US20240068183A1

US20240068183A1 - Overhang support system and associated devices and methods

Info

Publication number: US20240068183A1
Application number: US18/454,637
Authority: US
Inventors: Cliff Plymesser; Anthony Houge; Daniel M. Reus
Original assignee: Wilian Holding Co
Current assignee: Wilian Holding Co
Priority date: 2022-08-23
Filing date: 2023-08-23
Publication date: 2024-02-29

Abstract

A web shoe comprising a main body and a hinged flap attached to the main body via a bolt. The hinged flap rotates about the bolt relative to the main body. In the closed position the main body and hinged flap are configured to secure a pin within an opening defined by the main body and hinged flap.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims the benefit under 35 U.S.C. § 119(e) to U.S. Provisional Application 63/400,105, filed Aug. 23, 2022, and entitled Web Shoe for Bridge Overhang and Associated Systems and Methods, which is hereby incorporated herein by reference in its entirety for all purposes.

TECHNICAL FIELD

The disclosure relates to concrete forming and particularly to devices, systems, and methods for constructing poured overhangs.

BACKGROUND

As would be appreciated, when concrete bridge decks are poured, part of the deck overhangs the outside beam. The wet concrete must be supported by temporary formwork. This temporary formwork is typically supported by brackets bolted to the top flange of the bridge girder. Once the concrete has gained enough strength, the formwork and brackets are removed and can then reused on a different section of the bridge or on another project.
In various prior known cases, these brackets have been supported through the flange of the outside beam. In some cases, the bracket is bolted to the web of the beam. As would be appreciated, these prior known brackets must be installed and removed individually which is very labor intensive and can be unsafe requiring workers to be below the brackets to install and remove the brackets at each section.
There is a need in the art for improved and more safe systems for pouring and supporting bridge decks/overhangs.

