CONCRETE FORM EXTENDER

Description

PRIORITY CLAIM

This application claims the benefit of priority to U.S. Provisional Patent Application No. 63/735,522 , filed Dec. 18, 2024, and titled “FORM EXTENDER FOR CONCRETE FORMS”, which is incorporated herein by reference in its entirety.

BACKGROUND

In the construction industry, concrete forming represents a common task in creating building foundations, driveways, sidewalks, and other concrete structures. Concrete forms can be formed on-site using dimensional lumber, particularly 2×4, 2×6, and 2×8 boards, to create the boundaries and shapes for concrete pours.

When constructing a given concrete form, contractors often need to cut lumber to exact measurements, resulting in material waste and increased labor time. Once the lumber is cut to size, contractors use stakes, nails, and other fasteners to secure forms in place.

When contractors encounter existing structures in building the concrete forms (such as landscape edging, fence posts, deck posts, or sprinkler systems), additional cuts or modifications to the lumber are needed to accommodate such features.

BRIEF SUMMARY

In various embodiments, a form extender for use in concrete construction is provided. This form extender comprises a sheet metal body featuring multiple bends among different portions of the sheet metal to create a tension-based attachment portion. This attachment portion is designed to be removably secured to a form member. The sheet metal body is shaped to extend beyond the form member, providing a form extension surface. The form extension surface refers to the planar surface of the sheet metal body which serves as a boundary for concrete while maintaining alignment and continuity with the form member during the concrete pouring, screeding, and finishing operations.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced.

FIG. 1 is a schematic diagram illustrating a concrete forming system in a residential construction environment, according to some examples.

FIG. 2 is a perspective view illustrating a form extender with multiple sides and dimensions that provide a tension-based attachment mechanism, according to some examples.

FIG. 3 is a cross-sectional view illustrating the angles and bends that provide the tension-based attachment mechanism of a form extender, according to some examples.

FIGS. 4A and 4B are perspective views illustrating an angled form extender, according to some examples.

FIG. 5A is a top view illustrating an angled form extender, according to some examples.

FIG. 5B is a back view illustrating an angled form extender, according to some examples.

FIGS. 6A and 6B are perspective views illustrating a form extender with notched portions for accommodating obstacles, according to some examples.

FIG. 7 is a top view illustrating a form extender spanning a gap between form members in a concrete forming system, according to some examples.

FIG. 8 is a top view illustrating form extenders configured to create a corner transition in a concrete forming system, according to some examples.

FIG. 9 is a flow diagram illustrating a process for implementing a form extender in concrete construction operations, according to some examples.

FIG. 10 is a flow diagram illustrating a process for manufacturing a form extender, according to some examples.

FIG. 11 is an example template for cutting a planar blank from sheet metal to provide a form extender, according to some examples.

FIG. 12 is an example template for cutting a planar blank from sheet metal to provide a form extender with notched portions, according to some examples.

DETAILED DESCRIPTION

The disclosed examples provide a form extender that represents a practical approach to common concrete forming pitfalls. In particular, the form extenders disclosed herein can reduce excess cutting of lumber (and wasting said lumber) and can reduce labor time by quickly fitting the form extender to gaps in the form or around obstacles in the construction site. As disclosed, the form extenders use a tension-based attachment mechanism that does not need additional fasteners and can aid in creating an aesthetic finished appearance. Additionally, the use of corrosion resistant sheet metal allows the form extenders to be re-used over hundreds of job sites, providing cost-savings in the long run from avoiding excess lumber usage.

FIG. 1 illustrates a concrete forming system and application environment. The system includes a form 102 positioned between a residential structure and a garage structure. The residential and garage structures illustrate typical construction environments where the forming system may be implemented. A concrete delivery vehicle is shown positioned near the forming system, representing the concrete pouring operation that may utilize the form 102.

