Patent Publication Number: US-8991802-B1

Title: Tool for aligning highway barrier modules

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates, generally, to highway barrier module installation. More particularly, it relates to a tool that facilitates alignment of barrier modules atop a retaining wall. 
     2. Description of the Prior Art 
     A highway barrier wall is formed of a plurality of barrier modules that are placed end-to-end alongside an elevated highway or overpass to prevent vehicles that leave the road from falling. The modules are placed atop a retaining wall that retains the earth atop which the highway is built. 
     A piece of heavy construction equipment such as a front loader, an excavator or the like unloads the barrier modules one at a time atop the retaining wall. The heavy equipment operator works with a work crew until each module is properly aligned, i.e., the operator applies a lifting force to each module so that the workers can manually shove or pry it into a desired position and then removes the lifting force. If the alignment is unacceptable, the procedure is repeated until the heavy module is in an acceptable position. 
     The primary drawback of this well-known installation technique is that the heavy equipment operator and of course the heavy equipment must remain at the site of each barrier wall module until each module is properly aligned with its adjacent modules. The heavy equipment and its operator are billed hourly so substantial monies could be saved if the alignment process required less time. 
     The prior art teaches that elongate boards can be used during the barrier module alignment process. An elongate board is placed on each side of a barrier module junction and a through bolt is used to pull the opposed boards toward one another, thereby causing two (2) adjacent barrier modules to enter into flush alignment with one another. 
     The problem with this well-known procedure is that it can only align adjacent barrier modules with one another but it cannot adjust the position of the barrier modules with respect to the underlying retaining wall. Since a retaining wall is unlikely to be perfectly straight, the barrier modules will meander, flush with one another at each barrier module junction but collectively following a non-straight path of travel defined by the retaining wall. 
     There are no prior art tools that enable alignment of barrier modules relative to a meandering retaining wall so that adjacent barrier modules are not only flush with one another, but are also longitudinally aligned with one another so that the barrier modules collectively form a straight line even when mounted atop a non-straight retaining wall. 
     In view of the art considered as a whole at the time the present invention was made, it was not obvious to those of ordinary skill in the art how the known barrier alignment methods could be improved. 
     SUMMARY OF THE INVENTION 
     The long-standing but heretofore unfulfilled need for a device that facilitates flush alignment of adjacent highway barrier modules atop retaining walls and which enables barrier modules to collectively form a straight barrier even when mounted atop a non-straight retaining wall is now met by a new, useful, and non-obvious invention. 
     The novel structure is a tool for aligning barrier wall modules atop a retaining wall so that each member of an adjacent pair of modules is flush with one another and so that a large plurality of modules can be collectively placed into a straight line atop a non-straight retaining wall. 
     The novel tool includes a flat base adapted to be transversely disposed relative to a longitudinal axis of a retaining wall. The flat base is also adapted to be positioned between adjacent barrier wall modules disposed in end-to-end relation to one another atop the retaining wall. 
     The flat base includes a central part, a flat first arm and a flat second arm. The first and second flat arms are integrally formed with and extend from the central part in opposite directions relative to one another and in co-planar alignment with the flat central part. 
     A retaining wall-receiving notch is cut out from the central part of the novel tool. The notch has a depth sufficient to receive a predetermined vertical extent of a retaining wall therein and has a width sufficient to receive a predetermined width of the retaining wall. Since retaining walls are provided in various widths, the notch has a width greater than the width of most retaining walls. Barrier modules also have a retaining wall-receiving notch formed in their bottom walls as well, and said notches are also wider than the widest retaining walls for the same reason and to provide a tolerance for field alignment. 
     The flat base further includes a first elongate bolt and a second elongate bolt. The first and second elongate bolts are secured to and extend from respective free ends of the first and second flat arms in opposite directions relative to one another and in longitudinal alignment with the first and second flat arms. 
     A first nut is in screw-threaded engagement with the first elongate bolt and a second nut is in screw-threaded engagement with the second elongate bolt. 
     A first housing ensleeves the first flat arm and the first elongate bolt and is slideably mounted with respect to the first flat arm and the first elongate bolt. The first housing moves toward the central part, i.e., in an outboard-to-inboard direction, when the first nut is advanced toward the central part. 
