Abstract:
A bridge deck construction form is provided capable of being used in a series of interlocking forms. The system uses an interlocking grid of plastic forms upon which the concrete is poured. The forms have male and female interlocking connectors around their perimeter to allow the forms to lock together end to end and side to side. The top surface of the form is smooth, and a series of hand grip indentations and fork lift fork receiving recess indentations are provided about the vertical perimeter apron to allow for easy handling and manipulation of the forms, whether by hand or by fork-lift, during placement, removal, shipping, storage, transport, or the like.

Description:
RELATED APPLICATIONS 
     The present invention was first described in Disclosure Document No. 468,498, filed on Feb. 7, 2000. There are no previously filed, nor currently any co-pending applications, anywhere in the world. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to concrete decking on bridges and, more particularly, to a lightweight form decking apparatus for extending between the concrete or steel beams of a bridge structure to facilitate pouring concrete decking on the bridge in a safe, quick and efficient manner. 
     2. Description of the Related Art 
     Bridge deck construction and replacement is a never-ending and ongoing process. The forces of crossing traffic coupled with the environment, force repair and/or replacement on a regular basis. If one were to watch this process of bridge deck repair, one would notice the large amount of lumber and plywood used to make forms for the concrete pour. These forms must be joined together using common carpentry techniques which consume a great deal of time. Also, most of the lumber and plywood must be moved into place using manual hand labor. This also takes a good amount of time all of which leads to higher construction costs. At the end of the job, most of the lumber is discarded which results in large waste of wood, forming an environmental impact as well. 
     In the related art, concrete decking is typically poured on bridges by initially positioning concrete or steel beams on pilings or other supports to span the river, stream, highway, rail road track or other obstacle. Cross-members, commonly called “whalers” are adjustably positioned between the concrete beams at spaced intervals by means of U-bolts spanning the concrete or steel beams and plywood decking is nailed or otherwise attached to the whalers or to spacers positioned on the whalers to provide a support or form at a selected level determined by adjustment of the whalers, for the concrete poured on the bridge to define the bridge decking. After the concrete decking is cured, the plywood forms and spacers are commonly laboriously removed at great expense from the bridge decking. The positioning of the typically 4 ft.8 ft. plywood sheets and spacers on the whalers between the concrete or steel beams before pouring of the concrete is also hazardous to the workers, since the workers must traverse the whalers and the beams to both position and fasten the plywood panels in place. This job is both dangerous and time-consuming and results in a considerable delay in completing the highway or road system, of which the bridge is an integral part. 
     Numerous attempts have been made to correct for the foregoing problems. A search of the prior art did not disclose any patents that read directly on the claims of the instant invention; however, the following references were considered related: 
     U.S. Pat. No. 5,483,716 issued in the name of Bumaman; 
     U.S. Pat. No. 5,104,089 issued in the name of Shook et al.; and 
     U.S. Pat. No. 3,311,939 issued in the name of Yamamoto et al. 
     U.S. Pat. No. 5,792,552 issued in the name of Langkamp et al. describes a reusable concrete form panel sheeting. 
     U.S. Pat. No. 5,682,635 issued in the name of Tolliver et al. discloses bridge and road construction and method of removing a worn deck structure. 
     U.S. Pat. No. 5,533,221 issued in the name of Majnaric et al. describes a method and apparatus for bridge construction. 
     U.S. Pat. No. 5,309,691 issued in the name of Tolliver et al. disclose shear connected structural units. 
     U.S. Pat. No. 4,123,031 issued in the name of Hyre describes improvements in concrete roadway slab forming. 
     And, U.S. Pat. No. 4,087,220 issued in the name of Koss discloses an apparatus for building a concrete bridge superstructure. 
     Accordingly, it is an object of this invention to provide a new and improved form decking apparatus for temporarily mounting on conventional, adjustable whalers or supports between the beams of bridges to support the concrete decking. 
     SUMMARY OF THE INVENTION 
     Therefore, it is an object of the invention to indicate a device of the type disclosed above which avoids the disadvantages inherent in the state of the art. 
     In particular, the device is to provide a new and improved form decking that aid in the forming and pouring of concrete for a bridge deck. 
