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Tilt-up concrete panel and forming system therefore    
United States Patent6067757   
Link to this pagehttp://www.wikipatents.com/6067757.html
Inventor(s)Olson; Timothy (Post Falls, ID); Hardison; Robert (Post Falls, ID)
AbstractA concrete wall panel for tilt-up construction provides polymeric peripheral elements defining panel and orifice edges and medial fastening strips extending in the panel between the peripheral elements, all of which remain as part of the finished panel to accept traditional self-penetrating nail, screw and staple fasteners historically used in wood construction. The peripheral elements are of solid configuration to provide a form for pouring plastic concrete that forms the panel embodying them. The fastening strips extend through the panel between opposed panel surfaces and are formed by two initially releasably interconnected elements defining voids therebetween to allow thickness adjustment and convenient placement and support of structural components within the panel. The fastening strips define spaced areas to receive traditional wood fasteners and may carry index strips on opposed exposed surfaces to visually indicate strip location and fastening areas. The peripheral elements allow joinder of adjacent panels with each other and both the peripheral elements and the fastening strips allow joinder of structural elements on one or both panel surfaces by self-penetrating fasteners of wood construction.
   














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Drawing from US Patent 6067757
Tilt-up concrete panel and forming system therefore - US Patent 6067757 Drawing
Tilt-up concrete panel and forming system therefore
Inventor     Olson; Timothy (Post Falls, ID); Hardison; Robert (Post Falls, ID)
Owner/Assignee    
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Publication Date     May 30, 2000
Application Number     09/252,955
PAIR File History     Application Data   Transaction History
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Litigation
Filing Date     February 17, 1999
US Classification    
Int'l Classification    
Examiner     Kent; Christopher T.
Assistant Examiner    
Attorney/Law Firm     Bergman; Keith S.
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Patent Tags     tilt-up concrete panel forming therefore
   
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Baxter
52/309.11
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Mensen
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Kim
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What we claim is:

1. A structure supportable on a planar forming surface for formation of and embedment in a concrete panel for tilt-up wall construction comprising, in combination:

a plurality of rigid interconnected peripheral elements of similar extrudable cross-section, in coplanar array and having outer surfaces and inner surfaces, said peripheral elements forming peripheral edges and edges of optional internally defined orifices of the concrete panel to define a form for edges of panel concrete, said peripheral elements having

coplanar upper and lower edges for positioning on the forming surface,

first means for embedment of concrete facing surfaces in panel concrete for attachment thereto,

second means for releasable attachment of form braces, to outer surfaces distal from panel concrete,

third means for attachment of at least one fastening strip to extend between inner surfaces of at least two peripheral elements and

fourth means for fastenably receiving self-penetrating fasteners of wood construction; and

at least one elongate fastening strip, having at least one planar surface element with an outer outer surface coplanar with one coplanar surface of the edges of the peripheral elements, said at least said at least one fastening strip

extending fastenably between two peripheral elements for positional maintenance and

having means for fastenably receiving therein self-penetrating fasteners of wood construction.

2. The structure of claim 1 wherein the means for fastenably receiving self-penetrating fasteners of wood construction in structure elements comprise forming the peripheral elements and fastening strips from foamed polymeric material.

3. The structure of claim 1 wherein the means for embedment of concrete facing surfaces of the peripheral elements in panel concrete comprise

paired opposed elongate channels defined in spaced relationship in the inner concrete facing surfaces of the peripheral elements, each channel of the pair angulated inwardly toward the opposed channel.

4. The structure of claim 1 having

a plurality of form braces releasably fastened to the outer surfaces of the peripheral elements in spaced relationship for releasable fastening to the forming surface to positionally maintain the peripheral elements on the forming surface for forming concrete in the form defined by the peripheral elements.

5. The structure of claim 1 having concrete within the form defined by the peripheral elements.

6. The structure of claim 1 further characterized by each peripheral element having:

a medial body portion, with a plurality of spaced frangibly connected portions removable to define holes therethrough, connecting two similar spaced side elements,

the inner surfaces of the side elements defining means for receiving and positionally maintaining end portions of fastening strips and

the outer surfaces of the side elements defining spaced channels angulated in parallel relationship to receive fastening dogs of form braces for releasable interconnection.

