Insulating concrete form (ICF) system with modular tie members and associated ICF tooling

A tool for forming an ICF block having a pair of spaced apart panel members forming the ICF block and a plurality of tie members positioned transversely between said panel members at spaced apart locations along the length of the panel members, said same tool being capable of receiving tie members forming the ICF block having varying widths wherein each such tie member includes a foldable web member extending between a pair of side wall bracket members, each side wall bracket member including a fastening plate and a shut-off plate, each tie member forming the ICF block further including at least one tool engaging slot, said tool comprising:

• at least one male tool and at least one female tool, said at least one female tool having outer walls and a cavity for cooperatively receiving said at least one male tool;
• said at least one male tool including a plurality of spaced apart pairs of plate members positioned along the length of said male tool, each pair of plate members having respective end portions and each pair of plate members forming an internal male tool cavity therebetween configured to receive the foldable web members associated with at least some of the tie members forming the ICF block in a folded position, each pair of plate members being separated by a pair of openings positioned and located along the length of said at least one male tool at each location where a tie member forming the ICF block will be located in the ICF block, each pair of said openings being formed by the respective end portions of adjacent plate members;
• each of the respective adjacent plate member end portions forming said pair of openings including an edge portion, at least one of said respective pairs of edge portions being positioned and located for engaging the at least one tool engaging slot associated with each of the tie members forming the ICF block;
• each tie member forming the ICF block being slidably insertable within the respective pair of openings and having its respective shut-off plates positioned and located adjacent the inner surfaces of the pair of panel members when the ICF block is formed and having its foldable web member positioned within a respective internal male tool cavity in a foldable position, at least one of the respective edge portions forming said respective pair of openings being insertable into the at least one tool engaging slot of the tie member forming the ICF block for holding the tie member within the pair of openings with the web member foldable within a respective internal male tool cavity of said male tool;
• a space formed between one surface of each of said respective plate members and the corresponding outer walls of said at least one female cavity when said at least one male tool is inserted therewithin defining the panel members forming the ICF block.

A tool for forming an ICF block having a pair of spaced apart panel members each having inner and outer surfaces and a plurality of tie members positioned transversely between said panel members at spaced apart locations along the length of the panel members, said same tool being capable of receiving tie members forming the ICF block having varying widths wherein each such tie member includes a foldable web member extending between a pair of side wall bracket members, each side wall bracket member including a fastening plate and a shut-off plate, each tie member forming the ICF block further including a pair of tool engaging slots spaced from each of said shut-off plates, said tool comprising:

• at least one male tool and at least one female tool, said at least one female tool having outer walls and a cavity for cooperatively receiving a corresponding male tool;
• said at least one male tool including a plurality of spaced apart pairs of plate members positioned along the length of said male tool, each pair of plate members having respective end portions and each pair of plate members forming an internal male tool opening therebetween configured to receive the foldable web members associated with tie members forming the ICF block, each pair of plate members being separated by a pair of spaces positioned and located along the length of said at least one male tool at each location where a tie member forming the ICF block will be located in the ICF block, each pair of said spaces being formed by the respective end portions of adjacent plate members;
• each of the respective adjacent plate member end portions forming pair of spaces including an edge portion, said respective pairs of edge portions being positioned and located for engaging the pair of tool engaging slots associated with each of said shut-off plates;
• each tie member forming the ICF block being slidably insertable within said spaces and having its respective shut-off plates positioned and located adjacent the inner surfaces of the pair of panel members when the ICF block is formed and having its foldable web member positioned within a respective internal male tool opening, the respective plate member edge portions forming said spaces engaging the pair of tool engaging slots associated with each of said shut-off plates for holding a tie member forming the ICF block within the spaces with the web member foldable within a respective internal male tool opening;
• a space formed between one surface of each of said respective plate members and the corresponding outer walls of said at least one female cavity when said at least one male tool is inserted therewithin defining the panel members forming the ICF block.

