HEAVY DUTY SPANNING FORMS AND RELATED SYSTEMS AND METHODS

Abstract

A metal concrete form panel having a face sheet secured to a perimeter flange that includes side rails and end rails. One or more tie ribs extend between the end rails. A bolt block is secured in each corner to the perimeter flange where the side rails meet the end rails. A bar is located spaced inside each side rail and extended between and secured to each of the pair of opposing bolt blocks of the associated end rail and also secured to each intervening tie rib and to the face sheet.

Claims

1. A modular metal concrete form panel, comprising: (a) a face sheet secured to a perimeter flange having side rails and end rails; (b) a bolt block secured to the face sheet and further secured to the perimeter flange where the side rails meet the end rails; and (c) a strengthening bar disposed inside each side rail at a distance from each side rail and extended between and secured to each of the pair of opposing bolt blocks of such end rail, wherein the strengthening bar is secured to the face sheet.

2. The form panel of claim 1, wherein the perimeter flange comprises a lip disposed on the side rails and the end rails.

3. The form panel of claim 2, wherein the bolt block comprises a protrusion disposed in a notch defined in the lip of the end rails, whereby the bolt block is secured directly to the side rail and the lip of the side rail.

4. The form panel of claim 1, further comprising at least one rib disposed between the end rails and attached at one end to a first of the side rails and at another end to a second of the side rails.

5. The form panel of claim 4, wherein the strengthening bar is disposed through the at least one rib and attached thereto.

6. The form panel of claim 4, further comprising at least one cross rib attached at a first end to the at least one rib and attached at a second end to one of the end rails.

7. A modular form panel for concrete construction, the form panel comprising: (a) a face sheet; (b) a flange disposed around a perimeter of the face sheet, the flange comprising first and second opposing side rails and first and second opposing end rails; (c) four bolt blocks attached to the face sheet, the first and second side rails, and the first and second end rails, wherein each of the four bolt blocks is disposed in a separate corner of the face sheet; (d) at least one rib disposed between and parallel with the first and second end rails and attached at a first end to the first side rail and at a second end to the second side rail; (e) a first reinforcement bar disposed between and parallel with the first and second side rails and attached at a first end to a first of the four bolt blocks and at a second end to a second of the four bolt blocks; and (f) a second reinforcement bar disposed between and parallel with the first and second side rails and attached at a first end to a third of the four bolt blocks and at a second end to a fourth of the four bolt blocks.

8. The form panel of claim 7, wherein each of the first and second side rails and the first and second end rails comprises a lip disposed thereon.

9. The form panel of claim 8, wherein a first notch is defined between a first end of the lip of the first end rail and the first side rail, a second notch is defined between a second end of the lip of the first end rail and the second side rail, a third notch is defined between a first end of lip of the second end rail and the first side rail, and a fourth notch is defined between a second end of the lip of the second end rail and the second side rail.

10. The form panel of claim 9, wherein a first of the four bolt blocks comprises a first protrusion disposed in the first notch, wherein the first bolt block is attached to the first side rail and the lip of the first side rail, a second of the four bolt blocks comprises a second protrusion disposed in the second notch, wherein the second bolt block is attached to the second side rail and the lip of the second side rail, a third of the four bolt blocks comprises a third protrusion disposed in the third notch, wherein the third bolt block is attached to the first side rail and the lip of the first side rail, and a fourth of the four bolt blocks comprises a fourth protrusion disposed in the fourth notch, wherein the fourth bolt block is attached to the second side rail and the lip of the second side rail.

11. The form panel of claim 7, wherein the first and second reinforcement bars are disposed through a notch defined in the at least one rib and are attached to the at least one rib.

12. The form panel of claim 7, wherein the first reinforcement bar is disposed at a distance from the first side rail such that the first reinforcement bar is closer to the first side rail than the second side rail, and the second reinforcement bar is disposed at a distance from the second side rail such that the second reinforcement bar is closer to the second side rail than the first side rail.

13. The form panel of claim 7, wherein the first end of the first reinforcement bar is attached to an end of the first bolt block that is opposite an end of the first bolt block attached to the first side rail, the second end of the first reinforcement bar is attached to an end of the second bolt block that is opposite and end of the second bolt block attached to the first side rail, the first end of the second reinforcement bar is attached to an end of the third bolt block that is opposite an end of the third bolt block attached to the second side rail, and the second end of the second reinforcement bar is attached to an end of the fourth bolt block that is opposite an end of the fourth bolt block attached to the second side rail.

