Footer cleat for insulating concrete form
Methods of constructing concrete walls that include placing a plurality of cleats along a wall perimeter, securing the cleats to a surface under the wall perimeter, placing a plurality of insulating concrete forms along the perimeter, and placing concrete into the insulating concrete forms to form the insulating concrete wall. The cleats include a base plate, a first vertical flange extending approximately perpendicular from the base plate, and a second vertical flange extending approximately parallel to the first vertical flange. The space defined by the first vertical flange, second vertical flange and the base plate, is adapted to receive a bottom portion of a form component or a bottom portion of a form. The insulating concrete forms are placed along the perimeter such that a bottom portion of the form components or a bottom portion of the form are press fit into the defined space.
1. A method of constructing an insulating concrete wall comprising:
placing a plurality of cleats along a wall perimeter, wherein the cleats consist of a base plate, a first vertical flange extending approximately perpendicular from the base plate, and a second vertical flange extending approximately perpendicular from the base plate and approximately parallel to the first vertical flange, wherein the space defined by the first vertical flange, second vertical flange and the base plate, is adapted to receive a bottom portion of a form component or a bottom portion of a form;
securing the cleats to a surface under the wall perimeter;
placing a plurality of insulating concrete forms along the perimeter such that a bottom portion of the form components or a bottom portion of the form are press fit into the space defined by the first vertical flange, second vertical flange and the base plate; and
placing concrete into the insulating concrete forms to form the insulating concrete wall.
2. The method according to claim 1 , wherein the cleats comprise a material selected from the group consisting of metal, construction grade plastics, composite materials, ceramics, and combinations thereof.
3. The method according to claim 2 , wherein the metal is selected from the group consisting of aluminum, steel, stainless steel, tungsten, molybdenum, iron and alloys and combinations of such metals.
4. The method according to claim 2 , wherein the construction grade plastics are selected from the group consisting of reinforced thermoplastics, thermoset resins, reinforced thermoset resins and combinations thereof.
5. The method according to claim 1 , wherein the insulating concrete forms comprise a rectangular foamed plastic body having one or more beam forms and one or more column forms defined therein.
6. The method according to claim 5 , wherein the first vertical flange contacts an outward facing surface of the rectangular foamed plastic body and the second vertical flange contacts an inner facing surface of the rectangular foamed plastic body.
7. The method according to claim 1 , wherein the insulating concrete form comprises
(A) a first panel member comprising:
(1) a first outer panel side including a first wall surface area extending generally vertically thereon;
(2) a first inner panel side positioned oppositely from said first outer panel side; and
(3) at least two first slots in the first inner panel side adapted to accept a connecting member;
(B) a second panel member comprising:
(1) a second outer panel side including a second wall surface area extending generally vertically thereon and facing oppositely from said first panel member;
(2) a second inner panel side positioned oppositely from said second outer panel side and facing said first inner panel side of said first panel member; and
(3) at least two second slots in the second inner panel side adapted to accept a connecting member; and
(C) at least two connecting members detachable and securable with respect to said first panel member and said second panel member adapted to maintain a spatial distance therebetween for defining a molding chamber therebetween, the connecting members comprising:
(1) a first flange detachably and securably extending within said first slot of said first panel member;
(2) a second flange detachably and securably extending within said second slot of said second panel member; and
(3) a mid-section portion.
8. The method according to claim 7 , wherein:
(A) the first panel member is press fit into one or more first cleats such that the first vertical flange contacts the first outer panel side and the second vertical flange contacts the first inner panel side; and
(B) the second panel member is press fit into one or more second cleats such that the first vertical flange contacts the second outer panel side and the second vertical flange contacts the second inner panel side.
9. The method according to claim 7 , wherein the first panel member and the second panel member each have a male end comprising a tongue edge and a female end comprising a female groove edge that facilitates a tongue and groove union between corresponding members.
10. The method according to claim 7 , wherein the connecting member comprises a material selected from the group consisting of plastics, metal, construction grade plastics, composite materials, ceramics, and the like.
11. The method according to claim 1 , wherein the insulating concrete forms comprise an expanded polymer matrix.
12. The method according to claim 11 , wherein the expanded polymer matrix comprises one or more polymers selected from the group consisting of homopolymers of vinyl aromatic monomers; copolymers of at least one vinyl aromatic monomer with one or more of divinylbenzene, conjugated dienes, alkyl methacrylates, alkyl acrylates, acrylonitrile, and/or maleic anhydride; polyolefins; polycarbonates; an interpolymer of a polyolefin and in situ polymerized vinyl aromatic monomers; and combinations thereof.
13. The method according to claim 11 , wherein the polymer matrix comprises carbon black, graphite or a combination thereof.
14. The method according to claim 1 , wherein the concrete comprises one or more cements selected from the group consisting of Portland cements, pozzolana cements, gypsum cements, aluminous cements, magnesia cements, silica cements, and slag cements.
15. The method according to claim 1 , wherein the concrete is light weight concrete.
16. The method according to claim 1 , wherein the concrete comprises
8-20 volume percent cement,
11-50 volume percent sand,
10-31 volume percent expanded thermoplastic particles,
9-40 volume percent coarse aggregate, and
10-22 volume percent water;
wherein the expanded thermoplastic particles have an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.02 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3.
17. The method according to claim 1 , wherein rebar is placed in one or more molding chambers of the insulating concrete forms prior to placing the concrete.
18. The method according to claim 1 , wherein a water impervious fabric is placed over at least a portion of an outward facing surface of the insulating concrete forms.
19. An insulating concrete wall constructed according to the method of claim 1 .
20. A building comprising the insulating concrete wall according to claim 19 .