BRIEF SUMMARY

Disclosed herein are implementations of a web shoe for supporting a series of brackets which in turn support formwork for use on bridges or other overhanging structures. The various implementations described herein allow for the use of the EFCO® Heavy Duty Bridge Overhang Bracket (HDBOB), or similar structure, with a shoe and horizontal and vertical adjustment mechanisms.
In construction safety is key, as such, the various implementations described herein include a system that may be fully implemented without the need for a person or persons to stand beneath the HDBOB or any other component of the system while it is suspended from a crane.
In Example 1, a formwork support system comprising a web shoe comprising a main body and a hinged flap rotatably attached to the main body, wherein the hinged flap rotates relative to the main body and wherein in a closed position the main body and hinged flap form an opening.
Example 2 relates to the formwork support system of claim 1, wherein the hinged flap is rotatably attached to the main body by means of an axis.
Example 3 relates to the formwork support system of any of claims 1-2, wherein the axis is a bolt.
Example 4 relates to the formwork support system of any of claims 1-3, further comprising one or more holes in a rear portion of the main body, wherein the one or more holes are placed to allow the web shoe to be secured to a surface.
Example 5 relates to the formwork support system of any of claims 1-4, further comprising one or more removable vertical adjusters comprising a first elongate portion having a first end and a second end, a second elongate portion having a first end and a second end, an elongate projection extending transversely through the first end of the first elongate portion, an adjustment bolt extending vertically through the second end of the first elongate portion and the second end of the second elongate portion, and an axis point between the first end and second end of the second elongate portion, wherein the first elongate portion is rotatable relative to the second elongate portion at the axis point by actuation of the adjustment bolt.
Example 6 relates to the formwork support system of any of claims 1-5, wherein the elongate projection is configured to be inserted into the opening.
Example 7 relates to the formwork support system of any of claims 1-6, further comprising one or more removable horizontal adjusters comprising one or more planks and a thrust bolt assembly, comprising a thrust bracket attached to the plank and a thrust bolt inserted through the thrust bracket, wherein actuation of the thrust bolt urges the one or more planks horizontally.
Example 8 relates to the formwork support system of any of claims 1-7, wherein the one or more planks are connected to each other and form a deck.
Example 9 relates to the formwork support system of any of claims 1-8, wherein the thrust bolt assembly is configured to abut a section of formwork against a bridge girder.
In Example 10, a formwork support system comprising one or more shoes comprising a main body and a hinged flap rotatably attached to the main body, wherein the main body and the hinged flap define an opening when the hinged flap is in a closed position. The formwork support system also comprising one or more removable vertical adjusters comprising a first elongate portion having a first end and a second end, a second elongate portion having a first end and a second end, an elongate projection extending transversely through the first end of the first elongate portion, wherein the elongate projection is configured to sit within the opening of the shoe, an adjustment bolt extending vertically through the second end of the first elongate portion and the second end of the second elongate portion, and an axis point between the first end and second end of the second elongate portion, wherein the first elongate portion is rotatable relative to the second elongate portion at the axis point by actuation of the adjustment bolt.
Example 11 relates to the formwork support system of claim 10, wherein the hinged flap is rotatably attached to the main body by means of an axis.
Example 12 relates to the formwork support system of any of claims 10-11, further comprising a horizontal adjustment assembly comprising one or more planks, a thrust bracket attached to one or the one or more planks, and a thrust bolt inserted through the thrust bracket, wherein actuation of the thrust bolt urges the thrust bracket and one or more plank horizontally.
Example 13 relates to the formwork support system of any of claims 10-12, further comprising at least one opening in a rear portion of the main body for insertion of a bolt to attach one of the one or more shoes to a surface.
In Example 14 method of forming a bridge overhang comprising securing a web shoe to a surface via a bolt, assembling a gang of formwork brackets including a surface, a horizontal adjuster, and a vertical adjuster, where the horizontal adjuster is attached to the vertical adjuster and the surface is supported by the horizontal adjuster, and inserting an elongate projection of a vertical adjuster to the web shoe such that the gang of formwork is supported by the web shoe.
Example 15 relates to the method of claim 14, wherein the vertical adjuster comprises a first elongate portion having a first end and a second end, a second elongate portion having a first end and a second end, an adjustment bolt extending vertically through the second end of the first elongate portion and the second end of the second elongate portion, and an axis point between the first end and second end of the second elongate portion, wherein the elongate projection extends transversely through the first end of the first elongate portion.
Example 16 relates to the method of any of claims 14-15, further comprising actuating the adjustment bolt on the vertical adjuster.
Example 17 relates to the method of any of claims 14-16, further comprising urging the surface horizontally via the horizontal adjuster, the horizontal adjuster comprising one or more planks and a thrust bolt assembly, comprising a thrust bracket attached to the plank and a thrust bolt inserted through the thrust bracket, wherein actuation of the thrust bolt urges the one or more planks horizontally.
Example 18 relates to the method of any of claims 14-17, wherein the surface is a bridge girder.
Example 19 relates to the method of any of claims 14-18, further comprising: setting rebar and pouring concrete on the surface.
Example 20 relates to the method of any of claims 14-19, further comprising attaching a rail to the gang of formwork brackets.
While multiple embodiments are disclosed, still other embodiments of the disclosure will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the disclosure is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the disclosure. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a shoe, according to one implementation.

FIG. 1B is a side view of a shoe, according to one implementation.

FIG. 1C is a rear view of a shoe, according to one implementation.

FIG. 2A is a perspective view of the main body of the shoe, according to one implementation.

FIG. 2B is a top view of the main body of the shoe, according to one implementation.

FIG. 2C is a side view of the main body of the shoe, according to one implementation.

FIG. 2D is a top view of the rear portion of the main body of the shoe, according to one implementation.

FIG. 2E is a front view of the rear portion of the main body interfacing with a bolt, according to one implementation.

FIG. 2F is a perspective view of the rear portion of the main body, according to one implementation.

FIG. 3A is a rear view of main body of the shoe, according to one implementation.

FIG. 3B is a front view of the rear portion of the main body, according to one implementation.

FIG. 3C is a side view of a side of the main body, according to one implementation.

FIG. 3D is a top view of one side of the main body, according to one implementation.

FIG. 3E is a top view of one side of the main body, according to one implementation.

FIG. 4A is a front view of the flap, according to one implementation.

FIG. 4B is a flat view of the flap, according to one implementation.

FIG. 5A is a side view of a shoe, according to one implementation.

FIG. 5B is a top view of the flap, according to one implementation.

