[ Nov. 4, 1975 United States Patent [191 ffet al.
Ratcli FLYING FORM [75] Inventors: Felix E. Ratcliff, Los Angeles; Pierce J. Walinsky, Sunnyvale, both of Calif.
[73] Assignee: Waco Scaffold & Shoring C0.,
754,303 10/1954 United Kingdom...................52/642 Primary Examiner-Francis S. Husar Schiller Park, Ill. Assistant Examiner-Carl Rowold June 12, 1974 Attorney, Agent, or FirmWatson D. Harbaugh [22] Filed:
.31 yS .E UCID. .nou M mm wmm n nmd fi o w mw M m nmrem mi r. ewm f M S n m mww .w p kd em Ckmmuc u m qewmfy .n mu 5 m m mm g m m et m m w m n l.mts .WJUVSIOB am a hdQS mmmm m do m b e O C d n m/mmm mmw wAmmuccw .HRMAJ m 9 3 17 9Q B2 49G 4 449M .920 4 E 5 2 .9 9 8 R M B 9 1B1 8 W H G41 m m 2 E n 1 m m 6 u 9 5 8 m "b2 7 u mcw A mmm o u m N 1. P L d W S Ld A U mm .1 .J] l 2 8 2 5 55 FL support equally spaced saddle hangers that are inter- References Cited connected by laminated wood joists whose ends verti- UNITED STATES PATENT S cally overlap and square the I-beams as well as provide a low profile with their vertically spaced rails disposed well above the upper and lower flanges, respec- 249/13 tively, of the I-beams. The metal members have rigid 249/219 R X wood-to-steel engagement at all points of readily re- 249/219 R leasable interengagements. 249/219 R 3,170,217 Williams 3,397,858 Williams 3,504,879 Strickland 3,776,499
3,843,084 974 Gregory et 3,863,877
14 Claims, 10 Drawing Figures Gregory US. Patent Nov. 4, 1975 Sheet 1 of 3 3,917,214
FIG I US. Patent Nov.4, 1975 SheetZ 0f3 3,917,214
FLYING FORM BACKGROUND OF INVENTION Many problems confront the building industry with the conventional flying forms with regard to readyassembly, economy, stability and reusability. Knock apart wood assemblies have short lives and the waste of time and material is high. Welding and flame cutting of steel generally involved at a building site are extensive. Moreover, once assembly-welded and then disassembled by flame cutting, the parts are not the same for ready assembly at a new site.
Disassembly of flying forms is necessary because of their size. Even if light enough, they can only be transported intact, from site to site, by helicopter if expense is no objection. Delays incurred because of needed repairs are quite expensive where a timed building sequence is interrupted. Welded metal-t'o-metal securements are difficult and time consuming to repair. With the likelihood of such contingencies arising their cost is reflected in bid prices. In both events the building cost is substantially high even though savings are being accomplished with conventional flying forms over earlier practices.
Futhermore, difficulty has been experienced with fastening plywood flooring to steel beams as well as securing the steel beams to I-beams for a knockdown assembly. This is particularly true when endeavoring to minimize the overall height of the formwork. by a substantial vertical compacting of the coacting elements.
It is also to be noted that since formwork plywood panels must be supported on minimum joist centers related to the thickness of the floor slab to be poured, the weight of the formwork is materially greater with metal joists. In fact, motorized lifts are generally required to handle the metal joists individually during assembly as distinguished from being light enough to be dropped in by hand, as in the present invention, and bolted into place without need for a lift or crane handling them.
SUMMARY OF INVENTION The present invention relates to site assembled and disassembled formwork for the pouring of successive concrete floor slabs supported on rollout column supports which are more particularly described in Mocny, et al., application Ser. No. 322,969. Once assembled the formwork sections are used as a unit supported for pouring one floor slab and then lowered and rolled out horizontally by a crane, lifted and again set in place on formwork supports above the first slab for the pouring of the next slab. Hence, they are referred to as flying forms.
