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Claims  |
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I claim:
1. In a slab-beam formwork system for receiving poured concrete in the
constructing of a roof or floor, comprising:
a generally U-shape channel form adapted to form a concrete beam for said
system and having an outwardly extending support means extending generally
in a horizontal plane and being part of at least one sidewall of said
channel form adjacent an opening for said receiving of said poured
concrete,
said support means consisting of at least two generally horizontal support
areas, one said area being on an upper elevational level in close
proximity to said opening of said channel form and the other of said area
being on a lower elevational level remote from said opening of said
channel form,
each of said areas adapted to support a structural member for the forming
of said slab, and said areas having means adapted to alternately support
said structional member in the pouring of said concrete whereby said
structural member is positionable on said one area on said upper
elevational level to become a composite part of said slab, or said
structural member is positionable on said other area on said lower
elevational level to be removed after the forming of said slab.
2. The slab-beam formwork system of claim 1, wherein said channel form is
metal and further comprising means associated with said support means
including lip means extending downwardly from said other area is said
lower elevational level for easy removal of said channel form from said
formwork and said formed slab and beam.
3. The slab-beam forming system of claim 1, wherein said structional member
is a corrugated metal deck located on said one area on said upper
elevational level, and further comprising a support member supported by
said other area in said lower elevational level, and adapted to
substantially support said metal deck and to be removed from said
formwork.
4. The slab-beam forming system of claim 1, wherein said structural member
is a metal deck located on said other area on said lower level, and
further comprising a support member supported by said one area in said
upper elevational level, and adapted to be substantially supported by said
metal deck and to be removed along with said metal deck after the forming
of said slab and beam.
5. The slab-beam formwork system of claim 1, further comprising a shoring
system adapted to support said formwork of said slab-beam system,
said shoring system consisting of a frame having at least and a plurality
of upright members, and a U-shape shoring head connected to each said
upright member, and
said U-shape shoring heads each adapted to substantially support said
channel form along the length of said channel form.
6. The slab-beam formwork system of claim 5, wherein said shoring system
further comprises adjustable means for adjusting the elevational level of
said each shoring head, and wherein said channel form consists of a bottom
wall and two opposed sidewalls generally slanting upwardly and outwardly
from said bottom wall, and wherein said shoring head consists of a bottom
wall and two opposed sidewalls generally slanting upwardly and outwardly
from said bottom wall at an angle generally corresponding to said
sidewalls of said channel form.
7. The slab-beam formwork system of claim 5, wherein a plurality of
concrete beams and slabs are alternately formed and, wherein said shoring
heads substantially extend the length and width of said slab-beam
formwork,
said shoring system further comprising means for selectively adapting said
shoring heads in a manner that substantial support is given to said slab
when a longer length slab is formed in said slab-beam system.
8. A method of forming a concrete slab-beam system for a roof or floor with
a formwork, the steps comprising:
providing a generally U-shape channel form with an opening for receiving
concrete and having outwardly extending flange means with at least two
supporting surfaces with one surface in an upper elevational level and
adjacent to said opening, and another surface in a lower elevational level
away from said opening and
in the step for forming a composite slab consisting of a metal deck
integrally cast with said concrete, positioning said metal deck onto said
one surface in said upper elevational level of cooperative flange units of
two neighboring cooperative channel forms.
9. A method of claim 8, the steps further comprising:
prior to said positioning of said metal deck onto said one surface, further
positioning a support member which is to be removed for said metal deck
onto said another surface in said lower elevational level of cooperative
flange means of said two neighboring cooperative channel forms, and
pouring said concrete onto said metal deck and into said opposed channel
forms.
10. A method of claim 9, the steps further comprising:
after the pouring of said concrete onto said metal deck and into said
channel form and when said concrete is sufficiently hardened, removing at
least said two cooperative channel forms and their said support member
from said formed slab-beam system.