FIG. 6A is a perspective view of a vertical adjuster, according to one implementation.

FIG. 6B is a top view of a vertical adjuster, according to one implementation.

FIG. 6C is a side view of a vertical adjuster, according to one implementation.

FIG. 6D is a close up view of an adjustment bolt interfacing with the vertical adjuster, according to one implementation.

FIG. 7A is a perspective view of the second elongate portion of the vertical adjuster, according to one implementation.

FIG. 7B is a top view of the second elongate portion of the vertical adjuster, according to one implementation.

FIG. 7C is a side view of the second elongate portion of the vertical adjuster, according to one implementation.

FIG. 7D is a rear view of the second elongate portion of the vertical adjuster, according to one implementation.

FIG. 8A is a perspective view of the first elongate portion of the vertical adjuster, according to one implementation.

FIG. 8B is a top view of the first elongate portion of the vertical adjuster, according to one implementation.

FIG. 8C is a side view of the first elongate portion of the vertical adjuster, according to one implementation.

FIG. 9A is a perspective view of the adjustment bolt of the vertical adjuster, according to one implementation.

FIG. 9B is a side view of the adjustment bolt of the vertical adjuster, according to one implementation.

FIG. 9C is a top view of the adjustment bolt of the vertical adjuster, according to one implementation.

FIG. 10A is a side view of the second elongate portion of the vertical adjuster, according to one implementation.

FIG. 10B is a side cutaway view of the second elongate portion of the vertical adjuster, according to one implementation.

FIG. 10C is a top view of the second elongate portion of the vertical adjuster, according to one implementation.

FIG. 11A is a perspective view of the first elongate portion of the vertical adjuster, according to one implementation.

FIG. 11B is a side view of the first elongate portion of the vertical adjuster, according to one implementation.

FIG. 11C is a top view of the first elongate portion of the vertical adjuster, according to one implementation.

FIG. 12 is a perspective view of the vertical adjuster in communication with the shoe on a bridge girder, according to one implementation.

FIG. 13 is a perspective view of the vertical adjuster in communication with the shoe on a bridge girder, according to one implementation.

FIG. 14A is a perspective view of a horizontal adjuster, according to one implementation.

FIG. 14B is a top view of a horizontal adjuster, according to one implementation.

FIG. 14C is a rear view of a horizontal adjuster, according to one implementation.

FIG. 15A is a perspective view of a horizontal adjuster plank, according to one implementation.

FIG. 15B is a top view of a horizontal adjuster plank, according to one implementation.

FIG. 15C is a side view of a horizontal adjuster plank, according to one implementation.

FIG. 15D is a rear view of a horizontal adjuster plank, according to one implementation.

FIG. 16A is a perspective view of a thrust bolt assembly for the horizontal adjuster, according to one implementation.

FIG. 16B is a side view of a thrust bolt assembly for the horizontal adjuster, according to one implementation.

FIG. 16C is a top view of a thrust bolt assembly for the horizontal adjuster, according to one implementation.

FIG. 17A is perspective view of the thrust bracket, according to one implementation.

FIG. 17B is a perspective view of a thrust bolt for the horizontal adjuster, according to one implementation.

FIG. 17C is a side view of the thrust bracket, according to one implementation.

FIG. 17D is a rear view of the thrust bracket, according to one implementation.

FIG. 17E is a side view of a thrust bolt for the horizontal adjuster, according to one implementation.

FIG. 18A is a top view of the horizontal adjuster plank, according to one implementation.

FIG. 18B is a side view of the horizontal adjuster plank, according to one implementation.

FIG. 18C is a front view of the horizontal adjuster plank, according to one implementation.

FIG. 19 is a perspective view of a gang attached to a vertical adjuster in turn attached to a shoe on a bridge girder, according to one implementation.

FIG. 20 is a perspective view of the horizontal adjuster on a gang, according to one implementation.

FIG. 21A shows a shoe being attached to a bridge girder, according to one implementation.

FIG. 21B shows a shoe installed on a bridge girder, according to one implementation.

FIG. 21C shows attachment of a c-caddy to a gang of brackets, according to one implementation.

FIG. 22A shows attachment of the vertical adjuster on the gang of bracket to the shoe, according to one implementation.

