Patent Publication Number: US-2023134687-A1

Title: Formwork system and method

Description:
RELATED APPLICATIONS 
     The present application is related to commonly assigned U.S. patent application Ser. No. [DOCKET NO 463/0042 (PA19192US)], entitled FORMWORK SYSTEM AND METHOD, by Huber et al., filed on even date herewith, commonly assigned U.S. patent application Ser. No. [DOCKET NO 463/0043 (PA19193US)], entitled STRIKING TOOL, by Huber et al., filed on even date herewith, commonly assigned U.S. patent application Ser. No. [DOCKET NO 463/0044 (PA19194US)], entitled MULTI-HEAD BOLT AND FASTENER SYSTEM, by Huber et al., filed on even date herewith, the teachings of each of which are expressly incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The invention relates to formwork systems for forming bridge pier caps on a bridge pier and methods of cycling the formwork systems. 
     BACKGROUND OF THE INVENTION 
     In constructing bridge pier caps, formwork systems are typically used to form the bridge pier cap. Such systems include dancefloor applications or self-spanning formwork. In operation, such formwork systems are constructed with respect to a bridge pier to allow for formation of the bridge pier cap. Once the bridge pier cap is formed, the formwork systems are removed (also referred to as striking) and moved to a different position at the site to form additional bridge pier caps (also referred to as cycling). 
     In dancefloor applications, to strike the form the upper side form will simply be lifted up, but the “dancefloor” needs to be lowered to the ground and dismantled piece by piece. To strike the form the upper side form will simply be lifted up, but the “dancefloor” needs to be lowered to the ground and dismantled piece by piece. 
     In self-spanning applications, to set the formwork the whole assembled unit is transported by a crane and placed on the installed jacks. The reinforcement is brought in afterwards, so workers have to climb into the form to do the final reinforcement work. To strike the form they split it at one of the bottom joints while the formwork is hanging on the crane. Therefore, workers have to access that joints with a manlift. 
     SUMMARY OF THE INVENTION 
     The present application overcomes the disadvantages of the prior art by providing a formwork system that can be split into two or more discrete parts for safer, easier, and faster cycling on a job site without the need to disassemble the entire platform. In this regard, the formwork system provides easy and fast striking, requires less assembly and disassembly time, reduces connections, provides safe access for reinforcement works, requires less manlift time, and provides crane independent striking. 
     Advantageously, the present application provides the ability to strike the system in fewer crane lifts, for example exactly two (or in other examples greater than two) crane lifts. The platform can be split in a longitudinal direction in two parts and the two discrete parts can be lifted by crane without requiring complete disassembly of the panels or connections to cycle. 
     One aspect of the disclosure provides a formwork system, comprising: at least one horizontal formwork element configured to support a concrete structure; a plurality of connection beams, at least one of the connection beams being releasably connected to the horizontal formwork element such that the formwork system is configured to split in a longitudinal direction and stricken or cycled from the concrete structure in two or more discrete parts. 
     In one example, the system further comprises a plurality of main beams configured to support the at least one horizontal formwork element and the respective plurality of connection beams. 
     In one example, at least one of the main beams is releasably connected to at least one connection beam. 
     In one example, the system further comprises a plurality of jacks fixed to a bridge pier configured to a least partially support the plurality of main beams. 
     In one example, the plurality of jacks, upon actuation, cause respective vertical displacement of the plurality of main beams. 
     In one example, actuation is caused at least in part by a gearbox assembly removably engageable with one of the plurality of jacks. 
     In one example, the system further comprises at least one working platform. 
     In one example, at least one connection beam is configured to releasably attach to the working platform. 
     In one example, the system further comprises a connection element between the horizontal formwork element and at least one connection beam configured for releaseable engagement between the horizontal formwork element and the at least one connection beam. 
     In one example, the connection element is configured to securedly receive a T-Bolt or a X-Bolt. 
     In one example, the system further comprises a plurality of vertically aligned side formwork panels configured to confront the concrete structure. 
     In one example, the system further comprises at least one vertical beam configured to indirectly attach to the concrete bridge pier cap. 
