Corner Beam for Concrete Formwork

This application claims the priority benefit of U.S. 63/651,928 (filed May 24, 2024), which is hereby incorporated herein by reference in its entirety.

Support structures can be erected in various use cases, such as concrete formwork or scaffolding (e.g., temporary scaffolding) for supporting workers and supplies/materials during construction projections. In some instances, the support structures can form a corner, such as for extending or wrapping around a corner of the construction project or otherwise connecting one span or length to another span or length at a different angle. Sometimes the corner can be cantilevered above, and extend outward relative to, an underneath structure. In these cases, some conventional systems include an underneath support beam secured beneath one or more other beams that form the corner, and an example of such a conventional arrangement is shown in. In some instances, a railing or other barrier can extend along the corner.

This detailed description is related to a support-structure corner beam, as well as various parts of the corner beam and assemblies that can be constructed using the corner beam. The corner beam can be used in various examples, such as concrete formwork, scaffolding, or other support structures. In examples, the corner beam simplifies corner constructions and contributes to easier and safer corner support-structure installation. For example, the corner beam can include end clips with a post (or other type of hook, tenon, projection, protuberance, etc.) that inserts into a pocket or recess of other beams. In addition, the corner beam can include a trough that extends along the side and that can connect to one or more other supports beams, such as the support beams (e.g., filler beams) described in U.S. Pat. No. 11,199,012 B2, which is incorporated herein by reference in its entirety.

Referring to, an example of a corner beamis depicted based on an example. The corner beamincludes, on each end, components (e.g., end clipsin) that can connect to the other beams, including a first support beam(e.g., first structural beam) and a second support beam(e.g., second structural beam). For example, the first support beamand the second support beamcan be oriented perpendicularly relative to one another, and in some instances, the corner beamcan span a distance between the first support beamand the second support beam. In examples, the first support beamand the second support beamcan include similar or the same features, and for brevity, only one of the support beamsormight be described in this disclosure—but it is understood that the same or similar description can also apply to the other support beamor.

The first support beamand the second support beamcan each include a respective end capand. In at least some examples, the corner beamcan span a distance between the first end capand the second end cap. As such, the corner beamcan function to support various loads, such as platforms, workers, supplies/materials, equipment, etc. In examples, the corner beamcan be referred to as a corner structural beam, a third structural beam (e.g., the third structural beam extending between the first structural beam and the second structural beam), and/or other similar terminology. For brevity, the end capis described herein, and it is understood that a similar description can apply to the end cap.

Referring to, the end capis shown in an enlarged view. In examples, the end capcan include a pocket(e.g.,that is partially exploded), that can connect to one or more other components of the formwork assembly. For example, the pocketcan receive a postof a railing (or other barrier or safety structure), such as where the postincludes an anchoring bracketthat securably inserts into the pocket. In at least some examples, the pocketcan also receive a portion of the corner beam. For example, the pocketcan operate similar to a mortise, slot, or other recess for receiving a mating portion (e.g., element) of the corner beam. The pocketin the end capis an example of a recess that can receive an end of the corner beam(e.g., receive a portion of the end clipof the corner beam). In at least some examples, the end of the corner beamcan connect to one or more other recesses along the support beamsand.

The corner beamcan include a top portion, a bottom portion, a first side, a second side(opposite the first side), a first beam end, and a second beam endthat is opposite the first beam end(e.g., viewable in). In at least some instances, the first sideand the second sidecan include similar features (e.g., mirrored features), and the first beam endand the second beam endcan include similar features (e.g., mirrored features). For reference purposes, the corner beamcan include a longitudinal midline (e.g., longitudinal midline reference plane) that extends from the first beam endto the second beam endand that bisects the corner beaminto the first sideand the second side. In some examples, the first sideon one side of the longitudinal midline mirrors the second sideon the other side of the longitudinal midline, such that at least some features the corner beamare symmetrical on opposing sides of the midline.

