Patent Application
20240110341
The present disclosure is directed to reinforcement systems. The present disclosure is particularly applicable for use with paved surfaces such as, but not limited to, roads, parking lots, sidewalks, jogging and bike paths, etc. The installation of fiber-reinforced polymer (FRP) in slots cut into concrete is a technique developed over the years by the concrete repair industry and has become the generally accepted way to repair pre-cast concrete. The present disclosure is directed to a method and apparatus for strengthening concrete, more particularly directed to a method and apparatus for strengthening and/or repairing concrete connections, and still more particularly directed to a method and apparatus for repairing the flange-to-flange connections for pre-cast and pre-stressed double tee systems by connecting a device on the underside of the flange-to-flange connections for pre-cast and pre-stressed double tee systems.
Concrete structures are commonly used for buildings, parking garages, and the like. Over time, cracks can develop within concrete structures. If such cracks are left unrepaired, the cracks can result in failure of the structure. This is a particular problem for parking garages wherein large loads from vehicles daily travel over the concrete surface. To prevent the failure of the concrete structure without having to replace the structure, the damaged concrete structure is often repaired by cutting the damaged section away from a pre-existing concrete section, and then pouring new concrete into the cutout portion. However, new concrete does not always bond perfectly with the pre-existing concrete, thus resulting in the propagation of cracks in the joint between the old and new concrete.
Other methods have been used to repair damaged concrete structures and to maintain the mechanical connection between the new concrete section and a pre-existing concrete section. One prior art repair method involves first removing the damaged concrete and then drilling holes in the pre-existing concrete using a rotary impact hammer drill. Thereafter, an adhesive is placed into the holes, and reinforcing bars are inserted such that the bars extend beyond the outer wall of the pre-existing concrete and are generally perpendicular to the joint between the pre-existing concrete section and the gap defining the area where the new concrete is to be poured. The new concrete is then poured adjacently to the pre-existing concrete such that the ends of the reinforcing bars extend into the new concrete and bond with the new concrete when the new concrete cures. As a result, when the new concrete cures, it will be joined to the pre-existing concrete via the reinforcing bars. When attaching external fixtures to pre-existing concrete sections, holes are commonly drilled using a standard rotary drill, and the anchors are either bonded or friction-fitted within the drilled holes. The external fixtures are then mounted onto the anchors.
Several disadvantages are associated with these past methods of repair and attachment of newly poured concrete. For instance, the drilling of multiple holes into the existing concrete is a slow and labor intensive process. Additionally, the vibrations associated with the drilling of the holes can cause an entire section of concrete to fail. Moreover, once a hole is drilled, it must be subsequently cleaned of dust and concrete particles in order to permit the adhesive to properly bond to the concrete. Furthermore, cracks can form over time in the joint between the new concrete section and the pre-existing concrete. As such, when moisture seeps down these cracks, the metallic reinforcing bars will rust, corrode, and subsequently fail, thereby necessitating further repair of the concrete section. Also, a phenomenon known in the industry as “burping” may occur, whereby air pockets become trapped within the hole once the reinforcing bar is installed, thereby preventing at least a portion of the adhesive from bonding with the reinforcing bar. Such defective bonding can lead to premature failure of the reinforced joint.
The repair of concrete structures such as a parking garage structure, a concrete driveway, or the like that is disposed above T-shaped concrete beams can be problematic. The concrete structures are typically joined together by metal clips. As cracks form in the concrete structures, moisture seeps into the concrete supports and corrodes the metal clips. Such metal clip corrosion ultimately causes the metal clip to fail, which can result in the collapsing of a concrete slab within the parking garage. One prior art method to repair this type of damage involves welding or bolting a supplemental joining apparatus to both supports, thereby retaining them together. This method is expensive and labor intensive. Additionally, the repair is aesthetically unappealing. Another prior art method to repair this type of damage involves cutting through the concrete to access and replace the failed metal clip. Again, this process is labor intensive and expensive.
Another prior art method to repair concrete structures disposed above T-shaped concrete beams is disclosed in U.S. Pat. No. 6,312,541, which is incorporated herein by reference. The '541 patent discloses the use of a half-moon-shaped molded composite insert that is inserted into a cut slot in the concrete slab. The slot is cut generally perpendicular to the T-shaped concrete beams and across the gap between two concrete structures. An epoxy material is used to secure the composite insert in the cut slot. The composite insert includes a plurality of cavities that facilitate in the bonding of the composite insert within the cut slot in the concrete slab. Although the molded composite insert is an improvement over prior art methods to repair damaged concrete, there remains a continued need to improve the strength and durability of the repaired concrete.