     In one example, the concrete structure comprises a bridge pier cap. 
     In one example, the bridge pier cap comprises one of a multi-column cap, a hammerhead, or a straddled cap. 
     In one example, a first part of the two discrete parts comprises a first connection beam and a first main beam. 
     In one example, a second part of the two discrete parts comprises at least the horizontal formwork panel with a second connection beam and second main beam. 
     In one example, the horizontal formwork element is a formwork panel with a formlining. 
     In one example, the plurality of main beams comprises at least a first main beam and a second main beam, wherein the first main beam is disposed below a first connection beam and the horizontal formwork element and a second main beam is disposed below a second connection beam and the horizontal formwork element. 
     In one example, the plurality of connection beams and the horizontal formwork are at approximately a same height relative to a horizontal axis when connected. 
     In one example, a longitudinal axis of at least one of the plurality of connection beams and a longitudinal axis of at least one of the plurality of main beams are substantially parallel along the longitudinal direction. 
     In one example, an axis in a length direction of the horizontal formwork element and an axis of the connection beams in the longitudinal direction are substantially parallel to each other. 
     Another aspect of the disclosure provides a method of striking a formwork system, comprising: splitting the formwork system in a longitudinal direction into two discrete parts by releasing a connection between one of a plurality of connection beams and a horizontal formwork element; removing a first discrete part of the formwork system; and removing a second discrete part of the formwork system. 
     In one example, the first discrete part comprises at least one of the connections beams. 
     In one example, the first discrete part further comprises a first main beam. 
     In one example, the second discrete part comprises at least the horizontal formwork and a second connection beam. 
     In one example, the second discrete part further comprises a second main beam. 
     In one example, the method further comprises lowering the formwork system vertically before removing the first discrete part of the formwork system and the second discrete part of the formwork system. 
     In one example, one or more jacks are configured to lower the formwork system. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention description below refers to the accompanying drawings, of which: 
         FIG.  1 A  is side view of a formwork system according to one or more aspects of the disclosure; 
         FIG.  1 B  is an enlarged view of a portion A of the formwork system of  FIG.  1 A  according to one or more aspects of the disclosure; 
         FIG.  1 C  is a view of the formwork system of  FIG.  1 A  showing the operation of one or more jacks according to one or more aspects of the disclosure; 
         FIG.  2    is a side perspective view of a formwork system according to one or more aspects of the disclosure; 
         FIGS.  3 A- 3 H  depict various stages of striking and/or cycling a formwork system according to one or more aspects of the disclosure. 
     
    
    
     DETAILED DESCRIPTION 
       FIG.  1 A  is side view of a formwork system  100  configured with a sideform assembly according to one or more aspects of the disclosure and  FIG.  2    is a side perspective view of a formwork system  100  in a preparation stage for pouring a bridge pier cap. 
     The formwork system  100  can include a horizontal formwork element  108 , respective connection beams  120   a, b , and main beams  110   a, b . The main beams  110   a, b  can be supported by respective jacks  112   a, b  with respect to the bridge pier  114 , as will be described in greater detail below. The horizontal formwork element  108 , respective connection beams  120   a, b , and main beams  110   a, b  can be formed of any material, such as metal (e.g., steel), wood, a polymer, or any combination thereof. In some examples, the horizontal formwork element  108  can be a formwork panel, such as a soffit panel, and have a top layer of a form liner (e.g., formlining or skin layer). In one example, the horizontal formwork element can be a formwork element according to commonly assigned U.S. patent application Ser. No. [DOCKET NO 463/0042 (PA19192US)], entitled FORMWORK SYSTEM AND METHOD, by Huber et al., filed on even date herewith. 