7. The structure of claim 6 having a plurality of releasably interconnected form braces each comprising:

a planar base structurally supporting a perpendicularly extending vertical side with an angulated brace extending between the base and the vertical side,

plural spaced fastening dogs carried by the vertical side distal from the base and angulated in parallel orientation to fastenably engage within the spaced angulated channels defined in the peripheral elements, and the planar base having means for releasable interconnection with the forming surface.

8. The structure of claim 1 wherein the fastening strips further comprise:

two elongate planar surface elements interconnected in spaced parallel relationship by a plurality of spaced, cooperating pairs of male and female connecting elements with one of each pair of connecting elements extending inwardly from interconnection with the opposed surface elements, said connecting elements of each pair having inter fitting inner portions to releasably interconnect the surface elements in spaced parallel adjacency.

9. The fastening strips of claim 8 further having

continuous channels defined through the fastening strips and through the interconnected connecting elements and

at least some connecting elements having at least one radially extending fin to support auxiliary structural components to be carried within panel concrete.

10. The fastening strips of claim 8 further having end portions of each surface element defining connecting means to interconnect an adjacent surface element in linear array and

the outer surface of at least one surface element carrying an index tape to identify position of the surface element and positions of connecting elements extending therefrom.

11. The structure of claim 1 wherein the at least one fastening strip has

one elongate surface element coplanar with a first planar surface through the edges of the peripheral elements with at least two spaced first connecting elements extending into the form spacedly distant from the second planar surface through the edges of the peripheral elements, with first connecting means in the inner end portions of the first connecting elements and

a connecting strip in the form spacedly inward from the second planar surface through the edges of the peripheral elements having at least two spaced second connecting elements arrayed to interconnect with the at least two first connecting elements carried by the elongate surface element, said second connecting elements having inner end portions with second connecting means to interconnect with the first connecting means of the first connecting elements of the surface element and outer end portions extending substantially to the second planar surface through the edges of the peripheral elements.

12. The structure of claim 1 wherein the at least one fastening strip provides

one elongate surface element coplanar with a first planar surface through the upper edges of the peripheral elements and having at least two spaced first connecting elements extending into the form spacedly distant from the second planar surface through the lower edges of the peripheral elements, with first connecting means in inner end portions of the first connecting elements and

at least two second connecting elements each having at least three radially extending fins with legs, extending to the second planar surface, said second connecting elements extending inwardly into the form spacedly distant from the surface element and defining second connecting means to interconnect with the first connecting means of the at least two first connecting elements of the surface element.

13. A panel for tilt-up wall construction, comprising in combination:

a continuous concrete panel member with first and second substantially planar parallel sides, said concrete panel member defining peripheral edges and optional orifices;

a plurality of interconnected peripheral elements extending between the first and second sides of the concrete panel and forming the peripheral edges and edges of the optional orifices, each said peripheral element having

means for embedment surfaces adjacent the concrete panel member in the concrete panel member to form an integrated panel and

means for fastenably receiving self-penetrating fasteners of wood construction for attachment of construction materials to the peripheral elements.

14. The panel of claim 13 wherein

the peripheral elements have means for attachment of at least one fastening strip extending between two peripheral elements and embedded in the concrete panel member and said fastening strip having at least one planar surface element with an outer surface coplanar with

one planar side of the panel and

means for fastenably receiving self-penetrating fasteners of wood construction for attachment of construction material to the at least one fastening strip.

15. The panel of claim 13 wherein the peripheral elements

are arrayed with a continuous inner surface to create a form for the peripheral edges and optional orifice edges of the concrete panel member and

have means for releasable attachment of form braces on the peripheral edges of the peripheral elements distal from the concrete panel member.

16. The panel of claim 14 wherein the at least one elongate fastening strip comprises

two elongate planar surface elements interconnected in spaced parallel relationship by a plurality of spaced cooperating pairs of male and female connecting elements with connecting elements of each pair extending inwardly toward each other from interconnection with the opposed planar surface elements, said connecting elements of each pair having adjacent interfitting portions to interconnect the outer surfaces of each surface element in coplanar relation with the first and second panel sides.