Another prior art method to repair concrete structures disposed above T-shaped concrete beams is disclosed in U.S. Pat. No. 8,567,146, which is incorporated herein by reference. The '146 patent discloses a composite material for use in repairing concrete. A slot is cut into two adjacently positioned concrete slabs and the composite material is inserted into the cut and adhesively connected to the concrete slabs. Although the composite insert is an improvement over prior art methods to repair damaged concrete and/or to connect together adjacently positioned concrete slabs, the repair process requires that a slot be cut in the concrete deck.
Another prior art method to repair concrete structures for T-shaped concrete beams is disclosed in U.S. Pat. No. 8,800,232, which is incorporated herein by reference. The '232 patent discloses a flexible flange connection for use in a concrete structure that allow for deflection of adjacent pre-cast structures at or near the flange connection. The connection system utilizes a plurality of components that make the use of the flange connection system complicated and cumbersome.
In view of the current prior art methods to repair concrete, there remains a continued need to improve the strength and durability of the repaired concrete and/or connected concrete and to reduce cracking in the repaired and/connected concrete.
The present disclosure is directed to a method and apparatus for connecting, strengthening, and/or repairing concrete connections, and more particularly directed to a method and apparatus for repairing the flange-to-flange connections for pre-cast and pre-stressed double tee systems; however, it can be appreciated that the method can be used to connect other concrete systems and other non-concrete systems. The method and apparatus of the present disclosure includes the use of an improved plate system that is secured to the bottom region of the concrete. The method of the present disclosure is simple to implement, generally less expensive than welding a supplemental joining apparatus to the concrete, and eliminates the need to cut slots into the top surface of the deck of the concrete, thus minimizing the need to close off the complete concrete structure during the repair and/or connection process. In one non-limiting embodiment, the method of the present disclosure is absent the use of welding.
In one non-limiting aspect of the present disclosure, the improved plate system has a shape such that the improved plate system is generally located on each side of the central longitudinal axis of the connection location (e.g., central axis of the flange-to-flange connection for pre-cast and pre-stressed double tee systems, etc.). In one non-limiting embodiment, the improved plate system has a plate body wherein the length that is greater or equal to the width. In one non-limiting embodiment, the maximum longitudinal length of the improved plate system is 6-25 inches (and all values and ranges therebetween), and typically 8-16 inches. In another non-limiting embodiment, the maximum width of the improved plate system is 4-25 inches (and all values and ranges therebetween), and typically 6-14 inches. In another non-limiting embodiment, the thickness of the improved plate system is 0.1-3 inches (and all values and ranges therebetween), and typically 0.25-2 inches. In another non-limiting embodiment, the improved plate system includes a plurality of connections arrangements and each side of the central latitudinal axis (e.g., axis that is perpendicular to the longitudinal axis of the improved plate system and which axis passing through midpoint of the longitudinal length of the improved plate system) of the improved plate system generally has the same number of connection arrangements (e.g., 1-10 connection arrangement on each side and all values and ranges therebetween); however, this is not required. Such connection arrangements include, but are not limited to, holes, slots, clips, recesses, hooks, flanges, etc. In one non-limiting configuration, a plurality of the connection arrangements are the same shape, size, and/or configuration. In another non-limiting configuration, all of the connection arrangements are the same shape, size, and/or configuration. In another non-limiting configuration, at least one of the connection arrangements is in the form of a hole through the complete thickness of the improved plate system. In another non-limiting configuration, all of the connection arrangements are in the form of holes through the complete thickness of the improved plate system. When one or more of the connection arrangements are in the form of a hole, a screw, bolt, pin, rod, clip, cord, chain, etc. can be partially inserted into and/or through the hole to facilitate in the securing of the improved plate system to the concrete surface or other surface to be repaired. In another non-limiting aspect of the present disclosure, the improved plate system includes a plurality of connections arrangements that are spaced apart from one another and each side of the central latitudinal axis of the improved plate system has the same number of connection arrangements. In one non-limiting embodiment, the improved plate system has the same shape, size and/or thickness on each side of the central latitudinal axis of the improved plate system. In another non-limiting embodiment, the improved plate system has the same shape, size and thickness on each side of the central latitudinal axis of the improved plate system. In another non-limiting embodiment, the improved plate system has the same shape and size and a different thickness on each side of the central latitudinal axis of the improved plate system.