In examples, the corner beamcan include a first extension(e.g.,) that extends from the first beam end. For instance, the first extensioncan include a neck-like body that extends from the first beam endnear the top portion. In addition, the corner beamcan include a first tenon(e.g., post, pin, or other similar projection) that extends downward from the first extension. In at least some examples, the first tenoncan insert into the pocketof the end capto couple the corner beamto the first beam. In this sense, the pocketcan operate similar to a mortise that mates with the first tenon. In some examples, the first tenoncan insert into other recesses along the a beam that can function similar to the pocket.

The second beam end(e.g.,) can include elements similar to the first endfor mating with the second end cap, such as a second extension with a neck-like body extending from the second beam endnear the top portion and a second tenon that extends downward from the second extension. For brevity, the features of the second beam endmay not be illustrated, but it is understood that those elements can mirror the elements described with respect to the first beam end. In examples, the longitudinal midline of the corner beampasses through the first tenonand the second tenon that is associated with the second beam end.

The corner beamcan, in some instances, include a main central beam(e.g.,) having a first end portionand a second end portion. In some instances, the main central beamcan include lumber. In some examples, the main central beamcan include a metal beam. For example, the metal beam might include a metal tube (e.g., welded metal tube, extruded metal tube, etc.) or other style of metal beam (e.g., I beam, C-channel, etc.).

The corner beamcan include, at each end, a component that attaches to the first end portionand the second end portionof the main central beamand that is configured to attach to one of the other beams (e.g., to the end caporof the other beamor). In at least some examples, the corner beamincludes, at each end, an end clip. For example, the end clipscan attach to the first end portionand the second end portionof the main central beam. In addition, the end clipscan include the extensionand the first tenon. As such, the end clipscan function to connect to the first support beamor the second support beam. In at least some cases, the end clipsallow for easy installation into the end cap(s), since the tenoncan simply be inserted into the pocket(s)of the end cap(s). In addition, the postcan still be installed (e.g., as shown in) into the pocket. That is, both the anchoring bracketof the postand the tenonof the end clipcan be co-retained within the pocketof the end cap.

The end clipcan include various elements. For example, the end clipcan include a main body(e.g.,), which can include a top portion, a bottom portion, a proximal side, and a distal sidethat is opposite the proximal side. The main bodycan also include a first sideand a second side. In at least some examples, the end clipcan include one or more elements on the proximal sidefor attachment to the main central beamand one or more elements on the distal sidefor securement to another beam (e.g.,or).

The end clipcan include various mounting elements on the proximal sidefor attachment to the main central beam. For example, the end clipcan include a mounting insertthat extends from the proximal sideand that can be slid into an interior void(e.g.,) of the main central beam(e.g., an interior void at the end of the main central beam). The mounting insertcan include a size (e.g., height and width) that are smaller than the interior voidand that are shaped to fit into the interior void. For example, if the interior voidis rectangular shaped, then the mounting insertcan include a cross-sectional profile that fits into the rectangular-shaped interior void.

In at least some examples, the mounting insertcan include one or more openings or recesses(e.g., slots), which can receive a fastener(e.g. bolt) for attachment to the end portionof the main central beam. For example, the end portionof the main central beamcan also include aperturesthat can also receive the fastener. In at least some examples, the recessescan include elongated slots, which permit the end clipto be slid outward or inward in order to adjust an overall length of the corner beam. Adjusting the overall length can be useful in various use cases, such as when beams are misaligned or when needing to adjust to varied lengths of other beams. In some cases, the bolted end clipsallow for easier repair, since the end clipcan be easily, simply, and quickly removed and replaced (e.g., by simply decoupling the fasteners, sliding the end clip out, and reinserting a new end clip or a repaired end clip).

In at least some examples, the end clipcan include one or more other kinds of brackets or structures for attachment to the end of the main beam. For example, the end clipcan include a bracket or brace that fits at least partially around the outside of the end of the main beam.

In examples, the end clipcan include the extensionthat extends out from the distal sideand near the top portionof the main bodyof the end clip. In addition, the tenonor other pin, post, projection, protuberance, etc. can extend downward from the extension, such that there is a gap or void between the tenonand the distal side, which can permit the tenonto nest into the pocket. In some examples, the tenonis relatively broad and flat (e.g., as opposed to more cylindrical), which can reduce the tendency of the corner beamto pivot relative to the end cap.