14. The form panel of claim 7, further comprising at least one cross rib attached at a first end to the at least one rib and attached at a second end to one of the first and second end rails.

15. A method of constructing a concrete spanning beam, the method comprising: positioning at least first and second modular form panels adjacent to each other, each of the first and second modular form panels comprising: (a) a face sheet; (b) a flange disposed around a perimeter of the face sheet, the flange comprising first and second opposing side rails and first and second opposing end rails; (c) four bolt blocks attached to the face sheet, the first and second side rails, and the first and second end rails, wherein each of the four bolt blocks is disposed in a separate corner of the face sheet; (d) at least one rib disposed between and parallel with the first and second end rails and attached at a first end to the first side rail and at a second end to the second side rail; (e) a first reinforcement bar disposed between and parallel with the first and second side rails and attached at a first end to a first of the four bolt blocks and at a second end to a second of the four bolt blocks; and (f) a second reinforcement bar disposed between and parallel with the first and second side rails and attached at a first end to a third of the four bolt blocks and at a second end to a fourth of the four bolt blocks; aligning the first modular form panel with the second modular form panel such that the first end rail of the first modular form panel is in contact with the second end rail of the second modular form panel; positioning at least two bolts through at least two holes in a first of the four bolt blocks of the first modular form panel and through at least two holes in a first of the four bolt blocks of the second modular form panel, thereby attaching the first bolt block of the first modular form panel with the first bolt block of the second modular form panel; positioning at least two bolts through at least two holes in a second of the four bolt blocks of the first modular form panel and through at least two holes in a second of the four bolt blocks of the second modular form panel, thereby attaching the second bolt block of the first modular form panel with the second bolt block of the second modular form panel; and attaching a plurality of additional modular form panels to the first or second form panels or additional attached form panels by repeating the aligning and the positioning of the at least two bolts to create a panel assembly.

16. The method of claim 15, further comprising attaching the panel assembly to first and second supports such that the panel assembly is disposed on and supported by the first and second supports.

17. The method of claim 16, further comprising pouring concrete into the panel assembly to form a concrete structure that extends across and is supported by the first and second supports.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] FIG. 1 is a perspective view of a integrated concrete form component made up of a plurality of concrete form panels, according to one embodiment.

[0028] FIG. 2 is an elevation view of a rear side of a modular concrete form component, according to one embodiment.

[0029] FIG. 3 is a cross-sectional view taken along line A-A of FIG. 2, according to one embodiment.

[0030] FIG. 4 is a side view of the panel of FIG. 2, according to one embodiment.

[0031] FIG. 5 is a plan or top view of the panel of FIG. 2, according to one embodiment.

[0032] FIG. 6 is a cross-sectional view taken along line B-B of FIG. 2, according to one embodiment.

[0033] FIG. 7 is an expanded perspective view of a bolt block, according to one embodiment.

[0034] FIGS. 8A-8D are elevation views of various exemplary form panels of different sizes, according to certain embodiments.

[0035] FIGS. 9A-9C are expanded side views of various exemplary bolt blocks of different sizes that can be used in various form panel embodiments of different sizes, according to certain embodiments.

DETAILED DESCRIPTION

[0036] The various embodiments herein relate to a metal concrete form panel having an increased resistance to deflection and bending when coupled with other such panels to contain and form and support concrete spanning structures. In certain implementations, the form panel as described herein displays an increase in strength of up to at least 200%, and in some cases, 300%, in comparison to known form panels.

[0037] FIG. 1 depicts an integrated concrete form panel assembly 10 that is made up of a plurality of form panels 12 that have been assembled or coupled together for the construction of a concrete structure. More specifically, the integrated form panel assembly 10 spans from one support 14A to another support 14B such that the panel assembly 10 allows for pouring a concrete structure that cures such that it extends across and is supported by both supports 14A, 14B.