In another non-limiting aspect of the present disclosure, the improved plate system is circular or oval shaped. In another non-limiting configuration, the improved plate system has an even number of sides. In one non-limiting specific arrangement, the improved plate system has four, six, or eight sides. In another one non-limiting specific arrangement, the improved plate system has four sides. In another one non-limiting specific arrangement, the improved plate system has four sides, and at least two of the opposite facing sides have a non-linear shape (e.g., outward curved shape, inward curved shape, wave shape, U-shaped, C-shaped, S-shaped, etc.). In another one non-limiting specific arrangement, the improved plate system has four sides, and each of the opposite facing sides have a non-linear shape (e.g., outward curved shape, inward curved shape, wave shape, U-shaped, C-shaped, S-shaped, etc.). In another one non-limiting specific arrangement, the improved plate system has four sides, and each of the opposite facing sides have an inward curved shape, and the opposite sizes have the same shaped inward curved shape. In one non-limiting embodiment, the curved profile on one or more of the sides of the improved plate system are configured to curve inwardly to cause a reduction in longitudinal length and/or width of the improved plate system. In one non-limiting configuration, the radius of curvature of the curved profile located on a portion or along the full length of one or more sides of the improved plate system is a radius of curvature of 2-16 inches (and all values and ranges therebetween), and typically 3-8 inches.
In another non-limiting aspect of the present disclosure, the improved plate system includes a plurality of corner regions and each corner region includes a connection arrangement. In one non-limiting arrangement, when the improved plate system includes an even number of corners, a same number of connection arrangement are located on each side of the central latitudinal axis of the improved plate system, and the connection arrangements that are located in each of the corners can be oriented such that an axis through each of the connection arrangement passes within ±10% of the width of the improved plate system (and all values and ranges therebetween). In one non-limiting configuration, the improved plate system includes four (4) corners and a single connection arrangement located at each corner region, and each of the connection arrangements have the same size and/or shape. In another non-limiting configuration, the improved plate system includes four (4) corners and a single connection arrangement located at each corner region, and each of the connection arrangements have the same size and/or shape, and each of the connection arrangement are spaced from the outer perimeter of the improved plate system, and are spaced at similar distances from the outer perimeter of the improved plate system.
In another non-limiting aspect of the present disclosure, the improved plate system is formed of a durable material (e.g., metal, ceramic, fiber material, etc.). The improved plate system can be formed of one or more layers of material. In one non-limiting embodiment, the improved plate system is formed of less than 50 wt. % metal (e.g., 0-49.99 wt. % and all values and ranges therebetween). In another non-limiting embodiment, the improved plate system is formed of less than 10 wt. % metal. In another non-limiting embodiment, the improved plate system is partially or fully formed of a fiber and adhesive system. The fibers that can be used in the improved plate system include, but are not limited to, carbon fibers, glass fibers, aramid fibers [Kevlar™ Twaron™, etc.], boron fibers, hemp fibers, basalt fibers, nylon fibers, Dyneema™ fibers, Zylon™ fibers, fiberglass fibers, etc. The improved plate system can include a single type of fiber or multiple types of fiber. The fibers can be partially or fully coated, partially or fully saturated, and/or partially or fully incorporated in an adhesive material. The improved plate system can be partially or fully formed of a) one or more layers of fibers wherein the fibers are oriented in a parallel relationship to one another, b) two or more layers of fibers that are oriented in a nonparallel relationship to one another, and/or c) one or more fiber layers wherein each fiber layer includes two or more layers of fibers oriented in a non-parallel relationship to one another and wherein the two or more layers of fiber in the fiber layer are woven or non-woven. The one or more layers of fibers can be connected together by adhesive, stitching, heat bonding, adhesive stapling, partially or fully coated and/or immersed with/in a resin material and/or other type of polymer material, and/or by some other connection arrangement. In one non-limiting embodiment of the disclosure, the improved plate system can include one or more layers of fiber or an aggregate of fibers that have a tensile strength of at least about 50 KSI. The tensile strength is the maximum stress that the fiber can withstand before failure of the fiber. In one non-limiting aspect of this embodiment, the improved plate system includes one or more layers of fiber or an aggregate of fibers that have a tensile strength of about 50-800 KSI (and all values and ranges therebetween). In another non-limiting aspect of this embodiment, the improved