ADJUSTABLE SUPPORT SYSTEMS FOR POURED CONCRETE STRUCTURES AND RELATED SYSTEMS AND METHODS

BACKGROUND

Constructing a concrete bridge deck typically involves formwork between bridge girders to temporarily support wet concrete until the concrete is cured. Once the concrete is cured, the formwork is no longer needed and is either removed or left in place. Bridge contractors use two types of formwork depending on the project requirements. The first type is removable forms, which are typically plywood supported on lumber. Wood formwork and other types of scaffolding which are removable may be placed at a location where a concrete member is to be placed, and then removed after the concrete member cures. The second type is stay-in-place forms, which are typically precast panels, corrugated steel deck forms, or transparent deck forms. Stay-in-place forms are used to make construction more simple and efficient. Stay-in-place forms may include corrugated metal sheets that span transversely between longitudinal beams, which can support material such as concrete while the concrete cures.

Depending on the type of form and type of girder (typically precast concrete or steel beams), there are various connections for attaching the forms to the bridge girders to properly support the bearing loads at the form/girder interface. Once a form material and bridge type are known, a contractor is then responsible for designing and constructing an appropriate connection between the form and the girder. One important consideration for the connection is the ability to easily adjust the distance between the top of the girder and the bottom of the bridge deck, otherwise known as the haunch height. The haunch height is often specified by the bridge designer based on the girder camber and deck geometry such that a minimum deck thickness is maintained over the structure. However, it may be difficult to place the formwork such that the haunch height is constructed exactly per plan due to creep, shrinkage, variability in girder dimensions, and other factors related to bridge construction (e.g., settlement, temperature, material composition, etc.). Owing to the complexity involved in such a process, contractors generally make adjustments to the formwork elevations once the beams are set and just prior to the concrete deck pour to ensure the top and bottom of the concrete bridge deck will be at the specified elevations once the concrete deck construction is completed. Typically, once the formwork is installed between the girders, a dry-run is made to compare the measured concrete deck thickness to the specified thickness. If there are locations that may need to be adjusted up or down, the contractor must make the alignment change, which then requires additional time and labor prior to placing the concrete.

When removable plywood forms are used, the contractor designs the support structure and connections to accommodate vertical adjustments with a hanger and coil rod system. These types of support structures include steel hangers placed over a girder, which are attached to a coil rod and nut (i.e. greased on the end embedded in the concrete for easy removal from the concrete once cured) such that when the nut is tightened, it raises the bottom of the formwork (i.e., plywood supported by lumber). Additionally, the removable plywood forms require the contractor to remove or strip the forms from beneath the deck once the concrete cures.

For stay-in-place forms, the contractor often looks to the formwork supplier to design the support structures and connections. Typically, these designs involve steel angles welded to the top flange of the bridge. The contractor has the ability to place the angles at the required elevations on the beams to achieve the designer's haunch height. Alternatively, the contractor may construct a ladder system where parallel angles are welded to a steel strap. The steel strap is welded along the vertical leg of the steel angle at exact locations measured by the contractor such that when the ladder is set on the girder, the form rests on the horizontal leg of the angle to achieve the required haunch height.

While metal stay-in-place forms are used by contractors to achieve lower material cost, improved speed of construction, and less risk, they do, however, require specialty labor, e.g., welders, and materials customized to the bridge geometry. One disadvantage to welding is that the protective coating over the steel support is removed, exposing the steel to potential corrosion. Once the steel is welded to the bridge, it may be very difficult to make even minor elevation adjustments. Another disadvantage is the expense and shortage of skilled labor involved in welding, making it costly with longer lead times for schedule availability. Bridge deck forming options also need to consider future bridge deck replacement. For bridge deck replacements, the old bridge deck is first removed from the girders, the girders are sand blasted to remove old paint and corrosion, and a new concrete deck is formed and placed. In these situations, the steel straps used with stay-in-place forms cannot be placed prior to sand blasting because the entire surface of the top flange area must be exposed. Although removable forms may take longer and are more costly for these situations, the girders can be properly prepared and painted since the steel straps are not in conflict.