A tool for forming an ICF block having a pair of spaced apart panel members and a plurality of tie members positioned transversely therebetween at spaced locations along the length of the panel members, each tie member forming the ICF block including a pair of opposed side wall bracket members, said tool being capable of receiving a pair of opposed side wall bracket members associated respectively with each of the plurality of tie members forming the ICF block, each side wall bracket member including at least one tool engaging member, said tool comprising:

• a male tool and a female tool, said female tool having outer walls and a cavity for receiving said male tool;
• said male tool including a plurality of spaced apart plate members positioned along the length of said male tool, each plate member having a wall portion, each pair of plate members being separated by an opening, said opening being positioned and located along the length of said male tool at each location where a tie member forming the ICF block will be located in the ICF block, each said opening being formed by wall portions associated with adjacent plate members;
• each of said adjacent plate member wall portions forming each said opening including an edge portion, at least one of said edge portions forming each said opening being positioned and located for engaging the at least one tool engaging member associated with each of said side wall bracket members;
• each pair of opposed side wall bracket members being positionable within one of said openings and at least one of the edge portions forming said opening engages the at least one tool engaging member associated with one of said pair of opposed side wall bracket members and at least another one of the edge portions forming said opening engages the at least one tool engaging member associated with the other of said pair of opposed side wall bracket members for holding said pair of opposed side wall bracket members in spaced apart relationship within a respective opening;
• and
• a space formed between one surface of each of said respective plate members and the corresponding outer walls of said female tool cavity when the male tool is inserted within said female cavity defining the panel members forming the ICF block.

A tool for forming an ICF panel member having a pair of horizontally opposed longitudinal edges, a pair of vertically opposed longitudinal edges, and at least one side wall bracket member mountable therein, the side wall bracket member being associated with at least one tie member, said at least one side wall bracket member including at least one tool engaging member, said tool comprising:

• a male tool and a female tool, said female tool having outer walls and a cavity for receiving said male tool;
• said male tool including a plurality of spaced apart plate members positioned along the length of said male tool, each pair of plate members being separated by an opening, said opening being positioned and located along the length of said male tool at each location where the at least one tie member will be located in the ICF panel member, each said opening being formed by wall portions associated with adjacent plate members;
• each of said adjacent plate member wall portions forming each said opening including an edge portion, at least one of said edge portions being positioned within the at least one tool engaging member associated with said at least one side wall bracket member;
• said at least one side wall bracket member being positionable within one of said openings and at least one of the edge portions forming said opening being positioned within the at least one tool engaging member associated with said at least one side wall bracket member for holding said at least one side wall bracket member within a respective opening;
• and
• a space formed between one surface of at least one of said respective plate members and the corresponding outer wall of said female tool cavity when the male tool is inserted within said female cavity defining the ICF panel member.

A tool for forming a pair of ICF panel members, each panel member having a pair of horizontally opposed longitudinal edges, a pair of vertically opposed longitudinal edges, at least one tie member positioned transversely between said pair of panel members, the at least one tie member having a pair of side wall bracket members, and at least one side wall bracket member mountable within each of said panel members, each side wall bracket member including at least one tool engaging slot, said tool comprising:

• a male tool and a female tool, said female tool having outer walls and a cavity for receiving said male tool;
• said male tool including a plurality of spaced apart plate members positioned along the length of said male tool, each plate member having a wall portion, each pair of plate members being separated by a male tool opening, a male tool opening being positioned and located along the length of said male tool at each location where a tie member will be located in the respective ICF panel members, each said male tool opening being formed by wall portions associated with adjacent plate members;
• each of said adjacent plate member wall portions forming each male tool opening including an edge portion, at least one of said edge portions being positioned and located for insertion into the at least one tool engaging slot associated with each of said side wall bracket members;
• a pair of side wall bracket members being positionable within one of said male tool openings and at least one of the edge portions forming one of said male tool openings is insertable into the at least one tool engaging slot associated with one of said pair of the side wall bracket members and at least another one of the edge portions forming said male tool openings is insertable into the at least one tool engaging slot associated with the other of said pair of side wall bracket members for holding said pair of side wall bracket members in spaced relationship within a respective male tool opening, one of said side wall bracket members being mountable in one of said pair of panel members and the other of said side wall bracket members being mountable in the other of said pair of panel members;
• a space formed between one surface of each of said respective plate members and the corresponding outer walls of said female tool cavity when the male tool is inserted within said female cavity defining the ICF panel members.