17. The panel of claim 16 wherein the fastening strips further have

interconnecting channels defined through the fastening strips and through the interconnected connecting elements and

at least some connecting elements have fins to support auxiliary structural components carried within the panel concrete.

18. The panel of claim 14 wherein the surface element of the at least one elongate fastening strip carries

an index strip on its surface coplanar with one panel side indicating position of the surface element and positions of connecting elements extending therefrom.

19. A panel for tilt-up wall construction formed partially of concrete with forming structure embedded therein, comprising in combination:

a continuous concrete panel member with first and second substantially planar parallel sides, said panel member defining peripheral edges and optional orifices;

a plurality of interconnected peripheral elements extending between the first and second sides of the concrete panel member and forming the peripheral edges and edges of optional orifices in the concrete panel member, each said peripheral element having

means for embedment of sides adjacent the concrete panel member in the portion of the concrete panel member,

means for fastenably receiving self-penetrating fasteners of wood construction to attach structural components to the panel,

means for attachment of at least one fastening strip to attach structural components to the panel, and

means for releasable attachment of form braces to positionally maintain the peripheral elements on an underlying planar forming surface; and

at least one elongate fastening strip, extending between two peripheral elements and embedded in the panel concrete member,

having at least one planar surface element with an outer surface coplanar with one planar side of the panel and

means for fastenably receiving self-penetrating fasteners of wood construction to attach structural components to the at least one fastening strip.

20. The panel of claim 19 wherein the means for fastenably receiving self-penetrating fasteners of wood construction comprise

forming the peripheral elements and the at least one elongate fastening strip from foamed polymeric material optionally embodying particulated cellulosic filling material to allow fastenable penetration of self-penetrating fasteners into the peripheral elements and at least one fastening strip.
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II. BACKGROUND OF INVENTION

IIA. RELATED APPLICATIONS

There are no applications related hereto heretofore filed in this or any foreign country.

IIB. FIELD OF INVENTION

This invention relates generally to tilt-up concrete wall panels and more particularly to such a panel that has embedded fastening elements that provide peripheral forming and fastening means and internal fastening strips.

IIC. BACKGROUND AND DESCRIPTION OF PRIOR ART

Tilt-up type poured concrete walls have long been known for the building of various structures, especially those of light industrial design in a medial range between wood frame structures and poured in place reinforced concrete structures. Though the history of concrete tilt-up walls has been long and during that history the walls have been improved until they have become increasingly sophisticated and complex, there still remain problems with the structures and with their formation process, especially when used in lighter construction for smaller buildings. The tilt-up form of construction in fact has not become particularly popular nor extensively used in various lighter applications such as small office buildings, low-rise multi-dwelling units and individual residential housing units. The instant invention seeks to provide a type of tilt-up concrete wall and method for its formation which resolve various existing problems to make the construction method more adaptable to and appealing for such lighter construction.

Concrete panels not formed in place have long presented problems in connecting adjacent panels to each other and in connecting ancillary structural elements to the concrete panels. Though many and various methods of making such interconnections have become known, none have been so simple nor so standardized as the traditional nail or screw type self-penetrating fasteners used in wood frame construction. Since much lighter construction of smaller buildings and dwellings has been carried out by persons familiar with the traditional fasteners and fastening procedures used with wood frame structural elements, the use of preformed concrete panels, and especially those of the tilt-up type, has not become common in such lighter construction because of the difficulty and lack of

familiarity and facility in dealing with past concrete panel connectors. The instant tilt-up panel solves this problem by providing fastening elements about peripheral and orifice edges of the panel and fastening strips in the medial portions of the panels that all are formed of polymeric material that accepts traditional self-penetrating type fasteners applied in traditional fashion such as has historically been done in past light frame construction. The use of such fastening elements does not negate the use of traditional concrete panel interconnections with each other or with other structural elements, but is compatible with such interconnections.

Heretofore when traditional nail or screw fasteners have been used with concrete panels, fastening elements have been established in the panels to receive the fasteners, but it often has been a problem to locate the fastening elements after panel formation for positioning of fasteners. The instant fastening strips solve this problem by providing elongate fastening areas of linear array that may be in parallel relationship with traditional spacings similar to studs in a wall of traditional light frame construction. Additionally each fastening strip may be provided with visually exposed positioning tape that carries indicia indicating the position of fastening elements defined by the fastening strips so that the fastening elements may be readily located for use.