11. A method of claim 8, wherein said slab-beam system has a shoring frame
system for supporting said formwork thereof, the steps further comprising:
providing a plurality of generally U-shape shoring heads for supporting
said each beam channel form along its length, and
in the instance where added support is needed for a longer length slab
between said cooperative channel forms, using a shoring head and adjusting
it to substantially support said slab in its forming process at a location
between said neighboring beam channel forms.
12. A method of forming a concrete slab-beam system for a roof or floor
with a formwork, the steps comprising:
providing a generally U-shape channel form for forming said beam, and
having an opening for receiving concrete and outwardly extending flange
means having at least two supporting surfaces with one surface in an upper
elevational level adjacent to said opening, and another surface in a lower
elevational level away from said opening, and
in the step for forming a concrete slab, positioning a support member which
is to be removed onto said one surface in said upper elevational level of
cooperative flange means on two neighboring cooperative channel forms.
13. A method of claim 12, the steps further comprising:
prior to said positioning of said support member onto said one surface,
further positioning a structural member which is to be removed onto said
another surface of cooperative flange means of said two neighboring
channel forms, and
pouring said concrete onto said support member and into said opposed
channel forms.
14. A method of claim 13, the steps further comprising:
after the concrete has sufficiently hardened, removing said channel forms,
said structural member, and said support member from said formed slab-beam
system.
15. A method of claim 12, wherein said slab-beam system has a shoring frame
for supporting said formwork thereof, the steps further comprising:
providing a plurality of generally U-shape shoring heads for supporting
said each beam channel form along its length, and
in the instance where added support is needed for a longer length slab,
using a shoring head and adjusting it to substantially support said slab
along its length in its forming process at a location between said
neighboring beam channel forms.
16. A beam form for receiving poured materials such as concrete or the like
to form a beam upon solidification of said material, comprising:
a generally U-shape unitary metal channel with a bottom wall and two
opposing sidewalls extending upwardly and outwardly from said bottom wall
to form an opening for said receiving of said material,
stepped flange means associated with at least one said sidewall generally
laterally disposed relative thereto and consisting of at least two
supporting surfaces, one of said two surfaces of said flange means being
on an upper elevational level in close proximity to said opening and the
other of said surfaces being on a lower elevational level remote from said
opening of said channel, each of said surfaces having means adapted to
horizontally and alternately support a member whereby said member either
becomes an extension of said formed beam upon said member being supported
on said one of said two surfaces, or said member is removable with said
beam form after the forming of said beam.
17. The beam form of claim 16, wherein said two opposing sidewalls extend
upwardly at an angle in the range generally of 3.degree. to 8.degree., and
further comprising lip means associated with said other of said surfaces
in said lower elevational level of said flange means adapted to easily
remove said base form from said solidified beam. |
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Claims |
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Description |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to metal forms and a shoring head mounted on a
shoring frame supporting the metal form, more specifically, the invention
relates to a form for receiving concrete and a cooperating complementary
shoring head for metal deck concrete composite floors and roofs.
2. Description of the Prior Art
In building constructions, concrete beams and slabs comprising a roof or
floor, may be integrally cast as a unit through a complex formwork. Such
formworks frequently have wooden beam forms with wooden or metal decks
spanning the beam forms, or such form work frequently is of the "metal pan
convention form" consisting of a plurality of steel forms or metal pan
members. Depending on the desired length for the slab between these metal
pan members, the metal pan members may be interconnected or spaced-apart
with a deck bridging the spaced-apart pans. The area between the pan
members has a greater depth than that above the pan members and in the
pouring of the concrete, the beam is formed in this greater depth section,
whereas the slabs are formed integrally with the beams in the lesser depth
concrete section. Some "metal pan convention forms" are exemplified in
U.S. Pat. Nos. 1,073,906; 1,550,810; and 3,708,929.
The advantageous use of corrugated metal deck members, having alternating
ribs and valleys and an overlying layer of concrete with which it coacts
in a composite manner has been employed advantageously in roofs and
floors.