     A second housing ensleeves the second flat arm and the second elongate bolt and is slideably mounted with respect to said second flat arm and the second elongate bolt. The second housing moves toward said central part, i.e., in an outboard-to-inboard direction, when the second nut is advanced towards the central part. 
     The first housing has a parallelepiped structure that includes sidewalls disposed parallel to the first flat arm and the first elongate bolt, an inboard wall disposed transverse to the sidewalls and an outboard wall disposed transverse to the sidewalls. 
     The second housing has a parallelepiped structure that includes sidewalls disposed parallel to the second flat arm and the second elongate bolt, an inboard wall disposed transverse to the second housing sidewalls and an outboard wall disposed transverse to the second housing sidewalls. 
     The inboard wall of the first housing has a central aperture formed therein to slidingly receive the first elongate bolt. The inboard wall of the first housing also has a pair of rectangular slots in open communication with the central aperture that extend radially from the central aperture in opposite directions. The pair of rectangular slots slidingly receive the first flat arm. 
     The outboard wall of the first housing has a central aperture formed therein to slidingly receive the first elongate bolt. 
     The inboard wall of the second housing has a central aperture formed therein to slidingly receive the second elongate bolt. The inboard wall of the second housing has a pair of rectangular slots in open communication with the central aperture of the second housing that extend radially from the second housing central aperture in opposite directions. The pair of rectangular slots slidingly receive the second flat arm. 
     The outboard wall of the second housing has a central aperture formed therein to slidingly receive the second elongate bolt. 
     The respective inboard walls of the first and second housings are each preferably provided with a flange so that pressure applied to adjacent barrier modules by said first and second housings is spread over a large surface area. 
     The first housing is adapted to abut the first sides of two confronting barrier modules at their junction when the first nut is advanced and the second housing is adapted to abut second, opposite sides of those barrier modules when the second nut is advanced. Relative advancement of the first and second nuts therefore brings the two barrier modules into flush relation to one another at their junction or parting line. This particular function can also be performed by boards and a through bolt but the novel tool is easier to work with. 
     After the barrier modules have been positioned atop the retaining wall in flush relation to one another, the novel tool also enables longitudinal alignment of the barrier modules with one another even if the supporting retaining wall is not perfectly straight, i.e., if the retaining wall meanders relative to a straight path of travel. This important function cannot be performed by the prior art assembly of boards and a through bolt. 
     An important object of this invention is to facilitate the installation of elongate highway barrier modules by providing a tool that aligns adjacent barrier modules into flush relation with one another in the absence of an excavator, front loader, or other item of heavy equipment. 
     An even more important object is to enable straight alignment of barrier modules atop a retaining wall that is not straight. 
     A closely related object is to reduce the time and expense required to install elongate highway barrier modules by providing a tool that can be handled by two workers, one on each side of a retaining wall, with no further assistance provided by a piece of heavy equipment and its operator after the barrier modules have been positioned atop the retaining wall. 
     These and other important objects, advantages, and features of the invention will become clear as this disclosure proceeds. 
     The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts that will be exemplified in the disclosure set forth hereinafter and the scope of the invention will be indicated in the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed disclosure, taken in connection with the accompanying drawings, in which: 
         FIG. 1  is an end view of a highway barrier module seated atop a retaining wall; 
         FIG. 2  is a perspective view of the novel barrier module alignment tool; 
         FIG. 3A  is a side elevational view of the tool depicted in  FIG. 2 ; 
         FIG. 3B  is a side elevational view of the flat base of the tool; 
         FIG. 4  is a top plan view of the tool depicted in  FIGS. 2 and 3A ; 
         FIG. 5  is an end elevational view of the inboard wall of a housing; 
         FIG. 6  is an end elevational view of the outboard wall of a housing; 
         FIG. 7  is a perspective view of the second housing; 
         FIG. 8A  depicts meandering barrier modules atop a meandering retaining wall; and 
         FIG. 8B  depicts barrier modules in straight alignment with one another atop a meandering retaining wall as attained by the novel tool. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       FIG. 1  depicts a barrier module  12  positioned atop a retaining wall  14 . The top of retaining wall  14  is received within notch  13 . 
       FIG. 2  depicts an illustrative embodiment of the inventive structure which is denoted as a whole by the reference numeral  10 . 
     Flat base  16  is adapted to be transversely disposed relative to a longitudinal axis of retaining wall  14 . Flat base  16  is adapted to be positioned between adjacent barrier wall modules  12  disposed in end-to-end relation to one another atop retaining wall  14 . 
