Patent Application
20110271636
The present invention relates, in general, to concrete and metal structures and, more particularly, this invention relates to concrete diaphragms spanning the distance between a pair of longitudinally oriented support beans in the concrete bridge structure and, yet particularly, the instant invention relates to a form, system and method for forming-in-place such concrete diaphragm.
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As is generally well known, end, intermediate and continuity diaphragms are cast-in-place between a pair of spaced apart longitudinal beams in bridges as well as other structures affording vehicle and/or pedestrian traffic. Wood material is utilized in the field to build a form structure or through into which the concrete is poured and is allowed to set. After the concrete has been set, the wood form is removed. However, the construction and tear-down of the wood form requires considerable filed time slowing bridge construction process and increasing labor costs.
Accordingly, prior to the conception and development of the instant invention, efforts have been made to reduce time required to provide diaphragms. U.S. Pat. No. 6,345,403 issued to Nagle discloses precast concrete diaphragm for placement between longitudinal beams of the bridge structure. Ends of the diaphragm are adapted with pockets to receive concrete for tight joints.
However, it has been determined that there is a further need for reducing bridge construction costs and duration.
The invention provides, in combination with a diaphragm spanning a transverse distance between a pair of spaced-apart longitudinal members employed in a construction of a structure affording vehicle or pedestrian traffic, a form for forming the diaphragm from concrete material. The form includes a bottom wall having an inner surface thereof abutting a bottom surface of the diaphragm. There is a pair of side walls. Each of the pair of side walls upstands on the inner surface of the bottom wall at a respective longitudinal edge thereof and has an inner surface thereof abutting a respective side surface of the diaphragm. The pair of sides define each of a generally open top and a generally hollow interior of the form. There is also means for securely attaching each end of the form to one of a side surface of at least one of the pair of longitudinal members and an end of another form for forming the diaphragm from the concrete material.
The invention also provides, in combination with a diaphragm spanning a transverse distance between a pair of spaced-apart longitudinal members employed in a construction of a structure affording vehicle or pedestrian traffic, a system for forming the diaphragm from a concrete material. The system includes one or more bottom walls having an inner surface thereof abutting a bottom surface of the diaphragm. The system further includes a first plurality of side walls upstanding in series on the inner surface of the bottom wall at one longitudinal edge thereof and having an inner surface thereof abutting one side surface of the diaphragm. There is also a second plurality of side walls upstanding in series on the inner surface of the bottom wall at an opposed longitudinal edge thereof and having an inner surface thereof abutting an opposed side surface of the diaphragm. The first and second pluralities of side walls define each of a generally open top and a generally hollow interior of the form. A first means is provided for securely attaching ends of any two adjacent side walls therebetween. A second means is provided for securely attaching each outer edge of each outermost side wall to a side surface of the one of the pair of longitudinal members.
The invention also provides a method for forming the diaphragm from concrete material by using the aforedescribed form or system of forms.
It is, therefore, one of the primary objects of the present invention to provide a form for forming diaphragm from a concrete material.
Another object of the present invention is to provide a form for forming diaphragm from a concrete material that can be easily and simply installed.
Yet another object of the present invention is to provide a form for forming diaphragm from a concrete material that remains in place after concrete material has been set.
A further object of the present invention is to provide a system for forming diaphragm from a concrete material that accommodates diaphragm of different sizes.
Yet a further object of the present invention is to provide a method of forming diaphragm from a concrete material utilizing the above referenced form or system.
In addition to the several objects and advantages of the present invention which have been described with some degree of specificity above, various other objects and advantages of the invention will become more readily apparent to those persons who are skilled in the relevant art, particularly, when such description is taken in conjunction with the attached drawing Figures and with the appended claims.
Prior to proceeding to the more detailed description of the present invention, it should be noted that, for the sake of clarity and understanding, identical components which have identical functions have been identified with identical reference numerals throughout the several views illustrated in the drawing figures.
It is to be understood that the definition of a diaphragm applies to a bracing member manufactured from concrete material that spans the transverse distance between the main longitudinally oriented support beams or girders of a bridge or viaduct and assists in the distribution of loads.
The present invention is illustrated and described in combination with a bridge, although it will be apparent to those skilled in the relevant art that the present invention may be applied to other concrete or metal structures affording vehicle or pedestrian traffic and as such should not be interpreted as a limiting factor of the instant invention. For the sake of reference, such bridge may be of the type as disclosed in the U.S. Pat. No. 6,345,403 issued to Nagle wherein the support beams 14a through 14d are spaced apart from each other across the width of the bridge decking and are oriented in the longitudinal direction across the length of the bridge and wherein the conventional diaphragms that span the distance between the aforementioned support beams are labeled with numerals 18a through 18c and 20a through 20c and have a generally plate like shape. The teachings of U.S. Pat. No. 6,345,403 are incorporated into this document by reference thereto.
In the instant invention, the bridge structure is represented in various figures by a pair of longitudinal members, such as support beams 4, with the rest of the bridge structure omitted for the sake of brevity.
Reference is now made, to
Furthermore, the bottom wall 30 may include a pair of upstanding longitudinal flanges 38, wherein an inner surface 39 of each flange 38 substantially abuts a bottom portion of outer surface 44 of a respective side wall 40. When flanges 38 are provided, the form 20 includes means, generally designated as 50, for securing each longitudinal flange 38 to the respective side wall 40. Preferably, such means 50 includes pluralities of mechanical fasteners 52. In order to reduce labor costs associated with use of mechanical fasteners 52, such mechanical fasteners 52 are of a self-drilling type and, more specifically, that are commonly known as “TEK” self drilling screws. Although, it is within the scope of the present invention to secure longitudinal flange 38 to the respective side wall 40 by any other conventional means including welding, crimping, threaded fasteners in combination with matingly aligned through apertures and the like means.