plate system includes one or more layers of fiber or an aggregate of fibers having a tensile strength of at least about 200 KSI. In another non-limiting aspect of this embodiment, the improved plate system includes one or more layers of fiber or an aggregate of fibers having a tensile strength of at least about 300 KSI. In another non-limiting aspect of this embodiment, the improved plate system includes one or more layers of fiber or an aggregate of fibers having a tensile strength of about 300-700 KSI. In another non-limiting aspect of this embodiment, the improved plate system includes one or more layers of fiber or an aggregate of fibers having a tensile strength of about 350-675 KSI. In another and/or alternative non-limiting embodiment of the disclosure, the improved plate system can include one or more layers of fiber or an aggregate of fibers having a tensile modulus of at least about 3 MSI. Tensile modulus is an indicator of the stiffness of the fiber. Tensile modulus is the applied stress on the fiber, based on force and cross-sectional area of the fiber, divided by the observed strain at such stress level. In one non-limiting aspect of this embodiment, the improved plate system includes one or more layers of fiber or an aggregate of fibers having have a tensile modulus of about 3-60 MSI (and all values and ranges therebetween). In another non-limiting aspect of this embodiment, the improved plate system includes one or more layers of fiber or an aggregate of fibers having a tensile modulus of at least about 5 MSI. In another non-limiting aspect of this embodiment, the improved plate system includes one or more layers of fiber or an aggregate of fibers having a tensile modulus of at least about 8 MSI. In another non-limiting aspect of this embodiment, the improved plate system includes one or more layers of fiber or an aggregate of fibers having a tensile modulus of about 10-50 MSI. In another non-limiting aspect of this embodiment, the improved plate system includes one or more layers of fiber or an aggregate of fibers having a tensile modulus of about 10-35 MSI. The adhesive material and/or resin/polymer coating included in the improved plate system generally includes vinyl ester resins, epoxy resins, polyester resins, acrylic resins, polyurethane resins, phenolic resins, alkyd resins, polycarbonate resins, polyamide resins, and/or silicone resins. In another non-limiting embodiment of the disclosure, the adhesive material and/or resin/polymer coating includes resin material. In another non-limiting embodiment of the disclosure, the adhesive material and/or resin/polymer coating includes resin material that includes a vinyl ester resin. In another non-limiting embodiment of the disclosure, the adhesive material and/or resin/polymer coating includes a resin material that includes an epoxy resin.
In another and/or alternative non-limiting aspect of the present disclosure, the improved plate system optionally includes one or more outer layers of dielectric insulating material. The dielectric insulating material can be located on the top and/or bottom surface of the improved plate system. The thickness of each of the layers of dielectric insulating material is generally 0.01-3 inches (and all values and ranges therebetween). As used herein, a dielectric insulating material is a material having low conductivity and which creates obstruction in the flow of current. As defined herein, a dielectric insulating material has an electrical conductivity of less than 5.5×10−3 S/m, and typically, a dielectric insulating material has an electrical conductivity of less than 5.5×10−6 S/m. Non-limiting examples of dielectric insulating material includes fiberglass fiber layers, Kevlar™ fiber layers, resin material layers, etc. In one non-limiting embodiment of the disclosure, the improved plate system includes one or more fiberglass layers on the top and/or bottom surface of the improved plate system.
In another and/or alternative non-limiting aspect of the present disclosure, the improved plate system can optionally include two or more layers of fibers oriented in a nonparallel relationship to one another. In one particular configuration, one fiber layer runs in a plane nonparallel to the longitudinal axis of another fiber layer (e.g., +45° & −45°, +30° & −30°, +60° & −60°, +15-75° (and all values and ranges therebetween) & −15-75° (and all values and ranges therebetween), etc.).
In another and/or alternative non-limiting aspect of the present disclosure, the improved plate system is optionally at least partially formed by saturating and/or impregnating one or more fiber layers with an adhesive and/or resin/polymer material (e.g., resin material, etc.) and then pressing the adhesive and one or more fiber layers together until the adhesive and/or resin/polymer material dries and/or cures. A vacuum can optionally be applied during the pressing and drying/curing steps. The process for forming the improved plate system can be by a batch process or a continuous process. The adhesive material and/or resin/polymer material can be pre-applied and/or applied as the one or more fiber layers are brought together.
In another and/or alternative non-limiting aspect of the present disclosure, the improved plate system includes curved corners. The radius of curvature of the curved corners is generally about 0.1-2 inches (and all values and ranges therebetween).