[0038] One exemplary implementation of a metal concrete form panel 20 is depicted in FIGS. 2-7. The form panel 20 has a face sheet 22 and a perimeter flange 24 that extends from a rear side of the face sheet 22 (as best shown in FIGS. 3-7). The flange 24 extends from the back side of the face sheet 22 around the entire perimeter of the face sheet 22 and is made up of a pair of opposing side rails 26a and 26b and a pair of opposing end rails 28a and 28b. It is understood that the flange 24 (or the rails 26a, 26b, 28a, 28b) are secured to the face sheet 22 by weldments or similar attachment mechanism or methods. According to certain embodiments, the flange 24 (that is, each of the rails 26a, 26b, 28a, 28b) has a lip disposed thereon. More specifically, as best shown in FIGS. 2, 3, 4, 6, and 7, the side rails 26a, 26b have a lip 27 and the end rails 28a, 28b have a lip 29. The lips 27, 29 may also be referred to herein as formed returns.

[0039] As best shown in FIG. 2, the panel 20 also has ribs 30 and rib stiffeners (or cross ribs) 32 attached thereto. More specifically, the panel 20 has one or more ribs 30 that are disposed on the same side of the face sheet 22 as the side rails 26a, 26b and extend between the side rails 26a, 26b and are parallel with the end rails 28a, 28b. Each rib 30 is secured along its length by weldments or the like to the back side of the face sheet 22 and further is attached at its ends to the side rails 26a, 26b. In addition, the panel 20 has at least two rib stiffeners 32, each of which is a short member (by comparison to a rib 30, for example) that extends between a tie rib 30 and one of the end rails 28a, 28b as shown such that the rib stiffeners 32 are parallel to the side rails 26a, 26b. Each cross rib 32 is secured along its length to the back side of the face sheet 22 by weldments or the like and further is attached at its ends to a rib 30 on one end and one of the end rails 28a, 28b on the other.

[0040] As best shown in FIGS. 2, 4, and 7, in accordance with one implementation, the form panel 20 also has four bolt blocks 34one in each corner of the panel 20. Each bolt block 34 is used in conjunction with a corresponding bolt block on a second, adjacent form to secure the instant form 20 to the adjacent form via bolts that are coupled to both of the corresponding blocks. Thus, the bolt blocks 34 on the form 20 and the bolt blocks on the adjacent forms (not shown) operate together to secure multiple form panels 20 together in a fashion similar to that shown in FIG. 1. Each bolt block 34 functions to transfer forces between and among the multiple form panels 20, thereby giving the form system 10 (the plurality of panels 20) its bending moment strength. As best shown in FIGS. 4 and 7, each bolt block 34 is a piece of metal 34 that is disposed in a corner of the panel 20 and secured along a side to one of the end rails 28a, 28b and at its end to one of the side rails 26a, 26b. Further, each bolt block 34 has at least two openings 35 defined therein that are configured to receive the bolts (not shown) that couple to the bolt block 34 and the corresponding bolt block on the adjacent form (not shown).

[0041] In one embodiment, the openings 35 in any of the bolt block 34 implementations disclosed or contemplated herein are sized to receive 1 inch bolts (not shown). Alternatively, the openings 35 can be sized to receive 1 inch bolts (not shown). In a further implementation, the openings 35 can be sized to receive any known bolt of any known size that is used for coupling form panels in concrete construction. In certain embodiments, each block 34 has four openings 35 and thus couples to an adjacent block 34 on an adjacent panel 20 via four bolts (not shown). Alternatively, the coupling could occur using three bolts (not shown). In a further alternative, two bolts (not shown) could be used. It is understood that the bolt block 34 can have two, three, four, or more openings 35 for receiving bolts (not shown).

[0042] In addition, according to one embodiment, the panel 20 also has two strengthening bars (or support bars or reinforcement bars) 36 as best shown in FIGS. 2 and 7 that extend between two bolt blocks 34 at a spaced distance from (and parallel to) the closest side rail 26a, 26b as shown. Each of the bars 36 is secured, for example by weldments, at opposite ends of the bar 36 to each of the bolt blocks 34. In one embodiment, the bar 36 is attached to the two bolt blocks 34 at the point on each block 34 that is farthest from the side rail 26a, 26b to which the block 34 is attached. Further, as best shown in FIG. 7, each bar 36 extends through an opening (or slot) 37 defined in each of the ribs 30 disposed between the two bolt blocks 34 and is secured to each such rib 30 by weldments or the like. In addition, the strengthening bar 36 is also attached to the face sheet 22, and can be attached by weldments or other known attachment methods or mechanisms. According to one implementation, each strengthening bar helps to prevent the face sheet 22, and thus the entire panel 20, from buckling near the compression flange, thereby resulting in a larger compression zone of the form 20 being able to resist more load. It is understood that, because the various panel embodiments (such as, for example, panel 20) disclosed or contemplated herein are modular panels, the location of the compression flange (along with the compression and tension zones discussed below) on the panel (such as panel 20) depends on how the loads are applied to the form assembly (and thus the individual, modular panels). Additionally, according to certain embodiments, each strengthening bar 36 can increase the area of the tension zone, thereby increasing the tensile flange capacity of the panel 20. Further, each strengthening bar 36 adds significant strength to the bolt bearing blocks 34 to which it is attached. That is, the bar 36 adds the necessary strength to the bolt blocks 34 to allow more, larger diameter high strength bolts, thereby increasing the strength of the connection between panels. This, in turn, increases the spanning capacity of the entire form system (like form system 10, for example).

