Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02599534 2007-08-30
Concrete Slab Depth Varying System
Field
The present invention relates to concrete slab form systems, commonly used for
the floors
of multi-story buildings, and more particularly to a support system of
cooperating structural
components that are used to support and form the variable depth portions of
concrete slabs.
Background
Historically, the concrete forming industry has generally relied on
form/support systems that
remain in place until the concrete has attained sufficient strength to support
itself and
construction loads applied from above. Depending on construction codes
applicable to the
jurisdiction in which construction is underway, the complete forming system
may be required
to remain in place up to seven days.
An alternative to the above that is sometimes utilized is generally referred
to as a "drop
head" system. This type of system allows removal (stripping) of form
components without
disturbing the slab supporting components. Drop head systems invariably rely
on the use of
a support component (shoring posts) and a beam to receive and support the form
panels.
Drop head systems are disclosed in U.S. Patent No. 5,614,122 to Schworer, U.S.
Patent
No. 5,310,153 to Jackson and U.S. Patent No. 1,907,877 to Roos. However, the
above
references fail to address two common drop head system deficiencies.
A first deficiency with existing drop head systems is the accommodation of
various slab
thicknesses. It is common practice to leave the problem of changes in slab
thickness up to
the contractor to solve on site. This contractor typically has carpenters
build single use forms
in the areas affected, significantly impacting productivity, material cost,
and labour cost.
A further deficiency in the prior art involves slab edges that require form to
cantilever out
beyond supporting walls or columns. The form must extend beyond the slab edge
to be
formed in order to provide workers with a place to stand when pouring the
concrete. These
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forms challenge the form designer to provide a convenient and safe means of
erecting and
dismantling the forms. Existing solutions are less than satisfactory due to
component
complexity and the potential exposure to accidental falls experienced by
workmen.
Summary
The slab depth varying system described herein provides a means to
conveniently
accommodate changes in concrete slab thickness. Changes in slab thickness are,
for
example, often required adjacent to columns. The applicant's slab depth
varying system
can be effectively employed in conjunction with existing concrete forming
systems. Existing
concrete form systems generally comprise a primary form at a first elevation
suspended by
shoring posts. The shoring posts generally include vertically spaced diametric
openings
through at least a portion of the posts. These openings are principally
utilized when
adjusting the height of the shoring posts.
The applicant's slab depth varying system provides saddle beams for supporting
a
secondary flat form at a desired second elevation below the primary form.
Coupling means
are provided for coupling the saddle beams to the shoring posts, which are
suspending the
primary form, at the second elevation. After concrete poured on the secondary
form has
had an opportunity to partially cure, stripping of the secondary form and the
saddle beams is
accommodated by a means of lowering the saddle beams from their initial height
to a lower
stripping height. The distance between the two heights is generally small,
typically between
0.5 and 1.75 inches.
Convenient and safe erection and support of concrete forms for forming slab
edges many
stories above a street below is another design challenge that has not been
well addressed
by prior art. The form panels have to cantilever out beyond the slab or
working surface
below because the workers need a working area about three feet wide beyond the
edge of
the slab under construction. Systems in use today rely on the installation of
horizontal
beams that cantilever over the edge of the working surface below. Form panels
are then
affixed to the beams. Anchoring of the inboard end of the beams required to
prohibit tipping
of the beams requires use of an attachment to the existing slab that works in
tension. Such
an attachment is difficult to economically and reliably establish.
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The saddle beams used in the applicant's slab depth varying system are
designed to rotate
about one end, in one or two planes, into the forming position and similarly
rotate in reverse
when stripping. This feature readily accommodates the installation of saddle
beams at slab
edges through the use of raking (not vertical) shore assemblies. The saddle
beam that is to
be installed in a cantilevered position is hung from a shoring post, usually
positioned two or
more feet back from the edge of a completed slab or working surface. The
raking shore, in
a generally horizontal position, is then attached to the lower edge of the
hanging saddle
beam with a connection that permits rotation. Workmen can then rotate the
saddle beam
into the pouring position by simply pushing outward on the raking shore
assembly without
leaving the safety of the slab they are working from. The raking shore
assembly is then
attached to a pre-installed shoe. Safety barriers can be affixed to the raking
shore assembly
to protect against accidents.
