Adjustable forms for poured concrete structures and related systems and methods
11339563 · 2022-05-24
Assignee
Inventors
Cpc classification
E01D21/00
FIXED CONSTRUCTIONS
E04B1/2403
FIXED CONSTRUCTIONS
International classification
Abstract
An apparatus for adjusting a haunch height and related systems and methods includes a support angle. The support angle includes first and second flanges, and a surface of the first flange includes a hole. The apparatus also includes a coil rod and a rotatable nut.
Claims
1. An apparatus for adjusting a haunch height for a horizontal panel, the apparatus comprising: a support system, the support system comprising a vertical support portion with a first flange and a horizontal support portion with a second flange, wherein a surface of the support system includes a hole, wherein the support system is configured to support the horizontal panel; a first coil rod at least partially extending through the hole; a first rotatable nut at least partially surrounding the first coil rod, wherein motion of the first rotatable nut adjusts a position of the vertical support portion of the support system to adjust a height of the horizontal panel; and a second coil rod, wherein the vertical support portion of the support system is coupled to the first coil rod and the horizontal support portion of the support system is coupled to the second coil rod, and wherein, when the apparatus is mounted to a flange of a bridge girder, the second coil rod extends parallel to the flange of the bridge girder.
2. The apparatus of claim 1, wherein the coil rod is threaded.
3. The apparatus of claim 2, wherein the threaded coil rod is seated within a threaded coupler.
4. The apparatus of claim 3, further comprising: a coupler, wherein a portion of the first coil rod is seated within the coupler, wherein the coupler is configured to be embedded within the flange of the bridge girder, and wherein the threaded coupler is embedded in the flange of the bridge girder.
5. The apparatus of claim 1, wherein the first rotatable nut is welded to the vertical support portion of the support system.
6. The apparatus of claim 1, further including a coil rod splicer supporting at least a portion of the support system.
7. The apparatus of claim 1, further including: a second rotatable nut coupled to the first coil rod and supporting at least a portion of the support system; and a washer or plate welded to the second rotatable nut and supporting at least a portion of the support system.
8. The apparatus of claim 1, wherein the apparatus is a stay-in-place form system configured to receive a concrete pour to form a bridge deck.
9. The apparatus of claim 1, wherein the support system is formed of a steel.
10. The apparatus of claim 1, further comprising a slotted strut angle configured to receive a field bolt, and a formwork, wherein rotation of the rotatable nut adjusts a position of at least one of the support system or the strut angle to adjust a position of the formwork.
11. The apparatus of claim 10, further comprising a support member and an at least partially transparent panel coupled to the support member.
12. The apparatus of claim 4, wherein the support system is a first support system, and wherein the second coil rod extends parallel to the flange of the bridge girder to a second support system positioned on another side of the flange of the bridge girder.
13. The apparatus of claim 1, further comprising at least one connectable strap, wherein the at least one connectable strap is positioned between the first rotatable nut and the first flange of the support system.
14. An apparatus for adjusting a position of a horizontal panel, the apparatus comprising: a vertical adjustable haunch support comprising: a support angle, the support angle comprising a first flange and a second flange, wherein a surface of the first flange includes a hole; a first coil rod at least partially extending through the hole; and a first rotatable nut at least partially surrounding the first coil rod, wherein motion of the first rotatable nut adjusts a vertical position of the support angle; a horizontal adjustable haunch support, comprising: a second coil rod; a bearing plate; and a second rotatable nut at least partially surrounding the second coil rod, wherein motion of the second rotatable nut adjusts a horizontal position of the support angle; and a coupler configured to be embedded within a flange of a bridge girder, wherein the first coil rod is seated within the coupler, wherein the bearing plate is coupled to the first coil rod and to the second coil rod, and wherein, when the coupler is embedded within the flange of the bridge girder, the second coil rod extends parallel to the flange of the bridge girder.
15. The apparatus of claim 14, wherein the support angle is a first support angle, wherein the bearing plate is a second support angle that forms another horizontal adjustable haunch support, and wherein the second coil rod couples the horizontal adjustable haunch support to the another bearing plate of another horizontal adjustable haunch support.
16. The apparatus of claim 14, wherein the support angle is formed of a steel.
17. The apparatus of claim 14, wherein the apparatus is a stay-in-place form system configured to receive a concrete pour to form a bridge deck.
