Abstract:
A construction hanger comprises a brace including a first elongated member; an arm extending from one end of the first elongated member at an angle thereto, the arm and the elongated member cooperating to engage the surface of a construction support member; a guide at the end of the elongated member opposite the one end, the guide being capable of receiving a hanger member, the guide being positioned on or formed within the brace and at an angle thereto; the guide tying the hanging member to the construction support member by means of the brace.

Description:
RELATED APPLICATIONS 
       [0001]    This application is a division of U.S. patent application Ser. No. 13/613,444 filed Sep. 13, 2012, which claims the benefit of U.S. Provisional Application Ser. No. 61/534,630 filed on Sep. 14, 2011, the contents of both of which are hereby incorporated by reference in their entirety. 
     
    
     FIELD 
       [0002]    The invention relates to a construction hanger for use in assembling concrete forms and, more particularly, tying the form members to a construction support member such as an I-beam. This invention provides an attachment of overhanging brackets, scaffolding, or other accessories to steel, concrete, or other bridge beams or construction support members. 
       BACKGROUND 
       [0003]    In order to construct concrete sections of roads, bridges, buildings, or other components, a form is provided into which the concrete is poured and allowed to harden. These forms may take on a variety of shapes and configurations according to the use that they&#39;re put. 
         [0004]    In creating overpasses, standing walls, or other sections, a framework of steel girders, I-beams, or other supporting structure is assembled before pouring the concrete to provide a structure from which to assemble the form. The form is supported on the girders or I-beams by means of construction hangers that support the weight of the form and concrete by distributing the load into the girder. Because the hangers may support the forms from within the volume of the form, they are usually unrecoverable after the concrete has been poured and allowed to harden. Therefore, it is preferable to provide economical hangers that can be inexpensively replaced as hangers are consumed. 
         [0005]    These hangers may also be used to support scaffolding or other accessories to support structure. 
         [0006]    An example of one prior art hanger generally includes a brace and a guide welded together to form the hanger. The brace may be formed from a steel bar bent around a beam flange to form a hook while the guide, which may be formed from a piece of stamped and bent steel, is welded to the bar opposite the hook. A support rod may be inserted through the guide and a form is attached to the support rod. By way of example, the support rod may be a threaded rod held in place by a hex nut or the like. 
       SUMMARY OF THE INVENTION 
       [0007]    According to a first aspect of the invention, a construction hanger comprises a brace or bracket formed or cut from a substantially flat metal plate and an arm extending from its distal end and a proximal end. where a guide having a channel is positioned and bonded or formed onto the brace. The term “brace” as used herein refers to that portion of the hanger  10  that engages the construction support member such as an I-beam. The term “hanger” refers to the brace in combination with the guide member that receives the hanger rod that ties the form to the support member. The term “hanger” does not include the rod itself. 
         [0008]    According to one variation of the first aspect of the invention, the brace includes an arm that is shaped to receive and/or engage a beam profile. The beam profile may be the profile of any of a variety of construction elements such as a square or tapered I-beam, a C-channel beam, a square beam, an angle-beam, or other type of beam that is well known to those having skill in the art. 
         [0009]    According to another variation, the guide member is bonded to the brace by means of welding, one or more fasteners, an interference fit, or other technique known to those having skill in the art. The guide member may have a variety of constructions, including but not limited to a round tube, a square tube, and a U-channel. The function of the guide is to retain the hanger rod by which form members are tied to the construction supports. 
         [0010]    According to yet another variation, the guide includes a major axis that is at an angle to the brace. For example, the angle between the major axis and the brace may be at or about 45°. Other arrangements and angles are also anticipated, for example the angle between the clip and the brace may be 90°, and the brace and the guide need not be in the same plane. 
         [0011]    According to yet another variation, the brace may include a bearing surface or extension that is typically triangular in shape at the proximal end of the brace to which the guide member is bonded. 
         [0012]    In a second aspect of the invention the hanger includes one or more bearing plates. These bearing plates are optionally positioned on an underside of the brace and may be positioned between the distal and proximal ends. The bearing plates are positioned between the retainer or flange and the beam to provide surface area for load distribution. Alternatively, the bearing plates may be positioned on the upper surface of the arm forming the brace. 
         [0013]    Another aspect of the invention is a novel method for forming the hanger in accordance with the above-described aspects. A substantially flat sheet of material, for example plate steel, is provided. A brace is cut from the material, the retainer having a distal end with a flange having a profile approximately complementary to a beam profile so that when attached to the beam profile the retainer fits accurately and tightly to the beam profile. A guide is provided and may include a circular, square, or U-shaped cross section. The guide is bonded to the brace at a proximal end of the retainer. The angle between the guide and retainer may be approximately 45°. 