A tool for forming an ICF block having a pair of spaced apart panel members and a plurality of tie members positioned transversely therebetween at spaced apart locations along the length of the panel members, each panel member having a pair of horizontally opposed longitudinal edges, said tool being capable of receiving the tie members forming the ICF block, each tie member including a pair of side wall bracket members, each side wall bracket member including an interlocking mechanism, said tool comprising:

• a male tool and a female tool, said female tool having a cavity for cooperatively receiving said male tool;
• said male tool including a plurality of male tool openings positioned and located along the length of said male tool at each location where a tie member forming the ICF block will be located in the ICF block;
• each tie member forming the ICF block being slidably insertable within at least one male tool opening for holding the tie member within the male tool;
• said male and female tools including at least one row of teeth and sockets positioned and located on said tools for providing teeth and sockets associated with the opposed horizontal longitudinal edges of the panel members forming the ICF block, said teeth and sockets positioned on said tools including a pocket for receiving each interlocking mechanism associated with each side wall bracket member at each location where a tie member forming the ICF block will be located in the ICF block, said pocket overlapping a portion of at least one tooth and at least one socket;
• a space formed between said male tool and said female tool cavity when the male tool is inserted within said female cavity defining the panel members forming the ICF block.

A tool for forming an ICF block having a pair of spaced apart panel members and a plurality of tie members positioned transversely therebetween at spaced apart locations along the length of the panel members, each panel member having a pair of horizontally opposed longitudinal edges, said tool being capable of receiving tie members forming the ICF block, each tie member including a pair of side wall bracket members, each side wall bracket member including an interlocking mechanism, each tie member further including at least one tool engaging member, said tool comprising:

• a male tool and a female tool, said female tool having outer walls and a cavity for cooperatively receiving said male tool;
• said male tool including a plurality of spaced apart pairs of plate members positioned along the length of said male tool, each pair of plate members being separated by a male tool first opening, a male tool first opening being positioned and located along the length of said male tool at each location where a tie member forming the ICF block would be located in the ICF block, each male tool first opening being formed by wall portions associated with adjacent plate members;
• each of said adjacent plate member wall portions forming each male tool first opening including an edge portion, at least one of said edge portions being positioned and located for engaging the at least one tool engaging member associated with each of the tie members forming the ICF block;
• each tie member forming the ICF block being slidably insertable within a male tool first opening and at least one of the edge portions forming a male tool first opening engages the at least one tool engaging member of each of the tie members forming the ICF block for holding each tie member within a male tool first opening;
• said male and female tools including at least one row of teeth and sockets positioned and located on said tools for providing teeth and sockets associated with the opposed horizontal longitudinal edges of the panel members forming the ICF block, and wherein said teeth and sockets positioned on said tools include a pocket for receiving each interlocking mechanism associated with each side wall bracket member at each location where a tie member forming the ICF block will be located in the ICF block;
• a space formed between one surface of each of said respective plate members and the corresponding outer walls of said female tool cavity when the male tool is inserted within said female tool defining the panel members forming the ICF block.