     Flat base  16  includes flat central part  18 , flat first arm  20  and flat second arm  22 . First and second flat arms  20 ,  22  are integrally formed with and extend from flat central part  18  in opposite directions relative to one another and in co-planar alignment with said flat central part. 
     Flat base  16  further includes first elongate bolt  24  and second elongate bolt  26 . First and second elongate bolts  24  and  26  are secured to and extend from respective free ends of first and second flat arms  20 ,  22  in opposite directions relative to one another and in longitudinal alignment with the first and second flat arms. Notches  21  and  23  provide connection points for the respective inboard ends of bolts  24  and  26 , said connection preferably being made by welding. 
     First nut  28  is in screw-threaded engagement with first elongate bolt  24  and second nut  30  is in screw-threaded engagement with second elongate bolt  26 . 
     First housing  32  ensleeves first flat arm  20  and first elongate bolt  24  and is slideably mounted with respect to said first flat arm and said first elongate bolt. First housing  32  is movable toward central part  18  when first nut  28  is advanced toward said central part, i.e., in an outboard-to-inboard direction. 
     Second housing  34  ensleeves second flat arm  22  and second elongate bolt  26  and is slideably mounted with respect to said second flat arm and said second elongate bolt. Second housing  34  is movable toward central part  18  when second nut  30  is advanced toward central part  18 , i.e., in an outboard-to-inboard direction. 
     Retaining wall-receiving notch  36  is cut out from central part  18 . Notch  36  has a depth sufficient to receive a predetermined vertical extent of retaining wall  14  therein and has a width sufficient to receive a predetermined width of said retaining wall. Central part  18  may be provided with a vertical extent that exceeds the vertical extent of the first and second arms in order to maintain a robust central part even when a large notch is cut therefrom. 
     In a preferred embodiment, first housing  32  has a parallelepiped structure that includes sidewalls  38  disposed parallel to first flat arm  20  and first elongate bolt  24 . Inboard wall  40  is disposed transversely to sidewalls  38  and is preferably provided with flanges as depicted so that inboard wall  40  has a height and width extent that exceeds the height and width extent of housing  34 . Outboard wall  42  is also disposed transversely to sidewalls  38 . 
     Inboard wall  40  of first housing  32  has a central aperture  50  formed therein to slidingly receive first elongate bolt  24 . Inboard wall  40  also has a pair of rectangular slots, collectively denoted  52 , formed therein in open communication with central aperture  50  and extending radially from said central aperture in opposite directions, said pair of rectangular slots  52  slidingly receiving first flat arm  20 . 
     Outboard wall  42  of first housing  32  has central aperture  54  formed therein to slidingly receive first elongate bolt  24 . 
     In the preferred embodiment, second housing  34  has a parallelepiped structure that includes sidewalls  44  disposed parallel to second flat arm  22  and second elongate bolt  26 . Inboard wall  46  is disposed transversely to second housing sidewalls  44  and outboard wall  48  is disposed transversely to said second housing sidewalls. 
     Inboard wall  46  of second housing  34  has the same structure as inboard wall  40  of first housing  32 , i.e., it includes a central aperture formed therein to slidingly receive second elongate bolt  26  and it further includes a pair of rectangular slots formed therein in open communication with the central aperture, said rectangular slots extending radially from the central aperture in opposite directions and slidingly receiving second flat arm  22 . 
     Outboard wall  48  of second housing  34  has central aperture  56  formed therein to slidingly receive second elongate bolt  26 . 
     In the preferred embodiment, the respective inboard walls  40  and  46  of first and second housings  32  and  34  include flanges as depicted so that pressure applied to adjacent barrier modules  12  by said first and second housings is spread over a large surface area. Inboard walls  40  and  46  could be flangeless, i.e., they could have substantially the same dimensions of outboard walls  42  and  48 . 
     The inboard end of first housing  32  abuts a first, highway side of two (2) adjacent barrier modules  12  when first nut  28  is advanced and the inboard end of second housing  34  abuts a second, opposite side of the adjacent barrier modules  12  when second nut  30  is advanced. Accordingly, relative advancement of the first and second nuts in an outboard-to-inboard direction brings adjacent barrier modules  12  into flush relation to one another atop retaining wall  14 . 
