Patent Grant
11566424
Embodiments of the present invention generally relate to stay-in-place fascia forms and methods and equipment for installation thereof. Conventional construction methods for building bridges are known including those which use bridge brackets, scaffolding, and many other types of form support to support the loads from wet concrete. Fascia formwork is typically made from wood or steel and requires removal after the bridge is constructed. Known apparatus and methods involve substantial issues of safety and maintenance and protection of traffic (“MPT”). Known apparatus and methods also incur substantial labor cost, material cost, and costs associated with handling and disposal of such materials.
A common method of bridge building includes the use of bridge brackets installed along the fascia of the bridge and at or near the bottom of the bridge deck. Such brackets are typically installed with wooden forms that require removal after concrete placement. This method is labor intensive and results in high material costs. Moreover, disposal costs, MPT costs (if applicable), and safety costs are incurred.
Concrete paving machines are also known for bridge construction. Such machines use truss units to carry the machine and associated parts. They also use bogie wheel, rails, and screw jack adjustors to facilitate the paving process.
Briefly stated, in one aspect of the present invention, a concrete form is disclosed. This concrete form includes a vertical component and a horizontal component, the vertical component located substantially perpendicular to the horizontal component. Also, the form includes an interior surface, at least a portion of the interior surface providing a form for supporting uncured concrete; wherein the uncured concrete forms a concrete structural portion upon curing of the uncured concrete; and wherein the interior surface remains attached to the concrete structural portion after formation.
The foregoing summary, as well as the following detailed description of preferred embodiments of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings:
Certain terminology may be used in the following description for convenience only and is not limiting. The words “lower” and “upper” and “top” and “bottom” designate directions in the drawings to which reference is made. The terminology includes the words above specifically mentioned, derivatives thereof and words of similar import.
Where a term is provided in the singular, the inventors also contemplate aspects of the invention described by the plural of that term. As used in this specification and in the appended claims, the singular forms “a”, “an” and “the” include plural references unless the context clearly dictates otherwise, e.g., “a form” may include a plurality of forms. Thus, for example, a reference to “a method” includes one or more methods, and/or steps of the type described herein and/or which will become apparent to those persons skilled in the art upon reading this disclosure.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods, constructs and materials are now described. All publications mentioned herein are incorporated herein by reference in their entirety. Where there are discrepancies in terms and definitions used in references that are incorporated by reference, the terms used in this application shall have the definitions given herein.
Referring now to
When used for bridge building, form 100 contains the work area as soon as it is installed as discussed in greater detail below, which minimizes or eliminates fall hazards, thereby eliminating the time, costs (e.g., labor costs, removal costs, disposal costs, etc.), and downtime associated with installation of safety measures that are typically required (e.g., formwork, scaffolding, road closure, etc.) to contain the work area. That is, minimal or zero excess materials are needed to contain the work area since the form performs this task while also remaining in place after construction to become part of the structure being built. Also, the disruption of traffic or other environmental considerations beneath the structure being built is minimized as all work can be safely performed from atop the structure.
Now referring to
Vertical and horizontal components 102 and 104, respectively, have thicknesses T1 of approximately two inches (2″), however, alternate thicknesses may be substituted without departing from the scope of the present invention. Also, embodiments are envisioned in which the thicknesses of the vertical and horizontal components are not equal.
The height H1 of form 100 is approximately forty four inches (44″), the width W1 is approximately two feet (2′), and the length L1 is approximately sixty inches (60″), however, varied dimensions may be substituted to accommodate, for example, desired size of the structure being built as well as material strength and geometric boundaries. For example, alternate embodiments are envisioned in which width W1 is approximately twelve inches (12″), but the invention is not so limited.
As best seen in
Form 100 has an interior surface 106 that includes upwardly facing surface 108 of horizontal component 104, inwardly facing surface 110 of vertical component 102, and inwardly facing surface 234 of joining component 210. In the exemplary embodiment of the present invention shown in
Interior surface 106 provides a form for supporting uncured concrete as discussed in greater detail below. Once the concrete has cured, form 100 remains in place and forms a structural portion of the bridge being built or remains in place as a permanent part that does not have structural significance. That is, interior surface 106 remains attached to the cured concrete after curing/formation of same. In this case, exterior surface 112 becomes an exterior surface of the bridge. In some embodiments such as the one depicted in
In some embodiments of the present invention such as that shown in
Additionally, in some embodiments of the present invention such as that shown in
Additionally, in some embodiments of the present invention such as that shown in
Form 100 may be formed of many different types of materials or combinations thereof, provided that the strength of the material, or combination of materials, is sufficient to hold the implied loads such as that of the uncured concrete. In the depicted embodiment, form 100 is made from 5,000 PSI fiber-reinforced concrete, however, other materials, or combinations of materials, including, but not limited to, polymers and/or high strength concretes may be substituted.
Optionally, form 100 may include an interior reinforcement 242. In the depicted embodiment, interior reinforcement 242 is a four-by-four (4″×4″) epoxy-coated, welded wire mesh that extends substantially throughout the height of vertical component 102 and the width of horizontal component 104 with the exception of a bend at the intersection thereof. The portion of the depicted interior reinforcement 242 located within vertical component 102 is located approximately equidistant from inwardly facing surface 110 and outwardly facing surface 116. The portion of the depicted interior reinforcement 242 located within horizontal component 104 is located approximately equidistant from upwardly facing surface 108 and downwardly facing surface 114. These two portions are connected to each other via a curve in the interior reinforcement, such curve having a radius of approximately four inches (4″). However, alternate locations and configurations may be substituted including, without limitation, reinforcements made of carbon mesh or other materials having tensile strength and reinforcements having partially exposed portions (portions that extend beyond the confines of form 100). Or interior reinforcement 242 may be omitted without departing from the scope hereof.