It is, therefore, desirable to use a support system with stay-in-place forms, which has the ability to use standardized, repeatable parts, with field adjustability in the vertical direction to adjust haunch heights easily from the top of the deck, without the need for welding and without costly labor. Additionally, a support system that is better suited for bridge deck replacements, not obstructing sand blasting and painting operations, is desired.

SUMMARY

Aspects of the present disclosure relate to, among other things, adjustable support systems for poured concrete structures, and related systems and methods. Various aspects of the present disclosure may be used for adjusting a haunch height such that a contractor, or other suitable person, may adjust a stay-in-place support system in the vertical direction (e.g., up or down) from a top surface of a deck. In one aspect, the disclosure describes, among other things, a structure that allows a contractor to set a haunch elevation from a top surface of a deck without welding the steel components together. Another aspect is the ability to adjust the vertical haunch height without breaking a weld and re-welding. Each of the aspects disclosed herein may include one or more of the features described in connection with any of the other disclosed aspects.

In some aspects, an apparatus for adjusting a haunch height may include a support angle, a rod or bar, a coupler, and a bolt. The support angle may include a horizontal portion and a vertical portion. The vertical portion may include a plurality of holes spaced apart from each other. At least one end of the rod or bar may be threaded. The coupler may include an internal threading. The bolt may be configured to extend through one of the plurality of holes in the support angle and into a portion of the coupler.

The apparatus may include one or more of the following aspects. The plurality of holes may be spaced apart vertically. The plurality of holes may be arranged in a plurality of columns. The plurality of holes may be arranged diagonally. The apparatus may include another support angle, another coupler, and another bolt. The apparatus may include a clip angle, another coupler, and another bolt. The apparatus may include a deck form coupled to or positioned on a portion of the horizontal portion of the support angle. The height of the support angle may be adjustable by repositioning the bolt in another hole of the plurality of holes in the support angle. The height of the support angle may be adjustable without a vertical rod.

In other aspects, a system for adjusting a haunch height may include a support angle, a rod or bar, a coupler, and a bolt. The support angle may include a horizontal portion and a vertical portion. The vertical portion may include a plurality of holes spaced apart and positioned at different heights on the vertical portion. The horizontal portion may be configured to support a deck form. At least ends of the rod or bar may be threaded. The coupler may include an internal threading. The bolt may be configured to extend through one of the plurality of holes in the support angle and into a portion of the coupler to adjust a height of the horizontal portion of the support angle and the deck form.

The system may include one or more of the following aspects. The support angle may be a first support angle, and the system may further include a second support angle coupled to another coupler via another bolt. The other coupler may be coupled to another end of the rod or bar. The heights of the horizontal portions of the first and second support angles may be variable based on the position of the rod or bar relative to the vertical portions of the first and second support angles. The plurality of holes may be arranged in a plurality of columns on the vertical portion of the support angle. The plurality of holes may be arranged diagonally on the vertical portion of the support angle. The height of the support angle may be adjustable by repositioning the bolt in another hole of the plurality of holes in the support angle. The height of the support angle may be adjustable without a vertical rod. The system may further include a clip angle, and the clip angle may be coupled to another coupler via another bolt. The other coupler may be coupled to another end of the rod or bar.

In yet another aspect, a system for adjusting a haunch height may include a support angle, a rod or bar, a coupler, and a bolt. The support angle may include a horizontal portion and a vertical portion. The vertical portion may include a plurality of holes spaced apart and arranged diagonally different heights on the vertical portion. The horizontal portion may be configured to support a deck form. At least ends of the rod or bar may be threaded. The coupler may include an internal threading. The bolt may be configured to extend through one of the plurality of holes in the support angle and into a portion of the coupler to adjust a height of the horizontal portion of the support angle and the deck form.

The system may include one or more of the following aspects. The plurality of holes may include four or more holes arranged diagonally on the vertical portion. The plurality of holes may include twelve or more holes arranged diagonally on the vertical portion. The support angle may be a first support angle. The system may further include a second support angle coupled to another coupler via another bolt. The other coupler may be coupled to another end of the rod or bar. The second support angle may include a horizontal portion and a vertical portion. The vertical portion may include a plurality of holes spaced apart and arranged diagonally different heights on the vertical portion. The horizontal portion may be configured to support a deck form. The heights of the horizontal portions of the first and second support angles may be variable based on the position of the rod or bar relative to the vertical portions of the first and second support angles.

