FIELD OF THE INVENTION
This invention relates to bulkhead assemblies for use with concrete forms, and more particularly, to bulkhead assemblies for use with concrete forms in making a variety of concrete structures (e.g., walls and slabs that have a single mat of rebar, and walls and slabs that have multiple mats of rebar).
BACKGROUND OF THE INVENTION
The construction of a concrete wall or slab often requires the wall or slab to be poured in multiple sections. This is usually dictated by the Engineer of Record (EOR) within the project specifications or by the contractor based on availability of forming materials or placement restrictions. In order for the wall or slab to be built in sections and retain its structural integrity, reinforcement bars (rebar) must connect one section to the next. To accomplish this, the rebar of a given section must penetrate the bulkhead so that once the concrete section is cured and the bulkhead is removed, the rebar will extend into the next section to be placed. In addition, the size and spacing of the rebar as well as the thickness of the concrete wall or slab varies by the design and use requirements set forth by the EOR.
Current industry practice is to construct the bulkheads with ¾ inch thick wood boards. Holes are drilled through the boards to accommodate the size and spacing of the rebar. The boards are then attached to the sides of the wall forms with nails or screws and additional support lumber. This piecemeal approach to bulkhead construction is time consuming and labor intensive. Each board must be cut and drilled to fit. Also, the space constraints for the craftsman are often inhibited by the narrow space between the wall forms and the temporarily secured rebar he or she is trying to form around. Removal of this system after placement is also challenging due to the aforementioned space constraints and the hardened concrete that has locked boards in place. The boards are often removed in splintered pieces by means of claw hammer and pry bar.
SUMMARY OF THE INVENTION
The invention is directed to a bulkhead assembly for use with: a concrete form that includes first and second spaced form sides; and a first reinforcement bar disposed between and extending longitudinally of the first and second spaced form sides.
In one aspect, the bulkhead assembly may include a first pair of channel assemblies that may be positioned between the first and second spaced form sides. Each of the first pair of channel assemblies may include a channel member and an elastomeric member that may be positioned longitudinally in the channel member. The elastomeric member may be constructed and arranged so that when it is positioned longitudinally in the channel member, a portion of the elastomeric member extends outward transversely from the channel member. The outwardly extending portion may include an outer end that extends longitudinally of the channel member. The first pair of channel assemblies may be positioned on opposite sides of the first reinforcement bar, with the elastomeric member outer ends facing one another and contacting the first reinforcement bar, thereby inhibiting uncured concrete from passing between the first pair of channel assemblies when uncured concrete is poured into the concrete form.
In another aspect, the bulkhead assembly may include a second pair of channel assemblies that may be positioned between the first and second spaced form sides, substantially coplanar with the first pair of channel assemblies. Each of the second pair of channel assemblies may include a channel member and an elastomeric member that may be positioned longitudinally in the channel member. The elastomeric member may be constructed and arranged so that when it is positioned longitudinally in the channel member, a portion of the elastomeric member extends outward transversely from the channel member. The outwardly extending portion may include an outer end that extends longitudinally of the channel member. The second pair of channel assemblies may be positioned on opposite sides of a second reinforcement bar disposed between and extending longitudinally of the first and second spaced form sides, with the elastomeric member outer ends facing one another and contacting the second reinforcement bar, thereby inhibiting uncured concrete from passing between the second pair of channel assemblies when uncured concrete is poured into the concrete form.
In a further aspect, the bulkhead assembly may include a bulkhead wall segment, or member, that may be positioned between the first and second pairs of channel assemblies, substantially coplanar with the first and second pairs of channel assemblies. If desired, a first angle member may be positioned between a bulkhead wall segment first end and the first pair of channel assemblies; and a second angle member may be positioned between a bulkhead wall segment second end and the second pair of channel assemblies. The first and second angle members may assist in supporting the bulkhead wall segment.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated into this patent document and constitute a part of this specification, illustrate embodiments of the invention and, together with the general description of the invention given above, and the detailed description of the drawings given below, serve to explain the principles of the invention. The drawings are schematic in nature and are not necessarily to scale. Where possible, like reference numbers are used for like components in describing various embodiments.
FIG. 1 is a perspective view of an embodiment of the bulkhead assembly, in accordance with the principles of the invention, positioned between first and second wall form sides.