Although channel beams can be used in the flying forms in the present invention because the beams are restrained throughout their length against lateral flexure and rotation, it is preferred to use rolled steel 1- beams with moderately wide flanges on the two main beams because of their lateral stability with assembled parts for knockdown storage or shipment between light laminated wood joists formed in an I crosssectional configuration with top and bottom rails connected by a vertical web. The joists are of exact length, and their square ends drop into place in the saddle brackets with the top and bottom rails disposed substantially above the respective upper and lower flanges of the main beams. The joists ends square the opposing sides of the I-beams.
When assembled the ends of the joists are not only disposed as mentioned but are also bolted to the brackets to serve dually as compression and tension members that unitize the assembly for handling by a crane with spread lift cables temporarily secured to the corners of the form to roll it out, to fly it, and position it for the next floor slab pouring.
The brackets project laterally at an elevation between flanges and are preferably secured by bolts to the main beams. Then when the beams are transported knocked down they can rest side by side with the brackets on the one side of one beam nested in the channel of the adjacent beam.
An object of the invention is to provide a vertically compacted profile so that the form may be lowered a long distance onto roll-out roller supports thereby not only avoiding horizontal movement interference with the bottom of the floor slab completed above it but permitting depending protuberances or reinforcing shapes to be integrally cast and used by the contractor in the design of the building.
A further object is to provide light flying forms which can be adjusted initially into final orientation on prelevelled rollers provided in Mocny, et al., Ser. No. 322,969 and then contacted thereafter by the stationary shoe supports with a given number of turns of a winged nut for proper final elevation, it being much easier to determine the levelling of the form supports before the form is lowered into place.
Additionally, joists of exact length ready for assembly are used, but if any shortening thereof is required it is easily done by a power saw as distinguished from cutting metal and welding it as required with fabricated metal joist. Moreover, the light joists are easier to handle without a power lift. Also the joists can be inverted from time to time to utilize both rails in nailing and the longevity thus expected can extend over a period of time involving the pouring of over a hundred floors. If a joist is weakened by damage, it is easily repaired on the job even though already in working position.
IN THE DRAWINGS FIG. 1 is a plan view of a flying form as placed in working position between two rows of a plurality of support columns defining a roll-out path.
FIG. 2 is a plan view of a couple of flying forms as placed in working position between successive rows of support columns defining at least two roll-out paths with a space between the forms intermediate two columns.
FIG. 3 is a segmented end view of a flying form as assembled on levelling blocks before being lifted into place as shown in FIGS. 1 or 2.
FIG. 4 is a sectional view from below the flying form as indicated at line 4-4 in FIG. 2 showing the formwork supports on opposite sides of a support column.
FIG. 5 is a view from below as indicated at line 5-5 in FIG. 2 showing the formwork support screw jack as engaged by the I-beams of the formwork.
FIG. 6 is a perspective view partially in section showing the assembled relation of the joists with the I- beams.
FIG. 7 is a sectional view taken on the line 77 in FIG. 6.
FIG. 8 is a sectional view taken on the line 8-8 in FIG. 7.
FIG. 9 is a sectional view taken on the line,99 in FIG. 7, and
FIG. 10 is an exploded view of the joist and bracket 1 support joint shown in FIG. 6.
DESCRIPTION OF PREFERRED EMBODIMENT Referring to FIGS. 1 and 2, in the making of a monolithic concrete building, at least four'spaced concrete floor support columns 12, six are illustrated, have four support screw jacks l4 temporarily secured thereto on opposite sides of each column as illustrated in FIG. 4. The mounting of the screw jacks determines the rollout paths for the forms. FIG. 1 illustrates a long form 11 which bridges two bays 21 and rolls parallel therewith as indicated by arrow 19. FIG. 2 shows two forms across two bays 21 which roll in the direction of the arrows 23 with respect thereto. The spacing of the columns in both directions in either case determines in part the length and spacing of the I-beams 28 which lengths are preferably related in part to the 4 by 8 feet dimensions of veneer boards used as flooring for the form as well as the spacing of the screw jacks.