An additional problem with the use of concrete panels in lighter construction in the past has been in providing an economical method for forming the peripheral edges of the panels and orifices defined therein for concrete placement and finishing. Various reusable, normally modular forming systems have heretofore become known, but these systems have generally been relatively expensive and have required substantial expertise for their use, both of which have prevented general acceptance of the systems. Since tilt-up wall formation for lighter construction generally is carried out at a building site to obtain greater economic benefits, most such wall panels have heretofore been formed with forming members, especially of wood, which generally have not been reusable, at least to any substantial degree or over any substantial period. The instant wall panel solves this problem by using the peripheral fastening elements as forming members that remain permanently embedded in the panel that they form. There is no necessity for additional forming elements that do not become a part of the ultimate panel structure and the process therefore provides a lower cost formation process that avoids waste of forming material. An additional ancillary benefit allows such peripheral fastening elements to be particularly configured to accept cooperating form braces that are simple of placement, easily aligned and multiply reusable. The configuration provided in the exterior surface of the peripheral elements to allow fastening of form braces also provide structure that can carry adhesive caulking compounds to aid the insulation and joinder of the edge portions of adjacent concrete panels to each other.

The internal fastening strips are compound structures having two outer surface elements joined in their medial portions, either directly to each other or proximally with a filler strip therebetween, to adjust to and accommodate different concrete panel thicknesses. This structure provides orifices between the opposed surface elements and their connecting structures to allow passage and support of various secondary structural elements that commonly are associated with concrete panels, such as elongate reinforcing bars, electrical wires and junction boxes, plumbing pipes and structures and the like. The connecting elements of the fastening strips are designed to provide chairs for support of these secondary structural elements in the medial portion of a panel, while at the same time providing exposed surface fastening structures to receive traditional fasteners. Fastening strips that have a surface strip on only one side may be used to provide a uniform concrete surface is on one panel side, if desired.

The forming structure in addition to providing the benefits indicated in general allows use of the traditional auxiliary elements and processes historically associated with tilt-up concrete panels in their common and habitually familiar forms.

Our invention resides not in any one of these features individually, but rather in the synergistic combination of all of its structures and processes that necessarily give rise to the functions and results flowing therefrom as herein specified and claimed.

III. SUMMARY OF INVENTION

The instant concrete panel for tilt-up construction provides peripheral fastening and forming elements about its edges that remain embedded in the finished panel and medial fastening strips that are embedded in the panel interior to allow fastening of structural elements to the panel and fastening of adjacent panels to each other. The peripheral fastening elements are formable by extrusion of polymeric material in solid configuration to allow their use as forms for the plastic concrete of the panel. The surface of the peripheral fastening elements distal from the concrete of the panel are shaped to releasably receive the form braces to positionally maintain the peripheral elements on a casting surface during the concrete forming process. The medial fastening strips are formed by one surface element having inwardly extending fastening elements or by two similar spacedly opposed surface elements releasably joined by connecting structure that positions the outer surfaces of the surface elements in coplanar relationship with the surfaces of the concrete portion of the panel. The fastening strip connecting structure provides voids to allow placement of structural elements in the concrete of the panel and supports for positional maintenance of these elements during panel formation. None of the elements of our panel prevent or interfere with the use of traditional components of concrete tilt-up panels, nor do the elements interfere with traditional methods of fastening such panels to each other or of fastening other structural components to the panels.

In providing such a product and forming method, it is:

A principal object to provide a poured concrete panel for tilt-up construction that has peripheral fastening elements about its outer and orifice edges that are formed of polymeric material that accepts traditional nail and screw fasteners of light frame construction applied in traditional fashion.

A further object is to provide such a panel wherein the fastening elements are of a solid configuration so that when they are joined to form closed figures about panel edges and orifices the fastening elements create a form for plastic concrete forming fastening elements in the panel.

A further object is to provide such peripheral fastening elements that releasably interconnect plural form braces that maintain the peripheral elements in proper forming array on a forming surface.