FIG. 22B shows attachment of the vertical adjuster on the gang of bracket to the shoe, according to one implementation.

FIG. 22C shows attachment of the vertical adjuster on the gang of bracket to the shoe, according to one implementation.

FIG. 22D shows attachment of the vertical adjuster on the gang of bracket to the shoe, according to one implementation.

FIG. 23 shows a worker being supported by the gang of brackets after installation, according to one implementation.

FIG. 24 shows the c-caddy being removed by a crane, according to one implementation.

FIG. 25A is a schematic view of the gang of brackets being adjusted by the vertical adjuster, according to one implementation.

FIG. 25B is a schematic view of the gang of brackets being adjusted by the vertical adjuster, according to one implementation.

FIG. 25C is a schematic view of the gang of brackets being adjusted by the vertical adjuster, according to one implementation.

FIG. 25D is a schematic view of the gang of brackets being adjusted by the horizontal adjuster, according to one implementation.

FIG. 26 is a schematic view of rebar installation and pouring of concrete on the gang of brackets, according to one implementation.

FIG. 27A is a schematic depiction of loosening the bolt securing the shoe to the bridge girder, according to one implementation.

FIG. 27B is a schematic depiction of re-attaching a c-caddy to the gang of brackets, according to one implementation.

FIG. 27C is a schematic depiction of removing the bolt securing the shoe to the bridge girder, according to one implementation.

FIG. 27D is a schematic depiction of removing the shoe from the vertical adjuster, according to one implementation.

FIG. 28 is a perspective view of a gang of brackets, according to one implementation.

FIG. 29 is a perspective view of a c-caddy, according to one implementation.

FIG. 30 is a schematic depiction of a top of the system with horizontal adjusters, according to one implementation.

FIG. 31 is a schematic depiction of a side of the system, according to one implementation.

FIG. 32 is a schematic depiction of the system installed on a bridge and in use, according to one implementation.

FIG. 33 is a schematic depiction of installation of a rail on the gang, according to one implementation.

FIG. 34A is a perspective view of scaffolding and brackets, according to one implementation.

FIG. 34B is a perspective view of an overhang bracket, according to one implementation.

FIG. 34C is a side view of a vertical support leg, according to one implementation.

FIG. 34D is a perspective view of a pipe brace clamp, according to one implementation.

FIG. 34E is a side view of collapsed vertical support leg, according to one implementation.

FIG. 34F is a perspective view of the bottom of a overhang bracket, according to one implementation.

FIG. 34G shows side and top views of beams used in the overhang bracket, according to one implementation.

FIG. 34H shows a close-up view of the pipe handrail clamp, according to one implementation.