Form 100 may optionally include a rabbet such as rabbet 218 to assist in placement of form 100 atop a structural member 302 (e.g., a girder, stringer, etc.) as discussed in greater detail below. In the depicted embodiment, rabbet 218 extends longitudinally along the distal lower corner of horizontal component 104 and it is substantially L-shaped. That is, when form 100 is viewed in its upright position, rabbet 218 is in the form of an L that has been inverted and rotated 90 degrees counterclockwise. However, alternate shapes may be substituted without departing from the scope hereof. Further, although structural member 302 is depicted in the shape of a traditional bridge girder, structural member may have virtually any shape or configuration and form 100 and/or rabbet 218 may be modified accordingly, as needed.
As best seen in
In the depicted embodiment, inserts 202 are compatible with a variety of form attachments 206. Form attachments 206 may perform any one of a number of functions including, without limitation, assisting with installation of form 100, increasing the strength of the interface between form 100 and the cured concrete, and the like. Form attachments 206 may be any one of a plurality of commercially available connection devices. For example, in the depicted embodiment, form attachments 206a and 206b are one-half inch (½″) threaded shank eye bolts with a shoulder as manufactured by Chicago Hardware, and form attachments 206c and 206d are exterior reinforcements. In the depicted embodiment, this exterior reinforcement is a reinforcement bar of Grade 60 (i.e., 60,000 PSI) such as an imperial size #4, one half inch (½″) diameter reinforcement bar that includes threads on its proximal end (e.g., these threads may be added during manufacturing or during construction of the structure) and a J-shaped hook on its distal end. However, alternate exterior reinforcements may be substituted without departing from the scope hereof. Form attachments 206 connect to form 100 by simply threading of same into a compatible insert such as insert 202 as discussed above.
Form attachments 206a and 206b facilitate attachment of a tie or the like during installation of form 100 and prior to the pouring of concrete as discussed in greater detail below. That is, the tie may be threaded through the eye of form attachments 206a and 206b prior to the tying thereof. In the depicted embodiment, form attachments 206a are threaded into inserts 202a, and form attachments 206b are threaded into inserts 202c as depicted in
Additionally, a form attachment 206a or 206b may be threaded into insert 202d to facilitate coupling of form 100 to a lifting cable 310 via a coupler 309 or the like prior to placement of same as discussed below. That is, coupler 309 or the like may be inserted through a form attachment 206 and/or a shackle coupled thereto to lift facilitate the lifting of form 100 from a stack of forms and/or from a form holder such as form holder 404 as described below with respect to
Form attachments 206c and 206d increase the bond between form 100 and the concrete poured adjacent thereto. That is, after the concrete is poured, exterior reinforcement-style form attachments 206c and 206d are encased therein and form a stronger, more permanent bond between form 100 and the poured concrete after curing of the latter. However, alternate form attachments 206, or varying quantities thereof, may be omitted or substituted without departing from the scope hereof. For example, form attachments 206 may include alternate hardware capable of coupling to, without limitation, S-hooks, shackles, coil rod ties, coil loop inserts, turnbuckles, washers and nuts, welded studs or hooked brackets and the like, some or all of which is capable of purposes including, but not limited to, attaching to existing or proposed steel, wood, or concrete structural members and facilitating the attachment of inboard formwork.
In one aspect of the depicted embodiment, interconnection clip 204 is optionally mounted on upwardly facing surface 118 of the vertical components 102 of adjacent forms 100. In the depicted embodiment, each approximate half of clip 204 is mounted atop upwardly facing surface 118 of the vertical components of two adjacent forms 100 as best seen in the side view of
As best seen in
Interconnection clip 204 may optionally include railing support 220. In the depicted embodiment, railing support 220 includes a cylindrical portion 230 suspended above top wall 224 by vertical railing support component 232. Vertical railing support component 232 is approximately the same diameter as the railing to be threaded therethrough and has an inside diameter of approximately one and five-eighth inches (1⅝″), and is located along the approximate longitudinal centerline of top wall 224. In the depicted embodiment, clip 204 only extends approximately one-tenth the length of form 100, however, other distances may be substituted including, without limitation, a distance equal to the full length of form 100. Cylindrical portion 230 sits atop vertical railing support component 232 and is approximately centered thereupon. It extends the full length of top wall 222. However, alternate configurations and/or locations may be substituted without departing from the scope hereof.
After installation of form 100, a railing (e.g., a cable, pipe, etc.) may be installed through railing support 220 to extend partially or throughout the length of the bridge or other structure in accordance with OSHA guidelines (to prevent or minimize falls during construction of the structure) or for other purposes. That is, in one embodiment of the present invention, the height of form 100 is sufficient to eliminate the need for a railing as per OSHA requirements. However, once the deck 318 is poured, the height between the top of form 100 and deck 318 may become less than the minimum required by OSHA. In such a scenario, a railing may be added to meet OSHA requirements. However, alternate configurations of railing support 220 may be substituted without departing from the scope hereof or support 220 may be omitted entirely. Railing support 220 may also be eliminated without departing from the scope hereof. In one such embodiment, the height of form 100 is increased to allow the panel to exceed the railing height required by OSHA, thereby eliminating the need for a railing.
Referring now to
In the depicted exemplary form 100, structural member attachment 304 is mounted approximately one and one half inches (1½″) from the inner edge of upwardly facing surface 306 of structural member 302, however, alternate locations may be substituted. Structural member attachments 304 are located such that approximately two (2) structural member attachments 304 are utilized for installation of each form 100 as best seen in
Also, alternate structural member attachments may be substituted without departing from the scope hereof. For example, structural member attachments may be type B4L standoff support studs, type R9L rope hook studs, Type R6P rectangular slotted studs, type SBL shoulder studs, type TBL internally threaded studs, all as manufactured by Nelson Stud Welding. Or, alternatively, structural member attachments may be designed to hook onto the side of structural member 302, thereby eliminating the need for welding thereof. One such structural member attachment is the Century Series Hanger having model no. C130 as manufactured by Dayton Superior.
