The disclosure relates to concrete forming and particularly to devices, systems, and methods for constructing poured overhangs.
As would be appreciated, when concrete bridge decks are poured, part of the deck overhangs the outside beam. The wet concrete must be supported by temporary formwork. This temporary formwork is typically supported by brackets bolted to the top flange of the bridge girder. Once the concrete has gained enough strength, the formwork and brackets are removed and can then reused on a different section of the bridge or on another project.
In various prior known cases, these brackets have been supported through the flange of the outside beam. In some cases, the bracket is bolted to the web of the beam. As would be appreciated, these prior known brackets must be installed and removed individually which is very labor intensive and can be unsafe requiring workers to be below the brackets to install and remove the brackets at each section.
There is a need in the art for improved and more safe systems for pouring and supporting bridge decks/overhangs.
Disclosed herein are implementations of a web shoe for supporting a series of brackets which in turn support formwork for use on bridges or other overhanging structures. The various implementations described herein allow for the use of the EFCO® Heavy Duty Bridge Overhang Bracket (HDBOB), or similar structure, with a shoe and horizontal and vertical adjustment mechanisms.
In construction safety is key, as such, the various implementations described herein include a system that may be fully implemented without the need for a person or persons to stand beneath the HDBOB or any other component of the system while it is suspended from a crane.
In Example 1, a formwork support system comprising a web shoe comprising a main body and a hinged flap rotatably attached to the main body, wherein the hinged flap rotates relative to the main body and wherein in a closed position the main body and hinged flap form an opening.
Example 2 relates to the formwork support system of claim 1, wherein the hinged flap is rotatably attached to the main body by means of an axis.
Example 3 relates to the formwork support system of any of claims 1-2, wherein the axis is a bolt.
Example 4 relates to the formwork support system of any of claims 1-3, further comprising one or more holes in a rear portion of the main body, wherein the one or more holes are placed to allow the web shoe to be secured to a surface.
Example 5 relates to the formwork support system of any of claims 1-4, further comprising one or more removable vertical adjusters comprising a first elongate portion having a first end and a second end, a second elongate portion having a first end and a second end, an elongate projection extending transversely through the first end of the first elongate portion, an adjustment bolt extending vertically through the second end of the first elongate portion and the second end of the second elongate portion, and an axis point between the first end and second end of the second elongate portion, wherein the first elongate portion is rotatable relative to the second elongate portion at the axis point by actuation of the adjustment bolt.
Example 6 relates to the formwork support system of any of claims 1-5, wherein the elongate projection is configured to be inserted into the opening.
Example 7 relates to the formwork support system of any of claims 1-6, further comprising one or more removable horizontal adjusters comprising one or more planks and a thrust bolt assembly, comprising a thrust bracket attached to the plank and a thrust bolt inserted through the thrust bracket, wherein actuation of the thrust bolt urges the one or more planks horizontally.
Example 8 relates to the formwork support system of any of claims 1-7, wherein the one or more planks are connected to each other and form a deck.
Example 9 relates to the formwork support system of any of claims 1-8, wherein the thrust bolt assembly is configured to abut a section of formwork against a bridge girder.
In Example 10, a formwork support system comprising one or more shoes comprising a main body and a hinged flap rotatably attached to the main body, wherein the main body and the hinged flap define an opening when the hinged flap is in a closed position. The formwork support system also comprising one or more removable vertical adjusters comprising a first elongate portion having a first end and a second end, a second elongate portion having a first end and a second end, an elongate projection extending transversely through the first end of the first elongate portion, wherein the elongate projection is configured to sit within the opening of the shoe, an adjustment bolt extending vertically through the second end of the first elongate portion and the second end of the second elongate portion, and an axis point between the first end and second end of the second elongate portion, wherein the first elongate portion is rotatable relative to the second elongate portion at the axis point by actuation of the adjustment bolt.
Example 11 relates to the formwork support system of claim 10, wherein the hinged flap is rotatably attached to the main body by means of an axis.
Example 12 relates to the formwork support system of any of claims 10-11, further comprising a horizontal adjustment assembly comprising one or more planks, a thrust bracket attached to one or the one or more planks, and a thrust bolt inserted through the thrust bracket, wherein actuation of the thrust bolt urges the thrust bracket and one or more plank horizontally.
Example 13 relates to the formwork support system of any of claims 10-12, further comprising at least one opening in a rear portion of the main body for insertion of a bolt to attach one of the one or more shoes to a surface.