The assembly of the knockdown flying form 11 embodying the invention is preferably made upon the ground as illustrated in FIG. 3. For this purpose corner blocks 25 are laid upon the ground 13 and levelled where workmen have easy mobility and walking access to all of the parts involved.
Accordingly, two I-beams 28 are located in place in their properly spaced and levelled positions on the blocks 25 for the assembly of the formwork. These beams are of a length suitable to span one or two bays 21 between the columns 12 and if there are more bays, other sections of the formwork are assembled and successively lifted into place to end-abut and be temporarily bolted end-to-end to the others for the pouring of the concrete.
The I-beams 28, once located properly in place have wood scantlings 32 (FIG. 7) secured permanently in place end-to-end on the top flanges 34 of the I-beams 28 by power driven metal piercing nails 36. Wood strips 38 are likewise secured to the facing sides of the I-beam webs 40 at a distance from the bottom flange 42 predetermined to clear the side guides 26 on the screw jacks. The horizontal dimension of the scantlings 32 equals the exposed width of the top flange 34 above it to define a vertical plane 44 at its edge. The wood may be dressed or undressed, whichever is available and less expensive and nail heads are reinforced by discs 37.
Brackets 46 are received along the scantlings 32 at spaced distances determined somewhat by the expected load of the flowing concrete when poured in place to become a floor slab. For their support they are provided with horizontal flanges 48 resting on the upper face 50 of the scantling 32. The flanges 48 are apertured at 49 (FIG. 10) to received wood screws 52 releasably securing them in place with vertical flanges 54 of the bracket disposed in said vertical plane 44' and against the opposing vertical faces of the laterally spaced scantlings 32.
A U-shaped strap forming a stirrup 56 (FIG. 10) disposed at a right angle to each vertical flange 54 has its upper edges 58 welded asat 60 to the vertical flange 54 to provide slings 62 receiving. cross joists 64 between the beams 28.'At the lower and closed end 66 of the stirrup a strap 68 disposed in the vertical plane is welded at to the sling 62 and apertured at 67 close to the sides of the stirrup 56 for securement to the strip 38 by removable bolts 70. The brackets 46 can be.
spaced differently at sites different in. relation to the load they will be required to bear and other dimensions from above, manually if desired, into the stirrups 56. i
and then to rest at their ends in supported relation against the vertical flange 54 and strap 68 in squared relation. Filler blocks 78, preferably of hardwood with their grain perferably disposed vertically, extend from rail 72 to rail 74 at both ends of the joist 64 and on both sides of the web 76 to fill the space between the .web
76 and the sides of the stirrups 56 for plumb alignment purposes at the top. When dropped into place openings 80 through the blocks 78 and openings 67 through the.
sides of the stirrups 56 coincide equidistant from the rails 72 and 74. They receive the bolts 70 which clamp the assembled parts in place to withstand compression and tension forces inter-exerted between the I-beamS 28 and the joists.
The frame of the form thus fashioned is ready to receive the veneer panels 84 on top of the rails 72 of the joists 64 which are wide enough for a good support for abutting ends of the veneer boards. The veneer panels 84 are cut, laid in place and then secured to the top rail 72 by a power nailer using flat headed wood nails for ready pull-out when desired.
Heavy eyebolts 17 are installed in the I-beam web 40 at opposite ends to receive snatch hooks 88 for a pyramidal cable sling with suitable spreaders to lift the formwork into place on the rollers 18.
By the time the formwork is ready for mounting on the form support screw jacks 16 the rollers 18 are preferably first levelled to receive the formwork rollably thereon as more particularly described in Mocny, et al., Ser. No. 322,969 with the guides 26 on the shoe supports 22 adjacent to each other. The flying form is then crane lifted into place on the rollers for a metal-tometal rolling contact therewith and moved into final position, either byitself or in end-abutting relation with another form to which it is then bolted. Thereafter the stationary shoe supports22 are raised equal distances frombelow to support the form and hold them in correct position against further movement.