The form 102 may comprise multiple form members arranged to create a concrete form perimeter. In some examples, the form members may include lumber such as standard sizes of 2×4, 2×6, 2×8, or 2×10 dimensional lumber. In other examples, the form members may include plastic or metal (e.g., steel) flatwork forms or rails. The form 102 functions to contain and shape concrete during pouring and curing operations.

The gap 104 represents a space between adjacent form members where additional form length is needed. The gap 104 may range from 0 inches to 48 inches depending on the specific forming requirements. In some examples, the gap 104 may occur due to using available lumber lengths that do not match required form dimensions. In some examples, the gap 104 may be a misalignment between two pieces of available lumber that are overlapping (e.g., a warped piece of lumber that is adjacent to a straight piece of lumber).

As shown in FIG. 1, available pieces of lumber do not fill the gap 104. A common technique to close the gap 104 may be to cut new lumber to a length that spans the remaining gap. According to the disclosed examples, a form extender may be used with the available pieces of form members, eliminating the need to cut additional lumber.

Many concrete contractors continue to rely on lumber-based forming methods, particularly for residential and smaller commercial projects. The concrete industry also uses metal and rigid plastic forms for large-scale projects like highways and extended sidewalk runs. The form extender apparatus described herein may be applied to any type of form to bridge gaps (e.g., create continuity) between form sections.

FIG. 2 illustrates a perspective view of a form extender 200 having multiple sides and dimensions that enable tension-based attachment to existing form members. The form extender 200 includes a first side 202, a second side 204, a third side 206, and a fourth side 208. These respective sides are also referred to as portions (e.g., first portion, second portion, third portion, fourth portion) of the sheet metal body. Respective sides of the form extender 200 have corresponding dimensions, including dimension 210, dimension 212, dimension 214, dimension 216, and dimension 218.

The first side 202 extends vertically to provide a form extension surface. In some examples, side 202 faces inward towards the concrete during pouring and finishing operations. When the form extender 200 is attached to a form member (e.g., lumber) as shown in FIG. 7, the side 202 can be continuous with one or more form members. The form extension surface refers to the planar surface of the sheet metal body which provides a continuous boundary across a gap between one or more form members. The continuous boundary provides containment for concrete while maintaining alignment and continuity with the form member during the concrete pouring, screeding, and finishing operations.

The second side 204, third side 206, and fourth side 208 comprise the attachment portion that secures to the form members. The tension-based attachment is created by the spacing between the bend in the third side 206 and fourth side 208 and the first side 202, which must be slightly less than the form member width. When the form extender 200 is positioned on a form member, the sheet metal flexes to accommodate the form member width, which applies an opposing force on the form member surface(s) as the form extender 200 is pressed onto the form member. This tension maintains the secure attachment without requiring additional fasteners. This can be better seen in FIG. 3, with the grip space 314.

The dimensions 210, 212, 214, 216, and 218 may vary based on the intended application. For example, the length dimension 210 may vary based on the gap (e.g., 104) and may range from 0 inches to 48 inches. In some examples, dimension 210 may range from approximately 11 inches to approximately 60 inches, such as 12 inches, 18 inches, 24 inches, 36 inches, 48 inches, or 60 inches, to accommodate various gap sizes encountered in concrete forming operations. The vertical dimension 212 may accommodate different lumber or steel form heights such as 2×4, 2×5, 2×6, 2×7, 2×8, 2×9, or 2×10 materials. In some examples, the vertical dimension 212 may be approximately 3.5 inches for accommodating a 2×4 form member, approximately 4.5 inches for accommodating a 2×5 form member, approximately 5.5 inches for accommodating a 2×6 form member, or approximately 6.5 inches for accommodating a 2×7 form member. These dimensions provide a form surface that maintains continuity with the respective form member heights (with respect to dimension 212) and across various gap sizes (with respect to dimension 210).

The dimensions 214, 216, and 218 establish the grip area that creates the tension-based attachment of the form extender to the existing form member, and may have varying values. For example, dimension 214 may be approximately 1.5 inches to accommodate standard 2×4, 2×6, 2×8, and 2×10 materials.

