Folded cardboard concrete form system

Abstract

A form system for assembling a structural frame includes a base sheet of cardboard, the base sheet having a plurality of folding sections for corrugating the base sheet into a first shape, at least one additional sheet of cardboard, the additional sheet having a plurality of folding sections for corrugating the additional sheet into a second shape, wherein at least part of the second shape corresponds to at least part of the first shape such that when the additional sheet is positioned adjacent to the base sheet, the base sheet and the additional sheet form a V-shaped cavity therebetween, and a concrete fill cast within the at least one V-shaped cavity.

1 . A system for assembling a structural frame, said system comprising:
 a base sheet of cardboard, the base sheet having a plurality of folding sections for corrugating the base sheet into a first shape;   at least one additional sheet of cardboard, the additional sheet having a plurality of folding sections for corrugating the additional sheet into a second shape;   wherein at least part of the second shape corresponds to at least part of the first shape such that when the additional sheet is positioned adjacent to the base sheet, the base sheet and the additional sheet form a V-shaped cavity therebetween; and   a concrete fill cast within the at least one V-shaped cavity.   
     
     
         2 . The system of  claim 1 , wherein the first shape of said base sheet includes alternating horizontal sections and V-shaped recessed sections. 
     
     
         3 . The system of  claim 2 , wherein each of the V-shaped recessed sections has a flat base and two diverging sides. 
     
     
         4 . The system of  claim 2 , wherein the second shape of said at least one additional sheet is defined by a triangular tube. 
     
     
         5 . The system of  claim 4 , wherein the triangular tube is disposed within one of the V-shaped recessed sections. 
     
     
         6 . The system of  claim 5 , wherein the second shape includes a tab that extends from a vertex of the triangular tube for mounting the triangular tube to a base of one of the V-shaped recessed sections. 
     
     
         7 . The system of  claim 2 , further comprising at least one further sheet of cardboard, the further sheet having a plurality of folding sections for corrugating the further sheet into a brace, said brace supporting the base sheet. 
     
     
         8 . The system of  claim 7 , wherein the brace comprises a third shape that corresponds to the first shape of said base sheet when the brace is positioned adjacent to the base sheet. 
     
     
         9 . The system of  claim 8 , wherein the third shape of said brace is a tube having a trapezoidal cross section, said brace is positioned under one of the horizontal sections and next to at least one of the V-shaped recessed sections. 
     
     
         10 . The system of  claim 1 , further comprising a wire grid disposed around an outside of the at least one additional sheet and a plurality of grid supports disposed within the V-shaped cavity for anchoring said wire grid to said base sheet. 
     
     
         11 . The system of  claim 1 , further comprising:
 a wire mesh disposed over the V-shaped cavity and above the base sheet and the at least one additional sheet; and   a concrete slab disposed over the wire mesh, wherein a portion of the concrete fill disposed within the V-shaped cavity adheres to the concrete slab when cured.   
     
     
         12 . A system for assembling a structural frame, said system comprising:
 a base sheet of cardboard, the base sheet having a plurality of folding sections for corrugating the base sheet into a first shape;   at least one additional sheet of cardboard, the additional sheet having a plurality of folding sections for corrugating the additional sheet into a second shape;   wherein at least part of the second shape corresponds to at least part of the first shape such that when the additional sheet is positioned adjacent to the base sheet, the base sheet and the additional sheet form therebetween a V-shaped cavity for receiving a fluid material to cast therein.   
     
     
         13 . The system of  claim 12 , wherein the base sheet and the at least one additional sheet are moisture treated for waterproofing. 
     
     
         14 . The system of  claim 12 , wherein the first shape of said base sheet includes alternating horizontal sections and V-shaped recessed sections;
 each of said V-shaped recessed sections has a flat base and two diverging sides; and   wherein the second shape of said at least one additional sheet is defined by a triangular tube.   
     
     
         15 . The system of  claim 14 , wherein the triangular tube is disposed within one of the V-shaped recessed sections. 
     
     
         16 . The system of  claim 14 , further comprising at least one further sheet of cardboard, the further sheet having a plurality of folding sections for corrugating the further sheet into a brace, said brace supporting the base sheet. 
     
     
         17 . The system of  claim 16 , wherein the brace comprises a third shape that corresponds to the first shape of said base sheet when the brace is positioned adjacent to the base sheet. 
     
     
         18 . The system of  claim 16 , further comprising at least one scaffolding for supporting and elevating the base sheet and brace;
 each scaffolding comprising at least one shoring support element disposed vertically, at least one runner mounted at a top end of the shoring support element and at least one cleat mounted to the runner;   the runner spanning the alternating horizontal sections and V-shaped recessed sections of the base sheet; and   the cleat being disposed under the base sheet at the flat base of one of the V-shaped recessed sections and holding the brace in place with respect to the runner such that the base sheet remains stationary on the at least one scaffolding.   
     
     
         19 . The system of  claim 12 , further comprising a wire grid disposed around an outside of the at least one additional sheet and a plurality of grid supports disposed within the V-shaped cavity for anchoring said wire grid to said base sheet. 
     
     
         20 . The system of  claim 12 , further comprising:
 a wire mesh disposed over the V-shaped cavity and above the base sheet and the at least one additional sheet; and   a slab disposed over the wire mesh, said slab comprising precast fluid material;   wherein a portion of the fluid material disposed within the V-shaped cavity adheres to the slab when cured.