In another and/or alternative non-limiting aspect of the present disclosure, the improved plate system has a tensile strength along the x-y axis or longitudinal axis of at least about 50 KSI (e.g., 50-150 KSI and all values and ranges therebetween), a compressive strength along the x-y axis or longitudinal axis of at least about 40 KSI (e.g., 40-135 KSI and all values and ranges therebetween), a compressive strength through the z axis or thickness of at least about 5 KSI (e.g., 5-12 KSI and all values and ranges therebetween), a shear strength through the z axis or thickness of at least about 10 KSI (e.g., 10-30 KSI and all values and ranges therebetween), and/or an inter laminar shear along the x-y axis or longitudinal axis of at least about 1 KSI (e.g., 1-3 KSI and all values and ranges therebetween).
In another and/or alternative non-limiting aspect of the present disclosure, the improved plate system includes a base plate and one or more detachable shims on one or both sides of the base plate of the improved plate system. The shims adjust the surface profile of the top surface of the improved plate system (e.g., adjust thickness of the improved plate system, etc.) for instances when the improved plate system is to be connected to non-flush or non-level concrete surfaces. In many situations, the bottom surface of two separated concrete structures or slabs may not be flush or level with one another. In such a situation, when a rigid or semi-rigid plate is connected to one concrete surface positioned lower than the other concrete surface, a space exists between the plate and the other concrete surface. As such, when the plate is secured to both concrete surfaces, the plate is caused to bend. Such bending of the plate can result in damage to the plate. To avoid this problem, shims have typically been used to fill the gap. However, the size and shape of the shims can still result in the plate system not being properly connected to the concrete. Also, the use of shims on one section of the concrete and not the other can result in non-uniform forces being applied to the two connected concrete structures, thereby increasing the incidence of cracking. The improved plate system of the present disclosure overcomes this significant problem. In one non-limiting embodiment, the improved plate includes one or more removable layers, removable sections, or shims on a top portion and/or bottom surface of the base plate of the improved plate system. The one or more removable layers, removable sections, or shims address the unevenness of two adjacently positioned concrete sections when connecting the improved plate system to such concrete sections. In one non-limiting configuration, the improved plate system includes a single removable layer, removable section, or shim. In another non-limiting configuration, the improved plate system includes a plurality of removable layers or removable sections or shims. In another non-limiting configuration, each removable layer, removable section, or shim has the same shape or configuration, and optionally the same thickness. In another non-limiting configuration, each removable layer, removable section, or shim has the shape of half or nearly half (e.g., 40-60% of the top surface and all values and ranges therebetween) the top surface of the improved plate system. In another non-limiting configuration, one or more or all of the removable layer, removable section, or shim to not overlay the central latitudinal axis of the improved plate system. The removable layer, removable section, or shim can be formed of one or more layers of material (e.g., metal, wood, ceramic, fiber layer, etc.) that are detachable connected to base plate of the improved plate system or to another removable layer, removable section, or shim. In one non-limiting configuration, one or more or all of the removable layers, removable sections, or shims are formed of the same material as the material used to form the base plate. In another non-limiting configuration, one or more or all of the removable layers, removable sections, or shims are formed of a different material from the material used to form the base plate. In another non-limiting configuration, the size, shape and/or material of two or more of the removable layers, removable sections, or shims can be the same or different. The detachable connection for the one or more removable layers, removable sections, or shims can be formed by 1) a breakable bonding material, 2) a breakable clip, 3) a breakable groove, 4) breakable seam, etc.). Such detachable connection is generally selected so as to minimize or prevent damage to the base plate and/or another one of the removable layers, removable sections, or shims that remain connected to the improved plate system when the removable layer, removable section, or shim is removed from the improved plate system. In another non-limiting configuration, the one or more of the removable layers, removable sections, or shims are only positioned on or above the top surface of the base plate. In use, the one or more removable layers, removable sections, or shims can optionally be used only when required. For example, there is provided an improved plate system including one removable layer, removable section, or shim that each have a thickness of 5-50% (and all values and ranges therebetween) the total thickness of the improved plate system, absent the thickness of any ribs or reinforcement structures. The improved plate system is to be connected to the bottom surface of two adjacently positioned concrete sections. The bottom surface of the concrete sections that are to be connected are flush or level. In such arrangement, the one removable layer, removable section, or shim remains in its original position and is not removed from the improved plate system when the improved plate section is connected to the bottom surface of the two concrete sections. In another example, there is provided an improved plate system that includes one removable layer, removable section, or shim. The improved plate system is to be connected to the bottom surface of two adjacently positioned concrete sections. The bottom surface of concrete section 1 is not non-flush or is uneven with the bottom surface of concrete section 2. In this example, the bottom surface of concrete section 1 extends below the bottom surface of concrete section 2. In such arrangement, the one removable layer, removable section, or shim is removed from the top surface of one side of the improved plate section. A majority (e.g., 55-100% and all values and ranges therebetween) of the region of the improved plate section where the removable layer, removable section, or shim was removed is positioned against the bottom surface of concrete section 1 and a majority (e.g., 55-100% and all values and ranges therebetween) of the other half of the improved plate section wherein a removable layer, removable section, or shim has not been removed from the improved plate system is positioned against the bottom surface of concrete section 2.
