Patent Application
20060255236
This invention relates to waler clamp assemblies for holding concrete wall forms in alignment during pouring and curing of a concrete wall.
Waler clamps are used in the construction industry to hold adjacent panels of concrete wall forms in proper alignment with each other while concrete is being poured between spaced apart wall forms. Typically, the panels comprising the wall form include frames having vertical and horizontal members that are used for attaching the panels together in an edge-to-edge abutting relationship. The vertical frame members define a series of horizontal openings used for attachment of a waler clamp. The waler clamps are used for supporting a waler board that is wedged between the wall form frame and a wedge driven through openings in the waler clamp to hold the waler board firmly against the frame, thereby maintaining the panels in straight alignment during pouring and curing of concrete between the forms.
U.S. Pat. No. 5,562,845 discloses a typical waler clamp assembly having an upper plate with a hook for attaching the waler clamp to a vertical frame member of a concrete wall form, a lower plate spaced below the upper plate, and a distal end web connecting the upper and lower plates. A waler board is inserted between the upper and lower plates and wedged against the vertical frame member by driving a wedge through openings defined in the upper and lower plates. A recognized disadvantage with this waler clamp is that there is very little reinforcement or rigidity to prevent downward deflection or longitudinal twisting of the plate as the wedge is being driven into place. As a result, this waler clamp is susceptible to damage, and, therefore, has relatively limited reusability before failing to maintain proper alignment.
U.S. Pat. No. 6,322,047 discloses a similar waler clamp assembly that attempts to overcome the susceptibility to damage inherent in previous waler clamps by adding a reinforcing leg that interconnects the upper and lower plates, and extends upwardly from the lower plate and outwardly toward the end web. A notable disadvantage with this arrangement is that the waler board must be placed on top of the upper plate, instead of between the upper plate and lower plate, as is conventional. Thus, the waler board placed on the waler clamp can become easily dislodged by inadvertently bumping the waler board or by inadvertently placing weight at the end of the waler board before it is firmly wedged in place. This could conceivably present safety issues. Another disadvantage is that the reinforcing leg of the clamp must be welded or otherwise securely fixed to the upper plate. This additional manufacturing step, beyond the normal cutting and bending operations used for manufacturing previously known waler clamps, adds significantly to the cost of manufacturing the waler clamp.
The waler clamp assembly of this invention includes reinforcing features that do not interfere with, but instead facilitate placement of a waler board between upper and lower plates of the waler clamp, whereby accidental dislodgement of a waler board prior to firmly wedging the waler board in place is prevented, while at the same time providing excellent rigidity and strength against deformation and twisting as the waler board is wedged into position. Further, the waler board of the invention can be fabricated without any welding operations, using only cutting and bending operations to achieve the desired rigidity.
The waler clamp includes an upper plate having a hook for engaging a wall form, a lower plate spaced below the upper plate, the upper and lower plates interconnected at respective longitudinal edges on one side of the plates by a side web, the side web having an opening adapted to receive a waler board. The upper and lower plates each define a wedge opening through which a wedge may be driven to firmly secure a waler board against vertical frame members of adjacent wall forms to hold the wall forms in proper alignment.
In accordance with certain embodiments of the invention, an end flap extends at an angle from the side web and projects between the upper and lower plates in proximity to distal ends of the upper and lower plates.
These and other features, advantages and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims and appended drawings.
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Waler clamp 10 is used by first inserting hook 22 through horizontal openings 20 of adjacent vertical wall frame members 16 and 17 and positioning waler clamp 10 so that tooth 44 is disposed in and cooperates with slot 46 defined between vertical frame members 16 and 17, projecting rib 50 of vertical frame member 17 engages notch 48 of upper plate 28, and vertical frame member-engaging proximal edge 24 bears against outer edges 26 and 27 of vertical frame members 16 and 17. Thereafter, waler board 12 is inserted through opening 38 of side web 36. Typically, each waler board 12 is supported by two or more waler clamps 10.
Alternatively, rather than inserting waler board 12 through opening 38, as described above, waler board 12 may be placed on top of upper plate 28 of waler clamp 10, as shown in
Because waler board 12 is circumscribed by web 36, rather than being placed loosely on top of upper plate 28, there is little risk that waler board 12 will become inadvertently dislodged by jarring, bumping or placing weight on waler board 12, whereby enhanced construction site safety is achieved. At the same time, side web 36 in combination with end flap 42 provide excellent strength, rigidity and reinforcement that prevents downward deformation and/or twisting of upper plate 28 or lower plate 32 when wedge 14 is driven downwardly to firmly secure waler board 12 against vertical frame members 16 and 17. Thus, the invention provides a combination of improved safety and reusability by simultaneously allowing placement of waler board 12 between upper plate 28 and lower plate 32 while also providing reinforcement against deformation and twisting. Further, reinforcement against deformation and twisting is provided without requiring welding or any other attachment of a reinforcing leg to the upper or lower plates. Instead, waler clamp 10 can be fabricated by appropriately cutting (stamping) metal sheet and bending the resulting stamped metal sheets so that upper plate 28, lower plate 32, and side flap 42 project at right angles from side web 36.
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The above description is considered that of the preferred embodiments only. Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and not intended to limit the scope of the invention, which is defined by the following claims as interpreted according to the principles of patent law, including the doctrine of equivalents.