A further object is to provide such a panel that has elongate fastening strips embedded in the medial concrete portion to accept traditional self-penetrating type wood fasteners.

A further object is to provide such fastening strips that may carry index strips on the exposed surfaces to indicate strip position and fastening structure location.

A still further object is to create such peripheral elements and fastening strips that may be formed by extrusion or molding from resinous or polymeric plastics, especially those of a reclaimed, filled and foamed nature.

A still further object is to create such a panel that allows attachment and use of traditional surfacing materials of light frame construction and the habitually familiar fasteners and fastening processes of such construction without prohibiting the fastening structures and methods commonly used in present day concrete tilt-up panel construction.

A still further object is to provide such a panel and forming method that are of new and novel design, of rugged and durable nature, of simple and economic use and otherwise well suited to the uses and purposes for which they are intended.

Other and further objects of our invention will appear from the following specification and accompanying drawings which form a part hereof. In carrying out the objects of our invention, however, it is to be understood that its features are susceptible of change in ordering, design and structural arrangements, with only preferred and practical embodiments of the best known mode being illustrated in the accompanying drawings and specified, as is required.

IV. BRIEF DESCRIPTION OF DRAWINGS

In the accompanying drawings which form a part hereof and wherein like numbers of reference refer to similar parts throughout:

FIG. 1 is an orthographic plan view of an assemblage of peripheral fastening elements, fastening strips and structural elements for a panel on a forming surface ready for concrete pouring.

FIG. 2 is an expanded, somewhat diagrammatic view of the various layers of a portion of the wall structure of FIG. 1, taken on a line such as 2--2 thereon in the direction indicated by the arrows, with views of individual layered members and components labeled respectively FIGS. 2A through 2G.

FIG. 3 is an enlarged and expanded medial cross-sectional view of the paired elements of a releasable connector structure extending between two opposed surface elements of a fastening strip.

FIG. 4 is an isometric surface view of a free-standing form of female connector element having support chairs for component structures.

FIG. 5 is an orthographic top view of the connector of FIG. 4.

FIG. 6 is a medial vertical cross-sectional view through the connector of FIG. 4, taken on the line 6--6 thereon in the direction indicated by the arrows.

FIG. 7 is a cross-sectional view of a compound connector structure having an extension connector between connectors of two opposed surface elements to expand the thickness of a fastening strip.

FIG. 8 is an orthographic top view of a portion of a peripheral fastening element of our panel.

FIG. 9 is an orthographic elevational view of the inner panel facing surface of the peripheral fastening element of FIG. 8.

FIG. 10 is an enlarged vertical cross-sectional view through the fastening element of FIG. 8, taken on the line 10--10 thereon in the direction indicated by the arrows.

FIG. 11 is a vertical cross-sectional view through a peripheral fastening element with a form brace shown in orthographic side view interconnected therewith.

FIG. 12 is an orthographic elevational view of the inner peripheral fastening element facing surface of the form brace of FIG. 11.

FIG. 13 is an orthographic top view of the form brace of FIG. 11.

FIG. 14 is an orthographic top view of the interconnecting end structures of surface elements of adjacent fastening strips.

FIG. 15 is an orthographic side view of the interconnecting end structures of the surface elements of FIG. 14.

FIG. 16 is a horizontal cross-sectional view through a typical external corner of two panels fastened in perpendicular relationship showing a method of interconnection.

Fi re 17 is an orthographic top view of a portion of a spacing tape that may be used to space fastening strips or connecting elements in spaced parallel relationship.

FIG. 18 is an orthographic top view of a species of fastening strip that does not have an exposed surface element.

FIG. 19 is a partially cut-away and expanded elevational view of a fastening strip having an exposed surface element with connecting elements that are releasably interconnected with the surface element.

FIG. 20 is an orthographic elevational view of the fastening strip of FIG. 18 positioned to show how it may be joined with the fastening strip of FIG. 19.

FIG. 21 is a partial horizontal cross-sectional view through the female interconnectable end structure of the surface element of the fastening strip of FIG. 19, taken on the line 21--21 thereon in the direction indicated by the arrows.

FIG. 22 is a vertical cross-sectional view through the female interconnectable end structure of the internal fastening strip of FIG. 19, taken on the line 22--22 thereon in the direction indicated by the arrows.