The open spaces 30 (FIG. 4) between laterally spaced forms (FIG. .2) intermediate the columns may be closed by plywood panels 90 bridging and resting on the exposed ends of top rails 72 of the joists but preferably are supported by small frames 92 resting on the exposed scantlings .32. Thereby the vertical space between the upper rail 72 and the scantling-32 receive a lay-in frame 92 of shop lumber or short 2 X 4-inch members supports narrow veneer panels 90 level with the other veneer panels 84. The lay-in frame 92 is then freed to be removed when one of the forms lateral thereto is lowered its full predetermined distance. This permits one edge of the narrow frame 92 to swing down at that side and free itself for removal intact for reuse.
After the pouring and the setting of the floor slab, the two formwork assemblies are unbolted and the one that is to be flown first is lowered all the way by the screw jacks 14 including the winged nut to ultimately rest on the rollers. This frees the narrow panel for removal whereupon the sling cables 88 are fished through the vertical space thus provided between the floor slab and form and attached to the eyebolts 17. The flying form is then rolled out until it is crane borne and lifted to its new position. This procedure is repeated for the remaining forms.
The invention will be further understood in view of further advantages attained thereby generally relating to longevity and easy usability.
Hardwood filler blocks and wide rails:
a. Carry the weight locallized on wide top and bottom rails at their ends to save the web against buckling and damage;
b. They protect with substantial thickness the web against side sway and twisting as well as bumps encountered by the head rail above the side supports of the saddle as when plywood panels are slid into place;
0. They coact with plywood floor panelling to strengthen against tear outs when the formwork is being handled as a flying form" by a crane;
d. Wooden joists exactly space the steel I-beams for accuracy throughout long use in the successive pouring of floor slabs;
e. They provide nail receiving supports for securing the plywood with either rail disposed upwardly, thereby doubling longevity.
The arrangement shown with the bottom rail located above the bottom flange and the top rail above the scantling:
a. Substantial vertical compaction and greater joint areas are attained;
b. Exposes the bottom l-beam flange for metal-tometal roll out as guided by side guides on the rollout support, without any side guides extending above the bottom flange interferring with the bottom rails;
c. Metal-to-metal roll-out contact has many advantages over the old metal roller-to-wood beam arrangement. Narrow wood beams would not be strong enough;
d. The drop of the I-beams by the screw jacks can be very substantial so that the formwork upon roll-out clears the bottom of the floor slab and any irregularities or depending protuberances intentionally provided on the lower surface thereof;
e. Parallel l-beams provide for easy roll-out;
f. Channel beams can be used if clearances are tight;
g. Joists cross brace the I-beams against rotation or bowing under load;
In storage or transportation lateral resting of brackets on one l-beam in the channel of the next beam beside it provides compactness for shipping or storage with the brackets left in place for repeated uses.
The arrangement shown with the top rails above the scantling provides vertical space within which to support the ends of lumber on the scantlings to carry veneer panels bridging the space between laterally adjacent formwork members across lateral bays between support columns.
What is claimed is:
1. Prefabricated knockdown roll-out formwork for support on height and level adjustable screw jacks having heads including rollers defining a roll-out path and friction shoes adjustable to support said formwork above said rollers a predetermined distance is said path, said formwork comprising: parallel spaced metal beams resting on said jacks and having coplanar head and, bottom flanges, each beam having a nailable header of substantial thickness secured to the upper face of its head flange and a side strip of nailable material spaced above the bottom flanges and secured to the beams on facing sides of the two beams, said side strip having a horizontal thickness substantially coextensive with the lateral extension of each head flange to define with the headers vertical parallel planes;
hanger means spaced along the headers in manner facing each other in pairs and having horizontal portions releasably secured against the top surfaces of the respective headers and vertical flanges lying in one of said vertical planes, and hanger means including depending stirrup members with upper portions secured to said vertical flanges and horizontal strap means secured to lower portions thereof and releasably fastened to said side strip;
laminated wood joist means defining nailable head and bottom rails interconnected by a web and having a height greater than the vertical depth of said stirrup members to locate the head rails a substantial distance above said head flange with the lower rail located well above the lower flange;
means including bolts releasably securing the ends of said joist means between the sides of the stirrup members against relative tension and compression forces exerted between said beams and said joist means; and
plywood panel means secured to the head rails of said joisst means to support poured concrete for a floor slab and to brace said formwork against horizontal strains.
