US-20260125870-A1 - CEMENT FORM

Abstract

A cement form made at least in part of a foam material can be used to form a cement foundation of a structure. The cement form can include a cement facing surface oriented vertically and configured to support a volume of cement. The cement can also include a ground facing surface oriented horizontally and configured to contact a ground support surface.

Inventors

• Lance N. Boyce
• Amber C. Boyce

Assignees

• MONO SLAB EZ FORM LLC

Dates

Publication Date

20260507

Application Date

20251229

Claims (20)

1. 1 . A method of manufacturing a cement form, comprising: providing an elongate block of foam material; and dividing the block of foam material diagonally along its length to form two elongate cement forms, each cement form having: a first portion defining a ground facing surface that extends horizontally and is configured to contact a ground surface; a second portion defining a cement facing surface that extends upward from the first portion and configured to contact, support, and form a volume of cement that is poured into a structure; and an intermediate portion defining an inclined surface extending upward at a diagonal angle relative to the ground facing surface and the cement facing surface and in a direction from the ground facing surface towards the cement facing surface, wherein the ground facing surface, the cement facing surface, and the inclined surface define at least a substantially triangular cross-section of the cement form along an entire length of the cement form.
2. 2 . The method of claim 1 , further comprising: forming a connector groove in each of the two elongate cement forms.
3. 3 . The method of claim 2 wherein a strip is removed to form the connector groove in each of the two elongate cement forms.
4. 4 . The method of claim 1 , wherein the first portion and the second portion form a right angle at a corner where the first portion and second portion meet and the intermediate portion is positioned on a side of the cement form opposite the corner.
5. 5 . The method of claim 1 , wherein the cement form is configured to insulate the volume of cement.
6. 6 . The method of claim 1 wherein the intermediate portion is a brace portion extending between the first portion and the second portion to support the first portion in an upright position.
7. 7 . The method of claim 1 wherein the intermediate portion is a support rib extending between the first portion and the second portion to support the first portion in an upright position.
8. 8 . The method of claim 1 wherein the intermediate portion includes a weight bearing portion extending between the first portion and the second portion.
9. 9 . The method of claim 1 wherein the cement form has an elongated shape.
10. 10 . The method of claim 1 wherein the first portion, the second portion, and the intermediate portion have a solid construction consisting essentially of the foam material.
11. 11 . The method of claim 1 wherein the ground facing surface and the cement facing surface are planar.
12. 12 . A method of forming a monolithic cement foundation, comprising: providing a cement form, the cement form including a foam material and comprising a ground facing surface that extends horizontally on a ground surface, a cement facing surface that extends upward from the ground facing surface, and an inclined surface extending upward at an angle relative to the ground facing surface and the cement facing surface, wherein the ground facing surface, the cement facing surface, and the inclined surface define at least a substantially triangular cross-section of the cement form along an entire length of the cement form; positioning the cement form on a ground surface and securing the cement form in a fixed position; supporting a volume of uncured cement against the cement form while in the fixed position; and at least partially covering the cement form with backfill material while in the fixed position.
13. 13 . The method of claim 12 wherein the cement form includes a connector groove.
14. 14 . The method of claim 13 , further comprising: connecting the cement form to an adjacent positioned cement form with a connector that is inserted into the connector groove.
15. 15 . The method of claim 12 wherein securing the cement form in a fixed position includes driving at least one stake through the cement form into the ground surface.
16. 16 . The method of claim 12 wherein at least a portion of the inclined surface is covered by the backfill.
17. 17 . The method of claim 12 wherein the inclined surface is positioned on a side of the cement form opposite a corner where the ground facing surface and the cement facing surface meet.
18. 18 . The method of claim 12 wherein the cement form is configured to insulate the volume of cement.
19. 19 . The method of claim 12 comprising a plurality of cement forms coupled together and aligned with a connecting member.