FIG. 23 is a vertical cross-sectional view through fastening strip of FIG. 20, taken on the line 23--23 thereon in the direction indicated by the arrows.

FIG. 24 is an expanded medial vertical cross-sectional view through two adjacent connecting elements of opposite gender of the fastening strips of FIGS. 19 and 20, taken as on the line 24--24 thereon in the direction indicated by the arrows.

V. DESCRIPTION OF THE PREFERRED EMBODIMENT

Our invention generally provides a concrete panel for tilt-up wall construction having embedded peripheral fastening elements 12 that are fastenable by form braces 11 on a forming surface 10 to serve as forming members, plural embedded fastening strips 13 and embedded auxiliary structural components 14 heretofore known in tilt-up concrete panel construction.

Peripheral fastening elements 12, as seen especially in FIGS. 8-10, are elongate, rigid elements of an extrudable cross-sectional configuration formed by medial body 15 joining similar side elements 16. The outer panel edge surface 17 of the peripheral element is substantially planar but defines spaced parallel fastening channels 18 angulated inwardly and downwardly, when the peripheral element is oriented in a forming position as illustrated in FIG. 11, to receive fastening dogs of form braces. The medial portion of body 15 defines spaced holes 55 having covers with frangible peripheries to allow removal for passage of structural elements, such as rebar and wires to be carried in a panel. The holes 55 preferably are spaced on sixteen inch centers in accordance with prior traditional concrete wall forming practices, but this spacing is not necessary. The side elements 16 are somewhat thicker than the body element 15 to provide a greater fastening area and additional strength and rigidity for the sides while conserving material.

Commonly with this construction, an elongate void or channel 19 will be formed in each side element to conserve material and improve the extrusion characteristics of the peripheral element. The thicker side element structure and thinner medial body structure by their nature define medial channel 15a on the inner side of the peripheral element for the same purposes. The inner panel facing surface of side element 16 defines two vertically spaced side channels 20, each extending inwardly in angulated orientation toward each other to provide structure that aids in bonding the peripheral element to adjacent concrete and provides somewhat more uniform thickness of portions of the cross-section of the peripheral elements, again to aid formation of the element by extrusion and conserve material while maintaining appropriate strength and rigidity.

Inner panel facing surfaces 21 of the side elements 16 define plural notches 22 in spaced relationship to receive end portions of fastening strips 13 to aid establishment and maintenance of the positional array of the fastening strips in the panel structure prior to embedment in panel concrete. The notches 22 preferably are arrayed on sixteen inch centers to provide fastening strips in the traditional and habitually familiar spacing of modern day light frame construction, though this particular spacing is neither necessary nor essential and other spacing arrays are within the ambit and scope of our invention. The notches 22 for manufacturing convenience may be created in all peripheral elements, or if desired only in those elements that do receive the end portions of fastening strips for positional maintenance, as commonly the fastening strips extend in spaced parallel array in only one direction in a concrete panel, usually vertically.

Form braces 11, that are releasably fastenable on the outer surface 10 of peripheral elements 12 to positionally maintain the peripheral elements as a forming structure on a forming surface 10, are illustrated particularly

in FIGS. 11-13. Each form brace provides horizontal base 23 supporting perpendicularly extending, upright side 24 at the peripheral element facing inner end with angulated support 25 communicating between the upright side 24 and base 23 to provide additional rigidity and strength. The base 23 defines plural spaced holes 26 to receive fasteners (not shown), generally of a double-headed form nail type, to positionally maintain the base on an underlying forming surface. The inner surface of upright side 24 defines vertically spaced, downwardly angulated fastening dogs 27 configured and arrayed to fastenably fit within the two vertically spaced channels 18 of an associated peripheral element to releasably interconnect with that element for positional maintenance on a forming surface.

It is to be noted with this interconnection of form brace and peripheral element that connection will be releasably maintained so long as the two elements are both supported and positionally maintained on a flat forming surface by reason of the downward angulation of both the fastening dogs and the side element channels, but this interconnection is readily releasable when the form brace is disconnected from the forming surface so that it may be removed in an upwardly and outwardly angulated direction.