A tool for forming an ICF block having a pair of spaced apart panel members and a plurality of tie members positioned transversely therebetween at spaced apart locations along the length of the panel members, said same tool being capable of receiving tie members forming the ICF block having varying widths wherein each such tie member includes a pair of side wall bracket members and a foldable web portion, each side wall bracket member including a fastening plate and a shut-off plate, the foldable web portion having opposite end portions and extending between said pair of side wall bracket members, the opposite end portions of said web portion being pivotally connected to said shut-off plates, each tie member forming the ICF block further including an interlocking mechanism associated with each opposite end of each of said side wall bracket members, said interlocking mechanism being positioned and located between said fastening plate and said shut-off plate, said interlocking mechanism including a pair of first and second interlocking members positioned adjacent to each other in a lateral offset arrangement, the first interlocking member of one end of each of said side wall bracket members being engageable with the second interlocking member of one end of each of said side wall bracket members associated with another one of said tie members forming the ICF block, each tie member further including at least one tool engaging member, said tool comprising:

• a male tool and a female tool, said female tool having outer walls and a cavity for cooperatively receiving said male tool;
• said male tool including a plurality of spaced apart pairs of plate members positioned along the length of said male tool, each pair of plate members being separated by a male tool first opening and foaming an internal male tool second opening therebetween configured to receive the foldable web portions of the tie members forming the ICF block, a male tool first opening being positioned and located along the length of said male tool at each location where a tie member forming the ICF block will be located in the ICF block, each male tool first opening being formed by wall portions associated with adjacent plate members;
• each of said adjacent plate member wall portions forming each male tool first opening including an edge portion, at least one of said edge portions forming each male tool first opening being positioned and located for engaging the at least one tool engaging member associated with each of the tie members forming the ICF block;
• each tie member forming the ICF block being slidably insertable within a respective male tool first opening and having its side wall bracket members engageable with a respective male tool first opening, the foldable web portion being positionable within a respective internal male tool second opening, and at least one of the edge portions forming a male tool first opening engages the at least one tool engaging member of each of the tie members forming the ICF block for holding each tie member within a male tool first opening with the foldable web portion within a respective internal male tool second opening;
• a space formed between one surface of each of said respective plate members and the corresponding outer walls of said female tool cavity when the male tool is inserted within said female cavity defining the panel members forming the ICF block.

A tool for forming an ICF block having a pair of spaced apart panel members and a plurality of tie members positioned transversely therebetween at spaced apart locations along the length of the panel members, said same tool being capable of receiving tie members forming the ICF block having varying widths wherein each such tie member includes a foldable web portion and at least one tool engaging member, said tool comprising:

• a male tool and a female tool, said female tool having outer walls and a cavity for cooperatively receiving said male tool;
• said male tool including a plurality of spaced apart pairs of plate members positioned along the length of said male tool, each pair of plate members being separated by a male tool first opening and forming an internal male tool second opening therebetween configured to receive the foldable web portions of the tie members forming the ICF block, a male tool first opening being positioned and located along the length of said male tool at each location where a tie member forming the ICF block will be located in the ICF block, each male tool first opening being formed by wall portions associated with adjacent plate members;
• each of said adjacent plate member wall portions forming each male tool first opening including an edge portion, at least one of said edge portions forming each male tool first opening being positioned and located for engaging the at least one tool engaging member associated with each of the tie members forming the ICF block;
• each tie member forming the ICF block being slidably insertable within a respective male tool first opening and the foldable web portion being positionable within a respective internal male tool second opening and at least one of the edge portions forming a male tool first opening engages the at least one tool engaging member of each of the tie members forming the ICF block for holding tie member within a male tool first opening with the foldable web portion within a respective internal male tool second opening;
• a space formed between one surface of each of said respective plate members and the corresponding outer walls of said female tool cavity when the male tool is inserted within said female cavity defining the panel members forming the ICF block, said tool further including a loading platform having a plurality of pairs of arm members associated therewith, said respective pairs of arm members being positioned and located so as to register with the plurality of male tool first openings when the loading platform is positioned adjacent thereto, each respective pair of arm members being configured to hold at least one tie member forming the ICF block in a position, said loading platform being movable into and out of said male tool, when loaded with a plurality of tie members forming the ICF block, the at least one tool engaging member associated with the respective tie members forming the ICF block will be engaged with at least a portion of a male tool first opening and the web portion associated with each tie member forming the ICF block will be positioned within a corresponding internal male tool second opening associated with said male tool when the loading platform is inserted within said male tool.