In at least some examples, the end clipcan include elements for handling the end clipand/or the corner beam. For example, at least one of the first sideor the second sidecan include an opening or a recessed side wall that, together with the top portion, forms a handlethat can be used for manually grasping the end clipand/or securing other carrying implements onto the end clip.

In examples, the corner beamcan be secured in position to the other beamsand/orvia one or more other connection points. For example, and referring also to, the bottom portioncan include one or more lower groovesand/or, which are configured to nest into a lower trough (e.g.,in) on the beamsand/or. In examples, the one or more lower grooves can include a first grooveand a second groovethat are oriented perpendicularly to one another, which can permit the corner beamto be installed either direction. That is, because the first endand the second endcan each include a respective end clipwith mirrored grooves, the corner beamcan be installed either direction (e.g., with the first endor the second endcoupled to the end cap). In at least some cases, this engagement between the grooveorand the troughcan impede rotation or other shifting of the corner beam.

The corner beamcan include one or more other elements. For example, in some instances, the corner beam can include a nailer. In at least some examples, the corner beamcan include a troughon each side for connecting to other beams(e.g.,), such as the beams described in U.S. Pat. No. 11,199,012 B2. For example, a troughcan extend along each side (e.g.,and) of the corner beam, such as from one endof the main central beamto the opposing end(e.g., see the troughsandin).

An example of a beam(e.g., filler beam) is shown in, including a first endhaving a first lower edgethat fits into the troughof the other beamand a second endhaving a second lower edgethat fits into a trough that is similar to the troughand that is on the second sideof the corner beam. In addition, the first endand the second endinclude respective hinged connectionsand(e.g., piano-hinge style) that pivot or rotate, such that an orientation of the lower edgesandcan be adjusted to match the orientations of the troughs on the first beamand the corner beam. This also permits the orientation of the filler beamto be tailored base on the use case.

End clips of the present disclosure can include one or more other features. For example, referring to, another example end clipis depicted, which unless otherwise described can include features similar to the end clip. In examples, the end clipcan include an L-shaped bracket, which includes a first armand a second armthat is perpendicular to the first arm. In examples, the first armcan be removably coupled (e.g., via one or more fasteners) to the extension. In addition, the second armcan include the tenon for securing the corner beam to another beam. In examples, the L-shaped bracketwith the removable attachment allows for easy, quick, and less costly replacement or repair in the event that the L-bracket (e.g., second arm) is damaged.

Based on the above, a corner beam of the present disclosure can include any one or more of the following features or characteristics diagonal beam connecting perpendicular main beams to create corner condition; eliminates cantilevered low beam as shown in; provides a troughfor a filler beam, which can span between the corner beamand another beam (e.g.,or); integrated nailerfor deck attachment; adjustable length end clipsto accommodate misalignment; locks into beam end capwhile still allowing installation of guardrail post; interlocks into lower troughto prevent rotation; bolted end clipsfor ease of repair; ambidextrous design reduces the likelihood of improper installation; and/or safer install from top of deck while tied off.

As used herein, a recitation of “and/or” with respect to two or more elements should be interpreted to mean only one element, or a combination of elements. For example, “element A, element B, and/or element C” may include only element A, only element B, only element C, element A and element B, element A and element C, element B and element C, or elements A, B, and C. In addition, “at least one of element A or element B” may include at least one of element A, at least one of element B, or at least one of element A and at least one of element B. Further, “at least one of element A and element B” may include at least one of element A, at least one of element B, or at least one of element A and at least one of element B.

This detailed description is provided in order to meet statutory requirements. However, this description is not intended to limit the scope of the invention described herein. Rather, the claimed subject matter may be embodied in different ways, to include different steps, different combinations of steps, different elements, and/or different combinations of elements, similar or equivalent to those described in this disclosure, and in conjunction with other present or future technologies. The examples herein are intended in all respects to be illustrative rather than restrictive. In this sense, alternative examples or implementations can become apparent to those of ordinary skill in the art to which the present subject matter pertains without departing from the scope hereof.