         [0014]    According to another variation, one or more bearing plates may be provided. These bearing plates are bonded to the brace in a perpendicular arrangement so as to distribute the load between the retainer and a beam to which the hanger may be attached. The bearing plates may be attached to the flange or directly to the brace and may either protrude to form a bearing surface corresponding to the beam profile or may be flush with a bearing surface of the brace. 
         [0015]    Another aspect of the invention is a novel method for using the hanger in accordance with the above-described aspects. According to this aspect, a hanger is provided comprising a brace cut from a sheet of material and having an arm having a profile corresponding to a beam profile and a proximal end having a guide member. The hanger is provided on a beam having the beam profile such that the flange engages the beam profile to prevent movement along the length of the retainer or about an axis parallel to the major length of the beam. A support rod is provided that engages the guide. A load may then be applied to the support rod so that the force is transmitted axially through the support rod to the guide and subsequently to the retainer and beam. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]      FIGS. 1A-1C  respectively illustrate three embodiments of construction hanger braces in accordance with the invention. 
           [0017]      FIGS. 2A-2D  respectively illustrate brace elements useful in providing hangers in accordance with different embodiments of the invention. 
           [0018]      FIG. 3  is a perspective view of a hanger in accordance with one embodiment of the invention. 
           [0019]      FIGS. 4-6  illustrate embodiments of the invention in which the hanger includes one or more barrier plates to distribute the forces acting on the hanger. 
           [0020]      FIG. 7  illustrates a hanger in accordance with one embodiment of the invention in engagement with an I-beam. 
           [0021]      FIG. 8  illustrates a further embodiment of the invention in which the hanger includes a pair of guide members. 
       
    
    
     DETAILED DESCRIPTION 
       [0022]      FIG. 1A  illustrates a partial view of a hanger  10  in accordance with one embodiment of the invention wherein the hanger includes a circular tube  12  that functions as a guide member for the hanger rod that is assembled with the hanger to assemble a concrete form member with a construction support member such as an I-beam.  FIG. 1B  on the other hand illustrates an embodiment in which the guide member is a square tube  14  and  FIG. 1C  illustrates an embodiment in which the guide member is a U-shaped channel member  16 . In each embodiment, the guide member  12 ,  14  or  16  is carried on a brace  20  including an elongated bar  22 . The bar terminates in an end surface  26  ( FIG. 2 ). In the illustrated embodiment, the bar  22  is formed with a triangular extension  28  which provides additional support for the guide member and distributes the forces acting on the guide member over a longer lineal surface. 
         [0023]      FIG. 2  illustrates four embodiments ( FIGS. 2A-2D  respectively) for brace members  10  that can be used in constructing a hanger in accordance with various embodiments of the invention. The brace member  20  includes an elongated bar  22  from which an arm  24  extends. The arm  24  extending from the elongated bar  22  is shaped to engage a construction support member as discussed in more detail below. The brace  20  includes a sloped end surface  26  which can be bonded to or formed into a guide member such as members  12 ,  14  and  16  illustrated in  FIG. 1 .  FIG. 2  illustrates an embodiment of the invention in which the guide member is carried on the sloped end surface  26  that is in the same plane as the brace member  20 . It is not essential that the hanger be constructed in this fashion. The end surface could be formed such that the guide member is located in at any desired angle with respect to the brace member within or out of the plane of the plate forming the brace  20 . In the embodiment shown in  FIG. 2 , the brace members  20  each include a bearing extension  28  which is generally triangular in shape (note the dotted lines) and which further extends or widens the surface  30  of the elongated bar  22  and the end surface  26 . This facilitates bonding the guide member to the brace  20  and distributes forces over a larger surface area. 
         [0024]      FIG. 3  illustrates an embodiment of the invention in which a tubular guide  12  is bonded to the brace  20  by a weld line  32 . However, those skilled in the art will appreciate that other techniques than welding may be used to bond and/or form the guide member  12  on the end of the brace  10 . The guide member can be formed separately and bonded to the brace  20  using an adhesive or weld, or the guide member can be a metal formed extension of the brace member  20  and the guide member is formed by bending the metal of the brace member. In this embodiment, there is no end surface  26  as shown in the embodiments of  FIG. 2 . Instead the metal plate forming the end of the brace  20  would be formed into a tube. 
         [0025]      FIG. 7  illustrates an example of the hanger  10  in position on an I-beam  36 . The arm  25  includes a right angle extension which receives the rectangular shape or profile of the I-beam. A threaded hanger rod  38  is inserted in and through the guide member  12  and retained by a threaded nut  40 . The rod member engages the construction form and ties or hangs the form in position from the the I-beam thereby transferring load from the support rod to the hanger and the beam. 