As used herein, the terms “comprises,” “comprising,” “having,” “including,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements, but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Unless stated otherwise, the term “exemplary” is used in the sense of “example,” rather than “ideal.”

It may be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosure, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein, and constitute a part of this specification, illustrate exemplary aspects of the present disclosure and together with the description, serve to explain the principles of the disclosure.

FIG. 1A is a side view of a plurality of adjustable support assemblies and deck forms, according to aspects of the present disclosure.

FIG. 1B is a side view of one adjustable support assembly and two deck forms of FIG. 1A, according to aspects of the present disclosure.

FIG. 2A is a perspective view of a plurality of another adjustable support assemblies, according to aspects of the present disclosure.

FIG. 2B is a side view of the adjustable support assembly of FIG. 2A, according to aspects of the present disclosure.

FIG. 3A is a side view of a support angle of an adjustable support system, according to aspects of the present disclosure.

FIG. 3B is an enlarged side view of a portion of the support angle of FIG. 3A, according to aspects of the present disclosure.

FIG. 4 is a side view of another support angle of an adjustable support system, according to aspects of the present disclosure.

FIG. 5 is a perspective view of another support angle assembled in an adjustable support system, according to aspects of the present disclosure.

FIGS. 6A-6C are different views of an adjustable support system separate from a bridge girder, according to aspects of the present disclosure.

DETAILED DESCRIPTION

The present disclosure is now described with reference to exemplary aspects of structure and construction methods for an adjustable support system for stay-in-place forms. Some embodiments are depicted and/or described with reference to the structure and construction methods of an adjustable haunch with continuous angles, an adjustable haunch with continuous angles connected by an assembly of bars, couplers and bolts, vertical adjustable haunch supports with discontinuous angles, a vertical support adjustable haunch with continuous angle support, an adjustable haunch with integrated support and formwork, and an adjustable haunch with continuous angled support. These references are provided for convenience and are not intended to limit the present disclosure unless incorporated into the appended claims. Accordingly, the concepts and novelty underlying each embodiment may be utilized for any type of adjustable support system, and may be made out of any material or materials. Additionally, this application incorporates by reference previously filed U.S. application Ser. No. 15/951,935, now U.S. Pat. No. 10,801,198, and previously filed U.S. application Ser. No. 17/009,053, now U.S. Pat. No. 11,339,563, in each of their entireties.

The disclosure below provides structures and construction methods to adjust the vertical supports of a stay-in-place form system using bolts, couplers and tension bars in the horizontal direction only, without the need for welding. As described above, while contractors often prefer stay-in-place forms over removable forms, bridge owners must contend with any consequences relating to welding steel angles to a top flange of a beam. Contractors are facing increased labor costs for specialty welding, and difficulties adjusting the haunch height once the weld is completed. To speed up construction, decrease labor costs, and make easier the adjustment of the haunch height, an adjustable connection without the need for welding is described below. Thus, the present disclosure describes a structure that may allow the contractor to adjust the haunch elevation, e.g., haunch height, from the top surface of the bridge deck without the need for welding the form support, e.g., formwork, to the girder. The embodiments of the present disclosure allow the contractor to adjust the height of the haunch more easily by, for example, connecting a bolt through one hole of a cluster of holes in a vertical portion of a support angle to a receiving coupler attached to a tension bar resting on the top flange of the bridge girder. The support angle may also support the formwork at the appropriate height. Unlike welded connections that would need broken and re-welded, the connection described can be changed at any time prior to the deck placement through un-bolting and re-bolting the bolt and the coupler in a different (e.g., higher or lower) position, as determined by the contractor.

Exemplary aspects of the present disclosure are illustrated in FIGS. 1A-6C attached hereto. FIGS. 1A and 1B depict various aspects of this disclosure, for example, in which an adjustable support apparatus or system 100 includes a support angle 102. Specifically, FIG. 1A illustrates a plurality of adjustable support assemblies 100. The adjustable support assemblies 100 may be mounted to, positioned on, or otherwise coupled to a respective girder 104 (e.g., a bridge girder), for example, to one of the interior girders in a bridge. Each adjustable support assembly 100 may support one side of a deck form 106, such that one side of the deck form 106 is supported by an adjustable support assembly 100, and another side of the deck form 106 is supported by another adjustable support assembly 100. In this aspect, the plurality of adjustable support assemblies 100 and the plurality of deck forms 106 may be used to form a bridge deck 108, for example, by pouring concrete over the deck forms 106.