DETAILED DESCRIPTION

Provided for herein is a shoe and bracket assembly for the installation of a ganged bridge overhang formwork assembly onto a wall/support beam/flange. The shoe and bracket assembly will be discussed in further detail below.
As noted above, prior known techniques for forming a bridge overhang are labor and time intensive. The shoe described herein allows a contractor to install a shoe onto the web of a beam, then install a series (also referred to herein as a “gang”) of brackets with a crane. After concrete hardening the series of brackets can be removed with a crane, as well. This design allows the gang to be installed and removed with no personnel located underneath the gang while it is supported by the crane making for safer installation and removal, as well as increasing productivity by increasing the ease and speed of installation and removal.
The various implementations may also incorporate vertical and horizontal adjustments which are accessible from the top of the gang. By assessing the adjustment mechanisms form the top of the gang, the various implementations, provides better and safer access to the adjustment mechanisms and increases productivity, by increasing the ease and speed, of fine tuning the final location of the gang.
Turning to the figures in more detail, FIGS. 1A-5B show the shoe 10 and components thereof from various views. The shoe 10 includes a main body 12 and hinged flap 14. The hinged flap 14 is configured to pivot about an axis 16 relative to the main body 12. In various implementations the axis 16 is defined by a freely rotating bolt 16.
In various implementations, when in the closed position the main body 12 and hinged flap 14 define an opening 22 for securement of a bracket assembly and/or vertical adjuster, as will be discussed further below. When in the open position the flap 14 is rotated to create entrance to the opening 22, where a pin or other similar component can be inserted through the entrance into the opening 22. After insertion the flap 14 may also, under its own force, rotate about the axis/bolt 16 and secure the pin in place within the opening.
In various implementations, the main body 12 includes a back/rear portion 18 configured to abut an attachment surface, such as the web of a beam, when installed. In these and other implementations, the shoe 10 can be affixed to a surface via a bolt 21 inserted through an opening 20 in the rear portion 18 of the main body 12 (shown for example in FIG. 2E). In various implementations, the bolt 21 is secured through the opening 20 with a coil nut. As would be understood a coil nut, or similar device, is used such that when removing the shoe 10, as described below, the bolt 21 can be rotated without also rotating the nut.
FIGS. 5A and 5B show an alternative implementation of the shoe 10. In these and other implementations, the hinged flap 14 is configured to be beyond parallel when closed. That is the hinged flap 14 is angled toward the center of the shoe 10 when in the closed position. As can be seen in FIG. 5B, the angle of the flap 14 is increased to facilitate closing of the flap 14 past parallel.
Continuing with FIGS. 1A-5B, in various implementations, the flap 14 includes a hook 15 for gripping the pin 32 and partially defining the opening 20. In the length and angle of the hook 15 may vary between implementations, compare FIG. 1B and FIG. 5A. The hook 15 is configured to create a wedge to keep the flap 14 closed despite wear.
Turning to FIGS. 6A-11D, in various implementations, the web shoe system 100 further includes a vertical adjuster 30 (also referred to herein as a link beam 30). In various implementations the vertical adjuster 30 is configured to attach a gang of brackets to the web shoe 10. The vertical adjuster 30 also provides for adjustment of the gang of brackets vertically, such that the brackets are at the correct/desired angle relative to the bridge/overhang/installation point.
In various implementations, the vertical adjuster 30 includes an elongate portion 32 having an elongate projection 34 at one end. In various implementations, the elongate projection 34 is a pin 34, a latch pin 34, a bolt 34, or other similar item, as would be appreciated by those of skill in the art. The elongate projection 34 is configured to fit within the opening 22 of the shoe 10. In various implementation, the elongate projection 34 may be inserted through and opening 33 in the elongate portion 32 (as shown in FIG. 11A) or
The vertical adjuster 30 further includes a second elongate portion 36 disposed above the elongate portion 32 and configured to pivot relative to the first elongate portion 32 via an axis point 38, such as a bolt 38. In various implementations, the axis point 38 is between the first and second end of the first elongate portion 32, and optionally at a substantially midway point of the first elongate portion 32.