     Novel alignment tool  10  enables a heavy equipment operator to deposit a large number of barrier modules  12  along the extent of a retaining wall  14  and to leave the area to perform other work, there being no need for the heavy equipment operator to provide further assistance in the alignment process for each barrier module. Two workers, one on each side of a pair of adjacent barrier modules, can perform the needed alignment in the absence of further heavy equipment assistance once the operator has deposited the barrier modules atop the retaining wall in closely spaced, end-to-end relation to one another. The only other tool required is a wrench for each worker to facilitate turning of nuts  28  and  30 . 
     It is possible to simplify novel tool  10  by eliminating one of the two flat arms  20 ,  22 . The alignment work can be accomplished by using only one (1) of said two (2) flat arms, i.e., tool  10  could have one (1) arm and be used from one side of the barrier wall and then from the other side to do the same job. 
     In the one arm apparatus, the flat base includes a flat end part and a flat arm. A retaining wall-receiving notch is cut out from the end part. The notch has a depth sufficient to receive a predetermined vertical extent of a retaining wall therein and has a width sufficient to receive a predetermined width of the retaining wall. 
     The flat arm is integrally formed with and extends from the end part in co-planar alignment with the end part. The flat base includes an elongate bolt which is secured to and extends from the flat arm in longitudinal alignment with the flat arm. A nut is in screw-threaded engagement with the elongate bolt. A housing ensleeves the flat arm and the elongate bolt and is slideably mounted with respect to the flat arm and the elongate bolt. The housing is movable toward the end part when the nut is advanced toward the end part. The housing is adapted to abut a first side of a pair of confronting barrier modules when the nut is advanced. Advancement of the nut brings the adjacent barrier modules into flush relation to one another. 
     The housing has a parallelepiped structure that includes sidewalls disposed parallel to the flat arm and the elongate bolt. An inboard wall is disposed transverse to the sidewalls as is an outboard wall. 
     The inboard wall of the housing has a central aperture formed therein to slidingly receive the elongate bolt. The inboard wall of the housing also has a pair of rectangular slots in open communication with the central aperture. The slots extend radially from the central aperture in opposite directions. The pair of rectangular slots slidingly receive the flat arm. 
     The outboard wall of the housing has a central aperture formed therein to slidingly receive the elongate bolt. The inboard wall of the housing includes a flange so that pressure applied to adjacent barrier modules by the housing is spread over a large surface area. 
     The novel device performs two (2) functions, one of which can be performed by prior art devices and one of which cannot. 
     In the first function, the novel structure brings two barrier modules into flush relation with each other at their juncture. Prior art devices that employ boards and a through bolt interconnecting the boards can also perform that function. The novel structure does not require boards and a through bolt and can thus perform the alignment function in a better way, but the alignment function alone can be performed by said prior art boards and through bolts. 
     In the second function, which cannot be performed by prior art devices, the novel apparatus can shift a plurality of adjacent, flush barrier modules into a straight alignment with one another even when mounted atop a non-straight barrier wall. 
     Both functions are performed after an excavator, front end loader, or other piece of heavy equipment has deposited the barrier modules atop a retaining wall and left the area. 
     More particularly, after positioning the notch of the novel tool over the top of the retaining wall and performing the flush alignment procedure, the second function is performed by pulling adjacent barrier modules inward by loosening the inside nut and tightening the outside nut, or by pushing adjacent barrier modules outwardly by loosening the outside nut and tightening the inside nut. This brings the barrier modules into longitudinal alignment with one another even if they are mounted atop a non-straight retaining wall. 
       FIG. 8A  depicts barrier modules  12  immediately after they are placed on the top of retaining wall  14 . They are offset and out of alignment with one another. 
       FIG. 8B  depicts barrier modules  12  after novel device  10  has performed its two (2) functions: 1) The barrier modules are clamped so that their abutting ends are not offset from each other; and 2) The barrier modules are aligned in a straight line on top of meandering retaining wall  14 . The second function cannot be performed by prior art devices. 
     The notch formed in the bottom wall of barrier modules  12  is indicated by parallel dotted lines  13 . 
     It will thus be seen that the objects set forth above, and those made apparent from the foregoing disclosure, are efficiently attained and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing disclosure or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. 
     It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention that, as a matter of language, might be said to fall therebetween.