Patent Publication Number: US-2021164244-A1

Title: Heavy duty spanning forms and related systems and methods

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application claims priority as a continuation of U.S. patent application Ser. No. 16/440,379, filed Jun. 13, 2019 and entitled “Heavy Duty Spanning Forms and Related Systems and Methods,” which claims the benefit under 35 U.S.C. § 119(e) to U.S. Provisional Application 62/684,444, filed Jun. 13, 2018 and entitled “Bolt Bearing Block for Heavy Duty, Spanning Forms,” both of which are hereby incorporated herein by reference in their entireties. 
    
    
     FIELD 
     This various embodiments herein relate generally to concrete forming systems and, more particularly, to steel forms for concrete construction, and even more specifically to a heavy duty spanning form panel having a bolt bearing block for connection to other heavy duty spanning form panels. 
     BACKGROUND 
     Concrete construction forms are generally prefabricated by the manufacturer for use in a particular structural application such as corner forms, linear wall forms, or form parts for assembly on the job to build concrete structures. Modular beam forming systems that span from support to support are well known in the industry. The term “modular form” means one of several form members that can be connected together to make a longer member. This invention is the method, mechanism, and/or device that increases the strength of the connection between the forms and hence the spanning capacity of the form system. 
     As mentioned above, there are modular beam forming systems that can span from support to support. The beam sides and soffit are formed using flat form panels bolted in a U-shaped configuration, while the side panels of the beam forming system are the members that span from support to support. The side forms have similarities to a wide flange beam, or at least they share terminology; there is a top flange, a bottom flange and a web that separates the flanges. Similar to wide flange beams, one flange will resist tension while the opposing flange will resist compression. The tension and compression flanges of adjacent modular form panels need to be connected to transfer the tension and compression forces. Each form panel has a welded connection at the corner of the panel that receives high strength bolts such that adjacent panels can be connected together. Typically, these connections consist of a steel bolting block, steel form panel face sheet, steel top or bottom member or flange, steel end rail of the modular form, and the weld that binds all these connection pieces together. In order to increase the spanning capacity of the form, it is generally understood that it is necessary to (1) increase the size and strength of the face sheet and top or bottom flange: (2) increase the amount of weld between these members and the bolt bearing block; and (3) increase the size and/or number of high strength bolts. 
     Known modular, spanning beam forms were originally invented in the early 1960&#39;s by EFCO Corp., and the original form is sold under the “Plate Girder” trademark. That original design has been copied by other form companies. This known form is a face sheet backed up by supporting members (also called “ribs”) that connect to top and bottom “rails” often referred to as top and bottom flanges. Similar to wide flange beams, the face sheet is the web and the top and bottom rails are the top and bottom flanges of the spanning member. The top and bottom flanges resist tension or compression forces similar to the flanges in wide flange beams. The tensile and compressive forces in the flanges of the form need to be transferred to the adjacent panel by a bolted connection, which is provided by components on each of the two coupled forms that are referred to as “bolt bearing blocks” (or “bolt blocks”). On each form, the high strength bolts bear on the bolt blocks, which are steel blocks welded to the face sheet and the top or bottom flange. Generally, the spanning capacity is limited by the strength of the bolts and/or the strength of the bolt block connection. 
     When the known Plate Girder™ forming system was introduced in the mid-1960s, it was common to manufacture forms using steel with 36 ksi yield strength. Due to advances in steel production technologies, there is now a desire to manufacture form panels using steel with 50 KSI or higher yield strengths in an effort to increase the spanning capability of the form system without a corresponding increase in the weight of the form panels. One disadvantage to utilizing the higher strength steels is that the form panel components must be adequately stiffened - especially those components subjected to compression forces - in order for the components to be able to support the higher stresses due to the higher form panel loads. Higher loads also add to the loads that need to be resisted by the bolts and bolt bearing blocks. Further, in recent years, new, higher strength concrete formulations have been introduced and are becoming widely used in the construction of poured concrete structures. With higher strength concrete comes longer spans and the requirement for the formwork to be able to support the longer spans. 
     There is a need in the art for an improved modular concrete form panel with an improved form panel connection to address the disadvantages of the known form systems for spanning applications described above. 
     BRIEF SUMMARY 
     Discussed herein are various modular form panels for concrete construction having components that strengthen the panels and further enhance the load bearing capacity of the resulting form panel assembly. 
     In Example 1, a modular metal concrete form panel comprises a face sheet secured to a perimeter flange having side rails and end rails, a bolt block secured to the face sheet and further secured to the perimeter flange where the side rails meet the end rails, and a strengthening bar disposed inside each side rail at a distance from each side rail and extended between and secured to each of the pair of opposing bolt blocks of such end rail, wherein the strengthening bar is secured to the face sheet. 
     Example 2 relates to the form panel according to Example 1, wherein the perimeter flange comprises a lip disposed on the side rails and the end rails. 