FIG. 1B illustrates one adjustable support assembly 100, for example, supporting respective sides of two deck forms 106. As shown, the adjustable support assembly 100 may be mounted to, positioned on, or otherwise coupled to a girder 104, for example, to a top flange 104A of the girder 104. As mentioned above, the girder 104 in FIG. 1B is an interior girder in a bridge Additionally, the adjustable support assembly 100 includes at least one support angle 102, for example, two support angles 102 on opposing sides of the top flange 104A of the girder 104. The support angle(s) 102 may extend from the respective side (e.g., opposing sides) of the top flange 104A of the bridge girder 104. The support angle(s) 102 may include a vertical portion 102A (e.g., substantially vertical) and a horizontal portion 102B (e.g., substantially horizontal). The horizontal portion 102B of the support angle(s) 102 may extend away from the girder 104 when the support angle(s) 102 is/are mounted to, positioned on, or otherwise coupled to the girder 104. In some aspects, a portion of the deck form 106 may be coupled to the support angle(s) 102, for example, to the horizontal portion 102B. The portion of the deck form 106 may be coupled to the support angle(s) 102 via one or more coupling mechanisms 110, for example, one or more of a bolt, a screw, a nut, etc. Alternatively, the portion of the deck form 106 may be positioned on or otherwise supported by the support angle(s) 102 without one or more coupling mechanisms 110, for example, without a bolt, a screw, a nut, etc.

Moreover, as shown in FIG. 1B, vertical portions 102A of respective support angles 102 may be coupled via an adjustable coupling 112. The adjustable coupling 112 includes a rod or bar 114 with threaded ends 114A. In some aspects, the threading (e.g., threaded ends 114A) of the rod or bar 114 may extend only on the end portions, or the threading on the rod or bar 114 may extend the length of the rod or bar 114. Additionally, the adjustable coupling 112 may include two couplers 116, for example, to receive the threaded ends 114A of the rod or bar 114. In these aspects, the couplers 116 may include an internal threading, for example, to interact with the threaded ends 114A of the rod or bar 114. Each of the couplers 116 may be generally cylindrical with threaded holes extending through portions of the coupler 116. In some aspects, the threaded holes may extend through an entire length of each coupler 116. Furthermore, the adjustable coupling 112 may include two coupling elements 118 (e.g., bolts), for example, extending through portions of the vertical portions 102A of the support angles 102 and into a portion of the coupler 116. Additionally, as discussed below, the vertical portions 102A of the support angles 102 may include a plurality or cluster 220 of holes 224 (FIG. 2A), for example, allowing for adjustability (e.g., vertically and/or horizontally) of the position of the support angle 102 relative to the threaded rod or bar 114, and thus also adjust the position (e.g., vertical position) or haunch height of the deck form 106 relative to the bridge girder 104.

FIG. 2A is a perspective view of a plurality of another adjustable support assembly, apparatus, or system 200, and FIG. 2B is a side view of one adjustable support assembly 200 of FIG. 2A. As shown in FIGS. 2A and 2B, the adjustable support assemblies 200 may be mounted to, positioned on, or otherwise coupled to a bridge girder 204 (e.g., a steel bridge girder), for example, to an exterior or end girder of a bridge. In some aspects, FIGS. 2A and 2B illustrate an adjustable support assembly 200 that may be positioned at an end of a bridge (exterior-most girder). In these aspects, the adjustable support assembly 200 includes a support angle 202 and a clip angle 230. The support angle 202 and the clip angle 230 are coupled via a rod or bar 214 with threading 214A, for example, at least on the ends of the rod or bar 214. Additionally, the support angle 202 and the clip angle 230 may be coupled via couplers 216 on respective ends of the rod or bar 214, and also via bolts or other coupling elements 218.