         [0026]      FIGS. 4-6  illustrate embodiments of the invention in which hanger  10  includes one or more bearing plates  42 . In  FIG. 4  the hanger is an assembly of rectangular plate members as shown which form a rectangular opening in the brace member similar in shape to the hanger illustrated in  FIG. 3  which is formed from a cut metal sheet. The bearing plate  42  is situated on the lower portion of the arm  44  in this embodiment. In  FIG. 5 , two bearing plates  42  and  42 ′ are attached to the lower surface of the elongated member  22  of the brace  20 . These bearing plates function to distribute the forces that are acting on the hanger over a larger surface area of the construction support member to prevent damage or premature failure of the support member.  FIG. 6  illustrates an embodiment in which the bearing plate  42  is received in a cutout  46  in the elongated bar  22  forming the brace  20 . Alternative arrangements of bearing plates are also contemplated. For example, a single bearing plate may be utilized to engage the beam along the entire or major portion of the length of the brace. Alternatively, multiple bearing plates may be provided along the length of the brace. Finally, the retainer and flange may be constructed from components having an I- or T-shaped profile so that the bearing plate is integrally formed with the hanger. 
         [0027]      FIG. 8  illustrates another embodiment of the invention in which the hanger is formed from a plate  60  optionally having apertures  66  therein. The plate  60  is rectangular in shape and has a pair of tubular guide members  68   a  and  68   b  extending from each of its side edges. A pair of hanging rods  70   a  and  70   b  are inserted through the guide members and retained by threaded nuts  72   a  and  72   b.  Optional bearing plate  62  extends from a cutout in the bottom edge of the plate  60  such that the hanger is stabilized on the top of the I-beam  36 . 
         [0028]    Representative examples of construction support members with which hangers of the embodiments of the invention may be used include but are not limited to (a) an I- or T-beam; (b) a square or C-beam; (c) an I- or T-beam having a tapered top plate; and (d) any other type of beam having a square edge, including an I-beam, T-beam, C-beam, square beam, and angle beam. These variations are only proposed illustrations and are not intended to be limiting. 
         [0029]      FIGS. 1A-1C  show various embodiments of the guide (or tube) that may be used to engage and hold the support rod. According to these embodiments, the guide may be a round tube (top); square tube (middle); or C- or U-Channel (bottom). These embodiments are provided as illustrative and not intended to be limiting. For example, the guide may include an angle, hexagonal, or other shaped channels for accommodating a support rod. Alternatively, the support rod may be integrally formed with the hanger. 
         [0030]    In  FIG. 3 , the guide has been bonded to the brace by means of a fillet weld. However, it should be appreciated that other means of attaching the clip and braces together are anticipated. For example, the means may include bonding by an adhesive, tac or other type of weld, or other type of joint. Alternatively, the means may include physical attachment, including without limitation: screws, straps, interference fit, or other mechanical interface. Further, the guide may be integrally formed with the brace either in a finished state or additional machining, such as bending a guide to form a tube, may be performed to provide the guide. Further shown in  FIG. 3  is that the brace may be cut from ¼″ steel plate. 
         [0031]      FIGS. 5-7  show various alternative embodiments of the hanger, including the arrangement of the flange section and placement of optional bearing braces. The top (hereafter “ FIG. 5 ”) and middle (hereafter “ FIG. 6 ”) illustrations show the flange as a separately formed component formed from a number of flat bars which may be bonded (e.g. welded) or mechanically attached (e.g. screwed) to one another. The advantage of these arrangements is that the flange may be manufactured from several sections of steel bar. The bottom illustration (hereafter “ FIG. 7 ”) shows the flange according to the embodiments illustrated in e.g.  FIG. 2  as a single piece cut from a sheet of material, e.g. ¼″ steel plate. The advantage of this arrangement is that the number of steps for manufacture is reduced and the single-piece construction may be preferred to a welded multiple-piece construction in some applications. 
         [0032]      FIG. 8  also illustrates several variations of the location of bearing plates. As shown in  FIG. 5 , a single bearing plate is illustrated. This bearing plate is located on the portion of the flange that would engage the underside of an I-beam or similar.  FIG. 6  illustrates two bearing plates that may be positioned at the proximal and distal ends of the brace and would engage the top plate of an I-beam or similar.  FIG. 7  illustrates that a single bearing plate may be positioned at the proximal end (adjacent the guide) to engage the top of an I-beam or the like. Also shown in  FIG. 5  is that the bearing plates may be either flush with or protruding from the profile of the brace and flange.  FIG. 6  shows the bearing plates extending from the brace so that the bearing plates would contact the beam and the plate would not.  FIG. 7  shows that the bearing plates may be recessed so that the load is shared between the bearing plates and the brace. In the first instance, it is necessary to design the profile of the brace and flange to account for the increased spacing between the brace and flange. 
         [0033]    Having described the invention in detail and by reference to specific embodiments thereof it will be apparent that numerous variations and modifications are possible without departing from the spirit and scope of the disclosure.