FIG. 2 is a top view of the bulkhead assembly of FIG. 1, positioned between first and second wall form sides.
FIG. 3 is a perspective view of a bulkhead assembly substantially similar to the bulkhead assembly of FIG. 1.
FIG. 4 is an exploded view of the bulkhead assembly of FIG. 3.
FIG. 5 is an end view of an embodiment of a channel assembly for use in forming a bulkhead assembly of the present invention.
FIG. 6 is an exploded view of the channel assembly of FIG. 5.
FIG. 7 is an end view of another embodiment of a channel assembly for use in forming a bulkhead assembly of the present invention.
FIG. 8 is an exploded view of the channel assembly of FIG. 7.
FIG. 9 is a perspective view of another embodiment of the bulkhead assembly, in accordance with the principles of the invention, positioned between first and second wall form sides.
FIG. 10 is a top view of the bulkhead assembly of FIG. 9, positioned between first and second wall form sides.
FIG. 11 is a perspective view of a further embodiment of the bulkhead assembly, in accordance with the principles of the invention, positioned between first and second wall form sides.
FIG. 12 is a top view of the bulkhead assembly of FIG. 11, positioned between first and second wall form sides.
FIG. 13 is a perspective view of an additional embodiment of the bulkhead assembly, in accordance with the principles of the invention, positioned between first and second wall form sides.
FIG. 14 is a top view of the bulkhead assembly 13, positioned between first and second wall form sides.
FIG. 15 is a perspective view of yet another embodiment of the bulkhead assembly, in accordance with the principles of the invention, positioned between a first slab form side and a second slab form side (not shown), with the bulkhead assembly shown in cross section.
FIG. 16 is a side view of the bulkhead assembly of FIG. 15, positioned between a first slab form side and a second slab form side (not shown), with the bulkhead assembly shown in cross section.
DETAILED DESCRIPTION OF THE DRAWINGS
With reference to FIGS. 1-6, a particular embodiment 10 of the bulkhead assembly, in accordance with the principles of the invention, is shown, with the bulkhead assembly 10 positioned between a first form side 12 and a second form side 14. A first mat 16 and a second mat 18 of reinforcing bars also are in position between the first and second form sides 12, 14; and the bulkhead assembly 10 is assembled so as to allow a portion of each of the horizontal reinforcing bars (as at 20 and 22 in FIGS. 1 and 2) of each of the two mats 16, 18 to pass through and extend outward from the bulkhead assembly 10. The terms “reinforcement bar” and “reinforcement bars” also may be referred to in this patent document as “rebar.”
Referring to FIGS. 1-4, the bulkhead assembly 10 includes a first pair of channel assemblies 24, a second pair of channel assemblies 26, and a bulkhead wall segment or member 28 positioned between the pairs of channel assemblies. Referring to FIGS. 5 and 6, each channel assembly includes a channel member 30 and an elastomeric member 32 positioned longitudinally in the channel member. The channel member 30 includes a base wall 34, a first sidewall 36, and a second sidewall 38, with the first and second sidewalls spaced from one another and extending outwardly from the base wall. The base wall 34, first sidewall 36, and second sidewall 38 assist in forming a substantially U-shaped cross-section. Each of the first and second sidewalls 36, 38 includes a longitudinally extending outer end that includes a curved portion (as at 40), with part of the curved portion contacting the elastomeric member 32. A portion 42 (FIG. 5) of the elastomeric member 32 extends outward transversely from the channel member 30; and the outwardly extending portion includes an outer end 44 that extends longitudinally of the channel member.
Referring to FIGS. 1-2, the first pair of channel assemblies 24 is positioned on opposite sides of the first mat 16, with the elastomeric member outer ends (as at 44 in FIGS. 5 and 6) facing one another and contacting the horizontal reinforcing bars of the first mat 16, and with a portion of each of the first mat horizontal reinforcement bars (e.g., portion 20) passing between and extending outward from the first pair of channel assemblies 24. The second pair of channel assemblies 26 is positioned on opposite sides of the second mat 18, with the elastomeric member outer ends (as at 44 in FIGS. 5 and 6) facing one another and contacting the horizontal reinforcing bars of the second mat 18, and with a portion of each of the second mat horizontal reinforcement bars (e.g., portion 22) passing between and extending outward from the first pair of channel assemblies 24.