In another and/or alternative non-limiting aspect of the present disclosure, the improved plate system can optionally include one or more ribs or stiffness structures to increase the stiffness and/or strength of the improved plate system (e.g., improve vertical and/or horizontal stiffness of the improved plate system). When such ribs or stiffness structures are optionally used, such ribs or stiffness structures are generally positioned on the bottom surface of the improved plate system (e.g., bottom surface of the base plate of the improved plate system, etc.); however, this is not required. The materials used to form the ribs or stiffness structures are non-limiting (e.g., metal, wood, ceramic, plastic, fiber composite, etc.). In one non-limiting configuration, the material used to form the ribs or stiffness structures includes less than 50 wt. % metal (e.g., 0-49.99 wt. % and all values and ranges therebetween). In another non-limiting configuration, the material used to form the ribs or stiffness structures is formed of 10-100% (and all values and ranges therebetween) of the same material used to form the base plate of the improved plate system. The shape and size and material of the ribs or stiffness structures are also non-limiting. In one non-limiting embodiment, there is provided a single rib structure that runs generally centrally (±10%) down the full or partial (e.g., 30-99.99% of the longitudinal length and all values and ranges therebetween) longitudinal length of the improved plate system. In another non-limiting embodiment, there is provided two rib structures that run down the full or partial (e.g., 30-99.99% of the longitudinal length and all values and ranges therebetween) longitudinal length of the improved plate system and are spaced on each size of the central latitudinal axis of the improve plate system. In another non-limiting embodiment, there is provided two rib structures that run parallel to opposite sides of latitudinal central axis of the improved plate system and are generally spaced equal distances from the latitudinal central axis of the improved plate system. In another non-limiting embodiment, there is provided two rib structures that are located on each side latitudinal central axis of the improved plate system and each of the rib structures has a non-linear shape (e.g., curved, S-shaped, C-shaped, L-shaped, etc.) and are generally spaced equal distances from the latitudinal central axis along the longitudinal length of the improved plate system. In another non-limiting embodiment, one or more rib structures can optionally be configured to partially or fully encircle one or more connection arrangements (e.g., hole through the improved plate system, etc.). Such rib structures that partially or fully encircle one or more connection arrangements can have generally the same shape, size, configuration, and/or composition, and also optionally be positioned at the same distance from the sides of the improved plate system. In another non-limiting embodiment, the rib structure can be shaped to form a full or partial box shape or full or partially trapezoidal shape on the bottom side of the improved plate system. Such box shaped or trapezoidal shaped rib structures can optionally be centrally positioned about the latitudinal central axis of the improved plate system.
In another and/or alternative non-limiting aspect of the present disclosure, the method for using the improved plate system includes the steps of using adhesive to partially or fully secure the improved plate system to the concrete surface. Many different types of adhesives can be used. Generally, the adhesive is an epoxy adhesive; however, other or additional adhesives can be used. When an epoxy adhesive is used, the epoxy is generally a two-part, 100% solids epoxy that is thixotropic in nature. However, other adhesives that include vinyl ester resins, polyester resins, acrylic resins, polyurethane resins, phenolic resins, alkyd resins, polycarbonate resins, polyamide resins, and/or silicone resins can also or alternatively be used. The curing time for the adhesive is generally about 1-5 hours, depending on the temperature. The bonding strength of the improved composite material to the concrete is at least about 1 KSI. In one embodiment of the disclosure, bonding strength of the adhesive to the concrete is 1-6 KSI (and all values and ranges therebetween). In another one non-limiting aspect of this embodiment, the bonding strength of the adhesive to the concrete is at least about 1.5 KSI. In another non-limiting aspect of this embodiment, the bonding strength of the adhesive to the concrete is at least about 1.8 KSI. In another non-limiting aspect of this embodiment, the bonding strength of the adhesive to the concrete is at least about 2 KSI. In another non-limiting aspect of this embodiment, the bonding strength of the adhesive to the concrete is about 2-5 KSI. In another non-limiting aspect of this embodiment, the bonding strength of the adhesive to the concrete is about 2.2-4 KSI. In another non-limiting aspect of this embodiment, the bonding strength of the adhesive to the concrete is about 2.4-3.2 KSI. As can be appreciated, one or more other connection arrangement can be used in combination with the adhesive to secure the improved plate system to the concrete surface (e.g., bolts, clips, rod, pin, screw, cord, bolt, etc.).