In yet another alternate embodiment, a formwork attachment may be substituted for, or used in addition to, the structural member attachment. One such formwork attachment is a galvanized hook that hooks into a slot that is cut into formwork such as formwork 312. Other formwork attachments may include, but are not limited to, Hook Bolts having model no. D1-J, D1LA, or D1L, coil loop straight inserts having model no. B16, Inside Tie Rods having model nos. D1 and D18, and/or a heavy duty screed support having model no. G15, all as manufactured by Dayton Superior.
After structural member attachments 304 are in place (as best seen in
Thereafter, form 100 is tied in place utilizing form attachments 206a, 206b, structural member attachments 304, and one or more tie(s) 314 as described below in order to secure form 100 to structural member 302.
Tie(s) 314 may be Inside Tie Rods as manufactured by Dayton Superior and having model no. D1 or D18. Tie rods may include various end fittings on one or both ends including, without limitation, turn buckle fittings. However, no such fittings are required to implement the present invention. Also, alternate structural member attachments and/or ties including, without limitation, Richmond tie rod units may be substituted without departing from the scope hereof.
Form 100 may be disconnected from lifting equipment 402 as soon as it is secured in place, and any form attachments required for connection of form 100 to lifting equipment 402 may be removed, reused, or left in place/unused. Any other desired form attachments including, without limitation, exterior reinforcements or the like may be installed. For example, form attachments 206c and/or 206d may be installed in inserts 202b and/or 202d to further increase the bond between the cured concrete and form 100 as described in greater detail above.
After form 100 is tied in place, it contains the work area as soon as it is installed as discussed in greater detail below, which minimizes or eliminates fall hazards, thereby eliminating the time, costs (e.g., labor costs, removal costs, disposal costs, etc.), and downtime associated with installation of safety measures that are typically required (e.g., formwork, scaffolding, road closure, etc.) to contain the work area. That is, minimal or zero excess materials are needed to contain the work area since the form performs this task while also remaining in place after construction to become part of the structure being built. Also, the disruption of traffic or other environmental considerations beneath the structure being built is minimized as all work can be safely performed from atop the structure.
Referring now to
After the concrete is poured and cured, the portion of ties 314b extending above deck 318 may optionally be removed from form attachments 206a as depicted in the side view of
The encasing of exterior reinforcement style form attachments 206c in the concrete deck 318 (and form attachment 206d in barrier 326) further couples form 100 to concrete deck 318 and barrier 326, and facilitates the ability of form 100 to accommodate the shear and moment forces placed thereupon by the weight of the concrete deck 318. As discussed above, the portion of tie(s) 314b that extend above upwardly facing surface 324 of concrete deck 318 may optionally be removed after curing of the deck concrete. Alternatively, it may be left in place and encased in barrier 326 (See
Finally, inboard barrier formwork 334 is put in place, ties 314c are installed to secure formwork 334 to form 100, and the railing system installed for safety purposes (i.e. clips 204 and railing 316) is removed in preparation for the pouring of the barrier concrete. The railing system may be removed before or after installation of the inboard barrier formwork 334. Ties 314c are coupled to formwork attachment 336, which may be identical to, or similar to, form attachment 206a, however, such attachment 336 is coupled to formwork 334 either prior to, or after, such formwork is set in place. Then, the concrete for barrier 326 is cast in place.
Now referring to
As depicted in
As best seen in
More specifically, form holder 404 includes a substantially rectangular, substantially horizontal base section 408. A substantially rectangular rear section 410 extends vertically from a first longitudinal side 418 of base 408, and a substantially rectangular front section 412 extends vertically from a second longitudinal side 420 of base 408. A substantially rectangular front intermediate section 416 extends at an angle of approximately forty five degrees from a first upper longitudinal end 422 of said front section to base 408, and a substantially rectangular rear intermediate section 414 extends at an angle of approximately forty five degrees from a second upper longitudinal end 424 of said rear section to base 408. Rear intermediate section 414 intersects front intermediate section 416 at an angle of approximately ninety degrees.
Additionally, in the depicted embodiment, rear intermediate section 414 has a height approximately equal to a height of form 402 minus the width of rear section 410. The height of front intermediate section 416 is then selected to be the height that allows front intermediate section 416 to be located substantially perpendicular to rear intermediate section 414 without extending beyond front section 412. Similarly, the height of front section 412 is selected to be equivalent to topmost edge 426 of front intermediate section 416. However, varying dimensions may be substituted without departing from the scope hereof.
In the depicted embodiment of the present invention, each of the base section 408, rear section 410, front section 412, rear intermediate section 414, and front intermediate section 416 are substantially rectangular and are not solid. Rather, these sections are comprised of a plurality of subframe support members 430 arranged to form substantially rectangular and/or square subframes 432 for each section. Many of these subframes 432 include angled support members 434 as depicted in
As also shown in
The above described configuration of form holder 404 allows a plurality of forms such as forms 100 to be stacked atop form holder 404 via lifting equipment such as lifting equipment 402 as described herein. In the depicted embodiment, spacers 428 are placed at predetermined intervals between form holder 404 and the bottommost form, and also between individual forms. In the depicted embodiment, spacers 428 are furring strips having a width of approximately one inch (1″), however, alternate spacers may be substituted without departing from the scope hereof. Form holder 404 may also be used as a shipping pallet during transportation/shipping of one or more forms.
Also, embodiments of the present invention are envisioned in which one or more layers of one or more sheets of plywood is placed atop the upwardly facing surface 440 of rear intermediate section 414 and/or front intermediate section 416 to cover all or at least a portion thereof. Form 100 may be placed directly atop the plywood, or spacers 428 may be incorporated between the plywood and form 100 without departing from the scope hereof.