     Briefly described according to the preferred embodiment of the present invention, a series of interlocking forms are provided that aid in the forming and pouring of concrete for a bridge deck. The system uses an interlocking grid of four foot by eight foot plastic forms upon which the concrete is poured. The forms have male and female interlocking tabs around their perimeter to allow the forms to lock together end to end and side to side. The top surface of the form is smooth and a lap joint around part or all of the perimeter&#39;s vertical sides provides for a finished smooth look when the invention is removed. 
     The bottom of the invention is a ribbed design for reinforcing and strength. 
     The invention is generally lighter than the conventional wood plywood system used in bridge deck construction. 
     The use of plastic in the present invention is more durable than the plywood and as such permits reuse many times. 
     The use of bridge deck construction forms of the present disclosure allows for the construction of concrete bridge decks in a manner that is quick, easy and efficient. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which: 
     FIG. 1 is a perspective view of a bridge deck construction form according to the preferred embodiment of the present invention; 
     FIG. 2 is a side elevational view thereof; 
     FIG. 3 is a top plan view thereof; 
     FIG. 4 is a bottom plan view thereof; 
     FIG. 5 a  is a front end elevational view thereof; 
     FIG. 5 b  is a front end elevational view according to a first alternate embodiment thereof; 
     FIG. 5 c  is a front end elevational view according to a second alternate embodiment thereof; 
     FIG. 5 e  is a front end elevational view according to a third alternate embodiment thereof; 
     FIG. 5 e  is a front end elevational view according to a fourth alternate embodiment thereof; 
     FIG. 6 is a top perspective view of a bridge deck construction form according to the preferred embodiment of the present invention shown in position upon a bridge deck; and 
     FIG. 7 is a side elevational view of the bridge deck construction form of FIG. 6 shown in position upon a bridge deck. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     1. Detailed Description of the Figures 
     Referring now to FIG. 1-4, a bridge deck construction form is shown, according to the present invention, generally noted as  10 . The form  10  is formed as generally rectangular, interlocking support form having a form upper surface  12  defining a rectangular outer perimeter. The form upper surface  12  is envisioned as having a smooth surface to facilitate releasing of the form from the concrete (as will be described in greater detail below), but can also be made having a non-skid, or textured surface if desired or required. The form  10  itself, due to its geometrically regular shape and structurally integral design, is capable of being formed of plastic or other material capable of injection molding, and therefore can be formed easily of recycled material. Also, it is envisioned that an insulated foam layer  50  (as shown in FIG. 5 b ) can also be easily incorporated above or below the upper surface  12  in situations where the form  10  will not be removed and insulation is desired or required, such as for roofing, flooring, or wall construction. 
     In further detail, the rectangular outer perimeter of the form  10  is comprised of a first side edge  16   a  parallel to a second side edge  16   b , and both perpendicular to a first end edge  18   a  parallel to a second end edge  18   b . Extending vertically downward from each end edge  18   a ,  18   b  at the outer perimeter is a vertical attachment apron  20 . Similarly, extending vertically downward from each side edge  16   a ,  16   b  at the outer perimeter is a vertical alignment apron  22 . 
     Referring now in greater detail in conjunction with FIG.  2  and FIG. 4, each vertical alignment apron  22  forms a number of structural, functional features that form important elements of the present invention. For example, the use of a “honch” board, or filler board is a widespread practice for providing surface continuity between the form upper surface  12  and the upper surface of the beam flange  58  (see FIG.  7 ). Accordingly, a honch board/filler board receiving slot  24  is formed as an angular recess between the upper surface  12  and the vertical alignment apron  22  and running the entire linear length of any or all of each side edge  16   a ,  16   b . This notch  24  is also depicted more clearly in FIG. 5 a . Further, a series of hand grip indentations  26  are spaced along each vertical alignment apron  22 . Each hand grip indentation  26  is formed inward from the outer surface of the vertical alignment apron  22 , and provides a gripping surface for a user to hand manipulate the form  10  into its proper position. Similarly, a series of aligned removal notches  28  are spaced along each vertical alignment apron  22  are formed along each vertical alignment apron  22 . Further, a fork receiving recess indentation  30  is shown, in conjunction with FIG. 4, as a raised void above the lower edge  32  of the vertical alignment apron  22  and extending as a channel along the entire width of the form  10 . Each fork receiving recess indentation  30  is designed and placed to allow for a gripper surface for a user to insert a fork lift lifting tine for manipulation of the form  10  during stocking, storing, transporting, and the like. Finally, at least one, but preferably a plurality of form alignment means  34  are formed along each vertical alignment apron  22  and spaced identically in such a manner that each alignment means  34  coincide and interact when the first side edge  16   a  of one deck construction from  10  is placed parallel and aligned to the second side edge  16   b  of a second construction form  10 . 