The support angle 202 (e.g., a vertical portion 202A of the support angle 202) includes a plurality or cluster 220 of holes 224. The plurality or cluster 220 of holes 224 may include a plurality of columns 222 of holes 224, for example, three columns 222 of holes 224. Additionally, holes 224 in adjacent columns 222 of holes 224 may be staggered or unaligned. For example, as shown, a middle column 222 may include a plurality of holes 224 (e.g., 4 holes), and the left and right columns 222 of holes 224 may include three holes, with the three holes 224 arranged at positions between the positions of respective pairs of holes 224 of the plurality of holes 224 in the middle column 222. Although not shown, the clip angle(s) 230 may also include a plurality or cluster of clip angle holes 232 as well. The bolts or other coupling elements 218 may be selectively positioned within one of the holes 224 of the plurality or cluster 220 of holes—224, which may allow for adjustments in the position (e.g., a height or orientation) of the support angle 202 relative to the girder 204. Moreover, as shown in FIG. 2A, the respective rods or bars 214 may be positioned in different holes 224 within the respective plurality or cluster 220 of holes 224.

As shown in FIG. 2B, the clip angle 230 includes a vertical portion 230A, for example, including one or more clip angle holes 232 to receive a bolt or other coupling element 218, such that the bolt or other coupling element 218 may be secured within a coupler 216 to secure the clip angle 230 to the adjustable support assembly 200. Moreover, the clip angle 230 includes a horizontal portion 230B, which may be positioned adjacent to a portion of the top flange 204A of the bridge girder 204. For example, at least a portion of the horizontal portion 230B of the clip angle 230 may abut or be positioned below a bottom portion or bottom surface of the top flange 204A of the bridge girder 204. In some aspects, the clip angle 230 may be a support angle (e.g., similar to support angle(s) 102 or 202) repositioned such that the horizontal portion (e.g., horizontal portion 102B or 202B) is positioned under the top flange 204A of the bridge girder 204 (e.g., instead of extending away from the bridge girder 204). In these aspects, the clip angle 230 may help to anchor or otherwise secure the adjustable support system 200 to the bridge girder 204.

FIG. 3A is a side view of the support angle 202, and FIG. 3B is an enlarged view of a portion of the support angle 202, for example, of a portion of the vertical portion 202A of the support angle 202. As shown in FIG. 3A, the support angle 202 may include three sets of a plurality or cluster 220 of holes 224. Each set of a plurality or cluster 220 of holes 224 may be spaced apart by a distance D, and each of the first and third set of a plurality or cluster 220 of holes 224 may be spaced from respective ends 202C, 202D of the support angle 202 by a distance D/2, such that an overall length L of the support angle 202 is equal to 3D. Moreover, as mentioned each set of a plurality or cluster 220 of holes 224 may include a number of columns 222 of holes 224. Although not shown, sets of a plurality or cluster 220 of holes 224 may instead include a number of holes 224 arranged irregularly, for example, not in columns or rows.

As shown in FIG. 3B, a lowest hole 224A of the set of a plurality or cluster 220 of holes 224 may be spaced from a bottom or toe 202E of the vertical portion 202A of the support angle 202 by a distance A, for example, approximately ⅝ of an inch. A highest hole 224B of the set of a plurality or cluster 220 of holes 224 may be spaced from a top 202F of the vertical portion 202A of the support angle 202 by a distance B, for example, approximately ⅝ of an inch. Furthermore, adjacent columns 222 of holes 224 may be spaced apart by a distance C, for example, approximately ¾ of an inch, for example, between the centers of the adjacent holes 224. Adjacent holes 224 in each column 222 may also be spaced apart by a distance E, for example, approximately ¾ of an inch between the centers of the holes 224. As mentioned, the arrangement of the holes 224 in adjacent columns 222 may be staggered. In this aspect, the center of a lowest hole (e.g., hole 224A) in the middle column 222A may be a distance F, for example, approximately 7/16 of an inch, lower than a center of a lowest hole (e.g., hole 224C) in a side column 222B. Similarly, the center of a highest hole (e.g., hole 224B) in the middle column 22A may be a distance (e.g., similar to distance F), for example, approximately 7/16 of an inch, higher than a center of a highest hole (e.g., hole 224D) in the side column 222B. The holes 224 of each column 222 and/or of each set of a plurality or cluster 220 of holes 224 may be regularly spaced (as shown), or alternatively, may be irregularly or unevenly spaced. Moreover, although the holes 224 are shown as being generally circular, this disclosure is not so limited, as the holes 224 may instead by generally ovular, triangular, rectangular (e.g., square), or otherwise shaped.

