Patent Publication Number: US-5524854-A

Title: Structural supporting bracket

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a concrete form structural support system, and in particular, to an adjustable structural support system for use with concrete overhang and an adjustable truss system for the use as a temporary support, in, for example, concrete falsework forming, concrete slab construction and the like. 
     Various types of structural concrete overhang support systems are used to underlie concrete falsework forms in concrete bridge deck overhang, concrete slab construction, and the like. Most or such structural overhang support systems incorporate a fixed member welded assembly component that serves as a structural support component in the system. For example, one such system, made by Dayton Superior Corporation, or Miamisburg, Ohio, includes a triangular cantilever support bracket having a top horizontal, double-formed channel member. The double channel member is spaced apart at the channel webs by spacer tubes and bolts. The webs of the channel members have a series of holes that allow the interconnection or the channels. This allows a space between the channels which provides an attachment point for the support of the horizontal member with the use or a bolt holder. The location or the bolt holder is changed by moving the bolt holder along the series of holes in the horizontal member. The space between the channel also allows for the interconnection of vertical and diagonal support struts. The struts are composed or different diameter tubes to allow the telescoping of the inner and outer robe. The strut robes have a series or holes to interconnect the inner and outer member with a fastener to allow telescoping adjustment. The space between the channels also allows the use or an adjustable carrier at the end or the upper diagonal strut. The adjustment or the bolt carrier changes the location or the upper strut member. The change of location or the upper strut member allows a change in the level of the channel member. Despite the reduction in weight with the use or channel members, the length of the channel member is fixed and welded. The location of the upper strut adjuster is fixed and welded. 
     Another type of system, made by the Williams Form Engineering Corporation of Grand Rapids, Mich., includes a fixed and assembled triangular shaped bracket or support having a vertical and a horizontal leg. The triangular support has a hole in the vertical leg of the triangle that allows attachment of the triangle to a fixed support structure. The horizontal leg of the triangle has access holes consisting of adjustment fasteners have adjustment fasteners have supports at the ends to allow a beam to be placed within the supports. The level of the beam can be changed by the adjustment fasteners. Despite the simplicity of the fixed triangle, the support of the triangle and the adjustment of the triangle require separate systems. 
     Another type of support system, made by Contractor&#39;s Engineer, Inc. of Neodesha, Kans., includes a diagonal strut with an attachment point for the adjuster fastener. The strut allows support of one end of the horizontal beam with the use of a support bracket at the end of the support strut. The opposite end of the horizontal beam is supported with a fastener and plate at the support structure. Despite the adjustment of the horizontal beam by the strut support, the adjustment is at one end. The support strut is not a complete unit set and is supported from one support fastener. 
     While the aforementioned overhang systems have inherent advantages including adjustability, good load beating characteristics, and durability, there are some inherent drawbacks. First of all, the above mentioned structural supporting systems have fixed horizontal support lengths. Supports narrower than the fixed horizontal length of the support member require modification of the horizontal support member. Such prior art devices require additional support adjustment and attachment systems to complete the system. The prior art systems are limited to the function set forth. Additional support requirements, such as slab support between a pair of support girders, or slab support with spans between support girders that would require truss applications, would increase the overall cost of the support systems. The additional cost of such prior art devices is higher than it needs to be. Finally, such prior art devices have not provided the desired versatility and adjustability to be used as separate systems, and thereby have limited the productivity of construction workers in using such prior art systems. 
     SUMMARY OF THE INVENTION 
     One object of the present invention is the provision of a new and improved structural support system for use as a temporary support in concrete slab construction and the like, for example, concrete falsework forming in bridge deck construction. 
     Another object is the provision of such a structural support system which substantially reduces the amount of material and components required, as compared to prior art design, while increasing versatility, adjustability and productivity in the use of such systems. 