Accordingly, there is described herein embodiments of the applicant's slab
depth varying
system.
Brief Description of the Drawings
Embodiments of the applicant's slab depth varying system will now be described
by way of
example and with reference to the accompanying drawings in which:
FIG. 1 shows a perspective view of one embodiment of a slab depth varying
systems.
FIG. 2 shows a plan view of a coupling means of the slab depth varying system
of FIG. 1.
FIG. 3 shows a side view of the coupling means of FIG. 2.
FIG. 4 shows a plan view of another coupling means of the slab depth varying
system.
FIG. 5 shows a side view of the coupling means of FIG. 4.
FIG. 6 shows a side view of a saddle beam of the slab depth varying system of
FIG. 1.
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FIG. 7 shows a front view of the saddle beam of FIG. 6.
FIG. 8 shows a side view of a support pin of the slab depth varying system of
FIG. 1.
FIG. 9 shows a schematical view of one embodiment of a slab depth varying
systems.
FIG. 10 shows a perspective view of a mounting shoe of the slab depth varying
system of
FIG. 9.
FIG. 11 shows a perspective view of a safety barrier adaptor of the slab depth
varying
system of FIG. 9.
FIG. 12 shows a plan view of another coupling means of the slab depth varying
system.
FIG. 13 shows a side view of the coupling means of FIG. 12.
FIG. 14 shows a perspective view of the coupling means of FIG. 12 coupled to
the saddle
beam of FIG. 6.
Detailed Description
Existing concrete form systems generally comprise a primary form at a first
elevation
suspended by shoring posts. The shoring posts generally comprise vertically
spaced
diametric openings through at least a portion of the posts. These openings are
principally
utilized when adjusting the height of the shoring posts.
The applicant's slab depth varying system for an existing concrete form system
is herein
described in detail. As used herein, slab depth varying system is used to vary
the depth of a
slab being poured. As would be appreciated by those skilled in the art, the
slab depth can
be varied, for example, to accommodate concrete beams or to provide a lowered
edge for
the slab being poured. The slab depth varying system generally comprises
saddle beams
for supporting a secondary flat form at a second elevation and coupling means
for coupling
the saddle beams to the shoring posts of an existing concrete form system.
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FIG. 1 shows an embodiment of the applicant's slab depth varying system 200
installed on
an existing concrete form system 100. Coupling means 300 generally comprise
post
connecting means 310 for connecting the coupling means to a shoring post 110
and beam
connecting means 350 extending from the post connecting means 310 for
connecting the
coupling means to a saddle beam 400.
The post connection means 310 of coupling means 300 are lockable to the
shoring post 110
in different orientations. The orientation of the post connection means 310
determines the
vertical position of the beam connecting 350 means relative to the shoring
post.
With reference to FIGS. 2 and 3, the post connecting means 310 can comprise,
for example,
two clamp portions 312 that are hingedly coupled to each other at their
adjacent ends by two
fastening elements 314. It would be appreciated by one skilled in the art that
the clamp
portions 312 can be conveniently assembled around the shoring post 110 by, for
example,
hingedly coupling the two clamp portions 312 at one end with one of fastening
elements
314, positioning the clamp portions adjacent one side of the shoring post 110,
rotating the
clamp portions around the fastening element until the uncoupled ends are
adjacent on the
opposite side of the shoring post, and then coupling the uncoupled ends with
the other
fastening element. The fastening elements 314 can be, for example, pins with
apertures for
receiving cotter pins.
Other means for clamping would, however, be known to those skilled in the art.
For
example, rather that two clamp portions 312, a single collar could be used
which would be
slid over the shoring post 110 prior to the attachment of a drop head. Other
coupling means
could include two pins rather than a hinge. The above are merely examples and
those
skilled in the art would appreciate that other coupling means are possible.
The clamp portions 312 have vertically spaced openings 316 therethrough.