2. The construction defined in claim 1 in which said joist means including said joist rails on opposite sides of the web engage the sides of said stirrup member under compression and have aperture means therethrough for the bolt means arranged equidistant from said rails for inverted reuse of the joist means in said stirrup members.
3. The construction defined in claim 2 in which said joist means are square at their ends and collectively engage said headers and strips to plumb the beams and support them against rotation under load as they rest upon the screw jack heads and when the formwork is supported by crane at formwork corners.
4. The construction defined in claim 2 in which said filler blocks and rails at the joists include plywood panel elements extending across said wood headers and are supported in abutting relation with said plywood panel means by said filler blocks and rail ends of said joists.
5. A flying form comprising:
a pair of parallel spaced metal beams disposed with parallel flanges along the head and bottom of their webs, respectively;
a wood header of substantial thickness rigidly secured to the upper face of the head flange and colevel wood strips secured a spaced distance above the bottom flange against the facing sides of said beam webs, said strips having a horizontal thickness substantially equal to the width of each head flange to define with the head flanges a pair of vertical parallel planes;
hanger means spaced along the tops of the wood headers facing each other in pairs and each having hori zontal portions releasably secured against the top surface of the headers and a vertical portion lying in one of said vertical planes, said hanger means including depending stirrup members with upper edge portions secured to said vertical portion, and strap means secured to the lower edges of the stirrup member and releasably fastened against the side strip;
laminated wood joists each having ahead rail and bottom rail inteerconnected by a web and of a height greater than the depth of said stirrup members whereby the head rail is located a substantial distance above the wood header with the lower rail well above the lower flange;
means releasably securing the ends of each joist between the sides of a stirrup member including filler blocks extending from rail to rail at both ends and on .both sides of the web filling the spaces between the web and stirrup; and
clamping means interconnecting the stirrup members and said blocks and web in place against compression and tension forces exerted between the metal beams and the joists.
6. The flying form defined in claim including veneer panel forming a flooring and secured to the head rails for bracing said beams and joists against distortion from a geometric squareness.
7. In the construction of a building having at least three parallel pairs of columns the combination of formwork roll-out support means on opposite sides of the central pair of columns and opposing pairs of rollout support means on the facing sides on each of the two outer pairs of columns including screw jacks supporting rollers at a predetermined level with their axes paralleled in four pairs defining two paralleled formwork roll-out paths;
a pair of parallel spaced metal beams having top and bottom flange means disposed at the sides of each roll-out path resting on said respective rollers; wood headers secured to the top flanges of said beams;
hanger means spaced along the tops of said wood headers extending towards each other in spaced pairs and having horizontal flanges secured to the top flange means with stirrup members depending therefrom;
joist means terminally supported within said stirrup means between each pair of beams with their upper edges disposed colevel within a limited height above said headers, and defining a space between said rollout paths and intermediate said pair of columns;
veneer panel means secured and marginally terminating within a spaced distance related to the end of said joists;
means bridging said space and above the adjacent joist means including panel means carried thereby colevel with said coextensive veneer panel means; and
means for lowering one of said adjacent beams to increase the space between the tops thereof to release the space bridging means from the form support on one side for its removal downwardly from the form support on its other side. r 8. In the construction of a building having atrleast three parallel pairs of columns with formwork support means on opposite sides of the columns of the central pair of columns and on the sides of the two outer pairs of rollers where they face the central pair of columns, said supporting means includingscrew jacks, support ing rollers at a predetermined level with their axes parallel in four pairs defining two parallel formwork rollout paths; the combination of a pair of parallel spaced beams disposed at the sides of each roll-out path resting on said respective rollers; nailable members defining the tops of said beams; support means secured in, spaced relation along the tops of said members and extending towards each other in spaced pairs bordering each of said paths and having depending stirrup means; joist means terminally supported in said stirrup means between each pair of support means with theirupper I edges disposed above the level of said members, said beams defining open space between saidroll-out paths and intermediate the columns of said central pair of columns;
panel means secured to said joists and marginally terminating coextensively a spaced distance related to the end 'of said joists and said open space between said roll-out paths;
means bridging said open space above the adjacent headers including secondary panel means carried by the beams colevel with said coextensive panel means; and
means for lowering at least one of said space defining beams to release the bridging means for movement downwardly from its supported position for removal and reuse.