There has evolved a design in composite slabs which allows longer
longitudinal spans. This has been disclosed in U.S. Pat. No. 3,967,426,
issuing on July 6, 1976. A metal deck has a plurality of longitudinally
oriented hollow ribs and a flat panel section disposed between adjacent
ribs. At predetermined locations, segments of the metal deck are
interrupted to create a downwardly extending slab beam oriented generally
transversely with respect to the hollow ribs. In this system, wooden forms
may still be used to form the concrete beam.
In the above designs for forming a series of concrete slabs alternating
with a series of concrete beams, complex formworks are involved, which, in
turn, require a complex scaffolding design to support these formworks.
Safety regulation standards limit the length of the slab between the
beams, and until the teachings of U.S. Pat. No. 3,967,426, the range for
the length of the slab was substantially less than that given by the
composite deck of the U.S. Pat. No. 3,967,426. More beams or joists were
required to support the lesser length for the slabs. Arrangements for
forming a slab-beam floor or roof assembly requires the complex formworks
and scaffolding arrangements, for these present methods for forming a
slab-beam system results in high labor costs. In addition, intensive labor
is involved in erecting and removing these various formworks and their
related scaffolding designs.
In some instances, disassemblage of these present slab-beam systems is such
that the beam form may not be reusable in that the several wooden parts
may also be disassembled.
There remains, therefore, a substantial need for an economical means of
forming a concrete slab-beam system so as to permit greater design
flexibility of building design and improved economy of constructing the
slab-beam system. In addition, there is a particular need for such
slab-beam systems which simplify the formwork design and scaffolding or
shoring frames for supporting the formwork thereby lessening labor costs
thereof. There is a need to simplify a beam form which is unitary and
reusable and designed to support a structural member for forming a slab,
which slab may include a metal deck exemplified by the type disclosed in
the above mentioned U.S. Pat. No. 3,967,426. There is a need to provide a
beam form, and a shoring head that are designed so that the beam form sits
directly on the shoring head, of the shoring frame. There is a need to
decrease the need for labor and thus, costs, in the erecting and
disassemling stages of the form works and scaffolding, and to provide a
slab-beam system which greatly increases the efficiency of forming
concrete slab-beam and floors and roofs.
SUMMARY OF THE INVENTION
The above described needs have been met by the formwork and shoring frame
of the present invention. In a formwork design for forming the slab-beam
system a metal beam form is in a generally "U" configuration; and in a
shoring frame design, a "U" shape shoring head complements and supports
the metal beam form. The metal beam form has two laterally opposed
outwardly extending horizontally disposed support means near the opening
of the beam form. Preferably the support means has two surfaces, each
arranged in a stepped fashion; i.e. one surface area is lower than the
other surface area. Depending on the type of concrete slab which is to be
formed, the structural member longitudinally spanning two adjacent beam
forms can be supported either by the upper or the lower surface area. The
support means of the beam form may consist of either a double stepped
flange unit or a single flange unit supporting a support member which
provides a surface area which may support the structural member. If
desired, the beam form can be used in conjunction with a single beam as
distinguished from a pair of adjacent beams.
Reinforcing rods with a reinforcing stirrup member partially encompassing
the transversely arranged rods may be mounted in the beam form area.
In one preferred embodiment, a metal deck is supported in a lower flange
area and plywood is supported on an upper flange area of each two adjacent
cooperating beam forms. In another preferred embodiment a composite slab
may be formed by positioning a metal deck on an upper flange area of the
beam form, with a wooden member supported by the lower flange area, which
wooden member braces the beam form and gives added support to the metal
deck. In both these two preferred embodiments, the beam form has two
opposed outwardly extending support means in the form of a stepped flange
with two flange areas in different elevations. In a third and fourth
embodiment of the invention, a beam form with a single flange is used
which is wide enough to provide a first supporting surface area and to
support a support member, which in turn provides a second surface area
which first and second surface areas may alternately support a metal deck
in the forming of a slab. In a broader sense, it is an object of this
invention to provide a metal beam form which is simple in design, which is
easy to use and remove, and which has means for supporting a metal deck
used to form a slab-beam construction.