As best seen in FIGS. 3 and 4, the bulkhead assembly 10 further includes a first angle member 46 positioned between the bulkhead wall segment 28 and the first pair of channel assemblies 24, and a second angle member 48 positioned between the bulkhead wall segment and the second pair of channel assemblies 26.
An optional key and water stop assembly 50 is shown attached to the bulkhead assembly 10. In further detail, the optional key and water stop assembly 50 is fastened to the bulkhead wall segment 28; and the assembly 50 extends outward from the segment 28 in a direction generally perpendicular to the bulkhead assembly 10. The particular key and water stop assembly 50 shown includes a pair of beveled key members 51a, 51b and a water stop 53, with a portion of the water stop positioned between the key members, and another portion of the water stop extending outward from the key members in a direction generally perpendicular to the bulkhead assembly 10.
The key and water stop assembly 50 forms a keyway in an end of a section of concrete being placed. After the section has been placed, the bulkhead assembly 10 and the key and water stop assembly 50 may be removed (e.g., in preparation for placing an adjoining concrete section). Then when an adjoining section of concrete is placed, the keyway is filled with concrete from the adjoining section. Key and water stop assemblies can be especially useful in forming joints between adjacent concrete sections when the resulting concrete structure is used to retain water. If desired, the key members may be made of wood; and the water stop may be made of a pliable material that includes ribbed contours. The ribbed contours of the water stop impede the movement of water through the joint.
As will be appreciated, a bulkhead assembly in accordance with the principles of the invention may be used with any suitable formwork system. With reference to FIGS. 1 and 2, a few components of one exemplary formwork system are shown. Other components of the exemplary formwork system have been omitted in order to better show the bulkhead assembly 10, and the positioning of various components of the bulkhead assembly relative to the formwork system and the two reinforcing mats 16, 18. Referring to FIGS. 1 and 2, the first form side 12 of the formwork system includes a form facing 52, a series of horizontal beams (as at 54), and a vertical beam 56 (FIG. 2). The second form side 14 of the formwork system includes a form facing 58, a series of horizontal beams (as at 60), and a vertical beam 62 (FIG. 2). A tie rod 64 extends from vertical beam 56 to vertical beam 62. The formwork system further includes a series of end wall beams (as at 66 in FIG. 2).
A bulkhead assembly in accordance with the principles of the invention may be formed using any suitable materials. For example, if desired, the channel assembly channel members may be strut channel (e.g., Unistrut® strut channel from Atkore International, Inc.). The channel assembly elastomeric members may, if desired, be formed of rubber (e.g., a neoprene rubber). And the angle members may, if desired, be formed of any suitable metal. Also, the bulkhead wall segment may, if desired, be formed of wood; and if desired, the wood may include one or more panels of plywood (e.g., two panels of plywood overlaid one against the other).
The components of a bulkhead assembly in accordance with the principles of the invention may be fastened together and to the formwork system in any suitable fashion and with any suitable fasteners or fastening materials. With regard to an elastomeric member and a channel member of the invention, if desired, a channel assembly may be formed (of these two components) and maintained without the use of any fastening materials or substances (e.g., without the use of screws, nails, bolts, adhesives, and the like). For example, a portion of the elastomeric member may be positioned longitudinally in the channel member; and the elastomeric member portion may remain in, or be kept in, the channel member (e.g., not fall out of the channel member) without the use of any fastening materials or substances (e.g., without the use of screws, nails, bolts, adhesives, and the like).
With reference to FIGS. 7 and 8, an alternate embodiment 70 of a channel assembly is shown. In this embodiment, the channel assembly 70 includes a channel member 72 and an elastomeric member 74 positioned longitudinally in the channel member. The channel member 72 includes a base wall 76, a first sidewall 78, and a second sidewall 80, with the first and second sidewalls spaced from one another and extending outwardly from the base wall. The base wall, first sidewall, and second sidewall assist in forming a substantially U-shaped cross-section. Each of the first and second sidewalls 78, 80 includes a longitudinally extending outer end (as at 82) that is straight (i.e., that does not include a curved portion). And the width of the elastomeric member 74 corresponds with the full interior width (from sidewall 78 to sidewall 80) of the channel member 72. The elastomeric member 74 contacts each of the sidewalls along substantially the full length of the sidewalls. A portion 84 of the elastomeric member 74 extends outward transversely from the channel member 72; and the outwardly extending portion includes an outer end 86 that extends longitudinally of the channel member.
