Patent Application
20240254769
A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the xeroxographic reproduction by anyone of the patent document or the patent disclosure in exactly the form it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
The present invention relates generally to building construction, and particularly to an improvement in reinforced concrete with modular prefabricated rebar components.
The methods for building reinforced concrete structures are well known in the construction industry. In some technologically advanced countries, the traditional methods for building with reinforced concrete have been overtaken by the use of prefabricated modular building construction. Nevertheless, in situ or on-site construction methods are still extensively used, particularly in those countries where labor is relatively cheap and/or load bearing steel framing for buildings is relatively expensive.
The most common method of constructing reinforced concrete buildings known to the applicant, consists of the sequential steps of binding rebar together into bundled bars, and then using formwork to cast a foundation, binding rebar together into bundled bars, and then using formwork to cast the load bearing floor beams together with a floor slab, binding rebar together into bundled bars, and then using formwork to cast floor support pillars, binding rebar together into bundled bars, and then using formwork to cast upper floor beams an upper floor slab and finally forming the walls by in-filing between the beams and pillars with a wall panel, brick, doors, windows or the like, as desired. The sequence of building is repeated during the construction of additional floors.
Typical rebar-based systems employ cylindrical steel rebar interlocked into a skeletal cage inside a concrete matrix. In such systems, steel rebar is used for carrying the tensile stresses and improving member ductility. The rebar is usually used as longitudinal and lateral (transverse) reinforcements in such systems for columns, beams and other related reinforced concrete structures. The process of arranging numerous longitudinal and transverse reinforcement with tie wires into a skeletal cage, then placing formwork around the cage pouring concrete into the interstices is labor intensive, and hence expensive. Moreover, the complexity of such systems increases the likelihood of loose tolerances and related lowering of load-carrying capacity.
In steel-concrete composite systems, steel profiles (for example, I-beams) are placed inside the member to provide higher axial strength. This system helps provide a high strength in a relatively small cross-sectional area to avoid the limitations of traditional rebar-based systems, where the spacing of the bars in a relatively small section may be less than the allowable amount. Composite sections are usually used in high rise buildings, where a high axial strength with the minimum area provided for columns are desirable. The concrete cover protects the steel against fire, moisture and other environmental elements. The high metal reinforcement ratio, as well as its placement near the center of the reinforced concrete member, may result in a relatively inefficient system with limited ductility, flexural and torsional resistance.
The prior methods of connecting rebar on site have a number of drawbacks. Overlapping reinforcing bars (lap splicing) requires a large amount of additional steel for the overlapping sections, and the strength of the overlapping joint is weak. It is also time consuming and labor-intensive to hand tie all of the overlapping areas together on the site. Furthermore, press joints require a large crimping press that is difficult to maneuver on site. Also, a welded joint is cumbersome to install on site and uses high heat to melt the weld, which can affect the strength of the reinforcing bar around the weld depending on the type of rebar used. Standard mechanical couplers can also be employed, which use various means to connect rebar together: threading, locking shear bolts, or internal grouting to hold rebar together. None of the existing mechanical rebar couplers are quick to install or easy to use on the site.
Most often, the reinforced concrete uses rebar held together with twisted wire, which serves to hold the rebar securely in place. Previous attempts have been made to improve the rebar support structures, certain features of which are generally described in U.S. Pat. No. 6,883,289 to Juedes et al; U.S. Pat. No. 6,837,017 to Hardy, Jr. et al.; U.S. Pat. No. 6,732,484 to Sotelo et al.; U.S. Pat. No. 6,629,393 to Pignataro; U.S. Pat. No. 6,571,526 to Queen; U.S. Pat. No. 6,526,721 to Nash; U.S. Des. Pat. No. D483,246 to McPherson; U.S. Pat. No. 6,354,054 to Verelli et al.; U.S. Pat. No. 5,819,493 to LeMoignan; U.S. Pat. No. 5,664,390 to Sorkin; U.S. Pat. No. 5,456,051 to Queen et al.; U.S. Pat. No. 4,756,641 to Hartzheim; U.S. Pat. No. 4,644,727 to Hanson et al.; U.S. Pat. No. 4,598,523 to Tolliver; U.S. Pat. No. 3,728,836 to Gates; and U.S. Pat. No. 1,268,887 to A. F. Schroeder, all of which are incorporated herein by reference.