In some examples, the form extender 200 may be manufactured from a sheet metal material such as galvanized steel, stainless steel, carbon steel, alloy steel, or any suitable formulation of steel including but not limited to steel with a corrosion resistant coating (e.g., a paint coat, powder coat, etc.). In some examples, the sheet metal used for form extender 200 may have any suitable thickness, such as a thickness of 18 gauge, 19 gauge, 20 gauge, etc. In other examples, the form extender 200 may use an increased thickness of 17 gauge, 16 gauge, or lower gauges (e.g., to support increased lengths of the form extender 200).

In some examples, the thickness of the sheet metal used for form extender 200 may be selected based on a determination of malleability of the material (e.g., for bending the sheet metal into the desired shape of the form extender). In some examples, the thickness of the sheet metal used for form extender 200 may be selected based on another determination, such as the ability of the sheet metal to provide a tension-based attachment of the form extender. In another example, the thickness of the sheet metal used for form extender 200 may be selected based on a determination of providing an unobtrusive thickness profile to a construction worker when screeding (e.g., adjusting poured concrete with a straight edge) and finishing (e.g., providing a finished surface with a trowel or other hand tool) concrete poured into a form having form extender 200.

FIG. 3 illustrates a cross-sectional view of a form extender 300 showing examples of the angles and bends that create the tension-based attachment mechanism.

The form extender 300 includes a first interior angle 302 and a second interior angle 304 formed by the sheet metal bends. The interior angles work in conjunction with an exterior angle 306 to create the tension-based attachment mechanism. The angles may be formed by a first bend 308, a second bend 310, and a third bend 312.

The first interior angle 302 may have any suitable value, such as approximately 90 degrees. In some examples, the first interior angle 302 may range from approximately 88 degrees to approximately 92 degrees. The second interior angle 304 may have any suitable value, such as a value between 80 and 95 degrees. In some examples, the second interior angle 304 may range from approximately 90 degrees to approximately 95 degrees. The exterior angle 306 may have any suitable value to provide the edge created by the third bend 312 with sufficient pressure to maintain a tension-based attachment mechanism. For example, the exterior angle 306 may range from approximately 35 degrees to approximately 45 degrees, such as approximately 39 degrees.

The first bend 308 and the second bend 310 form the upper attachment points that interface with the form member. The third bend 312 creates the lower attachment point, completing the tension-based securing mechanism.

The grip space 314 can be a width that represents the distance between opposing surfaces of the form extender 300 which comprise the tension-based attachment mechanism. The arrangement of angles and bends shown in FIG. 3 creates a grip between the side 202 (having height “C”, corresponding to dimension 212) and the edge formed at the third bend 312 (e.g., the space interior to the form extender 300 which spans the width of the grip space 314) to maintain the form extender's position during screeding (e.g., adjusting poured concrete with a straight edge) and finishing (e.g., providing a finished surface with a trowel or other hand tool) while allowing tool-free removal of the form extender 300 from the form members.

FIGS. 4A and 4B illustrate perspective views of a first form extender 400 and a second form extender 401 having an angled configuration. The form extender 400 and form extender 401 each comprise a sheet metal body with multiple bends that create a tension-based attachment mechanism, similar to the form extender 200 described above in FIG. 2.

FIGS. 4A and 4B provide respective front and side perspective views of the form extender 400 and the form extender 401, and have slightly different widths and heights to fit concrete forms of different sizes.

The form extender 400 and the form extender 401 include an elongated portion (corresponding to the dimension labeled “B” in FIG. 5A and FIG. 5B) that transitions to a shortened portion (corresponding to the dimension labeled “G” in FIG. 5B) at an angle, typically less than 90 degrees, although a number of other suitable transition angles may be used. In other examples, the elongated portion transitions to the shortened portion at an angle of approximately 45 degrees. The use of an angle at 45 degrees enables the form extender to maintain form continuity at corner intersections, as shown in FIG. 8 and discussed below.