Preferably, the
vertical spacing of the clamp portion openings 316 is less than the vertical
spacing of the
post openings 112 of shoring post 110. When the clamp portions 312 are coupled
to each
other, the vertically spaced openings 316 are paired in diametric opposition;
there is, for
example, a lower pair of openings and upper opening pair openings.
The clamp portions 312 are locked in position around the shoring post 110 by a
locking pin
320 inserted through one pair of the clamp portion openings 316 and one of the
post
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openings 112. The locking pin 320 can be, for example, a pin with an aperture
for receiving
a cotter pin. The clamp portions 312 are round to accommodate a round shoring
post.
Alternatively, the clamp portions can be square or rectangular if the shoring
post is square
or rectangular.
At least one of the clamp portions 312 is provided with beam connecting means
350. The
beam connecting means 350 can comprise, for example, U-shaped supports 352
extending
from the lower half or upper half of the clamp portions' outer surface. With
reference to
FIG. 3, the U-shaped supports 352 extend from the lower half of the clamp
portions' outer
surface.
It would be appreciated by one skilled in the art that the clamp portions 312
can be locked to
the shoring post 110 at a particular post opening 112 in different
orientations. For example,
the locking pin 320 can be inserted through the lower pair or the upper pair
of vertically
spaced openings 316. The clamp portions 312 can also be inverted and then
locked to the
shoring post. The different orientations of the clamp portions 312 can be
utilized to adjust
the vertical position of the U-shaped supports 352.
The U-shaped supports 352 can be fixedly attached to the clamp portions 312 as
shown in
FIGS. 2 and 3. As will be appreciated by those skilled in the art, the
orientation of the
saddle beams 400 is determined by the orientation of vertically spaced
openings 316 and
post openings 112. In general, the assembly of a shoring post system in which
panels are
affixed to a drop head will determine the orientation of post openings 112. In
addition or
alternatively, the U-shaped supports can be attached to the clamp portions'
outer surface by
vertical hinge means (not shown). The vertical hinge means allow the U-shaped
supports to
rotate in a generally horizontal plane around the hinge means. This rotation
in a horizontal
plane facilitates the attachment of saddle beams 400 to the U-shaped supports
352 and
allows for flexibility in the orientation of installed saddle beams relative
to the shoring posts
110.
With reference to FIGS. 4 and 5, the U-shaped supports 352 can alternatively
be attached to
the clamp portions' outer surface by a vertical fine adjustment means
comprising, for
example, vertical screws 370. The vertical screws allow for fine adjustment of
the vertical
position of U-shaped supports 352 relative to the clamp portions 312 and allow
the U-
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shaped supports to rotate in a generally horizontal plane around the vertical
screws 370.
When the clamp portions 312 are being attached to a shoring post 110, the
height of the U-
shaped supports can be roughly adjusted by selecting the appropriate post
opening 112 and
clamp portion 312 orientation. The vertical screws 370 can then be used for
fine height
adjustment until the U-shaped supports are at a desired height.
Another aspect of applicant's slab depth varying system 200 is the ability of
the saddle
beam 400 to move from a first pouring position, wherein the saddle beam
supports a
secondary cement form in a position for receiving poured concrete, to a second
stripping
position lower than the pouring position. The U-shaped supports 352 are
adapted to
support the saddle beam in the pouring position and the stripping position as
follows.
With reference to FIGS. 6 and 7, the saddle beam 400 generally comprises at
least one
beam opening at one end of the beam, for example, beam openings 402. The
saddle beam
also comprises an L-shaped retaining flange 404 extending from the top of the
saddle beam.
The retaining flange is generally parallel to the axis of the beam openings
402. It would be
appreciated by one skilled in the art that the saddle beam could be of various
lengths.