     Another object is the provision of such a structural support system which includes two identical brackets, used along a pair of support beams, both of which are fully adjustable along the length of the support beam as the support requirements change in the concrete slab construction, while permitting the adjustment of at least one of the brackets, and, preferably both of the brackets, along the length of the support beam to increase or decrease the span thereof. 
     Another object is the provision of such a structural support system having various bearing surfaces to allow the use of the brackets supported from a diagonal support element; 
     Another object is the provision of such a structural support system which has various supporting bearing surfaces to allow the use of the bracket means supported from a vertical support element. 
     Another object is the provision of such a structural support system which can be used on a variety of construction form settings. 
     Another object is the provision of such a structural support system having various supporting bearing surfaces to allow the use of a support element used at one beating point while being used in a truss application. 
     Another object is the provision of such a structural support system having various support bearing surfaces to allow the use of a support clement to be used at one bearing point while being used in an overhang support condition. 
     Another object is the provision of such a structural support system which is inexpensive and easy to manufacture; is simple and easy to install and use; provides versatility and flexibility in the use of the system in different construction environments; increases the productivity of construction workers in the use of such systems, is long wearing and durable in use; and is otherwise well adapted for the purposes intended. 
     Briefly stated, the structural support system of the present invention is constructed for the use as a temporary support in concrete falsework construction and the like. It includes dual, yet identical, brackets used along a pair of support beams. Both brackets are fully adjustable along the length of the support beam. The brackets can be adjusted as the support requirements change in the concrete slab construction by adjusting one, and preferably both, brackets along the length of the support beam to increase or decrease the support system span, as desired. The location and position of bearing surfaces will allow the brackets to be used as a support device in overhang concrete support or in truss applications. 
     The brackets include mounting means for mounting the brackets in concrete falsework construction. Specifically, the mounting means include support surfaces positioned between the support beams. The mounting means have a series of holes which allow suspension of the brackets from various fasteners suspended in the concrete falsework construction. 
     The support beams captured by the brackets are preferably formed from laminated veneer lumber or aluminum, or other equivalent structure, in order to provide a lightweight construction. 
     One of the brackets engages at least one free end of the support beams. This bracket end includes two vertically extended and laterally spaced apart elongate hollow bodies which slidably receive the beams. Each hollow body has an inner wall periphery, at least partially configured complimentary to one free end of the support beam, and integral mounting means extending between the hollow bodies for mounting the bracket, and thereby one or both the adjacent support beams, to the concrete form construction. Each of the hollow bodies is securable to one free end of the support beam. The mounting means include an integral support plate which extends horizontally and diagonally along the hollow bodies. The support plate has at least one, and preferably two, slotted holes to allow the engagement of support fasteners and system fasteners. The diagonal plate has holes for the use of a fastener for the support in the concrete support system. The integral mounting means preferably also include a second support plate extending from the first support plate running horizontally along the hollow bodies and connecting the laterally spaced hollow bodies. The horizontal plate has at least one hole for the use of a fastener for the support in the concrete support system. 
     Bearing or gripping plates are positioned horizontally along the support beam, within the hollow bodies, to facilitate gripping of the support beams. The gripping plates are formed with an angle extension of the plates running vertically to the support beams to limit movement after the support beams are installed, before the bearing plates are fully engaged against the lower edge of the support beam with the use of a threaded element. 
     The hollow bodies have holes in their vertical side walls to allow a round pin fastener to be installed after the support beams are installed. The round fastener is installed through at least one, and preferably both, of the support beams to secure the position of the brackets until the gripping means within the brackets is engaged. The round pin allows the brackets to rotate about the round pin. Rotation of the brackets with the gripping means installed will increase pressure against the gripping means and the upper surface of the hollow bodies. The increased pressure will limit the rotation of the bracket means along the support beams. 