     As shown in  FIGS.  1 A and  2   , the main beams  110   a, b  can have a length extending in the longitudinal direction (e.g., perpendicular to both the horizontal x direction and the vertical y direction) and can have a height in the vertical y direction greater than a width in the horizontal x direction. The main beams  110   a, b  can be parallel to one another and can be oppositely arranged relative to bridge pier  116 . The main beams  110   a, b  can vertically support the respective connection beams  120   a, b , which can also have a length extending in the longitudinal direction (e.g., perpendicular to both the horizontal x direction and the vertical y direction). Each of the longitudinal axes of the respective main beams  110   a, b  can be parallel to the longitudinal axis of the respective connection beams  120   a, b  in the longitudinal direction. The length of the respective connection beams  120   a, b  can be the same as a length of the main beams  110   a, b  in the longitudinal direction. A width of the respective connection beams  120   a, b  in the horizontal x direction can be the same as a width of the main beams  110   a, b , but in other examples the widths can be different. An axis of the horizontal formwork element  108  can be substantially parallel to one or both axis or axes of the connection beams  120   a, b  in the longitudinal direction. A height of the horizontal formwork element  108  and one or both of connection beams  120   a, b  can be the same relative to the horizontal direction. As shown in  FIG.  1 A  and  FIG.  2   , the connection beams  120   a, b  are offset horizontally relative to the main beams  110   a, b , such that a portion of the respective connection beams  120   a, b  extends beyond an outer edge of the main beams  110   a, b . The connection beams  120   a, b  can be permanently, semi-permanently, or releasably engaged to the main beams  110   a, b.    
     As shown, the main beams  110   a, b  can be disposed below the connection beams  120   a, b  and horizontal formwork element  108  relative to the vertical y direction. 
     The horizontal formwork element  108  can extend in the longitudinal direction (e.g., perpendicular to both the horizontal x direction and the vertical y direction) and can have a length less than a length of main beams  110   a, b . In this regard, two horizontal formwork elements  108  can be employed at opposing positions relative to the bridge pier  114  with the bridge pier  114  occupying a space defined between the elements  108 . In this regard, a combination of the lengths of the two elements  108  with the bridge pier  114  can combine to have a length in the longitudinal direction approximately equal to a length of main beams  110   a.    
     The horizontal formwork element  108  can have a height in the vertical y direction that is the same as a height of the connection beams  120   a, b . A width of the horizontal formwork element  108  in the horizontal x direction can correspond to a distance between inner surfaces of side formwork elements  102   a, b  and correspond to a width of the bridge pier cap  116  in the horizontal x direction. In some examples, a top surface of the horizontal formwork element  108  can be planar and form a continuous surface with a top surface of bridge pier  114 , thereby providing a flat surface for the formation and support of the bridge pier cap. 
     The length (oriented in longitudinal direction) of the horizontal formwork element  108  can be based on the metric measurement system and the width (oriented in horizontal x direction) of the horizontal formwork element  108  can be based on the imperial or US customary units measurement system or vice versa, or a combination of both. For example, the length of the horizontal formwork element  108  can be an integer multiple of one centimeter (for example, 5 centimeters, 57 centimeters, 96 centimeters, 130 centimeters, etc.) or a multiple of 50 centimeters (for example, 50 centimeters, 100 centimeters, 200 centimeters, etc.). The width of the horizontal formwork element  108  can be an integer multiple of an inch (for example, 1 inch, 2 inches, 10 inches, 47 inches, 98 inches, etc.) or an integer multiple of a foot (for example, 1 foot, 3 feet, 10 feet). Thus the panel can be used in different countries with different measurement systems without modification. Furthermore, the panel can be rotated (so that the length side now corresponds to the width side and vice versa), depending on whether the structure to be concreted (such as the bridge pier head) is aligned according to the metric or the imperial measurement system. 
     As shown in  FIG.  2   , the formwork system  100  can include one or more horizontal formwork elements  108  (as can be seen below in  FIG.  3 H ) and can be oppositely arranged forming a gap to allow bridge pier cap  116  to be formed atop the bridge pier  114 . In one example, reinforcement elements R can be used to allow bridge pier cap  116  to be concreted integrally with bridge pier  114 . 
     As shown in  FIG.  1 A , the formwork system  100  can be used to form any type of concrete structure(s), such as bridge pier cap  116 . The bridge pier cap  116  can be any type of bridge pier cap, such as a multi-column cap (e.g., cross beam), a hammerhead, or a straddled cap (e.g., straddled bent). 