FIG. 5A is a top view illustrating an angled form extender 500, according to some examples. In some examples, the angled form extender 500 can use a similar set of dimensions to form extender 200 shown in FIG. 2 and FIG. 3. In particular, the dimension D can correspond to dimension 214 and the dimension B can correspond to the dimension 210, or the length of the form extender.

FIG. 5B is a front view illustrating an angled form extender 500, according to some examples. In this view, the tension-based attachment mechanism (e.g., the dimensions of “E”, “F”, and “G”) can have a dimension that is smaller than the overall length of the form extender (shown as dimension “B”) by an amount ‘H’. For example, the attachment mechanism can be approximately 1 inch shorter (e.g., ‘H’ is a half-inch on each side) than the overall length of the form extender. This can be established with the use of an angle between dimensions “B” and “D” that is greater than 45 degrees but less than 90 degrees, such as between 70 and 85 degrees (visible in FIG. 5A but not visible in FIG. 5B).

FIGS. 6A and 6B are perspective views of a first notched form extender 600 and a second notched form extender 601 (e.g., shaped to fit concrete forms of different sizes) having a notched portion for accommodating various obstacles and transitions in the concrete form. The notched portion(s) may be configured to accommodate obstacles such as landscape edging, fence posts, deck posts, sprinkler systems, etc., while maintaining proper concrete containment. In some examples, the notched configuration enables the notched form extender 600 or notched form extender 601 to maintain form integrity around obstacles without requiring additional cuts or modifications to the form members.

In some examples, the notched portion 602 can be provided from any suitable amount of material removed from the front side of the notched form extender 600 or the notched form extender 601. The notched portion 602 can occur on any portion of the form extender, can have any suitable length, and can extend towards the flat edge of the form extender by any suitable amount. A template such as shown in FIG. 12 can be used to cut and bend sheet metal into the notched form extender 600 or the notched form extender 601. For example, for a form extender with an overall length of 18 inches, the notched portion 602 may be included in the central section of the form extender, and have a length of approximately 6.25 inches, with remaining attachment portions of the form extender being approximately 5.3 inches.

FIG. 7 illustrates a top view of a concrete forming system showing the relationship between form members and a form extender. The system includes a first form member 702 and a second form member 706 arranged with a gap 708 between them. The form extender 704 can be form extender 200 or form extender 300 as described above in FIG. 2 and FIG. 3. As shown in FIG. 7, the dotted line of form extender 704 indicates the position of the third bend 312 of FIG. 3 when the form extender is viewed from above.

The form extender 704 may be positioned across the gap 708 to provide a continuous form. In some examples, the gap 708 may range from 0 inches to 48 inches depending on the specific forming requirements. The form extender 704 can be positioned with any suitable amount of the form extender body overlaid on first form member 702 and second form member 706. For example, as shown in FIG. 7, the amount of overlap (e.g., amount of form extender 704 on first form member 702) on one side of the form extender 704 may be unequal to the amount of overlap on the complementary side of the form extender 704. The form extender 704 attaches to both the first form member 702 and second form member 706 through a tension-based mechanism that requires no additional fasteners.

The first form member 702 and second form member 706 may comprise standard lumber dimensions such as 2×4, 2×6, 2×8, or 2×10 materials. In other examples, the first form member 702 and the second form member 706 may be provided by rigid (or flexible) steel or plastic flatwork forms.

The thickness and material properties of the form extender 704 allow concrete finishing operations to proceed without interference while maintaining structural integrity during concrete pouring and curing. The system enables quick form assembly without cutting lumber or using fasteners while providing seamless form transitions.

FIG. 8 illustrates a corner configuration of a concrete forming system, where the gap in a concrete form occurs at a corner. The system includes a first form member 802 and a second form member 808 arranged at a 45 degree corner angle. Two form extenders 804 and 806 connect the form members at corner 810. One side of each of the form extenders 804 and 806 include a 45 degree angle, unlike the form extenders depicted in FIGS. 2 to 6B that transition between two sides with a larger angle.