[0043] In accordance with certain implementations, each bolt bearing block 34, such as, for example, the bolt bearing block 34 as shown in FIG. 7, has a protrusion 39 that extends out from the block 34 such that it is disposed adjacent to and flush with the lip 29 of the end rail 28a as shown. In other words, a portion of the lip 29 is removed such that an end 41 of the lip 29 is disposed at a distance from the side rail 26a, thereby defining a notch 43 formed between the lip end 41 and the side rail 26a. The protrusion 39 is disposed within the notch 43 and is attached (by a weld in one exemplary embodiment) directly to the lip 27 of side rail 26a. This configuration of the protrusion 39 disposed in the notch 43 and attached to the lip 27 results in a greater percentage of the bolt loading being transferred directly to the main structural components of the concrete form panel, thereby resulting in a more rigid bolt bearing block connection than prior connection designs. The prior, known connection designs have a bolt bearing block that is typically a simple bar that does not protrude into the notch in the end rail lip, which results in some of the bolt loading being indirectly transferred to the structural components of the panel, which can ultimately result in too much load being placed on those structural components.

[0044] It is understood that any form panel according to any embodiment disclosed or contemplated herein can be of any size desired for use in the concrete forming industry. Various exemplary sizes and configurations are depicts in FIGS. 8A-8D. While the various configurations as shown in these FIGS. 8A-8D can have any known dimensions, specific examples are also provided herein. For example, the form panel 40 as depicted in FIG. 8A can be 5 feet by 4 feet. Further, in another example, the form panel 42 shown in FIG. 8B can be 8 feet by 8 feet. Additionally, a further example is shown in FIG. 8C, in which the panel 44 is 10 feet by 8 feet. Another example is depicted in FIG. 8D, in which the panel 46 is 4 feet by 12 feet. It is understood that any known dimensions for any known panels can be used for the various panels 40, 42, 44, 46 depicted in FIGS. 8A-8D.

[0045] In a further specific example, Table 1 sets forth a chart of various panel sizes, including certain more common sizes identified with an X.

TABLE-US-00001 TABLE 1 X 1 X 2 X 4 X 6 X 8 X 12 2R 3R 4R 5R X X X X X 6R X X X X X 7R X X X X X 8R X X X X X 9R X X X X 10R X X X X 12R X X X X

[0046] As shown in FIGS. 9A-9C, It is understood that any bolt block according to any embodiment disclosed or contemplated herein can be of any size as necessary to fit within or be incorporated into the form panels of various sizes as described above for use in the concrete forming industry. Various exemplary sizes and configurations of the bolt blocks are depicted in FIGS. 9A-9C. For example, bolt block 52 of FIG. 9B is wider than bolt block 50 as shown in FIG. 9A. Further, bolt block 54 depicted in FIG. 9C is wider than bolt block 52 of FIG. 9B. It is understood that the various bolt blocks (such as blocks 34, 50, 52, 54) vary in size to accommodate the increased loading of larger form panels 20. Further, it is understood that the larger bolt blocks as contemplated herein can include additional bolt holes for additional or larger bolts.

[0047] The foregoing description and drawings comprise illustrative embodiments of the various embodiments. The foregoing implementations described herein may vary based on the ability, experience, and preference of those skilled in the art. The foregoing description and drawings merely explain and illustrate the embodiments, and the various implementations are not limited thereto, except insofar as the claims are so limited. Those skilled in the art who have the disclosure before them will be able to make modifications and variations therein without departing from the scope of the inventions.