Apparatus and method for supporting concrete beams, walls and the like

A reinforced box-like structure for forming a void area in a concrete formation, comprising:

• an enclosure having an interior chamber;
• a longitudinal rib extending in a normal direction from a wall of said enclosure into said interior chamber;
• an interior support unit formed of an interior piece that is separate from said enclosure having an inner layer and an outer layer, said outer layer of said interior piece having a plurality of parallel slits therethrough so as to define a plurality of parallel slit scores, said interior piece folded about said slit scores so as to define a plurality of support partitions each of which includes a double-thickness wall and defines a flat support surface;
• each of said support partitions engaging said longitudinal rib transversely and sized so as to extend across said interior chamber both vertically and horizontally with said flat support surfaces abutting said enclosure;
• whereby interior structural support of said enclosure is increased.

An assembly for forming a reinforced box-like structure that may be used to form a void area in a concrete formation, comprising:

• a flat outer sheet having a plurality of parallel crease lines thereon and a side edge reinforcing panel adjacent one of said parallel crease lines so that it may be folded into a position generally normal to the flat sheet to define a longitudinal rib;
• said longitudinal rib having a plurality of slots thereon extending generally perpendicular to said crease lines;
• a plurality of flat interior pieces that are separate from said flat outer sheet, each having a plurality of parallel slit scores thereon, a plurality of transverse slits extending transversely across said slit scores and panel sections on each side of said slit scores so that when each of said flat interior pieces are folded about said slit scores, said panel sections move into a side by side relationship to define a plurality of support partitions which include double-thickness walls and define flat support surfaces and said transverse slits fold in half to form unitary insertion slots in said partitions;
• whereby the insertion slots in the partitions may be interlocked with corresponding slots on the rib so that said partitions extend transversely relative to said rib so that said outer sheet may be wrapped about said partitions so that said flat support surfaces abut said outer sheet.

A method of making a reinforced box-like structure for forming a void area in a concrete formation, comprising:

• providing a flat outer sheet having a plurality of parallel crease lines thereon and a side edge reinforcing panel, said reinforcing panel having a plurality of slots thereon extending generally perpendicularly relative to said crease lines;
• providing a plurality of flat interior pieces that are separate from the flat outer sheet, each having a plurality of parallel slit scores thereon and a plurality of transverse slits extending transversely across said slit scores;
• folding each flat interior piece such that panel sections on each side of said slit scores move into side by side relationship to define a plurality of support partitions, each featuring a double-thickness wall and a flat support surface, whereby the transverse slits on said slit scores are folded in half to form unitary insertion slots in said partitions and whereby each folded interior piece defines an interior support member;
• folding the side edge reinforcing panel into a position generally normal to the flat sheet to define a longitudinal rib;
• attaching said support units to the longitudinal rib by registering the insertion slots in the partitions in interlocking relationship with corresponding slots on the rib, wherein said partitions extend transversely relative to said rib;
• and
• folding remaining panels of the outer sheet along said crease lines in wrapping relation around said support units, thereby defining an enclosure with an interior chamber, each of said support partitions extending across said interior chamber both horizontally and vertically with said flat support surfaces abutting said enclosure to increase the strength of the structure.

A reinforced box-like structure for forming a void area in a concrete formation, comprising:

• an enclosure having an interior chamber and defining a pair of opposing end openings;
• a longitudinal rib extending in a normal direction from a wall of said enclosure into said interior chamber;
• a pair of end panels, each of which engage said enclosure to cover said opposing end openings;
• a pair of locking end flaps, one of each attached to one of each of said end panels and each including an end slot therein, said end flaps inserted through one of each of said end openings of said enclosure with said end slots engaged by said longitudinal rib;
• an interior support unit formed of an interior piece having an inner layer and an outer layer, said outer layer of said interior piece having a plurality of parallel slits therethrough so as to define a plurality of parallel slit scores, said interior piece folded about said slit scores so as to define aplurality of support partitions each of which defines a flat support surface;
• each of said support partitions engaging said longitudinal rib transversely and sized so as to substantially fill a cross-sectional area of said interior chamber with said flat support surfaces abutting said enclosure;
• whereby interior structural support of said enclosure is increased.

An assembly for forming a reinforced box-like structure that may be used to form a void area in a concrete formation, comprising:

• a flat outer sheet having a plurality of parallel crease lines thereon and a side edge reinforcing panel adjacent one of said parallel crease lines so that it may be folded into a position generally normal to the flat sheet to define a longitudinal rib;
• said longitudinal rib having a plurality of slots thereon extending generally perpendicular to said crease lines;
• a plurality of flat interior pieces each having a plurality of parallel slit scores thereon, a plurality of transverse slits extending transversely across said slit scores and panel sections on each side of said slit scores so that when said flat interior pieces are folded about said slit scores, said panel sections move into a side by side relationship to define a plurality of support partitions which define flat support surfaces and said transverse slits fold in half to form unitary insertion slots in said partitions so that the insertion slots in the partitions may be interlocked with corresponding slots on the rib so that said partitions extend transversely relative to said rib so that said outer sheet may be wrapped about said partitions so that said flat support surfaces abut said outer sheet;
• a flat end piece having a slit score thereon, a transverse slit extending transversely across said slit score and panel sections on each side of said slit score so that when said flat end piece is folded about said slit score, said panel sections move into a side by side relationship to define an end support partition which defines a flat support surface and said transverse slit folds in half to form a unitary insertion slot in said end support partition and one of said panel sections being connected to an end bridge panel via a crease line with said end bridge panel being connected to an end panel via a crease line so that the unitary insertion slot of said end support partition may be inserted into a slot of said longitudinal rib so that said end panel may be folded to cover an end opening after said outer sheet is wrapped about said support partitions.

A method of making a reinforced box-like structure for forming a void area in a concrete formation, comprising:

• providing a flat outer sheet having a plurality of parallel crease lines thereon and a side edge reinforcing panel, said reinforcing panel having a plurality of slots thereon extending generally perpendicularly relative to said crease lines;
• providing a plurality of flat interior pieces each having a plurality of parallel slit scores thereon and a plurality of transverse slits extending transversely across said slit scores;
• folding each flat interior piece such that panel sections on each side of said slit scores move into side by side relationship to define a plurality of support partitions, each featuring a flat support surface, whereby the transverse slits on said slit scores are folded in half to form unitary insertion slots in said partitions and whereby each folded interior piece defines an interior support member;
• folding the side edge reinforcing panel into a position generally normal to the flat sheet to define a longitudinal rib;
• attaching said support units to the longitudinal rib by registering the insertion slots in the partitions in interlocking relationship with corresponding slots on the rib, wherein said partitions extend transversely relative to said rib;
• folding remaining panels of the outer sheet along said crease lines in wrapping relation around said support units, thereby defining an enclosure with an interior chamber, each of said support partitions substantially filling a transverse cross-sectional area of said interior chamber with said flat support surfaces abutting said enclosure to increase the strength of the structure;
• providing a pair of end panels;
• and
• engaging said enclosure with said end panels to cover opposing end openings defined by said enclosure.