Although two form extenders are shown in FIG. 8, in some examples, a single form member (such as form extender 200) may be modified to have an angle between a first segment of the form extender and a second segment. For example, a single form extender (e.g., the notched form extender 600 or the notched form extender 601) having a notch in the form extender body may be bent to create an angle at the notched position.

Returning to FIG. 8, the first form member 802 extends vertically, and the second form member 808 extends horizontally. A gap between first form member 802 and second form member 808 occurs at a corner intersection. The form extenders 804 and 806 include tension-based attachment portions (such as that described in form extender 200 and form extender 300 as described above in FIG. 2 and FIG. 3). The form extenders 804 and 806 meet at corner 810 in a 45-degree configuration to maintain form continuity around the corner. The corner 810 represents the intersection point where the form extenders 804 and 806 join to create a clean corner transition.

In other examples, the variations of form extenders discussed herein (e.g., form extender 200, form extender 300, form extender 400, form extender 401, form extender 500, form extender 600, form extender 601) may be positioned in a corner. For example, a single form extender may be positioned to adjoin and partially rest on top of a form member, to define an interior corner of a concrete form (e.g., where one face of the interior corner is created by the form member, and the other face of the interior corner is created by the form extender). It will be understood that the form extenders discussed herein can be deployed in a variety of angles and positions to uniquely define the usable area of the concrete form.

FIG. 9 illustrates an example process 900 for using a form extender in a concrete form. Although the example process 900 depicts a particular sequence of operations, the sequence may be altered without departing from the scope of the present disclosure. For example, some of the operations depicted may be performed in parallel or in a different sequence that does not materially affect the function of the process 900. In other examples, different components of an example device or system that implements the process 900 may perform functions at substantially the same time or in a specific sequence.

At block 902, according to some examples, the method includes arranging multiple form members in a concrete form.

At block 904, according to some examples, the method includes identifying a gap between a first form member and a second form member of the multiple form members.

At block 906, according to some examples, the method includes applying a form extender to the gap, as the form extender attaches through a tension-based technique on the first form member and on the second form member.

At block 908, according to some examples, the method includes pouring concrete into the concrete form having the form extender.

At block 910, according to some examples, the method includes smoothing (e.g., screeding, finishing) concrete poured into the concrete form, wherein the form extender does not impede the smoothing.

FIG. 10 illustrates an example process 1000 for manufacturing a form extender. Although the example process 1000 depicts a particular sequence of operations, the sequence may be altered without departing from the scope of the present disclosure. For example, some of the operations depicted may be performed in parallel or in a different sequence that does not materially affect the function of the process 1000. In other examples, different components of an example device or system that implements the process 1000 may perform functions at substantially the same time or in a specific sequence.

At block 1002, according to some examples, the method includes selecting sheet metal with a first thickness. For example, the sheet metal may be galvanized or stainless steel having an 18 gauge to 20 gauge thickness.

At block 1004, according to some examples, the method includes cutting a form extender out of the sheet metal using a cutting apparatus selected for cutting through the first thickness. For example, the cutting apparatus may be a laser cutter, plasma cutter, water-jet cutter, or any other suitable cutting mechanism. In some examples, the cutting apparatus may use any suitable pattern or template such as shown in FIG. 11 and in FIG. 12.

At block 1006, according to some examples, the method includes bending the form extender to produce a plurality of bends in the form extender. For example, block 1006 may include bending the form extender to have three bends such as first bend 308, second bend 310, and third bend 312 as shown above in form extender 300 as discussed in relation to FIG. 3. In some examples, the bends can be placed according to a pattern or template, such as shown in FIG. 11 and FIG. 12.

At block 1008, according to some examples, the method includes verifying that the plurality of bends provide a tension-based attachment portion that is configured to removably secure to a form member.