Referring to FIGS. 9 and 10, another embodiment 90 of the bulkhead assembly, in accordance with the principles of the invention, is shown, with the bulkhead assembly 90 positioned between a first fort side 92 and a second fort side 94. A single mat 96 of reinforcing bars also is in position between the first and second form sides; and the bulkhead assembly is assembled so as to allow a portion (as at 98) of each of the horizontal reinforcing bars of the mat to pass through and extend outward from the bulkhead assembly 90. The bulkhead assembly 90 includes a first pair of channel assemblies 24, a first angle member 46, and a bulkhead wall segment 28 positioned between the pair of channel assemblies. The first pair of channel assemblies 24 is positioned on opposite sides of the mat 96, with the elastomeric member outer ends (as at 44 in FIGS. 5 and 6) facing one another and contacting the horizontal reinforcing bars of the mat. A key and water stop assembly 50 is attached to the bulkhead assembly 90.
In FIGS. 9 and 10, a few components of another exemplary formwork system are shown. Other components of the exemplary formwork system have been omitted in order to better show the bulkhead assembly 90, and the positioning of various components of the bulkhead assembly relative to the formwork system and the reinforcing mat 96. Referring to FIGS. 9 and 10, the first form side 92 of the formwork system includes a form facing 52 and a series of horizontal beams (as at 100). The second form side 94 of the formwork system includes a form facing 58 and a series of horizontal beams (as at 104). Tie rods (as at 106) connect the first and second form sides 92, 94. The formwork system further includes a series of end wall beams (as at 108 in FIG. 10).
Referring to FIGS. 11 and 12, another embodiment 110 of the bulkhead assembly, in accordance with the principles of the invention, is shown, with the bulkhead assembly positioned between a first form side 112 and a second form side 114. A first mat 16 and a second mat 18 of reinforcing bars also are in position between the first and second form sides; and the bulkhead assembly 110 is assembled so as to allow a portion (as at 20 and 22) of each of the horizontal reinforcing bars of each of the two mats to pass through and extend outward from the bulkhead assembly. The bulkhead assembly 110 includes a first pair of channel assemblies 24 and a second pair of channel assemblies 26. The first pair of channel assemblies is positioned on opposite sides of the first mat 16, with the elastomeric member outer ends (as at 44 in FIGS. 5 and 6) facing one another and contacting the horizontal reinforcing bars of the first mat. The second pair of channel assemblies is positioned on opposite sides of the second mat 18, with the elastomeric member outer ends (as at 44 in FIGS. 5 and 6) facing one another and contacting the horizontal reinforcing bars of the second mat. A key and water stop assembly 50 is attached to the bulkhead assembly 110.
In FIGS. 11 and 12, a few components of an exemplary formwork system similar to that in FIGS. 9 and 10 are shown. Other components of the exemplary formwork system have been omitted in order to better show the bulkhead assembly 110, and the positioning of various components of the bulkhead assembly relative to the formwork system and the two reinforcing mats 16, 18. The first form side 112 of the formwork system includes a form facing 52 and a series of horizontal beams (as at 100). The second form side 114 of the formwork system includes a form facing 58 and a series of horizontal beams (as at 104 in FIG. 12). The formwork system further includes a series of end wall beams (as at 108 in FIG. 12).
Referring to FIGS. 13 and 14, another embodiment 120 of the bulkhead assembly, in accordance with the principles of the invention, is shown, with the bulkhead assembly positioned between a first form side 122 and a second form side 124. A single mat 96 of reinforcing bars also is in position between the first and second form sides; and the bulkhead assembly 120 is assembled so as to allow a portion (as at 98) of each of the horizontal reinforcing bars of the mat to pass through and extend outward from the bulkhead assembly. The bulkhead assembly 120 includes a first pair of channel assemblies 24. The first pair of channel assemblies is positioned on opposite sides of the mat 96, with the elastomeric member outer ends (as at 44 in FIGS. 5 and 6) facing one another and contacting the horizontal reinforcing bars of the mat.
