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US 12,723,405 B1Granted
Construction of ICF walls with integral concrete baseboards and internal conduits for wiring and other uses
AssigneeGodfrey & Company, Innovations LLC
InventorRobert C. Godfrey
Life of this patent
Estimating the term…
Abstract
An assembly and method for: (i) forming attractive integral concrete baseboards on ICF walls and (ii) installing electrical junction box housings or other fittings or housings in ICF walls, and running wiring and conduits through ICF walls for outlets, lights, switches and other electrical devices, without drilling channels through the concrete layer or cutting channels in the rigid foam panels of the ICF wall and without removing or compromising the integrity of the structural webs within the ICF blocks.
Claims12
A method of constructing a wall comprising steps of:
- a) forming an assembly on a slab or other foundation comprising
- two or more baseboard-forming ICF blocks which are connected together in a row, each of the two or more baseboard-forming ICF blocks comprising (i) an upwardly extending first rigid foam panel which is positioned on a first side of the row, (ii) an upwardly extending second rigid foam panel which is positioned on a second side of the row, (iii) an interior space formed between the first and the second rigid foam panels, and (iv) the second rigid foam panel having a lower end which is spaced above the slab or other foundation,
- opposing outer support panels between which the row of said two or more baseboard-forming ICF blocks is held, the opposing outer support panels comprising (i) one or more first outer support panels positioned outside of the first side of the row of said two or more baseboard-forming ICF blocks and (ii) one or more second outer support panels positioned outside of the second side of the row of said two or more baseboard-forming ICF blocks, each of the one or more second outer support panels having an inner upwardly extending contacting face, and
- a baseboard-forming spacer or series of baseboard-forming spacers which is attached to the second rigid foam panels on the second side of the row of said two or more baseboard-forming ICF blocks and is positioned between the one or more second outer support panels and the second rigid foam panels on the second side of the row of said two or more baseboard-forming ICF blocks, the baseboard-forming spacer or series of baseboard-forming spacers having (i) a bottom end, (ii) an inner edge of the bottom end which is nearest to the lower ends of the second rigid foam panels, and (iii) an outer edge of the bottom end which is substantially even with or lower than the inner edge of the bottom end and is spaced above the slab or other foundation, and
- a baseboard-forming cavity having (i) an upper end defined by the bottom end of the baseboard-forming spacer or series of baseboard-forming spacers, (ii) an outer upwardly extending side defined by the inner upwardly extending contacting face(s) of the one or more second outer support panels, and (iii) a bottom end defined by an upper surface of the slab or other foundation;
- b) pouring concrete into the interior spaces of the two or more baseboard-forming ICF blocks and into the baseboard-forming cavity and allowing the concrete to cure at least sufficiently for removing the opposing outer support panels and the baseboard-forming spacer or series of baseboard-forming spacers;
- and then
- c) removing the opposing outer support panels and the baseboard-forming spacer or series of baseboard-forming spacers.
5 more elements
A method of constructing a wall comprising steps of:
- a) forming an assembly on a slab or other foundation comprising
- two or more baseboard-forming ICF blocks which are connected together in a row, each of the two or more baseboard-forming ICF blocks comprising (i) an upwardly extending first rigid foam panel which is positioned on a first side of the row, (ii) an upwardly extending second rigid foam panel which is positioned on a second side of the row, (iii) an interior space formed between the first and the second rigid foam panels, and (iv) the second rigid foam panel having a lower end which is spaced above the slab or other foundation,
- each of the first rigid foam panels on the first side of the row of said two or more baseboard-forming ICF blocks having a lower end which is on, even with, or lower than an upper surface of the slab or other foundation,
- opposing outer support panels between which the row of said two or more baseboard-forming ICF blocks is held, the opposing outer support panels comprising (i) one or more first outer support panels positioned outside of the first side of the row of said two or more baseboard-forming ICF blocks and (ii) one or more second outer support panels positioned outside of the second side of the row of said two or more baseboard-forming ICF blocks, and
- a baseboard-forming spacer or series of baseboard-forming spacers which is attached to the second rigid foam panels on the second side of the row of said two or more baseboard-forming ICF blocks and is positioned between the one or more second outer support panels and the second rigid foam panels on the second side of the row of said two or more baseboard-forming ICF blocks, the baseboard-forming spacer or series of baseboard-forming spacers having (i) a bottom end, (ii) an inner edge of the bottom end which is nearest to the lower ends of the second rigid foam panels, and (iii) an outer edge of the bottom end which is substantially even with or lower than the inner edge of the bottom end and is spaced above the slab or other foundation;
- b) pouring concrete into the interior spaces of the two or more baseboard-forming ICF blocks and allowing the concrete to cure at least sufficiently for removing the opposing outer support panels and the baseboard-forming spacer or series of baseboard-forming spacers;
- and then
- c) removing the opposing outer support panels and the baseboard-forming spacer or series of baseboard-forming spacers.