     The formwork system  100  can engage with a sideform assembly comprising vertically aligned side formwork elements  102   a, b  (such as formwork panels) and formwork crossbeam  101 . The side formwork elements  102   a, b  and horizontal formwork element  108  generally define a volume for receiving poured concrete and hardening of the concrete for forming the bridge pier cap  116 . The formwork crossbeam  101 , side formwork elements  102   a, b , and the horizontal formwork element  108  can be formed of any suitable material, such as metal, a polymer, wood, or any combination thereof. The side formwork elements  102   a, b  confront the bridge pier cap  116  by virtue of the pouring and concreting process in forming the bridge pier cap  116 . The side formwork elements  102   a, b  can extend in the longitudinal direction and can have a height extending in the vertical direction that is greater than a height of the desired bridge pier cap  116 . 
     The side formwork elements  102   a, b  can be removably engaged with the formwork system  100  by respective connection elements  104   a, b . In this regard, the connection elements  104   a, b  can respectively extend from and be engaged with connection beams  120   a, b  such that the connection elements  104   a, b  can be disengaged, allowing for the side formwork elements  102   a, b  to be disengaged from the formwork system  100 . 
     The formwork system  100  can include respective working platforms  106   a, b  extending in the horizontal direction that are attached permanently, semi-permanently, or releasably with main beams  110   a, b  and/or connection beams  120   a, b . The working platforms  106   a, b  can include guardrails  118   a, b  extending in a vertical direction to provide a safe working space for a worker and/or to prevent equipment from falling off the platforms  106   a, b . The platforms  106   a, b  and the guardrail  118   a, b  can be formed of any suitable material, such as metal, a polymer, wood, or any combination thereof. 
     The horizontal formwork element  108  is releasably attached to both the left-hand connection beam  120   a  and the right-hand connection beam  120   b , with either or both capable of being detached or disengaged at the same time. In the example of  FIGS.  1 A-B  and  2 , the horizontal formwork element  108  is releasably attached (directly or indirectly) to the right-hand connection beam  120   b , forming an reverse L-shaped arrangement by virtue of the combination of side formwork element  102   b  and horizontal formwork element  108 . In other examples, the horizontal formwork element  108  is releasably attached (directly or indirectly) to the left-hand connection beam  120   a , forming a L-shaped arrangement by virtue of the combination of side formwork element  102   a  and horizontal formwork element  108 . 
     The right-hand connection beam  120   b , right-hand working platform  106   b  (optionally), right-hand main beam  110   b , and horizontal formwork element  108  can be stricken, cycled and moved as a single unit by virtue of connection element  122   b  shown in  FIG.  1 B . In other examples, the working platform  106   b  can be removed individually and separately while. 
     The formwork system  100  and the components thereof can be supported by bridge pier  114  by virtue of one or more jacks  112   a, b  that are anchored to the bridge pier  114  and support the main beams  110   a, b.    
       FIG.  1 B  is an enlarged view of a portion A of the formwork system of  FIG.  1 A  according to one or more aspects of the disclosure. As shown in  FIG.  1 B , connection elements  122   a, b  can be integrally formed into the connection beams  120   a, b  and horizontal formwork element  108  allowing for releasable engagement of the beams  120   a, b  and horizontal formwork element  108 . The connection elements  122   a, b  define openings for securedly receiving a fixation element, such as an X-bolt (having a bolt head in an X-shape), T-bolt (having a bolt head shape in a T-shape), or any other kind of bolt such that insertion and engagement of the bolt into the defined openings provides secure engagement between the connection beams  120   a, b  and the horizontal formwork element  108 . For example, a multi-head bolt could be used as the fixation element, as described in commonly assigned U.S. patent application Ser. No. [DOCKET NO 463/0044 (PA19193US)], entitled MULTI-HEAD BOLT AND FASTENER SYSTEM, by Huber et al., filed on even date herewith, the teachings of which are expressly incorporated herein by reference. The horizontal formwork element  108  can be removably engageable at opposing ends with the respective connection beams  120   a, b  by respective connection elements  122   a, b , which can be independently disengaged. 