FIG. 4 is a side view of a support angle 402, and FIG. 5 is a perspective view of another support angle 502 coupled to another support angle 502 to form an adjustable support system 500. As shown in FIG. 4, the support angle 402 may include two sets of a plurality or cluster 420 of holes 424, for example in a vertical portion 402A of the support angle 402. Similarly, as shown in FIG. 5, the support angle 502 may include two sets of a plurality or cluster 520 of holes 524, for example, in a vertical portion 502A of the support angle 502. Although not shown, support angles 402, 502 may include one plurality or cluster 420, 520 of holes 424, 524, or support angles 402, 502 may include three or more sets of a plurality or cluster 420, 520 of holes 424, 524. The holes 424, 524 of each plurality or cluster 420, 520 may be arranged in an angled or diagonal arrangement (i.e., arranged diagonally). The arrangement of the plurality or cluster 420, 520 of holes 424, 524 on the support angle 402, 502 may be similar to the arrangement(s) of the holes discussed above. Additionally, the spacing between the holes 424, 524 of each set of holes in the plurality or cluster 420, 520, and also the spacing between sets of the plurality or cluster 420, 520 of holes 424, 524, may be similar to the spacings discussed above.

As shown in FIG. 5, vertical portions 502A of respective support angles 502 may be coupled via an adjustable coupling 512. The adjustable coupling 512 includes a rod or bar 514 with threaded ends 514A. In some aspects, the threading of the rod or bar 514 may extend only on the end portions 514A, or the threading on the rod or bar 514 may extend the length of the rod or bar 514. Additionally, the adjustable coupling 512 may include two couplers 516, for example, to receive the threaded ends 514A of the rod or bar 514. Each of the couplers 516 may be generally cylindrical with threaded holes extending through portions of the coupler 516. In some aspects, the threaded holes may extend through an entire length of each coupler 516. Furthermore, the adjustable coupling 512 may include two coupling elements 518 (e.g., bolts), for example, extending through portions of the vertical portions 502A of the support angles 502 and into a portion of the coupler 516. Additionally, as shown, the coupling elements 518 may extend through respective holes 524 of the sets of a plurality or cluster 520 of holes 524. It is noted that FIG. 4 illustrates each set of a plurality or cluster 420 of holes 424 including twelve holes 424, and that FIG. 5 illustrates each set of a plurality or cluster 520 of holes 524 including four holes 524. Nevertheless, it is noted that the number, size, spacing, orientation, or general arrangement of the holes 424, 524 or sets of a plurality or cluster 420, 520 of holes 424, 524 may be selected based on the size of the support angles 402, 502, the size of the rod or bar 514, couplers 516, coupling elements 518 (e.g., bolts), and/or other aspects of the adjustable support system 512.

FIG. 6A is a side view of a support angle 602 coupled to a portion of the adjustable support system 612, and FIGS. 6B and 6C are perspective views of two support angles 602 coupled together to form the adjustable support system 612. As shown in FIG. 6A, the coupling elements 618 (e.g., bolts) and the couplers 616 may be coupled through respective holes 624 in the support angle 602 (e.g., through the vertical portion 602A of the support angle 602). As mentioned, the couplers 616 may each be coupled to threaded ends of the rods or bars 614. Furthermore, as shown in FIGS. 6B and 6C, two support angles 602 may be coupled via a plurality of rods or bars 614, couplers 616, and coupling elements 618 (e.g., bolts). Although FIGS. 6B and 6C illustrate single holes 624 through the support angles 602 being spaced apart, it is noted that each hole 624 in FIGS. 6B and 6C may instead be a cluster or set of holes (e.g., as shown in FIGS. 2A, 3A, 3B, 4, and 5), as discussed above.