In certain implementations, an adjustment bolt 40 extends through an opening 41B in the first elongate portion 32 at its second end and an opening 41A in the second elongate portion 36 at its second end. In these and other implementations, the adjustment bolt 40 includes a knob 42 located on the second elongate portion 36. The vertical adjuster 30 is configured to articulate the second elongate portion 36 relative to the first elongate portion 32 when the adjustment bolt 40 is actuated. For example as the adjustment bolt 40 is rotated clockwise the second end of the second elongate portion 36 may be raised (away from the first elongate portion 32), and vice versa as the adjustment bolt 40 is rotated counter-clockwise the second end of the second elongate portion 36 may be lowered (closer to the first elongate portion 32). As would be appreciated, as the second end of the second elongate portion 36 is actuated, the second elongate portion 36 rotates about the axis 38 defined in the first elongate portion 32.
FIGS. 12 and 13 show the vertical adjuster 30 inserted into a shoe 10 installed on a beam 2. As can be seen, the elongate projection 34 on the first elongate portion 32 fits within the opening 22 of the shoe 10. In these implementations, the hinged flap 14 secures the vertical adjuster 30 within the opening 22 of the shoe 10.
Turning now to FIGS. 14A-20 , one or more horizontal adjusters 50 (also referred to herein as a slide frame 50) configured to be attached to the vertical adjuster 30 or otherwise situated on the brackets disposed on the vertical adjuster 30, as will be shown further herein. In these implementations, the horizontal adjusters 50 extend from the vertical adjuster 30 to create a platform for supporting concrete forms. In various implementations, the horizontal adjuster 50 includes a horizontal thrust assembly 52 for horizontally adjusting the placement of the horizontal adjuster 50 relative to the bridge or other structure such that there is no gap between the formwork and the bridge when in use, as would be understood.
In various implementations, the horizontal adjuster 50 includes one or more planks 54 and a horizontal thrust assembly 52. The horizontal thrust assembly 52 includes a thrust bracket 56, a thrust bolt 58, and thrust knob 60, wherein actuation of the thrust knob 60 cause the thrust bolt 58 to turn, thereby causing movement of the thrust bracket 56 and horizontal movement of the planks 54. That is, the thrust bracket 56 is affixed to one or more planks 54, such that movement of the bracket 56 causes movement of the plank(s) 54. The bracket 56 is moved by actuation/rotation of the thrust bolt 58, optionally via a knob 60, nut, or similar structure.
Optionally multiple planks 54 may be bolted together such that more than one plank 54 may be moved via one horizontal thrust assembly 52.
Turning to FIGS. 21A-27D, in certain implementations, the shoe 10 is configured for use in conjunction with form brackets/scaffolding, including for example existing products, such as EFCO's Heavy Duty Bridge Overhang Bracket (HDBOB) 104, various alternative existing forming products and brackets may be used. FIGS. 21A-27D show an exemplary installation and use of the shoe 10 and gang of brackets 104. The term gang is used herein to refer generally to an assembly of multiple HDBOB frames 104 bolted together by joists 106 (such as EFCO® E-Beams 106) and pipe bracing with a plywood deck 108 as the forming surface for the concrete overhang, or similar configuration as would be appreciated by those of skill in the art.
As an initial step, for use of the system 100 described herein requires installation of a link beam 30 (referred to above as a vertical adjuster 30) and slide frame 50 (referred to above as a horizontal adjuster 50) onto a gang 104.
In a first step, the link beam 30 is a bolt link beam 30 situated in between webs of the top member of the gang 104. As discussed above, the link beam 30 rotates about a pin 38 by turning the vertical threaded rod 40 and is used to raise or lower the gang 104 once installed onto the shoe 10. In certain implementations, there is approximately 6″ of vertical adjustment range which accommodates the camber of the bridge girder as well as the camber of the concrete bridge overhang. The adjustment of the link beam 30 can be made from a plywood deck 108 (accessible through a small hole in the plywood), or from below the gang 104.
In a second step of the initial installation, the slide frame 50 and slide frame thrust bolt 52 are attached onto the top member of the gang 104. As discussed above, the slide frame 50 can be adjusted horizontally by adjusting the thrust bolt assembly 52 on the end of the slide frame 50 to move the joists 106 and plywood 108. This adjustment is required to ensure that the joists 106/plywood 108 of the formwork fits tightly against the top flange of the bridge girder 2 preventing any concrete leakage. The thrust bolt assembly 52 is accessible from either the plywood deck 108 or below the gang 104.
Turning now to the installation of a gang 104 onto bridge girder 2 using the shoe 10. In a first step, the web shoe 10 is bolted onto the web of the bridge girder 2, as shown in FIGS. 21A and 21B, with a bolt 21 and optional coil nut (not shown). The web shoe 10 is designed to support both the vertical and horizontal loads from the dead weight of the gang 104, dead loads, concrete loads, live loads, and screed loads.
