reinforcement bar in predetermined and precise locations within the non-polystyrene insulated concrete form.   
     
     
         15 . A system for securing non-polystyrene insulated concrete forms and positioning reinforcement bars during construction of a concrete structure, the system comprising:
 at least one of a non-polystyrene insulated concrete form;   a fastening clip having a top member, the top member further comprises at least one of a receptacle integrally formed in the top member, the fastening clip holds together at least two of the non-polystyrene insulating concrete form; and   a reinforcement bar holder having at least two of a parallel leg contoured and integrally formed to form a saddle between the interior surfaces of the parallel leg, the saddle is orientated to support a reinforcement bar and a connector integrally formed on the other end, the connector comprising at least one of a cross member and at least two of a connector leg, one end of the connector leg being integrally formed with the cross member and the other end of the connector leg comprising a foot, each of the foot being orientated on the connector leg, the connector leg either fastens with at least one of the receptacles which locates, orientates, and fastens the reinforcement bar holder with the top member or fastens with a second reinforcement bar holder, wherein the reinforcement bar holder supports the reinforcement bar in predetermined and precise location within the non-polystyrene insulated concrete form.   
     
     
         16 . The system in accordance with  claim 15 , wherein the fastening clip further comprises at least two of a clamping leg which are juxtaposed, wherein when the fastening clip is applied to at least two of the non-polystyrene insulating concrete form each of the clamping leg grips at least one of the non-polystyrene insulating concrete form minimizing slippage and separation. 
     
     
         17 . The system in accordance with  claim 16 , wherein the fastening clip further comprises a top member, each of the clamping leg are disposed at either end of the top member and one end of the clamping leg is formed integrally with the top member the other end of the clamping leg is a free end, each of the clamping leg form an acute angle to the longitudinal axis of the top member, wherein the distance between each of the clamping leg attach points with the top member is greater than the distance between each of the free end. 
     
     
         18 . The system in accordance with  claim 17 , wherein each of the clamping leg further comprises a foot integrally formed with the free end, the foot curving outwardly from the clamping leg forming a widened aperture between each of the clamping leg. 
     
     
         19 . The system in accordance with  claim 15 , further comprising:
 a horizontal reinforcement bar holder comprising a first end and a second end, a support saddle disposed and integrally formed at the first end, the second end is attachable to the fastening clip, wherein the support saddle engages a horizontally orientated reinforcement bar creating a fixed distance between the non-polystyrene insulating concrete form and the horizontally orientated reinforcement bar.   
     
     
         20 . The system in accordance with  claim 15 , further comprising:
 a horizontal reinforcement bar holder, used in combination with the fastening clip, comprising a first end and a second end, a support saddle disposed and integrally formed at the first end, a base is integrally formed between the first end and second end, the base comprising a plurality of removable extensions, a locator tab is integrally formed at the second end, wherein the support saddle engages a horizontally orientated reinforcement bar, the locator tab is inserted into a non-polystyrene insulating concrete form, the base contacts the surface of the non-polystyrene insulating concrete form creating a fixed distance between the non-polystyrene insulating concrete form and the horizontally orientated reinforcement bar and supporting the horizontally orientated reinforcement bar in predetermined and precise location within horizontal cavities of the non-polystyrene insulating concrete form.   
     
     
         21 . A method of securing non-polystyrene insulated concrete forms and positioning reinforcement bars during construction of a concrete structure, the method comprising:
 aligning at least two of a non-polystyrene insulating concrete form, the non-polystyrene insulating concrete form having a double middle web integral slot;   securing at least two of the non-polystyrene insulating concrete form with at least one of a fastening clip;   positioning at least one of a horizontal reinforcement bar holder within certain of the double middle web integral slot, the horizontal reinforcement bar holder having a saddle for retaining a reinforcement bar;   placing the reinforcement bar into the saddle;   positioning at least one of a horizontal-to-vertical reinforcement bar holder on the reinforcement bar, the horizontal-to-vertical reinforcement bar holder having a second saddle for retaining a second reinforcement bar;   placing the second reinforcement bar into the second saddle; and   filling the non-polystyrene insulating concrete form with concrete.