       FIG.  1 C  is a view of the formwork system of  FIG.  1 A  showing the operation of one or more jacks according to one or more aspects of the disclosure. 
     As shown, the jacks  112   a, b  are configured to support main beams  110   a, b  during pouring and hardening of bridge pier cap  116 . The jack  112   a  can include a head bearing  112   a - 2  that can directly or indirectly confront the main beam  110   a . The jack  112   a  can be affixed to bridge pier  114  by tie rod  112   a - 4  and nut  112   a - 6  in a removably engageable manner. 
     In  FIG.  1 C , jacks  112   a, b  can be identical, with jack  112   b  having a head bearing  112   b - 2 , and being fixed to bridge pier  114  by a tie rod (not shown) and nut (not shown). In this example, jack  112   b  is engaged with a gearbox assembly  112   b - 10  engageable with one or more ratchet or screwdriver elements  112   b - 12 . In this regard, the jack  112   b  includes a telescoping cylinder  112   b - 8  that moves vertically and can be raised or lowered by virtue of gearbox assembly  112   b - 10  that cooperates with a built-in gearbox assembly onboard the jacks  112   a, b  (not shown) when the gearbox assembly  112   b - 10  is actuated by ratchet or screwdriver elements  112   b - 12 . The gearbox assembly  112   b - 10  can have a first gear ratio and the built-in gearbox assembly of the jack  112   b  has a second gear ratio such that vertical motion of the telescoping cylinder  112   b - 8  is easier and faster. For example, rotation of the ratchet or screwdriver elements  112   b - 12  can result in actuation of the gearbox assembly  112   b - 10 , which in turn causes vertical movement of telescoping cylinder  112   b - 8 . This causes vertical movement of head bearing  112   b - 2  and thus vertical movement of main beams  110   a  and other elements of the formwork system. Each of the jacks  112   a, b  can be engageable with a gearbox assembly (e.g.,  112   b - 10 ) and can be vertically adjusted (e.g., by up to a distance D) simultaneously or independently from one another. 
       FIGS.  3 A- 3 H  depict side and perspective side views of a formwork system in various stages of striking and/or cycling according to one or more aspects of the disclosure. 
       FIG.  3 A  depicts the formwork system  100  engaged with a sideform assembly including side formwork elements  102   a, b  and formwork crossbeam  101 . In this stage, reinforcement elements R are vertically exposed in preparation for pouring concrete and forming bridge pier cap  116 . 
       FIG.  3 B  depicts a formwork system  100  engaged with side formwork elements  102   a, b  and formwork crossbeam  101 . In this stage, the bridge pier cap  116  has been poured and allowed to dry/form as a concrete structure in the volume defined at least partially between elements  102   a, b  and horizontal formwork element  108 . The drying can occur for some time after pouring. Once the concrete is formed, cycling can begin as described below. 
     In  FIG.  3 C , the formwork element  102   a, b  (and formwork cross beam  101 ) have been stricken (e.g. removed) from the bridge pier cap  116  for example via a crane. 
     Once removed, cycling and/or striking of the formwork system  100  can commence as described in greater detail below. 
     In  FIG.  3 D , the jacks  112   a, b  are lowered in connection with striking the side formwork panels  102   a, b  from the bridge pier cap  116  and two vertical beams (B) were respectively fixed to the connection beams  120   a, b  and attached to the concreted bridge pier head via two striking tools (S). For example, a gearbox assembly (such as gearbox assembly  112   b - 10  described above) can be engaged with the one or more of the jacks  112   a, b  and allow for a downward vertical motion of a head bearing and a resulting downward motion of main beams  110   a, b . This provides a corresponding downward vertical motion of horizontal formwork element  108 , connection beams  120   a, b  and allows for striking/removal of the horizontal formwork element  108  from the bridge pier cap  116 . As shown, vertical beam B confronts and is indirectly attached with the bridge pier cap  116  by striking tool S and can be stricken from the bridge pier cap  116  by one or more striking tools S which can cause the horizontal formwork element  108  and connection beams  120   a, b  as well as the main beams  110   a ,  110   b  to be retract slightly away from the bridge pier cap  116 . In one example, a striking tool can be used, such as the striking tool described in commonly assigned U.S. patent application Ser. No. [DOCKET NO 463/0043 (PA19193US)], entitled STRIKING TOOL, by Huber et al., filed on even date herewith, the teachings of which are expressly incorporated herein by reference. 