In another step, shown in FIG. 21C, the gang is lifted using a C-caddy 102 lifted by a crane, or other mechanism as would be understood by those of skill in the art. In these implementations, the C-Caddy 102 is temporarily secured to the bottom of the gang 104 using chains. Various alternative lifting mechanisms and machinery are possible and would be understood by those of skill in the art.
In a further step, shown in FIGS. 22A-D, once the pins 34 of the link beams 30 are just outside the mouth of the shoe 10, workers can pull the gang 104 into the shoe 10 using tag lines secured to the gang 104. As the gang 104 is pulled into the shoe 10, the pin 34 of the link beam 30 lifts the flap 14 of the shoe 10. Once the pin 34 is fully engaged into the shoe 10, the flap 14 will drop and secure the pin 34 within the opening, as discussed above. As would be understood, the workers can be located either on the plywood deck 108 of a previously installed adjacent gang 104 or located on the ground but not underneath the gang 104. When using the shoe 10, workers are no longer required under the gang 104 while it is suspended from the crane, increasing worksite safety. The gang 104 is now secured to the shoe 10 and therefore the bridge girder 2.
In another step, the crane and c-caddy 102 can be detached. Once the gang 104 is now fully supported by the shoe 10, workers can walk out on the plywood deck 108 to unchain the C-Caddy 102 from the gang 104, shown in FIGS. 23-24 .
In a further step the gang 104 can be raised or lowered to the final elevation by turning the vertical adjustment bolt 40 on the link beam 30 accessed through a small hole in the plywood deck 108, as shown in FIGS. 25A-C, and discussed above.
Another step is depicted in FIG. 25D, in this step, using the horizontal thrust assembly 52 at the back of the slide frame 50, the slide frame 50 and plywood deck 108 can be forced closer to the top flange of the bridge girder 2 until there is no gap.
In an optional step, shown in FIG. 26 , rebar can be installed and a concrete deck poured. Once the concrete has gained sufficient strength to carry its own weight, the formwork and gang 104 can be removed. In various implementations once detached the formwork and gang 104 can be cycled forward to another part on the bridge 2 to be reused. Alternatively, the formwork and gang 104 and be moved into storage or to an alternative worksite
To remove the gang 104, in one step shown in FIG. 27A, the bolt 21 is that secures the shoe 10 to the web of the bridge girder 2 is loosened. This bolt 21 can be accessed from inside of the bridge girder 2, again preventing the need for personnel underneath a suspended load. Even though the bolt 21 is loose, it will still support any live loads on the plywood deck 108 as the concrete loads are no longer applied since the concrete can support its own weight. This step can be completed for all gangs 104 in advance of removing the gang 104 with the crane.
In another step, using the crane or other implement, the C-caddy 102 is brought into position underneath the gang 104 assembly and secured with chains accessed from the plywood deck 108, as shown in FIG. 27B. Next the bolt 21 that secures the shoe 10 can be fully removed, as shown in FIG. 27C. The shoe 10, as described herein, is optionally designed to hang from the link beam 30 pin 34 and cycle with the gang 104, as shown in FIG. 27D. That is, in certain implementations the flap 14 is designed to only open manually, and therefor the shoe 10 will remain attached to the link beam 30 until the flap 14 is lifted and the shoe 10 manually removed.
In other step, the C-caddy and gang assembly is lowered until the formwork 104 is stripped away from the concrete. The entire assembly (including the gang 104, vertical adjuster 30, horizontal adjuster 50, and shoe 10) can be lowered to the ground. In another optional step, the shoe 10 can be manually removed from the link bracket pin 34. As previously noted, the gang 104 can be lifted to the next location on the bridge and the process repeated.
FIGS. 28-22 show another implementation of the bridge overhang system 100 utilizing the shoe 10, vertical adjuster 30, and horizontal adjuster 50 described herein. FIG. 28 depicts a gang 104 or section of brackets 104. FIG. 29 shows one implementation of a C-Caddy 102.
FIG. 30 is a top schematic view of a deck 108 including formwork and the horizontal adjusters 50. FIG. 31 shows a side schematic view of the gang 104. FIG. 32 is a detailed schematic, cross-sectional view of the shoe 10, vertical adjuster 30, horizontal adjuster 50, and gang 104 in use on a bridge 2.
As shown in FIG. 33 , the system 100 may include a rail 112 to span the gang 104 and between adjacent gangs 104 to limit concentrated loads applied to the brackets.
FIGS. 34A-H include various close-up views of components of the system 100.
Although the disclosure has been described with references to various embodiments, persons skilled in the art will recognized that changes may be made in form and detail without departing from the spirit and scope of this disclosure.