In Example 14 method of forming a bridge overhang comprising securing a web shoe to a surface via a bolt, assembling a gang of formwork brackets including a surface, a horizontal adjuster, and a vertical adjuster, where the horizontal adjuster is attached to the vertical adjuster and the surface is supported by the horizontal adjuster, and inserting an elongate projection of a vertical adjuster to the web shoe such that the gang of formwork is supported by the web shoe.
Example 15 relates to the method of claim 14, wherein the vertical adjuster comprises a first elongate portion having a first end and a second end, a second elongate portion having a first end and a second end, an adjustment bolt extending vertically through the second end of the first elongate portion and the second end of the second elongate portion, and an axis point between the first end and second end of the second elongate portion, wherein the elongate projection extends transversely through the first end of the first elongate portion.
Example 16 relates to the method of any of claims 14-15, further comprising actuating the adjustment bolt on the vertical adjuster.
Example 17 relates to the method of any of claims 14-16, further comprising urging the surface horizontally via the horizontal adjuster, the horizontal adjuster comprising one or more planks and a thrust bolt assembly, comprising a thrust bracket attached to the plank and a thrust bolt inserted through the thrust bracket, wherein actuation of the thrust bolt urges the one or more planks horizontally.
Example 18 relates to the method of any of claims 14-17, wherein the surface is a bridge girder.
Example 19 relates to the method of any of claims 14-18, further comprising: setting rebar and pouring concrete on the surface.
Example 20 relates to the method of any of claims 14-19, further comprising attaching a rail to the gang of formwork brackets.
While multiple embodiments are disclosed, still other embodiments of the disclosure will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the disclosure is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the disclosure. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.
Provided for herein is a shoe and bracket assembly for the installation of a ganged bridge overhang formwork assembly onto a wall/support beam/flange. The shoe and bracket assembly will be discussed in further detail below.
As noted above, prior known techniques for forming a bridge overhang are labor and time intensive. The shoe described herein allows a contractor to install a shoe onto the web of a beam, then install a series (also referred to herein as a “gang”) of brackets with a crane. After concrete hardening the series of brackets can be removed with a crane, as well. This design allows the gang to be installed and removed with no personnel located underneath the gang while it is supported by the crane making for safer installation and removal, as well as increasing productivity by increasing the ease and speed of installation and removal.
The various implementations may also incorporate vertical and horizontal adjustments which are accessible from the top of the gang. By assessing the adjustment mechanisms form the top of the gang, the various implementations, provides better and safer access to the adjustment mechanisms and increases productivity, by increasing the ease and speed, of fine tuning the final location of the gang.
Turning to the figures in more detail,
In various implementations, when in the closed position the main body 12 and hinged flap 14 define an opening 22 for securement of a bracket assembly and/or vertical adjuster, as will be discussed further below. When in the open position the flap 14 is rotated to create entrance to the opening 22, where a pin or other similar component can be inserted through the entrance into the opening 22. After insertion the flap 14 may also, under its own force, rotate about the axis/bolt 16 and secure the pin in place within the opening.
In various implementations, the main body 12 includes a back/rear portion 18 configured to abut an attachment surface, such as the web of a beam, when installed. In these and other implementations, the shoe 10 can be affixed to a surface via a bolt 21 inserted through an opening 20 in the rear portion 18 of the main body 12 (shown for example in
Continuing with
Turning to
In various implementations, the vertical adjuster 30 includes an elongate portion 32 having an elongate projection 34 at one end. In various implementations, the elongate projection 34 is a pin 34, a latch pin 34, a bolt 34, or other similar item, as would be appreciated by those of skill in the art. The elongate projection 34 is configured to fit within the opening 22 of the shoe 10. In various implementation, the elongate projection 34 may be inserted through and opening 33 in the elongate portion 32 (as shown in
The vertical adjuster 30 further includes a second elongate portion 36 disposed above the elongate portion 32 and configured to pivot relative to the first elongate portion 32 via an axis point 38, such as a bolt 38. In various implementations, the axis point 38 is between the first and second end of the first elongate portion 32, and optionally at a substantially midway point of the first elongate portion 32.