Forms 100 are stacked in a position in which they are rotated backwards at an angle of approximately forty five degrees. Form holder 404 of the depicted embodiment is capable of supporting approximately nine thousand (9,000) pounds, however, alternate load capabilities may be substituted without departing from the scope hereof.
As shown in
In the depicted embodiment, lifting equipment 402 is a crane. For example, lifting equipment may be a manually controlled davit crane as manufactured by Dayton and having model no. 7CZ12. However, lifting equipment having varying types of control may be substituted including, without limitation, hydraulic, motor-driven, and mechanically driven lifting equipment. In scenarios in which a hydraulic drive is used on the workbridge, the same operating engineer might control both the hydraulic drive system and the hydraulically controlled davit.
Lifting equipment 402 may rest directly atop, for example, the screed or other equipment used for leveling the concrete. This equipment including, without limitation, wheels and rails is installed as in known in the art for the purpose of leveling the concrete. In some embodiments of the present invention, a support 432 such as a beam or the like may be utilized to further support and/or raise the height of lifting equipment 402.
In the depicted embodiment, lifting equipment 402 is equipped with a cable 310 and associated coupler 309 or the like capable of lifting individual forms via a form attachment 206a and a coupler 309 located at the approximate center of gravity of form 100. One such form attachment is a one-half inch (½″) threaded shank eye bolt with a shoulder as manufactured by Chicago Hardware. Coupler 309 is passed through form attachment 206a. A shackle or the like may also be utilized to more securely attach coupler 309 to form attachment 206a. Thereafter, form 100 may be lifted from the stack of forms and/or form holder 404 and suspended over the side of the bridge relative to structural member 302 as shown in
The erection equipment allows quick installation. Further, safety is facilitated by making a positive connection with the form before it is lifted and after it is secured to the existing structure or structure being built. Moreover, the equipment allows a tie off point to facilitate safety before form 100 is installed and/or during conventional construction of the interior bridge deck bay when such construction follows the installation of form 100. However, the forms of the present invention may be installed utilizing other methods than that described herein without departing from the scope of the present invention.
Turning now to
In the depicted embodiment, the features of form 700 including, without limitation, inserts 702, interior surface 706, bevel 712, protrusion 716, and rabbet 718 are substantially identical to the equivalent components of form 100, namely, inserts 202, interior surface 106, bevel 212, protrusion 216, and rabbet 218 as discussed above. That is, the only substantial difference between form 100 and form 700 is that the latter includes recesses 703 and the dimensions thereof have been altered to accommodate recesses 703 while maintaining the structural integrity of form 700.
More specifically, height H7 of form 700 is approximately forty one inches (41″), width W7 is approximately thirty seven and one half inches (37½″), and length L1 is approximately sixty inches (60″), however, varied dimensions may be substituted to accommodate, for example, desired size of the structure being built, material strength and geometric boundaries, and/or varying recess sizes and/or quantities.
Form 700 has a thickness T7 of approximately three inches (3″); however, alternate thicknesses may be substituted without departing from the scope of the present invention.
As best seen in the plan view of
Referring next to
Recesses 813 decrease the weight of form 800. Although one (1) substantially rectangular, bi-level recess 813 is illustrated, varying quantities and/or shapes may be substituted without departing from the scope hereof.
In the depicted embodiment, the features of form 800 including, without limitation, insert 802d, interior surface 806, bevel 812, protrusion 816, and rabbet 818 are substantially identical to the equivalent components of form 100, namely, insert 202d, interior surface 106, bevel 212, protrusion 216, and rabbet 218 as discussed above. That is, the only substantial difference between form 100 and form 800 is that the latter includes recess 813, apertures 803 in lieu of inserts 202, and the dimensions thereof have been altered.
More specifically, the height H8 of form 800 is approximately forty one and 5/16 inches (41⅚″), the width W8 is approximately thirteen and 3/16 inches (13 3/16″), and the length L8 is approximately sixty inches (60″), however, varied dimensions may be substituted to accommodate, for example, desired size of the structure being built, material strength and geometric boundaries, and/or varying aperture sizes and/or quantities.
Form 800 has a thickness T8 of approximately two inches (2″); however, alternate thicknesses may be substituted without departing from the scope of the present invention.
As best seen in the plan view of
In the depicted embodiment, the center point of each aperture 803 is located at a height AH8 of approximately two feet (2′)as best seen in
As best seen in
Turning now to
In the depicted embodiment, the features of form 900 including, without limitation, inserts 902, horizontal component 904, interior surface 906, bevel 912, protrusion 916, and rabbet 918 are substantially identical to the equivalent components of form 100, namely, inserts 202, horizontal component 104, interior surface 106, bevel 212, protrusion 216, and rabbet 218 as discussed above. That is, the only substantial difference between form 100 and form 900 is that the latter includes vertical recesses 903, horizontal recess 913, and the dimensions thereof have been altered to accommodate recesses 903 and 913 while maintaining the structural integrity of form 900.
More specifically, height H9 of form 900 is approximately forty one inches and five sixteenths inches (41 5/16″), width W9 is approximately twenty five inches (25″), and length L9 is approximately sixty inches (60″), however, varied dimensions may be substituted to accommodate, for example, desired size of the structure being built, material strength and geometric boundaries, and/or varying recess sizes and/or quantities.
Form 900 has a thickness T9 of approximately two inches (2″); however, alternate thicknesses may be substituted without departing from the scope of the present invention.
As best seen in the plan view of
As best seen in the perspective and side views of
Turning next to
Similar to form 100, form 1000 is a relatively thin, substantially L-shaped panel that includes vertical component 1002 and horizontal component 1004. In the depicted embodiment, vertical component 1002 is located substantially perpendicular to horizontal component 1004, however, alternate orientations may be substituted.