18. An apparatus for adjusting a haunch height for a horizontal panel, the apparatus comprising: a support system, the support system comprising a vertical support portion with a first flange and a horizontal support portion with a second flange, wherein a surface of the vertical support portion includes a hole, wherein the support system is configured to support the horizontal panel; a first coil rod at least partially extending through the hole; a first rotatable nut at least partially surrounding the first coil rod, wherein motion of the first rotatable nut adjusts a position of the vertical support portion to adjust a height of the horizontal panel, a second rotatable nut coupled to the first coil rod and supporting at least a portion of the horizontal support portion; and a second coil rod, wherein the vertical support portion of the support system is coupled to the first coil rod and the horizontal support portion of the support system is coupled to the second coil rod, and wherein, when the apparatus is mounted to a flange of a bridge girder, the second coil rod extends parallel to the flange of the bridge girder.
19. The apparatus of claim 18, wherein the support system is formed of a steel.
20. The apparatus of claim 18, further comprising: a second rotatable nut coupled to the first coil rod and supporting at least a portion of the support system, wherein the apparatus is a stay-in-place form system configured to receive a concrete pour to form a bridge deck.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The accompanying drawings, which are incorporated herein, and constitute a part of this specification, illustrate exemplary aspects of the present disclosure and together with the description, serve to explain the principles of the disclosure.
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DETAILED DESCRIPTION
(18) The present disclosure is now described with reference to exemplary aspects of structure and construction methods for an adjustable bridge deck form. Some embodiments are depicted and/or described with reference to the structure and construction methods of an adjustable haunch with continuous angles, an adjustable haunch with continuous angles connect by a pair of straps, vertical and horizontal adjustable haunch supports with discontinuous angles, a vertical support adjustable haunch with continuous angle support, an adjustable haunch with integrated support and formwork, and/or an adjustable haunch with continuous angled support. These references are provided for convenience and are not intended to limit the present disclosure unless incorporated into the appended claims. Accordingly, the concepts and novelty underlying each embodiment may be utilized for any type of adjustable haunch, and may be made out of any material or materials.
(19) The disclosure below provides structures and construction methods to adjust the haunch height of a bridge deck without the need for welding. As described above, while contractors often prefer stay-in-place forms over removable forms, bridge owners must contend with any consequences relating to welding steel angles to a top flange of a beam. Contractors are facing increased labor costs for specialty welding, and difficulties adjusting the haunch height once the weld is completed. To speed up construction, decrease labor costs, and make easier the adjustment of the haunch height, an adjustable connection without the need for welding is described below. Thus, the present disclosure describes a structure that may allow the contractor to adjust the haunch elevation, e.g., haunch height, from the top surface of the bridge deck without the need for welding the form support, e.g., formwork, to the girder. The embodiments of the present disclosure allow the contractor to adjust the height of the haunch more easily by, for example, tightening a nut from the top of the bridge deck surface. Unlike the removable formwork connection, however, the entire support system disclosed may stay in place with the form over the service life of the bridge deck.
(20) Exemplary aspects of the present disclosure are illustrated in
(21) Specifically,
(22) During operation of adjustable haunch support system 22, a contractor, or other suitable professional, may rotate nut 30 to adjust the vertical alignment, or haunch height 24, of support system 22 as described. Rotatable nut 30 is rotated in a direction (e.g., counter-clockwise or clockwise) to adjust support angle 36 in an upward (or downward) direction, thus adjusting the height between girder 26 and formwork 29. In some embodiments, a coupler 34 may be embedded in a top flange 27 of girder 26. In some examples, coupler 34 may be embedded in girder 26 when girder 26 is formed (e.g., coupler 34 is inserted within an unhardened, poured concrete flange of girder 26). In some embodiments, a complimentary nut 30A is inserted on the opposing face of a flange of support angle 36 to further secure coil rod 28 to support angle 36 and rotatable nut 30. In some examples, a combination of similar rod(s), bolt(s), coupler(s), and/or other suitable fastening mechanisms may be used to secure support angle 36 to girder 26 and formwork 29. A stay-in-place formwork system 40 is shown mounted to a surface of formwork 29, however, other suitable stay-in-place formworks may be used. In some examples, such stay-in-place formwork systems may be removably attached to formwork 29. In any such examples, a concrete pour may be poured over formwork 29 and support system 22 to construct a bridge deck. Girder 26 is shown as a concrete beam, but may comprise any other suitable material or combination of materials including, e.g., but not limited to, steel, iron, etc.