In one embodiment, saddle beam 400 could be of various predetermined lengths
based on
the panel size of the panels being utilized for the main slab. Specifically,
in a system in
which beams are included in a slab, the main portion of the slab would be
supported by
panels on drop heads. If the panel size was, for example, 4 feet by 8 feet,
support posts
would necessarily be placed every 4 feet in one direction and every 8 feet in
the other
direction. In order to minimize the number of saddle beam 400 sizes required,
the saddle
beams could be affixed between adjacent support posts and thus, principally,
be either 4
feet or 8 feet in length. In operation the support posts and panels would be
erected on
either side of the concrete beam, and the post connecting means 310 would be
installed on
the shoring posts adjacent the concrete beam at a desired height. The saddle
beam 400
would be extended between the adjacent post connecting means 310 and a
platform and
beam sides could then be constructed utilizing a saddle beam 400 on either
side of the
concrete beam.
With reference to FIGS. 2 and 3, the U-shaped supports 352 comprise a base 354
and two
sides 356. The sides of the U-shaped supports have an opening 358
therethrough. The
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gap between the two sides 356 of the U-shaped supports is sized to receive one
end of the
saddle beam 400.
When one end of the saddle beam 400 is received between the sides 356 of U-
shaped
support 352, the saddle beam can be supported in the pouring position and the
stripping
position. A horizontal support pin 380 removably inserted through the openings
358 in the
sides 356 and beam opening 402 can support the saddle beam in the pouring
position.
Support pin 380 is, for example, a tampered support pin with an aperture 382
for receiving a
cotter pin, best shown in FIG. 8. An upper surface 360 of sides 356 can
support the
retaining flange 404 of the saddle beam and thereby support the saddle beam in
the
stripping position. When the saddle beam 400 is in the pouring position and
the support pin
380 is removed, by, for example, hammer strokes, the saddle beam falls until
the retaining
flange 404 catches the upper surface 360 of sides of U-shaped support 352.
Thus, the
saddle beam 400 transitions from the pouring position to the lower stripping
position.
In another aspect, the support pin 380 can rotatably support the saddle beam
in the pouring
position and the saddle beam 400 comprises at least one diagonal corner cutout
at an end
of the saddle beam, for example, cutouts 406. The cutouts 406 allow the saddle
beam to
rotate a distance around the support pin, preferably at least 45 degrees. This
rotation in a
vertical plane allows saddle beam 400 to hang-down after attachment to
coupling means
300 of the slab depth varying system 200.
With reference to FIG. 9, another aspect of applicant's slab depth varying
system 200 is a
raking shore assembly 500 for erecting over an open space one end of saddle
beam 400
that is locked at the opposite end to shoring post 110. This assembly could be
utilized, for
example, when the slab thickness is increased at the edge of the slab. The
raking shore
assembly 500 generally comprises a telescopic member 510 with a pivotal
connection 520
and a mounting shoe 530. The mounting shoe 530, as shown in FIG. 10, is pre-
installed to
a lower working surface 120 before erection starts. The telescopic member 510
is extended
to a length suitable for positioning the saddle beam 400 horizontally;
portions 512 and 514
are telescopic, with portion 514 sliding into portion 512. Portions 512 and
514 are pinned
together at approximately the required length before erection commences. The
telescopic
member can also include a fine adjustment means (not shown), for example, an
adjusting
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screw, for adjusting the length of the telescopic member. The telescopic
member 510
includes the pivotal connection 520 at one end.
Erection of the saddle beam 400 starts with the hanging of the saddle beam on
previously
installed shoring post 110. The pivotal connection 520 is then attached via
pins 522, as
shown in FIGS. 1 and 9, to the end of the saddle beam opposite the shoring
post 110. The
telescopic member 510 is then used to rotate the saddle beam into position and
is thereafter
affixed to an affixing means 532 of mounting shoe 530. The rotation of the
saddle beam can
be in a vertical plane around the support pin 380. The rotation of the saddle
beam can
additionally be in a horizontal plane around, for example, vertical screw 370
shown in FIG.
5, so that at no time do workmen have to work beyond the edge of the working
surface 120.
The telescopic member 510 can be affixed to the affixing means 532 with, for
example, a pin
affixed through concentric holes in the telescoping member and the affixing
means. FIG. 9
shows the completed installation.