It is another object of the present invention to provide a metal beam form
which projects downwardly in a hanging fashion beneath the level of an
adjacent composite slab.
A further object of the present invention is to provide an integral beam
form which remains unitary, and which therefore, may be readily reused in
successive slab-beam forming operations.
A still further object of the present invention is to provide a design for
a metal shoring head of a shoring frame which is complementary and
supports a metal beam form.
Yet another object of the present invention is to provide a metal beam form
and shoring device which may be arranged to add support to a metal deck
along its length. This feature becomes especially advantageous where some
composite slab designs may permit longer spans between adjacent beams.
These and other objects of the invention will be more fully understood from
the following description of the invention, on reference to the
illustrations appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of a section of a composite slab
and a beam form of this invention;
FIG. 2 is a vertical section through a slab-beam system, and is a first
preferred embodiment of the present invention;
FIG. 3 is a vertical transverse section taken on line 3--3 of FIG. 2,
showing a composite slab formed by the present invention;
FIG. 4 is partial enlarged view of FIG. 3;
FIG. 5 is a vertical section similar to FIG. 3, but showing a second
preferred embodiment of this invention;
FIG. 6 is a partial, enlarged view of FIG. 5;
FIG. 7 is an elevational view of a metal beam form of this invention;
FIG. 7a is a plan view of a metal beam form in FIG. 7;
FIG. 8a is a schematic view illustrating the support points for a shoring
frame of the first embodiment;
FIG. 8b is a schematic view illustrating the support points for a shoring
frame of the second embodiment;
FIG. 9 is a vertical section similar to FIG. 3, and showing a third
preferred embodiment of this invention; and
FIG. 10 is a vertical section similar to FIG. 3, and showing a fourth
preferred embodiment of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, there is shown a slab-beam construction for a roof
or floor formed by a first preferred embodiment of this invention. A
composite slab assembly 12 has a corrugated metal deck 14 with an
overlying concrete layer 16, and a transversely oriented downwardly
depending concrete beam 18 integrally connected to slab assembly 12. As
best seen in FIG. 2, metal deck 14 of slab assembly 12 has a plurality of
longitudinally oriented hollow ribs 20 (one of which is numbered) disposed
in generally parallel spaced relationship with respect to each other,
between which ribs concrete is received. This construction for a composite
slab may generally follow the teachings of U.S. Pat. No. 3,967,426, which
is incorporated herein by reference, and which therefore, will only be
discussed with the specificity necessary to understand the present
invention.
Generally, the novel aspects of the present invention lie in a construction
and use of a metal beam form 22 used in forming a slab-beam construction
as best shown in FIGS. 3, 4, 5, 6, 7, and 7a.
As seen in the Figures, FIGS. 4 and 6 illustrate a single beam 18; whereas
FIGS. 3 and 5 illustrate two adjacent spaced-apart beams 18 cooperating to
support a slab or slab assembly between their span.
The description of beam form 22 will be discussed with particular reference
to the two preferred embodiments depicted in FIGS. 3 through 7a. It is to
be appreciated that differences exist in the particular construction of
the slab adjacent the beam form 22, and that the design of beam form 22 is
similar throughout FIGS. 3-7a even though some of the numbers have been
eliminated from FIGS. 5 and 6 for clarity.
In these FIGS. 3-7a, particularly FIGS. 3, 4, and 7, beam form 22 generally
comprises a "U" shape channel made of a metal; for example, galvanized
steel. In the illustrated form, channel 24 includes a bottom wall 26 and
two opposing upstanding sidewalls 28 and 29 integral with bottom wall 26.
Sidewalls 28 and 29 are slanted upwardly and outwardly from bottom wall 26
to the top of beam form 22 at an angle preferably from 3.degree. to
8.degree. from the vertical, and are provided at their outer lateral
opposed ends with a double stepped flange unit 30 consisting of an upper
flange surface area 32, and a lower flange surface area 34. Connecting
these two flange areas 32 and 34 is a vertical wall 36, and at the extreme
edge of lower flange 34 is a vertical lip portion 38 (best seen in FIGS. 4
and 7). These parts for beam form 22 may be in the form of metal sheets
stitch welded together, or beam form 22 may be press formed from a unitary
steel flat plate.