     Example 3 relates to the form panel according to Example 2, wherein the bolt block comprises a protrusion disposed in a notch defined in the lip of the end rails, whereby the bolt block is secured directly to the side rail and the lip of the side rail. 
     Example 4 relates to the form panel according to Example 1, further comprising at least one rib disposed between the end rails and attached at one end to a first of the side rails and at another end to a second of the side rails. 
     Example 5 relates to the form panel according to Example 4, wherein the strengthening bar is disposed through the at least one rib and attached thereto. 
     Example 6 relates to the form panel according to Example 4, further comprising at least one cross rib attached at a first end to the at least one rib and attached at a second end to one of the end rails. 
     In Example 7, a modular form panel for concrete construction comprises a face sheet, a flange disposed around a perimeter of the face sheet, the flange comprising first and second opposing side rails and first and second opposing end rails, four bolt blocks attached to the face sheet, the first and second side rails, and the first and second end rails, wherein each of the four bolt blocks is disposed in a separate corner of the face sheet, at least one rib disposed between and parallel with the first and second end rails and attached at a first end to the first side rail and at a second end to the second side rail, a first reinforcement bar disposed between and parallel with the first and second side rails and attached at a first end to a first of the four bolt blocks and at a second end to a second of the four bolt blocks, and a second reinforcement bar disposed between and parallel with the first and second side rails and attached at a first end to a third of the four bolt blocks and at a second end to a fourth of the four bolt blocks. 
     Example 8 relates to the form panel according to Example 7, wherein each of the first and second side rails and the first and second end rails comprises a lip disposed thereon. 
     Example 9 relates to the form panel according to Example 8, wherein a first notch is defined between a first end of the lip of the first end rail and the first side rail, a second notch is defined between a second end of the lip of the first end rail and the second side rail, a third notch is defined between a first end of lip of the second end rail and the first side rail, and a fourth notch is defined between a second end of the lip of the second end rail and the second side rail. 
     Example 10 relates to the form panel according to Example 9, wherein a first of the four bolt blocks comprises a first protrusion disposed in the first notch, wherein the first bolt block is attached to the first side rail and the lip of the first side rail, a second of the four bolt blocks comprises a second protrusion disposed in the second notch, wherein the second bolt block is attached to the second side rail and the lip of the second side rail, a third of the four bolt blocks comprises a third protrusion disposed in the third notch, wherein the third bolt block is attached to the first side rail and the lip of the first side rail, and a fourth of the four bolt blocks comprises a fourth protrusion disposed in the fourth notch, wherein the fourth bolt block is attached to the second side rail and the lip of the second side rail. 
     Example 11 relates to the form panel according to Example 7, wherein the first and second reinforcement bars are disposed through a notch defined in the at least one rib and are attached to the at least one rib. 
     Example 12 relates to the form panel according to Example 7, wherein the first reinforcement bar is disposed at a distance from the first side rail such that the first reinforcement bar is closer to the first side rail than the second side rail, and the second reinforcement bar is disposed at a distance from the second side rail such that the second reinforcement bar is closer to the second side rail than the first side rail. 
     Example 13 relates to the form panel according to Example 7, wherein the first end of the first reinforcement bar is attached to an end of the first bolt block that is opposite an end of the first bolt block attached to the first side rail, the second end of the first reinforcement bar is attached to an end of the second bolt block that is opposite and end of the second bolt block attached to the first side rail, the first end of the second reinforcement bar is attached to an end of the third bolt block that is opposite an end of the third bolt block attached to the second side rail, and the second end of the second reinforcement bar is attached to an end of the fourth bolt block that is opposite an end of the fourth bolt block attached to the second side rail. 
     Example 14 relates to the form panel according to Example 7, further comprising at least one cross rib attached at a first end to the at least one rib and attached at a second end to one of the first and second end rails. 
     In Example 15, a method of constructing a concrete spanning beam comprises positioning at least first and second modular form panels adjacent to each other. Each of the first and second modular form panels comprises a face sheet, a flange disposed around a perimeter of the face sheet, the flange comprising first and second opposing side rails and first and second opposing end rails, four bolt blocks attached to the face sheet, the first and second side rails, and the first and second end rails, wherein each of the four bolt blocks is disposed in a separate corner of the face sheet, at least one rib disposed between and parallel with the first and second end rails and attached at a first end to the first side rail and at a second end to the second side rail, a first reinforcement bar disposed between and parallel with the first and second side rails and attached at a first end to a first of the four bolt blocks and at a second end to a second of the four bolt blocks, and a second reinforcement bar disposed between and parallel with the first and second side rails and attached at a first end to a third of the four bolt blocks and at a second end to a fourth of the four bolt blocks. The method further comprises aligning the first modular form panel with the second modular form