Vertical component 1002 and the proximal portion of horizontal component 1004 have thicknesses T1 of approximately three inches (3″). The thickness T2 of the distal end of horizontal component is thicker (i.e., three and seven thirty seconds (3 7/32) inches), however, alternate thicknesses may be substituted without departing from the scope of the present invention. That is, in the depicted embodiment, the thickness of horizontal component 1004 gradually increases starting at its intersection with joining component inwardly facing surface 1234, however, alternate sizing and configurations may be substituted without departing from the scope hereof.
The height H1000 of form 1000 is approximately forty inches (40″), the width W1000 is approximately fifteen and thirty-five hundredths inches (15.35″), and the length L1000 is approximately sixty inches (60″), however, varied dimensions may be substituted to accommodate, for example, desired size of the structure being built as well as material strength and geometric boundaries.
In the depicted embodiment, the features of form 1000 including, without limitation, insert 1202d, vertical component interior surface 1006, bevel 1212, vertical component upwardly facing surface 1222, horizontal component upwardly facing surface 1008, vertical component inwardly facing surface 1110, joining component inwardly facing surface 1234, joining component 1210, ornamental features 1240, horizontal component downwardly facing surface 1114, and protrusion 1216 are substantially identical to the equivalent components of form 100, namely, insert 202d, interior surface 106, bevel 212, upwardly facing surface 222, upwardly facing surface 108, inwardly facing surface 110, inwardly facing surface 234, joining component 210, ornamental features 240, downwardly facing surface 114, and protrusion 216 as discussed above with the following exceptions.
Rabbet 1218 is substantially identical to rabbet 218 of form 100 with the exception of top and side surfaces 1050 and 1052, respectively. More specifically, in the embodiment of the present invention depicted in
Also, in the depicted embodiment of the present invention, the upper corner of a distal end of horizontal component 1004 is in the form of chamfered edge 1214 rather than the rounded edge 214 shown for form 100. Further, chamfered edge 1214 is chamfered at an angle of approximately forty-five degrees relative to horizontal component upwardly facing surface 1008 and horizontal component distal vertical surface 1054, however, alternate angles may be substituted without departing from the scope hereof. However, alternate configurations and/or shapes for this edge may be substituted including, without limitation a squared edge, a rounded edge or edge treatment.
Additionally, form 1000 includes internal reinforcement 1056 as depicted in
Further, in form 1000, similar to form 100, the inserts 1202 of the substantially horizontal component 1004 and the substantially vertical component 1002 facilitate attachment of form 1000 to an existing structural member 302. However, the attachment mechanism 1060 utilized in conjunction with such form attachments differ.
More specifically, in the depicted embodiment, attachment mechanism 1060 includes, primary support 1253, secondary support 1254, primary tie system 1298, and secondary tie system 1252. In the depicted embodiment, primary tie system 1298 includes, rod 1249, rod insert 1250a, adjustable fastener 1251, and form attachment 1206a which are coupled to form 1000 and the top of structural member 302 diagonally at an angle of approximately forty-five (45) degrees, however alternate angles may be substituted without departing from the scope hereof.
In the depicted embodiment, the primary tie system 1298 includes at least one coil rod 1249 such as an inline, Dayton Superior B12 coil rod made of a rigid material such as steel etc. having a one-half (½) inch diameter capable of withstanding a load of at least 18,000 pounds. One end of rod 1249 is connected to rod insert 1250b of primary support 1253 and the other end of rod 1249 is connected to rod insert 1250a. The rod inserts 1250a and 1250b are constructed of a rigid material such as steel and the like and have a diameter of one half (½) inch and length of six (6) inches. In the depicted embodiment, these rod inserts are Dayton Superior one half inch (½″) diameter by six inch (6″) length B16 coil loop inserts.
Rod insert 1250a is connected to form 1000 by means of an adjustable fastener 1251 and form attachment 1206a. In the depicted embodiment, adjustable fastener 1251 is a turnbuckle with jaw ends made of a rigid material such as steel etc. and having a three quarter (¾) inch diameter, and form attachment 1206a is in the form of a one half (½) inch diameter shoulder eyebolt (also made of a rigid metal such as steel etc.) affixed to form 1000 by insertion into insert 1202d. Adjustable fastener 1251 allows the spacing connection between form attachment 1206a and rod 1249 to be fine-tuned by spinning it in either direction to engage the threads, which may be used, for example, to bring the form into a plumb position. This may be done via a wrench or the like.
Rod insert 1250b is integral to primary support 1253 as shown in
Upper and lower plates 1246 and 1245, respectively, have substantially rectangular shapes and are made of a rigid metal such as, but not limited to, steel. In the depicted embodiment, upper bent plate 1246 is four (4) inches wide, ten (10) inches long, and one half (½) inch thick, and it is bent at an angle of approximately forty-five (45) degrees relative to its longitudinal axis to receive and accommodate diagonally positioned primary tie system 1298, however alternate angles may be substituted without departing from the scope hereof. Lower plate 1245 is also substantially rectangular and made of a rigid material such as, but not limited to, ½-inch thick steel and having dimensions of two and one sixteenth (2 1/16) inches wide and seven and one quarter (7¼) inches long. In the depicted embodiment, lower plate 1245 is bent at an angle of approximately twenty-two and one half (22½) degrees from its longitudinal axis to receive and accommodate the position of secondary tie system 1252, which in the depicted embodiment is a secondary support rod. However alternate angles may be substituted without departing from the scope hereof.