9. The construction defined in claim 8 in which said secondary panel means of said space bridging means is supported on the adjacent ends of the joists bordering said space.
10. The construction defined in claim 8 in which said secondary panel means includes a frame spanning said space resting on the adjacent members and supporting said coextensive panel means.
11. A roll-out flying form comprising parallel spaced metal beams having facing channels defined by horizontal head and bottom flanges, each beam havinga nailable header secured to the upper face of the head flange marginally coextensive with said head flange edges and a nailable strip spaced substantially above the bottom flange and having a horizontal thickness disposing its exposed face in vertically co-planar relationship with said header edge,
hanger means correspondingly spaced along the tops of the headers facing each other in pairs and having horizontal portions releasably secured against the tops of 1 the headers and vertical flanges lying in one of said vertical planes, said hanger means including members with upper portions secured to the flanges and g a strap member secured to the lower end thereof releasably fastened to said nailable strip,
a plurality oflaminated wood joist means having head and bottom rails interconnected by a web and having a heightgreater than the depth of said hanger members whereby the head rail is located a substantial distance above said head flange and the lower rail is well above the bottom flange, and
means releasably securing the ends of said joists between the sides of the hanger members under compression and tension forces including blocks at both ends of the web filling the space between said head and bottom rails,
said releasable securing means including securement elements extending through said blocks, said web and the sides of said stirrup member, with said lower rail endwise positioned by said strap and strip.
12. In a knockdown flying form having spaced metal beams disposed with parallel webs and their respective head flanges disposed co-planar with spaced hangers secured to and depending from nailable headers secured to the respective head flanges and from nailable strips secured to the respective webs, said hangers having members having parallel sides disposed in vertical parallel orientation, in combination therewith, laminated wood joists cross-sectionally having an 1 configuration of a greater height than that of the members and terminally resting in said members to plumb and space said metal beams throughout their length,
said joists having spaced nail receivable rails interconnected by a web and symmetrically invertable for either rail to serve as the top rail and including filler blocks extending from rail to rail at both ends on both sides of the web filling the spaces between the web and stirrup, and
fastening means interconnecting the stirrup members and said blocks and webs to secure them in place against compression and tension forces occurring between the metal beams and the joists including aperture means through said blocks and web.
13. A prefabricated knockdown roll-out formwork comprising:
parallel spaced metal beams having co-planar head and bottom flanges, each beam having a header of substantial thickness secured to the upper face of its head flange and a nailable side strip secured to the beam above its bottom flange on facing sides of the two beams, said side strip having a horizontal thickness substantially coextensive with the width of each header flange to define with the headers vertical parallel planes;
means spaced along the headers facing each other in pairs and having portions releasably secured to the headers with a vertical portion lying in one of said vertical planes including depending support members with upper portions secured to said vertical portions and lower portions thereof fastened to said side strip;
joist means defining nailable head and bottom rails interconnected by a web and having a height greater than the depth of said support members to locate the head rail an appreciable distance above said head flanges with the lower rail located well above the lower flange;
means releasably securing the ends of said joist means to said support members against relative tension and compression forces exerted between said beams and said joist means; and
plywood panel means secured to the head rails of said joist means to support poured cement for a floor slab and to brace said formwork against horizontal strains.
14. The device defined in claim 13 in which said metal beams have channels along their sides opposite to said spaced means within which to accommodate such spaced means on another beam in nesting relation when said beams are side-by-side to protect said spaced means from damage during storage and transportation. l l