Adjustable Haunch Support System for Concrete Bridge Decks

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Solution Overview

Problem

Constructing concrete bridge decks with stay-in-place forms is challenging due to the difficulty in adjusting haunch height without welding, which increases labor costs and exposes steel to corrosion, and requires specialty labor, making it hard to inspect for corrosion or integrity issues during construction and the structure's life.

Innovation Solution

An adjustable haunch support system that allows for height adjustments from the top surface of the bridge deck using a coil rod and rotatable nut mechanism, eliminating the need for welding and allowing for easy inspection, comprising a support angle with a coil rod extending through holes, and a nut that adjusts the position of the support angle, enabling adjustments without welding to the girder.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding is used to attach formwork support to bridge girders, then the formwork can be securely attached, but the steel is exposed to corrosion and specialty labor is required

Engineering Contradiction:

Improveattachment strengthVSAvoidcorrosion risk

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The invention extracts the harmful welding process from the attachment system. Instead of welding the support angle to the girder, the system uses a separate coil rod that threads through the support angle and is secured with a nut, completely eliminating the welding operation and its associated corrosion risks while maintaining secure attachment

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The coil rod and nut assembly serves as an intermediary between the support angle and the girder. This intermediate fastening mechanism provides secure attachment without direct welding, allowing the support structure to be firmly attached while avoiding the harmful effects of welding on the steel components

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If welding is used to attach formwork support to bridge girders, then the formwork can be securely attached, but specialty labor is required increasing costs

Engineering Contradiction:

Improveattachment strengthVSAvoidlabor cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The invention removes the welding operation entirely from the attachment process. The support angle is attached using a coil rod and nut that can be installed with standard construction tools and labor, eliminating the need for expensive specialty welding labor while maintaining equivalent or superior attachment strength

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The coil rod and nut assembly represents a simple, inexpensive fastening system that replaces expensive welding operations. These components can be easily installed and adjusted by standard construction workers, significantly reducing both material and labor costs compared to welded attachments

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Adaptability or versatility

If the formwork is installed between girders, then the haunch height can be adjusted, but additional time and labor are required for adjustments

Engineering Contradiction:

Improvehaunch height adjustabilityVSAvoidadjustment time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The invention makes the haunch height adjustable through a dynamic mechanism. The coil rod can be threaded through the support angle at different positions, and the nut can be positioned at various locations along the coil rod, allowing the support angle to be vertically adjusted to achieve the precise haunch height required without time-consuming welding or complex repositioning operations

Inventive Principle:

Principle #15Dynamics

4Productivity

If stay-in-place forms are used, then construction is simplified, but inspection for corrosion and integrity is difficult

Engineering Contradiction:

Improveconstruction efficiencyVSAvoidinspection difficulty

Core Design Contradiction:

ProductivityVSDifficulty of detecting and measuring

Solution Approach 1:

The invention segments the formwork support system into distinct, accessible components. The support angle is separated from the girder by the coil rod and nut assembly, creating discrete elements that can be individually inspected for corrosion, damage, or loosening while maintaining the stay-in-place construction efficiency

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution reduces labor costs, eliminates the need for specialty labor, and allows for easier inspection of the concrete structure, providing a cost-effective and safer method to adjust haunch height without welding, thereby reducing the risk of corrosion and improving construction efficiency.

Implementation Method 1

a coil rod and rotatable nut mechanism, eliminating the need for welding and allowing for easy inspection, comprising a support angle with a coil rod extending through holes, and a nut that adjusts the position of the support angle

Methodology Applied

Scientific EffectScrew mechanism: Screw

Data Source

PatentUS11339563B2Adjustable forms for poured concrete structures and related systems and methods

Publication Date: 2022.05.24 CONTECH ENGINEERED SOLUTIONS LLC

AI summary

An apparatus for adjusting a haunch height and related systems and methods includes a support angle. The support angle includes first and second flanges, and a surface of the first flange includes a hole. The apparatus also includes a coil rod and a rotatable nut.