As seen in the top view of
Primary support 1253 is coupled to structural member 302 by means of fastener 1251. In the depicted embodiment, fastener 1251 is a threaded shear stud being made of a rigid material such as steel and the like welded to structural member 302. The apertures of upper and lower plates 1246 and 1245, respectively, are passed over the stud and a nut compatible with the threaded end of the stud is fastened atop upper plate 1246 to hold primary support 1253 in place relative to structural member 302 therewith. However, alternate sizes for upper bent plate 1246 and lower bent plate 1245, and alternate methods of attaching such plates to the structural member 302, to rod insert 1250b, and to each other may be substituted without departing from the scope hereof.
In the depicted embodiment, secondary tie system 1252 may be a coil rod similar to rod 1249 of primary tie system 1298, however, alternate ties or supports may be substituted.
In the depicted embodiment, as shown in
Secondary support 1254 is coupled to the upwardly facing surface 1008 of horizontal member 1004 via a fastener 1292 passing through aperture 1288 and into insert 1202c. For example, fastener 1292 may be a one half (½) inch diameter bolt.
Secondary tie system 1252 is attached at a first end by insertion and/or threading of secondary tie system into rod insert 1241. The second end of secondary tie system 1252 is passed through an aperture 1290 in secondary support 1254 and a retention mechanism 1292 is threaded onto the second end of secondary tie system 1252 until it is in contact with secondary support 1254, thereby holding secondary tie system 1252 in place. Retention mechanism may be a nut or the like.
Although the depicted attachment mechanism 1060 includes, primary support 1253, secondary support 1254, primary tie system 1298, and secondary tie system 1252, alternate attachment mechanisms 1060 are envisioned. For example, secondary support 1254 and secondary tie system 1252 may be omitted. Or, primary support 1253 and primary tie system 1298 may be omitted. Alternatively, various components of the attachment mechanism 1060 may be substituted for other components having equivalent functionality. And alternate methods of coupling the components of attachment mechanism 1060 may be substituted without departing from the scope hereof.
After form 1000 is tied in place, it contains the work area as soon as it is installed as discussed, which minimizes or eliminates fall hazards, thereby eliminating the time, costs (e.g., labor costs, removal costs, disposal costs, etc.), and downtime associated with installation of safety measures that are typically required (e.g., formwork, scaffolding, road closure, etc.) to contain the work area. The exposed ties having a load rating well-over that required to temporarily anchor fall protection lifelines. Minimal or zero excess materials are needed to contain the work area since the form performs this task while also remaining in place after construction to become part of the structure being built. Also, the disruption of traffic or other environmental considerations beneath the structure being built is minimized as all work can be safely performed from atop the structure.
After the form 1000 is installed as depicted in
After the concrete is poured and cured, the portion of attachment mechanism 1060 located above the deck which is not going to be encased in the barrier may optionally be removed from the form 1000 via dismantling turnbuckle with jaw ends 1251 from form attachment 1206a on one end and rod insert 1250a on the opposite end. The rod insert 1250a and form attachment 1206a may need to be cut away from the newly formed deck by means of a grinder and the like. Alternatively, they may be left in place and encased in the overall deck and barrier combination. The encasement of form 1000 facilitates the ability of form 1000 to accommodate the shear and moment forces placed thereupon by the weight of the overall deck and barrier.
Referring now to
Turning now to
Similar to form 1000, form 11000 is a relatively thin, substantially L-shaped panel that includes vertical component 11002 and an extremely minimal horizontal component 11004. In the depicted embodiment, vertical component 11002 is located substantially perpendicular to horizontal component 11004, however, alternate orientations may be substituted.
Vertical component 11002 has a thickness T1100 of approximately two and one quarter inches (2¼″). The thickness T1101 of horizontal component 1104 is thicker (i.e., approximately three (3) inches), however, alternate thicknesses may be substituted without departing from the scope of the present invention.
In the depicted embodiment, the features of form 11000 including, without limitation, insert 11202, bevel 11212, vertical component upwardly facing surface 11222, form inwardly facing surface 11010, joining component inwardly facing surface 11234, joining component 11210, ornamental feature 11240, downwardly facing surface 11114, and rabbet 11218 are substantially identical to the equivalent components of form 1000, namely, insert 1202, bevel 1212, upwardly facing surface 1222, inwardly facing surface 1010, inwardly facing surface 1234, joining component 1210, ornamental feature 1240, downwardly facing surface 1114, and rabbet 1218 as discussed above with the following exceptions.
In the depicted embodiment, as best seen in
Similar to form 1000, form 11000 is secured in place to concrete structural member 11102 via an attachment mechanism 11060 that includes primary supports 11253, secondary supports 11254, primary tie system 11298, and secondary tie system 11252. However, such supports vary in some manners from those utilized for form 11000.
First, primary support 11253 utilized with form 11000 includes a single plate 11246a only and rather than upper and lower plates. The angle of the bend in plate 11246 may be adjusted as needed to accommodate the angle at which the primary tie system 11298 will be installed. Primary support 11253 couples to concrete structural member 11102 via insertion of a form attachment 11206f such as a screw, bolt or the like through the aperture 11284 in plate 11246a into the concrete structural member, or an insert placed therein, wherein the head of the screw, bolt, or the like is larger than the aperture, thereby holding plate 11246a in place.
Primary tie system 11298 is substantially identical to primary tie system 12298, as described with reference to
Also, secondary supports 11254 differs from secondary support 1254 as shown in
After the form 11000 is installed as depicted in
Further, when the concrete for the barrier is poured, it is poured to a height that is higher than the upwardly facing surface 11222 of form 11000, and is held in place by removable form 11508. In this manner, the barrier is poured over form 11000. After the concrete is cured, the removable form 11508 is then removed from the outwardly facing surface of form 11000.
Referring next to
Similar to form 1000, form 12000 is a relatively thin, substantially L-shaped panel that includes a relatively short vertical component 12102 and a longer horizontal component 12104. In the depicted embodiment, vertical component 12102 is located substantially perpendicular to horizontal component 12104, however, alternate orientations may be substituted.