     Referring now in greater detail in FIG.  1  and FIG. 2, in conjunction with FIG. 5 a  through  5   e , each vertical attachment apron  20  forms a plurality of form adjacent form attachment means  36  are formed along each vertical alignment apron  22  and spaced identically in such a manner that each alignment means  36  coincide and interact when the first end edge  18   a  of one deck construction from  10  is placed parallel and aligned to the second end edge  18   b  of a second construction form  10 . Finally, as shown in FIG. 5 a  through  5   b , the front end elevational view of various alternate embodiment are shown depicting various configurations for each vertical attachment apron  20 . These various embodiment are depicted by way of example, and not by way of limitation, to indicate potential different embodiments to provide differing aesthetics, as well as support structure for various levels of vertical support structural integrity. 
     In any embodiment, it is envisioned that an “L” bracket fastener  38  will be utilized as described in greater detail below. To accommodate accepting each fastener  38 , a fastener receiving slot  40  is formed along each vertical attachment apron  20 . For purposes of disclosing the presently envisioned best mode of the invention, it is felt that each fastener receiving slot  40  will be formed two inches in vertical, linear length, and at a location two inches inwardly offset from the vertical attachment apron  22 . This regular spacing and regular sizing adds to the modular, interlocking nature generally exhibited by the present invention. 
     Finally, for purposes of disclosing the presently envisioned best mode of the invention, it is felt that each adjacent form attachment means  36  and form alignment means  34  would be best practices as similar, interchangeable, and interlocking male attachment dowels and female receiving apertures. As such, it is felt that each first side edge  16   a  and each first end edge  18   a  would form the female receiving apertures in a regularly space, linearly aligned manner about the vertical alignment apron  22  and vertical attachment apron  20 , respectively. In conjunction with these receiving apertures, it is felt that each second side edge  16   b  and each second end edge  18   b  would form the male attachment dowel in a regularly spaced, linearly aligned and corresponding manner about the vertical alignment apron  22  and vertical attachment apron  20 , respectively. 
     In this manner, it is anticipated that the forms  10  can be used in a modular, interlocking, replaceable and reusable fashion as described below. 
     2. Operation of the Preferred Embodiment 
     To use the present invention, when replacing a bridge deck, the old deck is removed, leaving the steel or concrete beams  50  (as shown best in FIG.  6  and FIG.  7 ). The beams  50  are usually spaced 7 feet, 6 inches apart, 8 feet apart, or 9 feet apart on centers, suggesting the need for different sized forms. The whalers  52  are placed or hung from the beams  50  by hanger brackets  54 . The form  10  is then placed on top of the whaler  52  and secured to the whaler  52  by the “L” brackets  38 . Once one form  10  is placed, other forms  10  are connected to it by the adjacent form attachment means  36 , end-to-end, and are aligned side-to-side by connecting adjacent forms  10  utilizing the form alignment means  34 , until all deck forms are in place. The deck is then adjusted to its proper height and honch boards  56  are placed from the receiving slot  24  to the beam flange  58 . 
     From this point, steel reinforcing bars  58  are laid on support chairs  60 , and then concrete  62  is poured. After the concrete  62  has hardened, whalers  52  are lowered and removed, and the forms  10  are removed by prying, if necessary, by inserting a prybar or hammer into the removal notch  28  on the forms. The forms  10  are then separated at the connection means  34 ,  36  and then lowered to the ground. The forms  10  can then be easily cleaned with water, and made ready for reuse. 
     As designed, a device embodying the teachings of the present invention is easily applied. The foregoing description is included to illustrate the operation of the preferred embodiment and is not meant to limit the scope of the invention. As one can envision, an individual skilled in the relevant art, in conjunction with the present teachings, would be capable of incorporating many minor modifications that are anticipated within this disclosure. Therefore, the scope of the invention is to be broadly limited only by the following claims.