The form brace 11 is a reusable element by reason of its releasable attachment to both the forming base and a peripheral element and therefore preferably is formed of some reasonably durable rigid material that allows substantial reuse in forming our panels. This material preferably is metal, such as softer steel or a harder aluminum alloy, because of the economy, strength and durability that such materials offer.

Fastening strips 13 are shown generally in FIGS. 2 and 18-20. Each fastening strip of the species of FIG. 2 provides spacedly parallel elongate surface elements 28 with planar outer surfaces 29. The end portions of these strips may conveniently, though not necessarily, be formed with connecting structures adapted to interconnect the ends of similar adjacent strips to easily provide compound strips formed by plural elements to provide desired length. One such type of connecting structure is illustrated in FIGS. 14-15 where it is seen to provide interlocking female end 30 that is essentially the mirror image of similar male structure 31 defined in the end of a second surface element to interfit therewith in a fashion that maintains surface element continuity and prohibits elongate or lateral motion of the joined elements relative to each other. This particular interconnecting structure is not novel per se nor essential to our invention and other connecting structures known for the same purposes are within the ambit and scope of our invention.

The surface elements 28 each define plural lineally aligned spaced holes 32, shown in FIG. 3, to cooperate with connecting elements extending between the surface elements to define continuous channels therethrough. The size and spacing of these holes is not critical and may vary while remaining within the ambit and scope of our invention, but necessarily will be dictated by the positioning of connecting elements associated therewith.

The dimensioning of the surface elements 28 is not critical, but they must be wide enough to accommodate structures interconnecting the opposed surface or connecting elements and must provide sufficient strength and rigidity for configurational maintenance during the forming and concrete casting and finishing processes. Preferably the surface elements are approximately 0.75 to 2.00 inches in width and approximately 0.75 to 1.0 inch in thickness when the surface element is formed from polymeric material. The length of the surface elements may be somewhat governed by the formation process therefore, but preferably for either extrusion or molding formation, especially in view of the interconnecting end portions, the length is from approximately four to eight feet.

Inner surfaces 33 of surface elements 28 structurally carry a plurality of similarly spaced, lineally arrayed and alternating female connecting elements 34 and male connecting elements 35. Each female connecting element 34 comprises a truncated conical structure, illustrated especially in FIG. 3, that has its base adjacent the inner surface 33 of the surface element 28 supporting it. The female connecting element 34 defines internal conical channel 36 extending from its inner end portion to an axially medial position with inter communicating cylindrical channel 37 extending outwardly from interconnection therewith to interconnect with one of the holes 32 defined in the surface element 28. The conical channel 36 is designed to provide a self-centering frictional connection with an interconnecting male element and to provide a stop to maintain two connected surface elements in parallel adjacency. The length of the female connectors 34 may vary in our fastening strip, but the distance between the inner end of the connector 34 and the outer surface 29 of surface element 28 supporting it should be related to configuration of the associated male connector so that two interconnected surface elements are coplanar with the opposed side surfaces of peripheral elements with which the surface elements are interconnected.

The male connecting elements 35 provide a body portion 35a similar to the female connecting element 34 and similarly oriented on a surface element 28 on a surface element 28, but in addition provides inwardly extending connector portions 35b of such smaller diameter and truncated conic configuration as to frictionally fit within channel 36 defined by an opposed inter fitting female connecting element. This construction defines a ridge between body portion 35a and conic connector portion 35b which fits against the inner end portion of female connector 34 to interconnect two opposed surfacing elements in a predetermined spaced relationship. The male connecting element 35 defines medial channel 38 that extends through both body portion 35a and connector portion 35b, with frangible web 39 that can be easily removed covering the inner end portion of the channel. The male connecting element 35 is structurally carried on the inner surface 33 of surface element 28 in a position whereat medial channel 38 is positioned over a hole 32 defined in the surfacing element to communicate with that hole.

Either the male or female connecting elements of FIG. 3, may be provided with one or more radially extending fins 40, in the instance illustrated comprising one, to provide additional support for the connector and define a chair structure for support of structural components to be contained within the wall panels, such as steel reinforcing rods and electrical and plumbing conduit. The fins preferably are of somewhat trapezoidal configu