In the depicted embodiment, the features of form 12000 including, without limitation, insert 12202, form interior surface 12006, bevel 12212, vertical component upwardly facing surface 12222, vertical component inwardly facing surface 12010, joining component inwardly facing surface 12234, joining component 12210, horizontal component downwardly facing surface 12114, and rabbet 12218 are substantially identical to the equivalent components of form 1000, namely, insert 1202, form interior surface 1006, bevel 1212, vertical component upwardly facing surface 1222, vertical component inwardly facing surface 1010, joining component inwardly facing surface 1234, joining component 1210, horizontal component downwardly facing surface 1114, and rabbet 1218 as discussed above with the following exceptions.
In the depicted embodiment, form 12000 is mounted parallel to, and tied atop, structural member 302. As shown in
Brackets 12206 are connected to structural member 302 and form 12000 via attachment mechanism 12060. In the depicted embodiment, attachment mechanism 12060 is substantially identical to attachment mechanism 1060 as described above with the exception of the primary tie system 12298. As best seen in
A first rod 12249a has a first threaded end that is connected to apertures in substantially vertical first bracket section 12208a by means of fastener 12210. In the depicted embodiment, fastener 12210 is a washer and coil nut, however, alternate fasteners may be substituted without departing from the scope hereof. A second end of first rod 12249a is connected to a first end of second rod 12249b via an adjustable fastener 12250. In the depicted embodiment, adjustable fastener 12250 is a cylinder-shaped, strut coil tie with a ¾-inch diameter and six-inch length. Adjustable fastener 12250 allows the spacing between rods 12249a and 12249b to be adjusted via rotation of adjustable fastener 12250 in either of two directions, typically via a wrench. The adjustable fastener facilitates placing the form 12000 in a substantially plumb position. A second end of second rod 12249b is coupled to a coil loop 12251, which is welded to upper plate 12246 in the same manner discussed above with respect to upper plate 1246 as shown in
Another difference in the form 12000 as compared to form 1000 is that the horizontal component 12104 includes horizontal component apertures 12502 in lieu of inserts 1202c. These apertures 12500 allow secondary support 12254 to be coupled to horizontal member 12104 and second bracket section 12208b via passage of a fastener 12503 (e.g., a bolt with a washer) through secondary support aperture 12500, horizontal component aperture 12502, and second bracket section aperture 12504 to connect all three components to each other, sandwiching form 12000 between secondary support 12254 and second bracket section 12208b. In some embodiments, the fastener 12502 is configured to receive a hollow plastic sleeve 12240 to create a small tunnel to allow access to the fastener 12503 after the poured deck cures.
Additionally, as seen in
After the form 12000 is installed as depicted in
Turning now to
Similar to form 100, form 13000 is a relatively thin, substantially L-shaped panel that includes vertical component 13002 and horizontal component 13004. In the depicted embodiment, vertical component 13002 is located substantially perpendicular to horizontal component 13004, however, alternate orientations may be substituted.
Vertical component 13002 and the proximal portion of horizontal component 13004 have thicknesses similar to the thicknesses of form 1000 as discussed in greater detail above. The height H13 and width W13 of form 13000 is approximately forty eight inches (48″), and the length L13 is approximately sixty inches (60″), however, varied dimensions may be substituted to accommodate, for example, desired size of the structure being built as well as material strength and geometric boundaries.
In the depicted embodiment, the features of form 13000 including, without limitation, insert 13202, form attachment 13206, form interior surface 13006, bevel 13212, vertical component upwardly facing surface 13222, vertical component inwardly facing surface 13010, joining component inwardly facing surface 13234, joining component 13210, horizontal component downwardly facing surface 13114, and rabbet 13218 are substantially identical to the equivalent components of form 1000, namely, insert 1202, form attachment 1206, form interior surface 1006, bevel 1212, vertical component upwardly facing surface 1222, vertical component inwardly facing surface 1010, joining component inwardly facing surface 1234, joining component 1210, horizontal component downwardly facing surface 1114, and rabbet 1218 as discussed above with the exceptions of the attachment mechanism 13060.
The attachment mechanism 13060 depicted in
As depicted in
In the depicted embodiment, primary support 13253 includes a primary fastener 13284, plate 13285, plate body fastener 13287, and plate base fastener 13286. As shown in
Plate 13285 is coupled to structural member 302 via sliding base aperture 13298 of plate 13285 over a seven-eighths (⅞) inch threaded shear stud welded to the structural member 302. A nut is then threaded over the stud until it contacts the upwardly facing surface of the base of plate 13285 in order to secure the plate 13285 to the structural member 302.
Also, the clevis 13284 is slid over the body of plate 13285 until its apertures 13297 align with body aperture 13299 of plate 13285. Thereafter, fastener 13287 is passed therethrough to couple primary fastener 13284 and the coupled primary support to plate 13285. In this manner, each tie back rod 13282 is coupled to structural member 302. Fastener 13287 is in the form of a clevis bolt and respective nut; however, alternate fasteners may be substituted.
Thereafter, or prior to such attachment, secondary tie system 13252 may be installed. In the depicted embodiment, secondary tie system includes a strut such as an interior angle strut, which may be installed via a form attachment coupled to an insert as described in greater detail herein. Or, in some instances, screws or the like may be drilled directly into form 13000.