panel such that the first end rail of the first modular form panel is in contact with the second end rail of the second modular form panel, positioning at least two bolts through at least two holes in a first of the four bolt blocks of the first modular form panel and through at least two holes in a first of the four bolt blocks of the second modular form panel, thereby attaching the first bolt block of the first modular form panel with the first bolt block of the second modular form panel, positioning at least two bolts through at least two holes in a second of the four bolt blocks of the first modular form panel and through at least two holes in a second of the four bolt blocks of the second modular form panel, thereby attaching the second bolt block of the first modular form panel with the second bolt block of the second modular form panel, and attaching a plurality of additional modular form panels to the first or second form panels or additional attached form panels by repeating the aligning and the positioning of the at least two bolts to create a panel assembly. 
     Example 16 relates to the method according to Example 15, further comprising attaching the panel assembly to first and second supports such that the panel assembly is disposed on and supported by the first and second supports. 
     Example 17 relates to the method according to Example 16, further comprising pouring concrete into the panel assembly to form a concrete structure that extends across and is supported by the first and second supports. 
     While multiple embodiments are disclosed, still other embodiments of the present invention 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 invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a integrated concrete form component made up of a plurality of concrete form panels, according to one embodiment. 
         FIG. 2  is an elevation view of a rear side of a modular concrete form component, according to one embodiment. 
         FIG. 3  is a cross-sectional view taken along line A-A of  FIG. 2 , according to one embodiment. 
         FIG. 4  is a side view of the panel of  FIG. 2 , according to one embodiment. 
         FIG. 5  is a plan or top view of the panel of  FIG. 2 , according to one embodiment. 
         FIG. 6  is a cross-sectional view taken along line B-B of  FIG. 2 , according to one embodiment. 
         FIG. 7  is an expanded perspective view of a bolt block, according to one embodiment. 
         FIGS. 8A-8D  are elevation views of various exemplary form panels of different sizes, according to certain embodiments. 
         FIGS. 9A-9C  are expanded side views of various exemplary bolt blocks of different sizes that can be used in various form panel embodiments of different sizes, according to certain embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     The various embodiments herein relate to a metal concrete form panel having an increased resistance to deflection and bending when coupled with other such panels to contain and form and support concrete spanning structures. In certain implementations, the form panel as described herein displays an increase in strength of up to at least 200%, and in some cases, 300%, in comparison to known form panels. 
       FIG. 1  depicts an integrated concrete form panel assembly  10  that is made up of a plurality of form assembly  10  that have been assembled or coupled together for the construction of a concrete structure. More specifically, the integrated form panel assembly  10  spans from one support  14 A to another support  14 B such that the panel assembly  10  allows for pouring a concrete structure that cures such that it extends across and is supported by both supports  14 A,  14 B. 
     One exemplary implementation of a metal concrete form panel  20  is depicted in  FIGS. 2-7 . The form panel  20  has a face sheet  22  and a perimeter flange  24  that extends from a rear side of the face sheet  22  (as best shown in  FIGS. 3-7 ). The flange  24  extends from the back side of the face sheet  22  around the entire perimeter of the face sheet  22  and is made up of a pair of opposing side rails  26   a  and  26   b  and a pair of opposing end rails  28   a  and  28   b.  It is understood that the flange  24  (or the rails  26   a,    26   b,    28   a,    28   b ) are secured to the face sheet  22  by weldments or similar attachment mechanism or methods. According to certain embodiments, the flange  24  (that is, each of the rails  26   a,    26   b,    28   a,    28   b ) has a lip disposed thereon. More specifically, as best shown in  FIGS. 2, 3, 4, 6, and 7 , the side rails  26   a,    26   b  have a lip  27  and the end rails  28   a,    28   b  have a lip  29 . The lips  27 ,  29  may also be referred to herein as “formed returns.” 
     As best shown in  FIG. 2 , the panel  20  also has ribs  30  and rib stiffeners (or “cross ribs”)  32  attached thereto. More specifically, the panel  20  has one or more ribs  30  that are disposed on the same side of the face sheet  22  as the side rails  26   a,    26   b  and extend between the side rails  26   a,    26   b  and are parallel with the end rails  28   a,    28   b.  Each rib  30  is secured along its length by weldments or the like to the back side of the face sheet  22  and further is attached at its ends to the side rails  26   a,    26   b.  In addition, the panel  20  has at least two rib stiffeners  32 , each of which is a short member (by comparison to a rib  30 , for example) that extends between a tie rib  30  and one of the end rails  28   a,    28   b  as shown such that the rib stiffeners  32  are parallel to the side rails  26   a,    26   b.  Each cross rib  32  is secured along its length to the back side of the face sheet  22  by weldments or the like and further is attached at its ends to a rib  30  on one end and one of the end rails  28   a,    28   b  on the other. 