In certain implementations, an adjustment bolt 40 extends through an opening 41B in the first elongate portion 32 at its second end and an opening 41A in the second elongate portion 36 at its second end. In these and other implementations, the adjustment bolt 40 includes a knob 42 located on the second elongate portion 36. The vertical adjuster 30 is configured to articulate the second elongate portion 36 relative to the first elongate portion 32 when the adjustment bolt 40 is actuated. For example as the adjustment bolt 40 is rotated clockwise the second end of the second elongate portion 36 may be raised (away from the first elongate portion 32), and vice versa as the adjustment bolt 40 is rotated counter-clockwise the second end of the second elongate portion 36 may be lowered (closer to the first elongate portion 32). As would be appreciated, as the second end of the second elongate portion 36 is actuated, the second elongate portion 36 rotates about the axis 38 defined in the first elongate portion 32.
Turning now to
In various implementations, the horizontal adjuster 50 includes one or more planks 54 and a horizontal thrust assembly 52. The horizontal thrust assembly 52 includes a thrust bracket 56, a thrust bolt 58, and thrust knob 60, wherein actuation of the thrust knob 60 cause the thrust bolt 58 to turn, thereby causing movement of the thrust bracket 56 and horizontal movement of the planks 54. That is, the thrust bracket 56 is affixed to one or more planks 54, such that movement of the bracket 56 causes movement of the plank(s) 54. The bracket 56 is moved by actuation/rotation of the thrust bolt 58, optionally via a knob 60, nut, or similar structure.
Optionally multiple planks 54 may be bolted together such that more than one plank 54 may be moved via one horizontal thrust assembly 52.
Turning to
As an initial step, for use of the system 100 described herein requires installation of a link beam 30 (referred to above as a vertical adjuster 30) and slide frame 50 (referred to above as a horizontal adjuster 50) onto a gang 104.
In a first step, the link beam 30 is a bolt link beam 30 situated in between webs of the top member of the gang 104. As discussed above, the link beam 30 rotates about a pin 38 by turning the vertical threaded rod 40 and is used to raise or lower the gang 104 once installed onto the shoe 10. In certain implementations, there is approximately 6″ of vertical adjustment range which accommodates the camber of the bridge girder as well as the camber of the concrete bridge overhang. The adjustment of the link beam 30 can be made from a plywood deck 108 (accessible through a small hole in the plywood), or from below the gang 104.
In a second step of the initial installation, the slide frame 50 and slide frame thrust bolt 52 are attached onto the top member of the gang 104. As discussed above, the slide frame 50 can be adjusted horizontally by adjusting the thrust bolt assembly 52 on the end of the slide frame 50 to move the joists 106 and plywood 108. This adjustment is required to ensure that the joists 106/plywood 108 of the formwork fits tightly against the top flange of the bridge girder 2 preventing any concrete leakage. The thrust bolt assembly 52 is accessible from either the plywood deck 108 or below the gang 104.
Turning now to the installation of a gang 104 onto bridge girder 2 using the shoe 10. In a first step, the web shoe 10 is bolted onto the web of the bridge girder 2, as shown in
In another step, shown in
In a further step, shown in
In another step, the crane and c-caddy 102 can be detached. Once the gang 104 is now fully supported by the shoe 10, workers can walk out on the plywood deck 108 to unchain the C-Caddy 102 from the gang 104, shown in
In a further step the gang 104 can be raised or lowered to the final elevation by turning the vertical adjustment bolt 40 on the link beam 30 accessed through a small hole in the plywood deck 108, as shown in
Another step is depicted in
In an optional step, shown in
To remove the gang 104, in one step shown in
In another step, using the crane or other implement, the C-caddy 102 is brought into position underneath the gang 104 assembly and secured with chains accessed from the plywood deck 108, as shown in
In other step, the C-caddy and gang assembly is lowered until the formwork 104 is stripped away from the concrete. The entire assembly (including the gang 104, vertical adjuster 30, horizontal adjuster 50, and shoe 10) can be lowered to the ground. In another optional step, the shoe 10 can be manually removed from the link bracket pin 34. As previously noted, the gang 104 can be lifted to the next location on the bridge and the process repeated.
As shown in
Although the disclosure has been described with references to various embodiments, persons skilled in the art will recognized that changes may be made in form and detail without departing from the spirit and scope of this disclosure.
This application claims the benefit under 35 U.S.C. § 119(e) to U.S. Provisional Application 63/400,105, filed Aug. 23, 2022, and entitled Web Shoe for Bridge Overhang and Associated Systems and Methods, which is hereby incorporated herein by reference in its entirety for all purposes.
Number | Date | Country | |
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63400105 | Aug 2022 | US |