     These and other advantages of the present invention will become more apparent from the ensuing description. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an isometric view of a structural support system of the present invention including support beams and associated brackets al opposite flee ends of the beams, together with a bracket positioned therebetween, as the present invention is assembled for use as overhang support in the falsework construction; 
     FIG. 2 is a fragmentary side elevation view illustrating the manner in which the structural support system of the present invention is used as a temporary support in concrete overhang falsework construction; 
     FIG. 3 is an isometric view of one type of support bracket used in the structural supporting system of the present invention; 
     FIG. 4 is a fragmentary side elevation view, partly in cross-section, illustrating the manner in which the support bracket of FIG. 3 is suspended by an associated diagonal fastener in concrete overhang falsework construction; 
     FIG. 5 is a fragmented side elevation view of the bracket of FIG. 3 used in a concrete overhang falsework construction setting using an associated diagonal support fastener extending through a support plate to support the concrete falsework construction; 
     FIG. 6 is a fragmentary side elevation view of an associated diagonal support and associated adjustment means of FIG. 5 for support of the concrete falsework construction; 
     FIG. 7 is an end view elevation of the support bracket of FIG. 3 illustrating the associated support beams being contained between hollow bodies of the brackets with diagonally spaced and supported plates and gripping means being engaged with an attachment pin extending through the support beams and hollow bodies for support of the concrete falsework construction; 
     FIG. 8 is a fragmentary view in side elevation of the support bracket of FIG. 3 including an associated vertical support fastener through alignment in support plates together with associated fasteners for support of the concrete slab falsework truss construction; 
     FIG. 9 is a fragmentary view in side elevation with associated bracket means of FIGS. 10-11 for the support of the concrete slab falsework truss construction; 
     FIG. 10 is an isometric view of the structural support system of the invention including the support beams and the associated bracket means at opposite free ends thereof, together with associated bracket means positioned therebetween, as the present invention is assembled for use in the truss application in concrete support system in falsework construction; and 
     FIG. 11 is a fragmentary side elevation view of the bracket of FIG. 3 used in a different concrete truss falsework construction setting using an associated vertical fastener for support of the concrete falsework construction; Corresponding reference numbers will be used throughout the various figures of the drawings. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The following detailed description illustrates the invention by way of example and not by way of limitation. This description will clearly enable one skilled in the art to make and use the invention, and describes several embodiments, adaptations, variations, alternatives and uses of the invention, including what I presently believe is the best mode carrying out the invention. 
     As best seen in FIGS. 1-2 of the drawings, a structural support system I of the present invention comprises an adjustable supporting bracket which is constructed for use as a temporary support in concrete falsework construction and the like, i.e., bridge deck forming where concrete falsework construction is required. When support system 1 is used in a concrete overhang construction environment, as shown in FIG. 2, the concrete overhang 9 is supported on a plywood or form sheet 13. Form sheet 13, in turn, rests on wooden blocks or spacers 11. Support system 1 supports spacers 11 to support the overhang, as will be described below. 
     In the concrete overhang support environment, the structural support system or adjustable support bracket 1 includes a pair of generally parallel, spaced apart supporting beams 3 which are received in a pair of spaced apart support brackets 5. The bracket 5 engages the two support beams 3 in spaced and supported relationship. A fastener 21 extends from one of the brackets 5 into the concrete overhang 9 to secure the bracket 5, and hence the support beams 3 and support system 1, to the concrete overhang falsework construction, as shown in FIG. 2. 
     Turning to FIG. 3, each bracket 5 includes two vertically extending and laterally spaced apart elongated hollow bodies 31a, defining axially extending openings. The bodies 31a are preferably substantially identical. In the overhang support system environment, of FIGS. 1-2, the openings of bodies 31a are sized and shaped to slidably receive the support beams 3, as illustrated in FIGS. 1-2 and 7. Preferably, the openings have a width slightly greater than the width of beam 3 and height somewhat greater than the height of beam 3. 