In a further embodiment, rather than attach the post coupling means 310 to
shoring post 110
immediately, a support pin could be placed underneath post coupling means 310,
holding
the post coupling means 310 in roughing its final height while allowing post
coupling means
310 to freely rotate about shoring post 110. Saddle beam 400 could then be
connected to
post coupling means 310 as described above. The connection in this case would
be done
over the existing slab. The saddle beam could then be rotated into place by
moving the
saddle beam in the vertical plain around support pin 380 and in the horizontal
plain by
rotating around shoring post 110. When saddle beam 400 is in its correct
orientation,
locking pin 320 can then be inserted through vertically spaced openings 316 to
connect post
clamping means 310 to shoring post 110. In this way, a workman never needs to
extend
beyond the edge of the existing slab.
It is also important when dealing with open spaces to erect safety barriers in
order to
prevent accidents. Accordingly, the pivotal connection 520 can include an
affixing means
526 for affixing a first safety barrier to the pivotal connection. A safety
barrier 528 can be
affixed to the affixing means 526 with, for example, a pin, the safety barrier
extending above
the saddle beam 400, generally perpendicular to the saddle beam.
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The mounting shoe 530 can also include a plurality of affixing means 534 for
affixing a
second safety barrier to the mounting shoe. A safety barrier 536 can be
affixed to the
affixing means 534, the safety barrier extending above the lower working
surface 120,
generally perpendicular to the lower working surface.
With reference to FIG. 11, the raking shore assembly 500 can also include a
safety barrier
adaptor 540 as a discrete component. The safety barrier adaptor 540 comprises
two
affixing means: first affixing means 542 for affixing the safety barrier
adaptor to the saddle
beam 400 and a plurality of second affixing means 544 for affixing a safety
barrier to the
safety barrier adaptor 540. The safety barrier adaptor is designed to be
affixed to the
saddle beam 400 concurrently with the pivotal connection 520.
With reference to FIGS. 12 to 14, another aspect of the applicant's slab depth
varying
system 200 is a securing means for preventing horizontal movement of the
saddle beam
400, generally along its axis away from the shoring post 100, that can
accommodate the
vertical transition of the saddle beam from the pouring position to the
stripping position. The
securing means can comprise, for example, aligned vertical slots 390 through
the sides 356
of one of the U-shaped supports 352 and a transition pin 392.
With reference to FIG. 14, the transition pin 392 can be removably inserted
through the slots
390 and a secondary beam opening 408 (best seen in FIG. 6) in saddle beam 400.
The
transition pin 392 can be secured in the inserted position by, for example,
one or more cotter
pins. The slots 390 are sized to prevent horizontal moment of the transition
pin 392
perpendicular to the pin's axis and, at the same time, allow the transition
pin to move
vertically between the upper and lower ends of the slots.
As will be appreciated by those skilled in the art, the transition pin 392
inserted through the
slots 390 and the secondary beam opening 408 of saddle beam 400 prevents
horizontal
movement of the saddle beam along its axis while allowing vertical movement of
the saddle
beam corresponding to the transition pin's own range of vertical movement. The
length of
the slots 390 is sized to accommodate the vertical transition of the saddle
beam from the
pouring position to the lower stripping position when the support pin 380 is
removed.
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The securing means are of particular utility when used in conjunction with the
raking shore
assembly 500. With reference to FIG. 9, once the support pin 380 has been
removed for
moving the saddle beam 400 from the pouring position to the stripping
position, the saddle
beam 400 and the raking shore assembly 500 are no longer fixed to the shoring
post 100.
The raking shore assembly 500 may then be free to fall away and down from the
working
surface 120, pulling the saddle beam 400 with it. This uncontrolled movement
could pose a
threat to worker and bystander safety. As will be appreciated by those skilled
in the art, the
described uncontrolled movement would be prevented by the securing means. The
transition pin 392 of the securing means would allow the saddle beam 400 to
move vertically
to the stripping position while maintaining the horizontal position of the
saddle beam on the
U-shaped supports 352. Accordingly, the raking shore assembly 500, connected
to the
saddle beam via pins 522, would also be maintained in its erect position.
All of the above features provide an illustration of preferred embodiments of
the applicant's
slab depth varying system, but are not intended to limit the scope of the
invention, which is
fully described in the claims below.
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