5 more elements
A method of constructing a wall comprising steps of:
- a) forming an assembly on a slab or other foundation comprising
- two or more baseboard-forming ICF blocks which are connected together in a row, each of the two or more baseboard-forming ICF blocks comprising (i) an upwardly extending first rigid foam panel which is positioned on a first side of the row, (ii) an upwardly extending second rigid foam panel which is positioned on a second side of the row, (iii) an interior space formed between the first and the second rigid foam panels, and (iv) the second rigid foam panel having a lower end which is spaced above the slab or other foundation,
- opposing outer support panels between which the row of said two or more baseboard-forming ICF blocks is held, the opposing outer support panels comprising (i) one or more first outer support panels positioned outside of the first side of the row of said two or more baseboard-forming ICF blocks and (ii) one or more second outer support panels positioned outside of the second side of the row of said two or more baseboard-forming ICF blocks, and
- a baseboard-forming spacer or series of baseboard-forming spacers which is attached to the second rigid foam panels on the second side of the row of said two or more baseboard-forming ICF blocks and is positioned between the one or more second outer support panels and the second rigid foam panels on the second side of the row of said two or more baseboard-forming ICF blocks, the baseboard-forming spacer or series of baseboard-forming spacers having (i) a bottom end, (ii) an inner edge of the bottom end which is nearest to the lower ends of the second rigid foam panels, and (iii) an outer edge of the bottom end which is lower than the inner edge of the bottom end and is spaced above the slab or other foundation, at least an outer portion of the bottom end of the baseboard-forming spacer or series of baseboard-forming spacers extending laterally outward and downwardly at an angle, or curving laterally outwardly and downwardly, to the outer edge of the bottom end of the baseboard-forming spacer or series of baseboard-forming spacers;
- b) pouring concrete into the interior spaces of the two or more baseboard-forming ICF blocks and allowing the concrete to cure at least sufficiently for removing the opposing outer support panels and the baseboard-forming spacer or series of baseboard-forming spacers;
- and then
- c) removing the opposing outer support panels and the baseboard-forming spacer or series of baseboard-forming spacers.
4 more elements
A method of constructing a wall comprising steps of:
- a) forming an assembly on a slab or other foundation comprising
- two or more baseboard-forming ICF blocks which are connected together in a row, each of the two or more baseboard-forming ICF blocks comprising (i) an upwardly extending first rigid foam panel which is positioned on a first side of the row, (ii) an upwardly extending second rigid foam panel which is positioned on a second side of the row, (iii) an interior space formed between the first and the second rigid foam panels, and (iv) the second rigid foam panel having a lower end which is spaced above the slab or other foundation,
- opposing outer support panels between which the row of said two or more baseboard-forming ICF blocks is held, the opposing outer support panels comprising (i) one or more first outer support panels positioned outside of the first side of the row of said two or more baseboard-forming ICF blocks and (ii) one or more second outer support panels positioned outside of the second side of the row of said two or more baseboard-forming ICF blocks, and
- a baseboard-forming spacer or series of baseboard-forming spacers which is attached to the second rigid foam panels on the second side of the row of said two or more baseboard-forming ICF blocks and is positioned between the one or more second outer support panels and the second rigid foam panels on the second side of the row of said two or more baseboard-forming ICF blocks, the baseboard-forming spacer or series of baseboard-forming spacers having (i) a bottom end, (ii) an inner edge of the bottom end which is nearest to the lower ends of the second rigid foam panels, and (iii) an outer edge of the bottom end which is substantially even with or lower than the inner edge of the bottom end and is spaced above the slab or other foundation;
- b) pouring concrete into the interior spaces of the two or more baseboard-forming ICF blocks and allowing the concrete to cure at least sufficiently for removing the opposing outer support panels and the baseboard-forming spacer or series of baseboard-forming spacers;
- and then
- c) removing the opposing outer support panels and the baseboard-forming spacer or series of baseboard-forming spacers,
- the method further comprising forming each of the two or more baseboard-forming ICF blocks from a starting ICF block having a spaced apart pair of rigid foam panels of equal height by removing a bottom end segment from one of the rigid foam panels of the starting ICF block.
5 more elements
Dependencies are inferred from the claim text.