In FIGS. 13 and 14, a few components of an exemplary formwork system similar to that in FIGS. 11 and 12 are shown. Other components of the exemplary formwork system have been omitted in order to better show the bulkhead assembly 120, and the positioning of various components of the bulkhead assembly relative to the formwork system and the reinforcing mat 96. The first form side 122 of the formwork system includes a form facing 52 and a series of horizontal beams (as at 100). The second form side 124 of the formwork system includes a form facing 58 and a series of horizontal beams (as at 104). Tie rods (as at 106) connect the first and second form sides 122, 124. The formwork system further includes a series of end wall beams (as at 108 in FIG. 14).
With reference to FIGS. 15 and 16, another embodiment 130 of the bulkhead assembly, in accordance with the principles of the invention, is shown, with the bulkhead assembly positioned between a first form side 132 and a second form side (not shown). This embodiment is oriented for use in forming a slab. A first mat 134 and a second mat 136 of reinforcing bars also are positioned between the first and second form sides, with the mats oriented for use in forming a slab. Each mat 134, 136 includes: horizontal reinforcing bars that extend longitudinally of the first form side (132) and the second form side (not shown), horizontal reinforcing bars that extend between the first and second form sides, generally perpendicular to the longitudinally extending bars and the first and second form sides. The bulkhead assembly 130 is assembled so as to allow a portion (as at 138 and 140) of each of the longitudinally extending horizontal reinforcing bars of each of the two mats to pass through and extend outward from the bulkhead assembly.
The bulkhead assembly 130 includes a first pair of channel assemblies 142, a second pair of channel assemblies 144, and a bulkhead wall segment 146 positioned between the pairs of channel assemblies. The first pair of channel assemblies 142 is positioned on opposite sides of the longitudinally extending bars of the first mat 134, with the elastomeric member outer ends (as at 44 in FIGS. 5 and 6) facing one another and contacting the longitudinally extending bars of the first mat. The second pair of channel assemblies 144 is positioned on opposite sides of the longitudinally ling bars of the second mat 136, with the elastomeric member outer ends (as at 44 in FIGS. 5 and 6) facing one another and contacting the longitudinally extending bars of the second mat. The bulkhead assembly further includes a first angle member 148 positioned between the bulkhead wall segment 146 and the first pair of channel assemblies 142, and a second angle member 150 positioned between the bulkhead wall segment 146 and the second pair of channel assemblies 144. In addition, the bulkhead assembly includes a vertical tie rod assembly 151. A key and water stop assembly 50 is attached to the bulkhead assembly 130.
In FIGS. 15 and 16, a few components of another exemplary formwork system are shown. Other components of the exemplary formwork system have been omitted in order to better show the bulkhead assembly 130, and the positioning of various components of the bulkhead assembly relative to the formwork system and the two reinforcing mats 134, 136. Referring to FIGS. 15 and 16, the first form side 132 of the formwork system includes a form facing 152 and a plurality of stakes (as at 154) driven into a subgrade fill 156. The second form side (not shown) of the formwork system is similar to the first form side. In addition, another plurality of stakes (as at 158) is positioned adjacent the face of the bulkhead assembly 130 that includes the vertical tie rod assembly 151.
A bulkhead assembly, in accordance with the principles of the invention, has many benefits and advantages. For example, the assembly can be modified to fit a variety of wall, slab, and rebar configurations. Also, the assembly may be installed more efficiently. For example, the components can be sub-assembled and slid into place.
In addition, because the rebar passes between the elastomeric members of adjacent channel assemblies, and the rebar is not constrained by other materials, the removal of the formwork requires much less force than conventional methods. Once the concrete has cured and the support structure or formwork structure has been removed from behind the bulkhead assembly, an entire channel assembly may be removed from the concrete section in one piece. The pair(s) of channel assemblies can be quickly scraped clean and immediately ready for reuse on the subsequent pour.
Also, after placement of a concrete wall- or slab-section, none of the bulkhead assembly components is constrained by cured concrete on more than one side, which makes removal much easier.
While the present invention has been illustrated by a description of embodiments, and while the illustrative embodiments have been described in considerable detail, it is not the intention of the inventors to restrict or in any way limit the scope of the following claims to such detail. Additional advantages and modifications readily will appear to those skilled in the art upon a reading of this patent document. The invention, in its broader aspects, is therefore not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described in this patent document. Accordingly, departures may be made from such details without departing from the spirit or scope of the inventors' general inventive concept.
Patent Application
20180355626