     As best shown in  FIGS. 2, 4, and 7 , in accordance with one implementation, the form panel  20  also has four bolt blocks  34 —one in each corner of the panel  20 . Each bolt block  34  is used in conjunction with a corresponding bolt block on a second, adjacent form to secure the instant form  20  to the adjacent form via bolts that are coupled to both of the corresponding blocks. Thus, the bolt blocks  34  on the form  20  and the bolt blocks on the adjacent forms (not shown) operate together to secure multiple form panels  20  together in a fashion similar to that shown in  FIG. 1 . Each bolt block  34  functions to transfer forces between and among the multiple form panels  20 , thereby giving the form system  10  (the plurality of panels  20 ) its bending moment strength. As best shown in  FIGS. 4 and 7 , each bolt block  34  is a piece of metal  34  that is disposed in a corner of the panel  20  and secured along a side to one of the end rails  28   a,    28   b  and at its end to one of the side rails  26   a,    26   b.  Further, each bolt block  34  has at least two openings  35  defined therein that are configured to receive the bolts (not shown) that couple to the bolt block  34  and the corresponding bolt block on the adjacent form (not shown). 
     In one embodiment, the openings  35  in any of the bolt block  34  implementations disclosed or contemplated herein are sized to receive 1¼ inch bolts (not shown). Alternatively, the openings  35  can be sized to receive 1 inch bolts (not shown). In a further implementation, the openings  35  can be sized to receive any known bolt of any known size that is used for coupling form panels in concrete construction. In certain embodiments, each block  34  has four openings  35  and thus couples to an adjacent block  34  on an adjacent panel  20  via four bolts (not shown). Alternatively, the coupling could occur using three bolts (not shown). In a further alternative, two bolts (not shown) could be used. It is understood that the bolt block  34  can have two, three, four, or more openings  35  for receiving bolts (not shown). 
     In addition, according to one embodiment, the panel  20  also has two strengthening bars (or “support bars” or “reinforcement bars”)  36  as best shown in  FIGS. 2 and 7  that extend between two bolt blocks  34  at a spaced distance from (and parallel to) the closest side rail  26   a,    26   b  as shown. Each of the bars  36  is secured, for example by weldments, at opposite ends of the bar  36  to each of the bolt blocks  34 . In one embodiment, the bar  36  is attached to the two bolt blocks  34  at the point on each block  34  that is farthest from the side rail  26   a,    26   b  to which the block  34  is attached. Further, as best shown in  FIG. 7 , each bar  36  extends through an opening (or “slot”)  37  defined in each of the ribs  30  disposed between the two bolt blocks  34  and is secured to each such rib  30  by weldments or the like. In addition, the strengthening bar  36  is also attached to the face sheet  22 , and can be attached by weldments or other known attachment methods or mechanisms. According to one implementation, each strengthening bar helps to prevent the face sheet  22 , and thus the entire panel  20 , from buckling near the compression flange, thereby resulting in a larger compression zone of the form  20  being able to resist more load. It is understood that, because the various panel embodiments (such as, for example, panel  20 ) disclosed or contemplated herein are modular panels, the location of the compression flange (along with the compression and tension zones discussed below) on the panel (such as panel  20 ) depends on how the loads are applied to the form assembly (and thus the individual, modular panels). Additionally, according to certain embodiments, each strengthening bar  36  can increase the area of the tension zone, thereby increasing the tensile flange capacity of the panel  20 . Further, each strengthening bar  36  adds significant strength to the bolt bearing blocks  34  to which it is attached. That is, the bar  36  adds the necessary strength to the bolt blocks  34  to allow more, larger diameter high strength bolts, thereby increasing the strength of the connection between panels. This, in turn, increases the spanning capacity of the entire form system (like form system  10 , for example). 
     In accordance with certain implementations, each bolt bearing block  34 , such as, for example, the bolt bearing block  34  as shown in  FIG. 7 , has a protrusion  39  that extends out from the block  34  such that it is disposed adjacent to and “flush” with the lip  29  of the end rail  28   a  as shown. In other words, a portion of the lip  29  is removed such that an end  41  of the lip  29  is disposed at a distance from the side rail  26   a,  thereby defining a notch  43  formed between the lip end  41  and the side rail  26   a.  The protrusion  39  is disposed within the notch  43  and is attached (by a weld in one exemplary embodiment) directly to the lip  27  of side rail  26   a.  This configuration of the protrusion  39  disposed in the notch  43  and attached to the lip  27  results in a greater percentage of the bolt loading being transferred directly to the main structural components of the concrete form panel, thereby resulting in a more rigid bolt bearing block connection than prior connection designs. The prior, known connection designs have a bolt bearing block that is typically a simple bar that does not protrude into the notch in the end rail lip, which results in some of the bolt loading being indirectly transferred to the structural components of the panel, which can ultimately result in too much load being placed on those structural components. 
     It is understood that any form panel according to any embodiment disclosed or contemplated herein can be of any size desired for use in the concrete forming industry. Various exemplary sizes and configurations are depicts in  FIGS. 8A-8D . While the various configurations as shown in these  FIGS. 8A-8D  can have any known dimensions, specific examples are also provided herein. For example, the form panel  40  as depicted in  FIG. 8A  can be 5 feet by 4 feet. Further, in another example, the form panel  42  shown in  FIG. 8B  can be 8 feet by 8 feet. Additionally, a further example is shown in  FIG. 8C , in which the panel  44  is 10 feet by 8 feet. Another example is depicted in  FIG. 8D , in which the panel  46  is 4 feet by 12 feet. It is understood that any known dimensions for any known panels can be used for the various panels  40 ,  42 ,  44 ,  46  depicted in  FIGS. 8A-8D . 
     In a further specific example, Table 1 sets forth a chart of various panel sizes, including certain more common sizes identified with an “X.” 
     