In another and/or alternative non-limiting aspect of the present disclosure, the method for using the improved plate system includes the steps of 1) optionally cleaning the bottom surface of the concrete surface, 2) attaching one or more anchors (e.g., bolts, clips, rod, pin, screw, cord, chain, etc.) to the bottom surface of the concrete surface, and 3) securing the connection arrangement on the improved plate system (e.g., position bolt end through holes in the improved plate system and then thread nuts on the bolts, etc.) to secure the improved plate system to the bottom surface of the concrete sections. The method can optionally further include the step of using an adhesive to facilitate in securing the improved plate system to the concrete. The method can optionally include removing one or more removable layers, removable sections, or shims from the top surface of the base plate or from above the top surface of the base plate of the improved plate section prior to securing the improved plate system to the concrete so as to account for unevenness in the two sections of the concrete to be repaired.
The improved plate section has several advantages, namely:
It is one non-limiting object of the present disclosure to provide a method and apparatus for repairing and/or connecting concrete that is not as labor intensive as previous repair systems.
It is another and/or alternative non-limiting object of the present disclosure to provide a method and apparatus for repairing and/or connecting concrete that will not corrode and/or reduce the amount of corrosion over time.
It is another and/or alternative non-limiting object of the present disclosure to provide a method and apparatus for repairing and/or connecting concrete that reduces the incidence of cracking at or near the concrete connection location.
It is another and/or alternative non-limiting object of the present disclosure to provide a method and apparatus for repairing and/or connecting concrete that includes the use of an improved plate system that includes less than 50 wt. % metal.
It is another and/or alternative non-limiting object of the present disclosure to provide a method and apparatus for repairing concrete that minimizes the risk of damaging pre-existing concrete during the repair process.
It is another and/or alternative non-limiting object of the present disclosure to provide a method and apparatus for repairing and/or connecting two adjacent pre-existing sections of concrete using an improved plate system that is connected to the underside of the concrete sections.
It is another and/or alternative non-limiting object of the present disclosure to provide a method and apparatus for repairing and/or connecting two adjacent pre-existing sections of concrete using an improved plate system that is connected to the underside of the concrete sections and wherein the improved plate system includes one or more reinforcement structures.
These and other objects and advantages will become apparent to those skilled in the art upon reading and following the description taken together with the accompanying drawings.
Non-limiting and non-exhaustive embodiments are described with reference to the following drawings, wherein like labels refer to like parts throughout the various views unless otherwise specified. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements are selected, enlarged, and positioned to improve drawing legibility. The particular shapes of the elements as drawn have been selected for ease of recognition in the drawings. Reference may now be made to the drawings, which illustrate various embodiments that the disclosure may take in physical form and in certain parts and arrangement of parts wherein:
A more complete understanding of the articles/devices, processes and components disclosed herein can be obtained by reference to the accompanying drawings. These figures are merely schematic representations based on convenience and the ease of demonstrating the present disclosure, and are, therefore, not intended to indicate relative size and dimensions of the devices or components thereof and/or to define or limit the scope of the exemplary embodiments.
Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the embodiments selected for illustration in the drawings and are not intended to define or limit the scope of the disclosure. In the drawings and the following description below, it is to be understood that like numeric designations refer to components of like function.
The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.
As used in the specification and in the claims, the term “comprising” may include the embodiments “consisting of” and “consisting essentially of.” The terms “comprise(s),” “include(s),” “having,” “has,” “can,” “contain(s),” and variants thereof, as used herein, are intended to be open-ended transitional phrases, terms, or words that require the presence of the named ingredients/steps and permit the presence of other ingredients/steps. However, such description should be construed as also describing compositions or processes as “consisting of” and “consisting essentially of” the enumerated ingredients/steps, which allows the presence of only the named ingredients/steps, along with any unavoidable impurities that might result therefrom, and excludes other ingredients/steps.