There is also means, generally designated as 60, for securely attaching each end of the form 20 to one of a side surface 6 of at least one of the pair of longitudinal support beams 4 and an end of another form 20 for forming the diaphragm 10 from the concrete material, as it will be explained further in this document.
Such means 60 includes a predetermined contour of outer end edge 62 of each side wall 40 so as to position such outer end edge 62 of the form 20 in operative mating alignment with the side surface 6 of one of the pair of longitudinal support beams 4. The of outer end edge 62 may be either positioned either in abutting relationship with the side surface 6 or in close proximity thereto by way of a small clearance preventing leakage of liquid concrete material. Furthermore, the means 60 includes provisions for securely attaching the outer end edge 62 of the form 20 to the side 6 of the longitudinal support beam 4.
Such provisions may include at least a pair of brackets 64 secured to both the surface 6 of the longitudinal support beam 4 and the side wall 40 with, for example, mechanical fasteners that may be provided as self drilling fasteners 52. The brackets 64 may have an L-shaped or may have a portion thereof embedded into the longitudinal support beam 4 as it is being poured and set.
Such provisions may also include a flange 68 upstanding on the outer end edge 62 of each side wall 40 and generally abutting the side surface 6 of the longitudinal support beam 4 and mechanical fasteners 53 suitable for securing the flange 68 directly to the side surface 6 of the longitudinal support beam 4. The flange 68 may be L-shaped, having one leg thereof secured to the outer surface of the side wall 40 at the outer end edge 62 thereof.
It is also within the scope of the instant invention to reinforce and stiffen the open top end 22 of the form 20 by way of a pair of elongated L-shaped members 70, each having one leg 72 thereof disposed in a generally vertical plane abutting either inner or outer side surface of a respective side wall 40 and having another leg 74 thereof disposed in a generally horizontal plane either outwardly or inwardly relative to the side wall 40.
It is further contemplated to brace at least the top open end 22 with a brace or braces 80 disposed transversely to the direction of the elongated L-shaped members 70.
The diaphragm 10 may be formed with a single form 20 spanning the entire distance between the pair of longitudinal support beams 4 or a system, generally designated as 100, may be provided as containing a plurality of such forms 20 positioned in series with each other along the length of the diaphragm 10.
When the plurality of forms 20 are provided, the outer ends of the most outer forms 20 will be attached to respective side surfaces 6 of the longitudinal beam member 6. The inner ends of the most outer forms 20 as well as the ends of the inner forms 20 will be secured therebetween by way of the self drilling fasteners 52 or any other suitable means.
When the ends of the forms 20 must be contoured when forming diaphragm 10 for end application of
When the plurality of forms 20 are provided, the length of each of the pair of angle shaped members 70 will be preferably substantially equal to a combined length of the plurality of forms 20 measured at the top edges thereof. In other words, the length of the elongated L-shaped members 70 is pre-determined to substantially span the entire transverse distance between the opposed vertical surfaces 6 of the pair of longitudinal support beams 4.
Furthermore, it has been found advantageous to select the length of the bottom wall 30 to substantially span the entire transverse distance between the opposed vertical surfaces 6 of the pair of longitudinal support beams 4. In this arrangement, a first plurality of side walls 40 upstand in series on the bottom wall 30 at one longitudinal edge thereof and have a bottom edge thereof secured to the bottom wall 30, preferably at the longitudinal flange 36 by way of the fasteners 52. Furthermore, a second plurality of side walls 40 upstand in series on the bottom wall 30 at the opposed longitudinal edge thereof and have a bottom edge thereof also secured to the bottom wall 30, preferably at the longitudinal flange 36 by way of the fasteners 52. The first and second pluralities of the side walls 40 define, in combination with the bottom wall 30, the open top and the hollow interior of the system 100.
The general method of forming a diaphragm 10 from a concrete material includes the steps of providing one or plurality of forms 20 having a bottom wall 30 and at least a pair of side walls 40, each of the at least pair of side walls 40 upstanding on the inner surface 32 of the bottom wall 30 at a respective longitudinal edge thereof and defining each of a generally open top 22 and a generally hollow interior 24 of the one or the plurality of forms 20. Then, positioning one or plurality of forms 20 substantially transverse to a direction of the pair of spaced-apart longitudinal members 4 at a location preselected for receiving the diaphragm 10. Next, securing ends of the form 20 or outermost ends of the plurality of forms 20 to a respective inner vertical surface 6 of the pair of spaced-apart longitudinal support beams 4. Depositing concrete material in a liquid form into the one or plurality of forms 20. Finally, solidifying the concrete material deposited into the one or plurality of forms 20. The form or forms 20 remain attached to the diaphragm 10 during use thereof. The aforedescribed optional elongated L-shaped members 70 and braces 80 are added prior to depositing concrete material into the form or forms 20.
The form or forms 20 may be preassembled on the ground level (not shown) and hoisted into position to be occupied by the diaphragm 10 or may be erected in place.
Thus, the present invention has been described in such full, clear, concise and exact terms as to enable any person skilled in the art to which it pertains to make and use the same. It will be understood that variations, modifications, equivalents and substitutions for components of the specifically described embodiments of the invention may be made by those skilled in the art without departing from the spirit and scope of the invention as set forth in the appended claims.