       
         
           
               
               
               
               
               
               
               
             
               
                   
                 TABLE 1 
               
               
                   
                   
               
               
                   
                 X1′ 
                 X2′ 
                 X4′ 
                 X6′ 
                 X8′ 
                 X12′ 
               
               
                   
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
               
               
               
            
               
                 2′R 
                   
                   
                   
                   
                   
                   
               
               
                 3′R 
               
               
                 4′R 
               
               
                 5′R 
                 X 
                 X 
                 X 
                   
                 X 
                 X 
               
               
                 6′R 
                 X 
                 X 
                 X 
                   
                 X 
                 X 
               
               
                 7′R 
                 X 
                 X 
                 X 
                   
                 X 
                 X 
               
               
                 8′R 
                 X 
                 X 
                 X 
                   
                 X 
                 X 
               
               
                 9′R 
                 X 
                 X 
                 X 
                   
                 X 
               
               
                 10′R  
                 X 
                 X 
                 X 
                   
                 X 
               
               
                 12′R  
                 X 
                 X 
                 X 
                   
                 X 
               
               
                   
               
            
           
         
       
     
     As shown in  FIGS. 9A-9C , It is understood that any bolt block according to any embodiment disclosed or contemplated herein can be of any size as necessary to fit within or be incorporated into the form panels of various sizes as described above for use in the concrete forming industry. Various exemplary sizes and configurations of the bolt blocks are depicted in  FIGS. 9A-9C . For example, bolt block  52  of  FIG. 9B  is wider than bolt block  50  as shown in  FIG. 9A . Further, bolt block  54  depicted in  FIG. 9C  is wider than bolt block  52  of  FIG. 9B . It is understood that the various bolt blocks (such as blocks  34 ,  50 ,  52 ,  54 ) vary in size to accommodate the increased loading of larger form panels  20 . Further, it is understood that the larger bolt blocks as contemplated herein can include additional bolt holes for additional or larger bolts. 
     The foregoing description and drawings comprise illustrative embodiments of the various embodiments. The foregoing implementations described herein may vary based on the ability, experience, and preference of those skilled in the art. The foregoing description and drawings merely explain and illustrate the embodiments, and the various implementations are not limited thereto, except insofar as the claims are so limited. Those skilled in the art who have the disclosure before them will be able to make modifications and variations therein without departing from the scope of the inventions.