(23) As shown in
(24) Another aspect of the present disclosure includes an adjustable haunch form support system 32 comprising an adjustable haunch support 35 with continuous angles (see
(25) Another aspect of the present disclosure includes an adjustable haunch form support system 42 comprising a horizontal adjustable haunch support 44 and a vertical adjustable haunch support 46 with discontinuous angles (see
(26) Another aspect of the present disclosure includes an adjustable haunch form support system 52 comprising a vertical adjustable haunch support 54 with continuous angles (see
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(28) Another aspect of the present disclosure includes an adjustable haunch form support system 62 comprising a vertically adjustable haunch support 64 with an integrated support 67 (see
(29) A further aspect of the present disclosure includes an adjustable haunch form support system 72 comprising a vertically adjustable haunch support 74 for continuous angled support (see
(30) With reference to
(31) With reference to
(32) With reference to
(33) Support member 110 may be coupled to flanges 27 via one or more coil rods, nuts, washers, or plates as discussed above. For example, nut 108A may couple support member 110 to a first flange 27 via an adjustable bearing angle 106 and coil rod 107. Similarly, nut 108B may couple support member 110 to a second flange 27 via another adjustable bearing angle 106 and coil rod 107. The connection via nut 108A may be static, and support member 110 may abut flange 27 where connected by nut 108A. In one aspect, however, the connection via nut 108B may be adjustable. For example, nut 108B may be coupled to a slot in either bearing angle 106 or flange 27 such that the position of bearing angle 106, coil rod 107, and/or nut 108B, and thus support member 110 may be adjustable relative to flange 27. The adjustability may allow for a contractor to selectively position support member 110 relative to girders 26, and thus relative to the bridge deck. For example, if girders 26 are not fully aligned, the adjustability of one side of support member 110, for example, via bearing angle 106B, may allow a contractor to make adjustments to ensure that support member 110 is flat or otherwise properly positioned to support the poured concrete. Additionally, although not shown, adjustable haunch form system 102 may include additional wedge or angle elements similar to support angle 95 and strut angle 97 of
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(35) Referring to
(36) Longitudinal bars 112 and crossbars 112 may support a panel (not shown). The panel may be formed of an acrylic or plastic, and may be at least partially clear or transparent. The panel may be preformed, and may be approximately ¼, ½, ¾, 1, or 2 inches thick. The panel may be approximately the same area as a top portion of support member 110, and may be secured to at least one of longitudinal bars 112 and crossbars 114 via an adhesive or other coupling mechanism. The panel may be the base of the concrete poured on support member 110 to form an at least partially transparent stay-in-place bridge deck. Support member 110, including the panel, may be sacrificial and remain coupled to girders 26 in the finalized bridge deck. As such, a contractor, an inspector, etc. may view and inspect various portions of the poured concrete from beneath the bridge deck during the construction and lifetime of the bridge deck. Additionally, support member 110 may be prefabricated and formed of stock materials for quick and/or easy coupling to girders 26.
(37) Some attributes of the previously described structures, systems, and construction methods for an adjustable haunch are recited here but are not exclusive of features or benefits of the present disclosure. The systems disclosed herein may include one or more of the following attributes. One attribute of the adjustable haunch features described herein is for the ability to adjust the haunch height from a top surface of a bridge deck. Other attributes include avoiding the need to retain or hire specialty labor, e.g., welders and carpenters, which are not be needed to install the support structure of the adjustable haunch. One other attribute is avoiding the need for welding for an attachment of the support structure to the bridge girder, as detailed above, which may reduce the risk of corrosion over time. Furthermore, the structures, systems, and construction methods discussed herein may further include the positioning and/or support of reinforcement members (e.g., rebar) in the portions of the bridge deck to receive the concrete.
(38) Other attributes of the systems herein include the ability to install the adjustable haunch on precast concrete, steel, timber girders, or girders made from other suitable material, all of which may be both continuously and suitably supported. Welding procedures are typically not allowed in negative bending moment regions of continuous bridge girders, however, the support structures and systems described in this disclosure may be used consistently across the bridge in negative bending moment regions of continuous bridge girders, as well as in positive bending moment regions.
(39) Other attributes of the adjustable haunch support systems described above include, for example, eliminating the requirement for specialized inserts or holes in a top flange of precast girders, or other suitable support beams. These attributes, consequently, may save material and precast concrete labor costs.
(40) Additional attributes of the systems described herein may also include improved safety. In some examples, most or all connections and adjustments may be made from the top of the bridge deck. In doing so, the systems herein may reduce or avoid the need for laborers, or other similar construction workers, below the bridge deck to remove any of the support systems described above once the concrete is cured. Consequently, the risk of a laborer being injured on the site may be reduced.
(41) Lastly, the support systems detailed above may be manufactured at reduced costs compared to other support systems. For example, the support systems detailed above may be manufactured using a simple, repeatable, and modular process. The support systems may be modular to help in reducing the material cost over time, which may make it simple for contractors, or other suitable professionals, to install.
(42) While principles of the present disclosure are described herein with reference to illustrative aspects for particular applications, it should be understood that the disclosure is not limited thereto. Those having ordinary skill in the art and access to the teachings provided herein will recognize additional modifications, applications, examples, and substitution of equivalents all fall within the scope of the aspects described herein. Accordingly, the present disclosure is not to be considered as limited by the foregoing description.