Moreover, one or more components of the adjustable support system may include one or more coatings, for example, corrosion-resistant coatings. In these aspects, one or more of the support angle, the couplers, the bars or rods, and/or the bolts may include one or more corrosion-resistant coatings. For example, one or more of the support angle, the couplers, the bars or rods, and/or the bolts may include a hot dip galvanized coating (e.g., may be dipped in molten zinc), an electroplating coating, and/or an epoxy coating. As discussed below, there is no need to weld the various components together to assemble the adjustable support system. Because there is no welding, there is no need to touch up or otherwise repair the corrosion-resistant coatings, as welding may interfere with or deteriorate corrosion-resistant coatings. Furthermore, in some aspects, the corrosion-resistant coating(s) of the various components of the adjustable support system may be the same or similar to any corrosion-resistant coating(s) on the bridge deck.

Furthermore, one or more components of the adjustable support system may be formed of a corrosion resistant material. For example, one or more of the support angle, the couplers, the bars or rods, and/or the bolts may be formed of stainless steel, one or more other corrosion-resistant materials, one or more composite materials, and/or one or more plastic materials. Similarly, one or more components of the adjustable support system may be formed of the same or similar material as one or more materials used in the bridge deck.

Various aspects of this disclosure may help to provide an adjustable support system, for example, for a stay-in-place form system. The adjustable support system includes holes in the support angle(s), for example, a cluster or set of holes in the vertical portion of the support angle. The cluster or set of holes may allow for adjustability on either side of the vertical portion of the support angle, for example, from above the bridge girder and the adjustable support system, to allow for the different sides of the adjustable support system (e.g., relative to the bridge girder) to have different heights. In these aspects, a user may disconnect the bolt and the coupler from one hole in the support angle, and reposition the bolt and the coupler through a different hole in the support angle. In some aspects, the cluster or set of holes may allow for the position of the support angle (e.g., the haunch height adjustment range) to be adjusted by approximately ½ of an inch, by approximately 1 inch, by approximately 2 inches, by approximately 4 inches, by approximately 7 inches, etc. The haunch height adjustment range may be dependent on the height of the vertical portion of the support angle and the corresponding positioning of the holes. For example, if the height of the vertical portion of the support angle is larger, and if the holes span a larger height of the vertical portion of the support angle, then the haunch height adjustment range may be larger.

The cluster or set of holes may allow for small, incremental changes (e.g., vertical changes) in the orientation or position (e.g., height) of the support angle, and thus of the deck form. Moreover, different portions of the support angle(s) (e.g., different clusters or sets of holes) may receive respective bolts (e.g., coupled to respective couplers) at different positions. In this aspect, different ends of the support angle may be at different heights, for example, relative to the bridge girder. Additionally, the support angles on either side of the bridge girder may be identical (e.g., no differences between support angles on the left and right side of the bridge girder), which may help to reduce production and/or installation costs.

The cluster or set of holes may also allow for different haunch heights, while also limiting the skew in the rod or bar (and in the couplers) connecting two support angles on either side of the bridge girder. Limiting the skew in the rod or bar (and in the couplers) may help to ensure that the threaded connections (e.g., between the rod or bar and the coupler, and between the coupler and the bolt) are maintained and remain secure. Moreover, the cluster or set of holes allows for the height or orientation of the support angles (and thus the deck forms) to be adjusted without requiring vertical rods or other vertical supports. Furthermore, the support angles may be arranged either in the “L” arrangement (e.g., as shown in FIG. 1B), or in a “7” arrangement (e.g., rotated 180 degrees such that the horizontal portion extends from the top of the vertical portion) in order to provide a variety of haunch heights relative to the bridge girder (e.g., a larger haunch height adjustment range).

Additionally, the holes of the cluster or set of holes may be spaced apart such that the structural integrity of the support angle is not compromised. For example, the cluster or set of holes may be spaced apart with solid portions of the support angle, as discussed above, such that each support angle is able to support the deck form, along with any poured material (e.g., concrete) on to the deck form.

As discussed herein, the adjustable support systems include one or more rods or bars that are threaded (at least on the ends). The rods or bars may be formed of rebar or another appropriate material. In these aspects, the adjustable support systems do not use steel straps. Instead, the rods or bars of the adjustable support systems may be positioned on the top flange of the bridge girder, which may help to reduce the risk or hazard of a contractor or other user tripping over, or otherwise being injured by, the rods or bars.