     In  FIGS.  3 E-F , the connection element  122   b  has been disengaged (while the connection element  122   a  remains engaged), allowing horizontal formwork element  108  to be separated and disengaged from main beam  110   b  and connection beam  120   b . As shown, the connection beam  120   b , main beam  110   b , working platform  106   b , connection element  104   b , and guiderail  118   b  can be removed as a first single discrete unit, such as by a crane. As shown in  FIG.  3 E , the first of two discrete units can be stricken or striked by a striking mechanism, resulting in a longitudinal split of the formwork system  100  generally along the longitudinal direction. Once stricken, the first discrete part can then transported by crane as shown in  FIG.  3 F , leaving behind the second discrete part relative to the bridge pier cap  116 . The second discrete part, for example, can already be attached to a crane or held in place on the bridge pier cap  116  via vertical beam B and striking tool S. In  FIG.  3 E , the first discrete unit can include at least main beam  110   b , and connection beam  120   b  and optionally working platform  106   b  and guardrail  118   b . In one example, the first discrete unit can include connection beam  120   b  or can include connection beam  120   b  and main beam  110   b . In a further example, the first discrete unit can optionally further include one or more of elements  106   b ,  104   b , and  118   b , while in other examples one or more of elements  104   b ,  106   b , and/or  118   b  can be removed as further discrete parts. 
     In  FIGS.  3 F-G , at least some or all of the remaining elements can be removed from the bridge pier cap as a second discrete single unit. As shown in  FIG.  3 F , the second of two discrete units can be removed by a second crane (or using the first crane a second time). In  FIG.  2 E , the second discrete unit can include horizontal formwork element  108 , working platform  106   a , horizontal formwork  110   a , connection element  104   a , connection beam  120   a , and guardrail  118   b . In one example, the second discrete unit can include horizontal formwork element  108  and connection beam  120   a . In another example, the second discrete unit can include at least horizontal formwork element  108 , main beam  110   a , and connection beam  120   a . In a further example, the second discrete unit can optionally further include one or more of elements  104   a ,  106   a ,  118   a , while in other examples one or more of elements  104   a ,  106   a , and/or  118   a  can be removed as further discrete parts. Advantageously, the formwork system is split in the longitudinal direction (e.g., along the longitudinal axis) into two discrete parts the assembly can be removed in two steps as two discrete units to reduce cycling time, where they can be assembled to an additional bridge pier for formation of additional bridge pier caps. 
     In  FIG.  3 H , the two discrete parts can be attached to a second bridge pier for formation of an additional bridge pier cap, restarting the concrete formation and cycling process. 
     While the stages of  FIGS.  3 A-H  depict disengagement of connection element  122   b , it is contemplated that instead connection element  122   a  can be disengaged, allowing for the horizontal formwork element  108  to be part of a discrete unit with connection beam  120   b , or with connection beam  120   b  and main beam  110   b  together, or either of the previous examples together with working platform  106   b  and/or guardrail  118   b.    
     The foregoing has been a detailed description of illustrative embodiments of the invention. Various modifications and additions can be made without departing from the spirit and scope of this invention. Features of each of the various embodiments described above may be combined with features of other described embodiments as appropriate in order to provide a multiplicity of feature combinations in associated new embodiments. Furthermore, while the foregoing describes a number of separate embodiments of the apparatus and method of the present invention, what has been described herein is merely illustrative of the application of the principles of the present invention. Accordingly, this description is meant to be taken only by way of example, and not to otherwise limit the scope of this invention.