In forming a slab-beam construction of the present invention, as FIG. 2
indicates a beam form 22 is arranged in a longitudinal direction and
supported by a shoring frame assembly 46. The manner in which the
components of this system are arranged may generally follow the practice
known in the art.
With particular reference to FIGS. 2, 3, and 4, beam form 22 is supported
by a shoring head 48 of shoring frame assembly 46. (FIGS. 2 and 3).
Shoring head 48 generally is a "U" shape channel with a bottom wall 50 and
two opposed sidewalls 52 and 53 generally slanting upwardly and outwardly
at an angle of preferably 3.degree. to 8.degree. from the vertical toward
its opening for receiving beam form 22. Shoring head 48 is made of a plate
metal, which can be either stitch welded together or integrally formed by
a press brake. Shoring head 48 is dimensioned such as to adequately
receive and support beam form 22. FIG. 2 shows several shoring heads 48
strategically located to support beam form 22 along its length. The
distance between and the number of support locations for beam form 22
along its length may depend on the overall length of the beam form 22 and
the type of metal deck used for the slab construction to give the desired
load bearing properties for the slab-beam construction, more of which will
be discussed shortly.
Referring particularly to FIG. 3, there is shown two opposed beam forms 22
each supported by a shoring head 48 directly contacting beam form 22. Each
beam form 22 is illustrated as having a formed concrete beam 18. Between
these two adjacent beams 18a, composite slab assembly 12 of FIGS. 1, 2, 3,
and 4 is formed. The slab-beam construction comprising composite slab 12
is obtained through utilization of double flange unit 30 of beam form 22.
In the assemblage of the formwork including the beam form 22 for this
slab-beam assembly and prior to the pouring of the concrete and with
particular reference to FIG. 3, metal deck 14 is positioned for horizontal
support atop upper flange surface area 32 of the double flange unit 30 of
two opposing beam form 22. Directly beneath and abutting metal deck 14 is
a wooden member 54, extending in a longitudinal direction parallel to the
length of beam form 22. Wooden member 54 is substantially supported by
vertical wall 36 and lower flange surface area 34, and the thickness of
wooden member 54 generally equals the distance between lower flange
surface area 34 and surface 32 of the upper flange to provide adequate
support to metal deck 14.
As can be seen in FIGS. 3 and 4, this feature of the double flange unit 30
is extremely important in forming a composite concrete slab assembly 12,
in that it provides a supporting upper flange area 32 which allows the
metal deck 14 to become an integral part of the slab formed between the
two beam forms 22 (FIG. 3), while still providing support for the metal
deck 14.
While this first embodiment has particularly been explained with regard to
two spaced-apart beam forms 22, it is to be understood that only one beam
form 22 may be used wherein a composite slab 12 is still formed
transversely to the concrete beam 18 as shown, for example, in FIG. 4.
A second preferred embodiment for a slab-beam construction is shown in
FIGS. 5 and 6. As mentioned earlier, some numbers have been eliminated in
these FIGS. 5 and 6; however, the same elements are contained herein. The
main difference is in the slab-beam construction, with the design for the
beam form 22 and shoring frame 46 being similar to the first embodiment.
This embodiment is generally used to form a concrete slab, which is
generally understood in the art as not being of a composite structure, in
that it does not contain a reinforcement metal deck similar to that of the
first embodiment. In forming this concrete slab 56, a generally flat sheet
of plywood 58 is arranged to be supported by upper flange surface area 32
and a corrugated metal deck 60 is arranged to be supported by the lower
flange surface area 34 of the double flange units 30 of the two opposing
beam forms 22. (FIGS. 5 and 6). During the disassembling of the formwork,
both plywood 58 and metal deck 60 are easily removed from the formed
hardened concrete slab 56, along with beam forms 22.
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