     A load plate 33 is placed at the bottom of each body 31a and the beams 3 sit on the respective load plate. The load plate 33 has a height slightly smaller than the difference between the height of the beam 3 and the body opening. Thus, when the load plate is placed in body 31a, the body opening is only slightly larger than the beam. The load plate 33 is vertically adjustable by way of a threaded bolt 35 which extends through a threaded opening in a bottom of body 31a. The bolt 35 and load plate provide a vertically adjustable gripping means for adjustably and fixedly the each hollow bodies 31a to the support beams 3. Simple threaded adjustment of each bolt 35 moves the load plate 33 into and out of the engagement with its associated support beam 3, thereby permitting attachment or removal of the support bracket 5 relative to the support beam 3, as will be appreciated. A nut is provided associated with the body 31a to secure the bolt in place, to ensure that the bolt, and hence the support system, will not loosen during use. 
     Bearing plates 37 and 37a are secured to the bodies 31a therebetween and hold the bodies in spaced apart relationship. Bearing plate 37 has upper and lower generally vertical sections which are joined together by a central diagonal section. The upper and lower sections are horizontally spaced apart so that one is near the back of the bodies and the other is near the front of the bodies. Plate 37 is generally vertically oriented between bodies 31a. Beating plate 37a is a generally planar plate positioned in a generally horizontal orientation between the bodies 31a near the bottoms thereof. Plate 37a has a bolt hole 37b formed therein. Bearing plate 37 has a bolt hole 39 formed in the diagonal section thereof and a bolt hole 39a formed at the junction of its vertical and diagonal sections. 
     An attachment pin 35a extends through one, and preferably both, of the bodies 31a and support beams 3 secure bodies 31a and beams 3 together. Pin 35a extends through holes 31b formed in the vertical side walls of the hollow bodies 31a. In order to secure attachment pin 35a engagement into support bracket 5, a simple hitch pin 35b is installed through a hole in attachment pin 35a. Other methods could of course be used to secure bracket 5 in place relative to beam 3. For example, pin 35 could have a threaded end which receives a nut, which would replace hitch pin 35b. Preferably a single attachment pin 35a is used to secure bracket 5 to beams 3 to allow for rotational or pivotal motion of support bracket 5 relative to beam 3. Load imposed on or against the bearing plates 37 and 37a, in the support overhang construction environment, will bear load on or against support bracket 5 when it is secured to the support beams 3. Rotation of beam 3 about attachment pin 35a creates a tight fit of the beam in the body 31a. The rotation of the beam will cause an edge of the load plate 33 and an edge of the top inner surface of the body 31a to grip or bite into the beam 3, to securely hold the beam in place. This creates a tighter, more secure, grip than would the use of only a friction grip when the beam 33 and body 31a are axially parallel. 
     In a concrete overhang falsework construction environment, as shown in FIG. 4, support system 1 is mounted to the overhang by a hanger unit 23 and a threaded fastener 21. One of the brackets 5 is preferably in close proximity to the hanger unit 23. Hanger unit 23 is preferably a vertically positioned I-beam having a vertical web and upper and lower cross bars. A screw receptacle (FIG. 2), preferably in the form of a block secured to the upper surface of the I-beam upper bar receives fastener 21. Fastener 21 extends through the diagonal section of bearing plate 37 of the bracket 5 located closest to hanger unit 23, through the screw receptacle, and into the concrete overhang, to facilitate securement of the support system to the overhang. 
     As shown in FIGS. 1-4, an adjustable fastener 47 is secured to bearing plate 37a of the bracket 5 adjacent the hanger unit 23. Fastener 47 allows for adjustment of the support bracket 1 in the concrete overhang support construction environment as shown in FIGS. 1-2 of the drawings. Fastener 47 is preferably a coil adjustable fastener having a threaded rod extending from opposing ends of an internally threaded tube. One end of the fastener 47 is threaded through hole 37b of support bracket load plate 37a. The opposite end of fastener 47 is secured to a support yoke 47a. An adjustable strut 47b is pivotably secured to yoke 47a, preferably at an end of the yoke remote from fastener 47, by a pin 49b. Strut 47b, in turn, is secured, at an end remote from yoke 47a, to the second support bracket 5 (i.e. the support bracket 5 remote from the hanger unit 23). The end or base of yoke 47a is situated on the bottom cross-bar of the hanger I-beam, near the intersection of the cross-bar and the vertical web. A pivot rod, which is secured to the bottom of yoke 47a, is positioned between the yoke and the cross-bar, and allows for pivotal movement of the yoke on the cross-bar relative to the hanger unit 23. 