Turning now to
The tie back rod 13282 and primary fastener 13684 connect to existing structural member 302 by means of a rectangular, bent plate 13685 with a length of nine and one quarter (9¼) inches, a width ranging from three inches (3″) to four and three quarters inches (4¾″), and a thickness of one (1) inch. However, the dimensions of plate 13685 may vary depending upon, for example, the governmental standard being met (e.g., OSHA 4:1 Failure (ULT), AASHTO ASD and 2:1 (ULT), AISC ASD AND 2:1 (ULT)). The plate 13685 is made of a rigid material such as Grade 50 steel and the like and has base aperture 13698. In the depicted embodiment, the body 13600 of plate 13685 is bent at an angle A1 of approximately twenty-five (25) degrees relative to the longitudinal axis of base 13602 of plate 13685. Also, base 13602 has a length L11 of approximately three and three eighths (3⅜) inches, and the body 13600 has a length L12 of approximately three and one sixteenth (3 1/16) inches with a bend length L13 of approximately one and three quarters (1¾) inch, however, alternate angles, lengths, and/or other dimensions may be substituted to accommodate, for example, varying sizes of forms.
Plate 13685 is coupled to structural member 302 via sliding base aperture 13698 of plate 13685 over a seven-eighths (⅞) inch threaded shear stud welded to the structural member 302. A nut is then threaded over the stud until it contacts the upwardly facing surface of the base of plate 13685 in order to secure the plate to the structural member 302.
It should be noted that although
Referring now to
The tie back rod 13282/primary fastener 13884 and the tie back rod 13252/secondary fastener 13887 connect to existing structural member 302 by means of a rectangular, bent plate 13885 with a length of approximately thirteen (13) inches, a width ranging from three inches (3″) to four and three quarters inches (4¾″), and a thickness of one (1) inch. However, the dimensions of plate 13885 may vary depending upon, for example, the governmental standard being met (e.g., OSHA 4:1 Failure (ULT), AASHTO ASD and 2:1 (ULT), AISC ASD AND 2:1 (ULT)). The plate 13685 is made of a rigid material such as Grade 50 steel and the like and has base aperture 13898. In the depicted embodiment, the body 13800 of plate 13885 is bent at two angles A1 and A2. Angle A1 is approximately forty-five (45) degrees relative to the longitudinal axis of base 13802 of plate 13885, and angle A2 is approximately twenty-five (25) degrees relative to the longitudinal axis of body 13800 of plate 13885. As depicted in
Plate 13885 is coupled to structural member 302 via sliding base aperture 13898 of plate 13885 over a seven-eighths (⅞) inch threaded shear stud welded to the structural member 302. A nut is then threaded over the stud until it contacts the upwardly facing surface of the base of plate 13885 in order to secure the plate to the structural member 13302.
Further, alternate attachment mechanisms 13060 may be substituted without departing from the scope hereof. Or, alternate components of the attachment mechanism 13060 including, but not limited to, primary support 13253, secondary support 13254, primary tie system 13298, and secondary tie system 13252 may be substituted without departing from the scope hereof.
Turning now to
As shown in
Primary support 14253 connects to a vertical support 13286 coupled to the structural member 302 by means of a cam-locking U-shaped bracket 14400. That is, the U-shaped plate includes a bite bit cam 14402 that bites into the vertical support 13286 when the plate and its associated cam are rotated relative to vertical support to create a clamping force on the vertical support. This clamping force prevents or minimizes movement of plate 14253 relative to vertical support 13286.
In an alternative embodiment, primary support 14253 is rotated one hundred and eighty degrees prior to attachment to the vertical support. And, optionally, a sleeve 14410 may be included within plate 14400 to further prevent or minimize movement of plate 14253 relative to vertical support 13286. Alternate embodiments are also envisioned in which one or more bolt and nut (and optionally washer) combinations are utilized to squeeze the U shaped plate around the vertical support. In any of the above described embodiments, embodiments are also envisioned in which the primary support 14253 is allowed to ride up (i.e., move vertically) the vertical support until a head or other interference limits movement thereof.
In embodiments of the present invention utilizing primary supports such as primary support 14253, the primary support is typically coupled to the vertical support prior to installation of the corresponding form. Next, the form, which has the tie rods pre-installed on it, is lifted into place. Next, the tie rods are coupled to primary support 14253. Although other sequences can be substituted. For example, the primary support 14253 could be installed at the same time the form is lifted into place and/or the tie rods could be installed after the form is lifted into place.
Referring now to
More specifically, height H14 of form 1400 is approximately forty one inches (41″), length L14 is approximately sixty inches (60″), and the width W14 varies. However, the dimensions of H14 and L14 may be substituted to accommodate, for example, desired size of the structure being built, material strength and geometric boundaries, and/or varying recess sizes and/or quantities.
Form 700 has a thickness T14 of approximately three inches (3″); however, alternate thicknesses may be substituted without departing from the scope of the present invention.
Further, the interior surface 1406 of vertical component 1402 of form 400 is angled at an angle of approximately 97.5 degrees from the interior surface 1407 of the horizontal component 1404. Or, in other words, the interior surface 1406 is angled outwardly at an angle A3 of approximately 7.5 degrees from a vertical plane perpendicular to the interior surface 1407 of the horizontal component 1404. However, varied angles may be substituted to accommodate the varying aesthetics of the form. Also, other forms shown herein as substantially perpendicular may be substituted with an obtuse form such as that shown in
Turning now to
The inserts of the middle rows are equidistantly spaced at distances of ID14 as shown in
However, alternate quantities of inserts and alternate configurations of inserts can be substituted without departing from the scope hereof.
As best seen in the plan view of
In the depicted embodiment, the center point of each aperture 803 is located at a height AH8 of approximately two feet (2′)as best seen in
Turning now to
Turning now to
When attached to an insert as shown in
Referring now to
The fastener 1652 also provides an attachment point for supports such as support 15253. In the depicted embodiment, support 15253 includes a U-shaped body 15256 with a coil 15257 at its open end. Support 15257 is held in place by strap 1648 by passing the fastener 1652 through the support as shown in
It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.
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| Number | Date | Country | |
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| Child | 16450456 | US |
| Number | Date | Country | |
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| Child | 16897984 | US | |
| Parent | 14099510 | Dec 2013 | US |
| Child | 15728085 | US |