FIG. 11 is an example template 1100 for cutting a planar blank from sheet metal to provide a form extender, according to some examples. As shown in FIG. 11, the solid line can be a cut line where a cutting apparatus can cut sheet metal, and the dashed line(s) can be locations for bending the template 1100 to angles such as shown in FIG. 3. The dimensions A-G shown in FIG. 11 can correspond to those used throughout, such as shown in form extender 300 in FIG. 3, and angled form extender 500 shown in FIGS. 5A and 5B. The cutting apparatus may cut the sheet metal in the example template of FIG. 11 using one cut or multiple cuts.

FIG. 12 is an example template for cutting a planar blank from sheet metal to provide a form extender with notched portions, according to some examples. As shown in FIG. 12, the solid line can be a cut line where a cutting apparatus can cut sheet metal, and the dashed line(s) can be locations for bending the template 1200 to angles such as shown in FIG. 3. The dimensions A-G shown in FIG. 12 can correspond to those used throughout, such as shown in form extender 300 in FIG. 3 and angled form extender 500 shown in FIGS. 5A and 5B.

The dimensions G1, G2, G3, and J can be used to define a notched portion 602 such as in form extender notched form extender 600. In some examples, G1 and G2 can define a remaining amount of material in the form extender. In some examples, G3 can define a notch length and J can define a notch depth.

The form extender may include several dimensions that affect the tension-based attachment mechanism. In some examples, the angular tolerance for the tension-based attachment bends may be specified as plus-or-minus 1 degree. In some examples, linear dimensions may have a tolerance of plus-or-minus one-sixteenth of an inch (for fractional dimensions), plus-or-minus 0.06 inches for two-place decimal dimensions, and plus-or-minus 0.01 inches for three-place decimal dimensions. In some examples, certain dimensions may be designated as critical dimensions that use increased tolerance control. For example, the interior grip dimension may be specified with an asymmetric tolerance of +0.000/−0.035 inches to ensure the form extender maintains sufficient tension on the form member without being too tight to install or to remove by hand.

A bend radius for all bends described herein may be approximately 0.6 inches to prevent stress concentrations while maintaining the designated angles.

The above-described examples relate to a form extender for use in concrete construction projects, however, the use of such form extenders may not be limited to concrete. For example, any suitable construction material that is applied to a form may use form extenders as disclosed herein.

The above-described examples are merely illustrative of some of the many specific examples that represent the principles described herein. Clearly, those skilled in the art may readily devise numerous other arrangements without departing from the scope as defined by the following claims.

Additional examples of the presently described embodiments include the following, non-limiting implementations. Each of the following non-limiting examples may stand on its own or may be combined in any permutation or combination with any one or more of the other examples provided below or throughout the present disclosure.

Example 1 is a form extender for concrete construction, comprising: a first portion of sheet metal extending along a length dimension and having a height in a vertical direction; a second portion of the sheet metal connected to a top edge of the first portion at a first bend, the second portion oriented at a first interior angle relative to the first portion; a third portion of the sheet metal connected to the second portion at a second bend, the third portion oriented at a second interior angle relative to the second portion, wherein the third portion extends in the vertical direction; a fourth portion of the sheet metal connected to the third portion at a third bend, the fourth portion oriented at an exterior angle relative to the third portion, wherein the third bend defines a grip space between the third portion and the first portion; wherein the second portion, third portion, and grip space create a tension-based attachment portion that is configured to removably secure to at least one form member of a concrete form that is positioned within the grip space; wherein the first portion provides a form extension surface that is configured to maintain continuity with the at least one form member.

In Example 2, the subject matter of Example 1 includes, wherein the sheet metal comprises one of stainless steel or galvanized steel, having a thickness of 18 gauge to 20 gauge.

In Example 3, the subject matter of Examples 1-2 includes, wherein the thickness provides a profile of the form extender attached to the at least one form member that permits a screeding tool to create a concrete surface without the screeding tool creating an irregularity at a location of the form extender.