     As seen in FIG. 4, a preliminary adjustment device 45 is provided to allow for preliminary adjustment of the support system 1. Adjustment device 45 is preferably a generally L-shaped or angle bracket which is placed on an upper surface of beam 3, and has an associated fastener or nut 45b. A coil bolt 45a extends intermediately through beam 3 through bracket 45 and nut 45b to provide another area for connection of support system 1 to the concrete overhang construction environment, as shown in FIGS. 1 and 2. Adjustment of the coil bolt 45a into engagement with hanger unit 23 will cause support bracket I to rotate about support fastener 21 and for beam 3 to rotate about pin 35a. Beam 3 will then come into secure contact with bracket 5. This also will provide the beams 3 with a slope, to form an overhang having a sloping surfaces. 
     A threaded rod 47c extends from the end of strut 47b to connect strut 47b to bearing plate 37 of the second bracket 5. (FIGS. 5 and 6) Rod 47c is used to make final adjustments of the support system 1 in a concrete overhang support construction environment. The threaded fastener 47c extends through the support bearing plate 37. An adjuster plate 41 is positioned adjacent a bottom surface of the bearing plate 37. Rod 47c extends through plate 41 and, by means of a nut, bears against the beating plate 37 by the use of the adjuster plate 41. Rotation of the adjuster plate 41 is restricted between the hollow bodies 31a to prevent rotation of the adjustable plate 41 as the threaded fastener 47c is adjusted. Final adjustment of the strut 47b will ensure a tight and secure installation of the support bracket 1 at the support fastener 21 and against the load supporting element 23 as it is intended. 
     A second embodiment of the support system is shown in FIGS. 7-11 for use in a concrete slab falsework truss application environment. In FIGS. 10 and 11, the support system 1 is shown used in a horizontal adjustable truss concrete construction environment. The use of a truss in a slab support construction environment will generally require the relative location of the bearing point of support be specifically located to support the load and force from the resulting construction loads. The truss as herein described uses the support beams 3, with support brackets 5 being installed at opposite and opposing ends of the support beams. The variable locations of the support brackets 5 and intermediate bracket means will complete a variable truss support unit 50. 
     In this embodiment, fastener 21a extends vertically, rather than diagonally, from hanger unit 23 to bearing plate 37. Fastener 21 is thus able to extend vertically through both hole 39 in bearing plate 37 and bole 37b in bearing plate 37a, to support and mount the support bracket 5 in the concrete slab falsework truss application. Support plate 37 has an additional slotted hole 39a which receives the coil bolt adjustable fastener 47. Fastener 47, in turn, is attached to a yoke 47a. A fastener 47 extends from each bracket to yoke 47a, which is positioned horizontally intermediate, and vertically below, brackets 5. (FIGS. 10-11) Yoke 47a, in turn, is pivotably attached, by means of a simple threaded fastener 49b, to a lower strut support 49a. Lower strut support 49a is spaced below beams 3 by a vertical, mid-span support beam 49 which is secured to beams 3. As seen in FIGS. 10 and 11, two oppositely directed yokes 47a are used, each of which is connected to one of the brackets by an adjustable fastener 47. 
     It will be appreciated, as shown in FIG. 10, that the connection of the two support yokes 47a to strut base support 49a supports the mid-span support strut 49 to support the mid-span of support beams 3. It will be apparent that the attachment of the intermediate brackets and supports that the truss support 50 (FIGS. 10 and 11) can be adjusted through a full range of level or cambered conditions in the support beam 3, as needed in the shape of the slab support surface in a truss support construction environment.