Furthermore, the adjustable support systems discussed herein may be simple and easy to install. For example, installation (and/or adjustment) of the adjustable support systems does not require welding, and thus does not require weld certification/training or weld inspection. Moreover, the adjustable support systems may be installed (and/or adjusted) immediately once the bridge girders are installed or otherwise set. In these aspects, the adjustable support systems do not require welders or special equipment for welding, which may help to accelerate construction or otherwise reduce downtime or inefficiencies.

Additionally, the adjustable support systems may include rods or bars, couplers, and bolts spaced apart. For example, the rods or bars, couplers, and bolts may be spaced apart by approximately one foot, approximately two feet, approximately three feet, approximately five feet, approximately seven feet, approximately ten feet, etc. In some aspects, the rods or bars, couplers, and bolts may be positioned between every two feet and 8 inches (e.g., depending on the size of the deck form being supported, and other factors), while welded steel straps usually require a smaller spacing, for example, between 1 foot to one foot and 6 inches (i.e., 1.5 feet). In these aspects, the adjustable support systems discussed herein may require less material(s) and/or less labor to install and/or adjust than welded steel strap systems.

Furthermore, the adjustable support systems discussed herein may require less (e.g., approximately one-third less) support rods or bars compared to existing hanger systems, which also reduces installation and/or adjustment time and/or necessary manpower, the cost of materials, the costs to ship/handle the materials, etc. Moreover, in some aspects, the rods or bars may be positioned on, above, and/or spaced apart from the bridge girder (see, e.g., FIG. 2B), which may help to allow for inspectors, contractors, or other professionals to visualize the bridge girder underneath or below the rods or bars. Furthermore, in these aspects, the inspectors, contractors, or other professionals may clean (e.g., sandblast, sweep, etc.), repair, repaint, or otherwise treat the bridge girder below the rods or bars. With greater spacing and less girder surface area obstructed, the rods or bars may be better suited for bridge deck replacements than steel straps for stay-in-place forms. The one or more rods or bars discussed herein may be more durable than steel straps.

Additionally, as welding processes are not necessary in the above systems or apparatuses, the protective coating(s), for example, on the one or more rods or bars discussed herein (typically galvanizing), will not be removed by welding. Additionally, the connections discussed herein may be more reliable with less factors influencing the bolt connection, for example, compared to welding the connection. Welding procedures require multiple steel materials, gas, flames, a dry environment, and expertise in making the weld to correct size and type. However, the systems and apparatuses discussed herein do not require welding procedures.

In these aspects, the support system detailed above may be manufactured at reduced costs compared to comparable support systems. The support system detailed above may be manufactured using a simple, repeatable, and modular process. The support system may also be modular to help in reducing the material cost over time, which may make it simple for contractors, or other suitable professionals, to install.

Moreover, various aspects of this disclosure provide one or more apparatuses or systems that may support one or more stay-in-place forms, one or more materials (e.g., wet concrete), and/or construction loads (e.g., contractors, etc.) during the formation of a bridge deck. Various aspects of this disclosure may provide one or more apparatuses or systems that support the loads from the reactions from the stay-in-place forms to the support angle(s). As such, the one or more apparatuses or systems may help to create a force couple with the girder, for example, putting tension in the rod or bar that extends between the support angles. As such, the one or more apparatuses or systems may help to both (1) provide for adjustability of the position of the stay-in-place form, and also (2) meet the load requirements for the stay-in-place form, the one or more materials, and/or various construction loads during the formation of the bridge deck. It is noted that the load support capabilities of the one or more apparatuses or systems may be adjusted or modified based on one or more of the rod diameter, hole diameters, coupler size/thickness, bolt size/grade, angle size/thickness, etc.

While principles of the present disclosure are described herein with reference to illustrative aspects for particular applications, it should be understood that the disclosure is not limited thereto. Those having ordinary skill in the art and access to the teachings provided herein will recognize additional modifications, applications, examples, and substitution of equivalents all fall within the scope of the aspects described herein. Accordingly, the present disclosure is not to be considered as limited by the foregoing description.

ADJUSTABLE SUPPORT SYSTEMS FOR POURED CONCRETE STRUCTURES AND RELATED SYSTEMS AND METHODS

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