20. 20 . A method of manufacturing a cement form, comprising: providing an elongate block of foam material; making a first cut along its length to form two elongate cement forms, each cement form having: a first portion defining a ground facing surface that extends horizontally and that contacts a ground surface; a second portion defining a cement facing surface that extends upward from the first portion and that is configured to contact, support, and form a volume of cement that is poured into a structure; and an intermediate portion defining an inclined surface extending upward: (i) at an angle relative to the ground facing surface and the cement facing surface and (ii) in a direction from the ground facing surface towards the cement facing surface, wherein the ground facing surface, the cement facing surface, and the inclined surface define at least a substantially triangular cross-section of the cement form along an entire length of the cement form. ` making a second cut to form a connector groove in a first cement form, and making a third cut to form a connector groove in a second cement form.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This is a continuation of U.S. Patent Application No. 17/450,188, filed 7 October 2021, which is a divisional of U.S. Patent Application No. 16/713,517, filed 13 December 2019, which is a divisional of U.S. Patent Application No. 15/967,259, filed 30 April 2018, now U.S. Patent No. 10,538,893, which is a continuation of U.S. Patent Application No. 14/698,674, filed 28 April 2015, now U.S. Patent No. 10,024,023, the disclosures of which are incorporated, in their entireties, by this reference. TECHNICAL FIELD The present disclosure generally relates to cement forms used to create cement structures such as building foundations. BACKGROUND Traditionally, cement forms are held in place with an arrangement of metal stakes, kickers and other supporting structure.  The traditional methods for forming a monolithic building foundation are particularly time intensive to set up and take down after the cement monolithic foundation is poured.  After the form is removed, dirt is backfilled around the foundation to provide support and soil grading. In certain cold climates, foam insulation sheets are positioned against the sidewall of the foundation and extending laterally from the sidewall after the form is removed and before dirt is backfilled around the foundation.  The foam insulation provides a desired R value that helps hold in heat from the building within the foundation, thereby providing protection again extreme expansion and contraction of the foundation resulting from outside temperature changes. GENERAL DESCRIPTION According to one aspect of the present disclosure, a cement form includes a first surface arranged vertically and configured to support a volume of cement, a second surface arranged horizontally and configured to contact a ground support surface, and at least one of a foam material and a polymer material. The cement form may have a wedge-shaped cross-section. The cement form may have a triangular cross-section shape. The cement form may further include a weight bearing surface facing at least in part in a vertical direction. The cement form may include a connector groove extending along at least a portion of a length of the cement form. The connector groove may be configured to receive a connecting member that extends between adjacent positioned cement forms. The cement form may include at least one aperture sized to receive a support stake extending through the cement form. Another aspect of the present disclosure related to a cement form that includes an elongate member having a wedge-shaped cross-sectional shape and is formed from a foam material. The elongate member may include a connector groove sized to receive a connecting member that spans between adjacent positioned cement forms. The elongate member may be configured to receive a support stake through the foam material to connect the cement form to a ground surface without pre-forming a pass-through bore in the elongate member sized to receive the support stake. The cement form may be configured to be at least partially covered with backfill dirt prior to forming a cement structure using the cement form. The elongate member may include a first surface arranged vertically and configured to support a volume of cement, and a second surface arranged horizontally and configured to contact a ground support surface. The foam material may include at least one of expanded polyethylene and high-density foam. A further aspect of the present disclosure relates to a cement form assembly that includes at least two cement forms each comprising at least one of a foam material and a polymer material, and each having at least one connector groove formed therein. The cement form assembly also includes at least one connecting member positioned in the connector grooves and spanning between the at least two cement forms to interconnect the at least two cement forms, and a plurality of support stakes extending through the at least two cement forms and into a ground support. The at least two cement forms may each have a wedge-shaped cross-section. The cement form assembly may also include an inner insert configured to be spaced inward from the at least two cement forms and arranged to be positioned under a cement structure formed using the cement form. The at least two cement forms each include at least one pass-through bore sized to receive one of the plurality of support stakes. Another aspect of the present disclosure relates to a method of forming a monolithic foundation. The method includes providing a plurality of cement forms each comprising a foam material, staking the plurality of cement forms to a ground surface, interconnecting at least some of the plurality of cement forms, covering at least a portion of the plurality of cement forms with backfill dirt, thereafter, pouring cement into contact with the plurality of cement forms to form a monolithic foundation, and leaving the plurality of cement forms covered and