Numerical values in the specification and claims of this application should be understood to include numerical values which are the same when reduced to the same number of significant figures and numerical values which differ from the stated value by less than the experimental error of conventional measurement technique of the type described in the present application to determine the value.
All ranges disclosed herein are inclusive of the recited endpoint and independently combinable (for example, the range of “from 2 grams to 10 grams” is inclusive of the endpoints, 2 grams and 10 grams, and all the intermediate values).
The terms “about” and “approximately” can be used to include any numerical value that can vary without changing the basic function of that value. When used with a range, “about” and “approximately” also disclose the range defined by the absolute values of the two endpoints, e.g., “about 2 to about 4” also discloses the range “from 2 to 4.” Generally, the terms “about” and “approximately” may refer to plus or minus 10% of the indicated number.
Percentages of elements should be assumed to be percent by weight of the stated element, unless expressly stated otherwise.
Although the operations of exemplary embodiments of the disclosed method may be described in a particular, sequential order for convenient presentation, it should be understood that disclosed embodiments can encompass an order of operations other than the particular, sequential order disclosed. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Further, descriptions and disclosures provided in association with one particular embodiment are not limited to that embodiment, and may be applied to any embodiment disclosed.
For the sake of simplicity, the attached figures may not show the various ways (readily discernable, based on this disclosure, by one of ordinary skill in the art) in which the disclosed system, method and apparatus can be used in combination with other systems, methods and apparatuses. Additionally, the description sometimes uses terms such as “produce” and “provide” to describe the disclosed method. These terms are abstractions of the actual operations that can be performed. The actual operations that correspond to these terms can vary depending on the particular implementation and are, based on this disclosure, readily discernible by one of ordinary skill in the art.
Referring now to the drawings wherein the showings are for the purpose of illustrating non-limiting embodiments of the disclosure only and not for the purpose of limiting same,
Referring now to
The material that is used to form the plate body generally is formed of less than 20 wt. % metal, and typically 0-5 wt. % metal, and more typically 0-1 wt. % metal. In one-non-limiting configuration, the body is formed of a plurality of non-metal fibers (e.g., carbon fibers, glass fibers, aramid fibers [Kevlar™, Twaron™, etc.], boron fibers, hemp fibers, basalt fibers, nylon fibers, Dyneema™ fibers, Zylon™ fibers, fiberglass fibers, etc.) that are bonded together by an adhesive or polymer material (e.g., resin, etc.).
Referring now to
The top surface of the shims 200 generally have a cross-sectional area that is less than a cross-sectional area of the top surface of the plate body 110 (e.g., the top surface of each of the shims has a cross-sectional area that is 5-80% (and all values and ranges therebetween) of the cross-sectional area of the top surface of the plate body). As illustrated in
The top surface of the plate body that is configured to receive the one or more shims includes a recessed region 150 as illustrated in
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A non-limiting method for using the improved plate system to repair the flange-to-flange connections for pre-cast and pre-stressed double tee systems includes the steps of:
When the improved plate system includes one or more shims, one or more of the shims can be removed to account for unevenness between the two concrete sections. The one or more shims are removed prior to securing the improved plate system on the underside of the two concrete sections.
The improved plate system is generally secured to the underside of the two concrete sections by the use of one or more concrete anchors; however, it will be appreciated that an adhesive material (e.g., resin material, etc.) can also be used with the one or more concrete anchors, or can alternatively be used instead of the one or more concrete anchors to secure the improved plate system to the underside of the two concrete sections.
It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained, and since certain changes may be made in the constructions set forth without departing from the spirit and scope of the disclosure, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. The disclosure has been described with reference to preferred and alternate embodiments. Modifications and alterations will become apparent to those skilled in the art upon reading and understanding the detailed discussion of the disclosure provided herein. This disclosure is intended to include all such modifications and alterations insofar as they come within the scope of the present disclosure. It is also to be understood that the following claims are intended to cover all of the generic and specific features of the disclosure herein described and all statements of the scope of the disclosure, which, as a matter of language, might be said to fall therebetween.
To aid the Patent Office and any readers of this application and any resulting patent in interpreting the claims appended hereto, applicants do not intend any of the appended claims or claim elements to invoke 35 U.S.C. 112(f) unless the words “means for” or “step for” are explicitly used in the particular claim.
The present application claims priority to U.S. Provisional Application Ser. No. 63/412,642 filed Oct. 3, 2022, which is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63412642 | Oct 2022 | US |