In Example 4, the subject matter of Examples 1-3 includes, wherein the height of the first portion is selected from a set of lumber heights of 2×4, 2×6, 2×8, or 2×10 lumber.

In Example 5, the subject matter of Examples 1-4 includes, wherein the second portion has at least one edge that is angled relative to the length dimension, the angled edge configured to create a corner transition in the concrete form.

In Example 6, the subject matter of Examples 1-5 includes, wherein the second portion, third portion, and fourth portion include a notched portion configured to accommodate obstacles while maintaining form continuity.

In Example 7, the subject matter of Examples 1-6 includes, wherein the form extender is shaped to remain secured to the form member during concrete pouring, based on the tension-based attachment portion securing the form extender to the form member without using an additional fastener.

In Example 8, the subject matter of Examples 1-7 includes, wherein the first interior angle ranges from approximately 88 degrees to approximately 92 degrees, inclusive; the second interior angle ranges from approximately 90 degrees to approximately 95 degrees, inclusive; and the exterior angle ranges from approximately 35 degrees to approximately 45 degrees, inclusive.

In Example 9, the subject matter of Examples 1-8 includes, wherein the length dimension ranges from approximately 11 inches to approximately 60 inches, inclusive.

In Example 10, the subject matter of Examples 1-9 includes, wherein the height in the vertical direction of the first portion is provided from one of: approximately 3.5 inches, approximately 4.5 inches, approximately 5.5 inches, or approximately 6.5 inches.

In Example 11, the subject matter of Examples 1-10 includes, wherein the grip space has a width dimension ranging from approximately 1.5 inches to approximately 2.1 inches, inclusive.

Example 12 is a method of using a form extender for concrete construction, comprising: arranging multiple form members in a concrete form; identifying a gap between a first form member and a second form member of the multiple form members; and applying a form extender to the gap, wherein the form extender uses a tension-based attachment to attach to the first form member and the second form member.

In Example 13, the subject matter of Example 12 includes, further comprising using the concrete form comprising the first form member, the second form member, and the form extender, to perform concrete pouring operations.

In Example 14, the subject matter of Examples 12-13 includes, further comprising smoothing a surface of concrete poured into the concrete form by passing a rigid body over the concrete form, wherein the form extender is configured to allow the rigid body to pass over the form extender unimpeded.

In Example 15, the subject matter of Examples 12-14 includes, wherein at least one of the first form member and the second form member are one of 2×4, 2×6, 2×8, or 2×10 lumber.

In Example 16, the subject matter of Examples 12-15 includes, wherein the gap between the first form member and the second form member is on a straight segment of the concrete form, and the form extender is shaped to accommodate a straight gap.

In Example 17, the subject matter of Examples 12-16 includes, wherein the gap between the first form member and the second form member is at a corner of the concrete form, and the form extender is shaped to accommodate a corner gap.

Example 18 is a method of manufacturing a form extender, comprising: selecting a sheet metal with a first thickness; cutting the sheet metal to define a planar blank having a length dimension and a height dimension; performing a first bending operation on the planar blank to create a first bend that defines a first portion and a second portion, the first portion having the height dimension; performing a second bending operation on the planar blank to create a second bend that defines a third portion connected to the second portion; and performing a third bending operation on the planar blank to create a third bend that defines a fourth portion, wherein the third bend defines a grip space between the third portion and the first portion, wherein the second portion, third portion, and grip space create a tension-based attachment portion that enables the form extender to be removably secured to at least one form member of a concrete form.

In Example 19, the subject matter of Example 18 includes, wherein the first thickness of the sheet metal has a thickness of 18 gauge or 20 gauge of one of galvanized steel or stainless steel, and wherein cutting the sheet metal is performed by a laser cutter.

In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the term “or” is used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments may be used, such as by one of ordinary skill in the art upon reviewing the above description. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment. The scope of the embodiments should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.