Claims

What is claimed is:

1. A formwork support system comprising a web shoe comprising:

(a) a main body; and

(b) a hinged flap rotatably attached to the main body,

wherein the hinged flap rotates relative to the main body and wherein in a closed position the main body and hinged flap form an opening.

2. The formwork support system of claim 1, wherein the hinged flap is rotatably attached to the main body by means of an axis.

3. The formwork support system of claim 2, wherein the axis is a bolt.

4. The formwork support system of claim 1, further comprising one or more holes in a rear portion of the main body, wherein the one or more holes are placed to allow the web shoe to be secured to a surface.

5. The formwork support system of claim 1, further comprising one or more removable vertical adjusters comprising:

(a) a first elongate portion having a first end and a second end;

(b) a second elongate portion having a first end and a second end;

(c) an elongate projection extending transversely through the first end of the first elongate portion;

(d) an adjustment bolt extending vertically through the second end of the first elongate portion and the second end of the second elongate portion; and

(e) an axis point between the first end and second end of the second elongate portion,

wherein the first elongate portion is rotatable relative to the second elongate portion at the axis point by actuation of the adjustment bolt.

6. The formwork support system of claim 5, wherein the elongate projection is configured to be inserted into the opening.

7. The formwork support system of claim 1, further comprising one or more removable horizontal adjusters comprising:

(a) one or more planks; and

(b) a thrust bolt assembly, comprising:

(i) a thrust bracket attached to the plank and

(ii) a thrust bolt inserted through the thrust bracket,

wherein actuation of the thrust bolt urges the one or more planks horizontally.

8. The formwork support system of claim 7, wherein the one or more planks are connected to each other and form a deck.

9. The formwork support system of claim 8, wherein the thrust bolt assembly is configured to abut a section of formwork against a bridge girder.

10. A formwork support system comprising:

(a) one or more shoes comprising:

(i) a main body; and

(ii) a hinged flap rotatably attached to the main body,

wherein the main body and the hinged flap define an opening when the hinged flap is in a closed position; and

(b) one or more removable vertical adjusters comprising:

(i) a first elongate portion having a first end and a second end;

(ii) a second elongate portion having a first end and a second end;

(iii) an elongate projection extending transversely through the first end of the first elongate portion, wherein the elongate projection is configured to sit within the opening of the shoe;

(iv) an adjustment bolt extending vertically through the second end of the first elongate portion and the second end of the second elongate portion; and

(v) an axis point between the first end and second end of the second elongate portion,

11. The formwork support system of claim 10, wherein the hinged flap is rotatably attached to the main body by means of an axis.

12. The formwork support system of claim 10, further comprising a horizontal adjustment assembly comprising:

(a) one or more planks;

(b) a thrust bracket attached to one or the one or more planks; and

(c) a thrust bolt inserted through the thrust bracket,

wherein actuation of the thrust bolt urges the thrust bracket and one or more plank horizontally.

13. The formwork support system of claim 10, further comprising at least one opening in a rear portion of the main body for insertion of a bolt to attach one of the one or more shoes to a surface.

14. A method of forming a bridge overhang comprising:

securing a web shoe to a surface via a bolt;

assembling a gang of formwork brackets including a surface, a horizontal adjuster, and a vertical adjuster, where the horizontal adjuster is attached to the vertical adjuster and the surface is supported by the horizontal adjuster; and

inserting an elongate projection of a vertical adjuster to the web shoe such that the gang of formwork is supported by the web shoe.

15. The method of claim 14, wherein the vertical adjuster comprises:

(i) a first elongate portion having a first end and a second end;

(ii) a second elongate portion having a first end and a second end;

(iii) an adjustment bolt extending vertically through the second end of the first elongate portion and the second end of the second elongate portion; and

(iv) an axis point between the first end and second end of the second elongate portion,

wherein the elongate projection extends transversely through the first end of the first elongate portion.

16. The method of claim 15, further comprising actuating the adjustment bolt on the vertical adjuster.

17. The method of claim 15, further comprising urging the surface horizontally via the horizontal adjuster, the horizontal adjuster comprising:

(a) one or more planks; and

(b) a thrust bolt assembly, comprising:

(i) a thrust bracket attached to the plank and

(ii) a thrust bolt inserted through the thrust bracket,

wherein actuation of the thrust bolt urges the one or more planks horizontally.

18. The method of claim 14, wherein the surface is a bridge girder.

19. The method of claim 14, further comprising: setting rebar and pouring concrete on the surface.

20. The method of claim 14, further comprising attaching a rail to the gang of formwork brackets.