A JP patent JP5411950B2 invention relates to a method for manufacturing a ready-made pile made of concrete using a reinforcing steel cage and a reinforcing steel cage for an appropriate pile used in this manufacturing method. The reinforcing steel material in the above is usually composed of one steel material formed in a spiral shape, but is composed of a large number of steel materials formed in an annular shape or an annular shape with a part thereof cut off.
A KR patent 1,010,50956B1 implies a method which is similar to the reinforced concrete column, but pre-assembles the rebar in the factory, imports it and assembles it. Columns made of rebar prefabrication are easy to pour concrete into the cross section by installing a simple formwork. Reinforcing bar prefabricated column (1) arranges the coarse reinforcing bar (2) to the height of about three floors in four corners of the square, and welds four coarse steel bars to the head plate (10) in the panel zone (12) to which each floor beam is attached. To connect. Four-sided head steel plate is formed in a box shape, and additionally the head head reinforcement steel plate 14 and the head root (3), if necessary inside the base frame. The four thick reinforcing bars and the rest of the main reinforcing bars are welded and assembled on the site by welding the band reinforcing bars 6 and the auxiliary band reinforcing bars 7 of horizontally necessary intervals horizontally, and then the concrete is poured into the cross section inside. It is a method of putting.
A CN patent 103362119B discloses Large-size rebar cage exempts from the method that is welded to connect and syndeton. Comprise upper strata main reinforcement and lower floor's main reinforcement, also comprise sleeve and spacing steel plate; Spacing steel plate is semicircular steel plate, and inner circumferential is uniformly distributed several semicircle limited impressions suitable with main reinforcement diameter; Unidirectional screw thread is established in sleeve; Upper strata main reinforcement is provided with the consistent screw thread of rotation direction with the link of lower floor's main reinforcement, and upper strata main reinforcement and lower floor's main reinforcement are interconnected by sleeve. Wherein, also junction plate is comprised; Junction plate is crescent; The two ends of two semicircular spacing steel plates are connected into positive circle by bolt by junction plate. The present invention adopts and exempts from welding connecting mode, easy to operate, and the upper and lower contraposition of reinforcing bar is accurate, and connect reliable, construction period shortens, and the Large-size rebar cage of 45 meters completes to connect and lay to put in place only needs 2 hours, and reaches and build the concrete condition of pile foundation.
U.S. Pat. No. 6,883,289 to Juedes et al. (the '289 patent) describes an apparatus and method for suspending and positioning structural reinforcement elements such as rebar within a framework for a slab-on-grade foundation or other type of concrete structure. Each rebar support comprises a plurality of rebar support arms that connect to other components of the foundation or concrete structure, and support one or more pieces of rebar in a desired orientation. The rebar support does not use tie wires, rather claps onto the rebar. The rebar support must be supported by a pre-existing tendon support in the structure.
U.S. Pat. No. 6,837,017 to Hardy, Jr. et al. (the '017 patent) describes a transverse bar assembly for use in constructing rebar mats for reinforcement of concrete paving. The assembly is capable of supporting and securing longitudinal reinforcing steel rods at their designed location and spacing in such a manner as to prevent the rebar mat from being displaced during concrete placement. The assembly includes a plurality of chairs and clips each having a lower portion that fixes to a transverse bar in the direction of its length and an upper portion for orthogonally receiving and holding locked in place a longitudinal bar. The chair also has a support extending to a base surface.
U.S. Pat. No. 6,732,484 to Sotelo et al. (the '484 patent) describes a chair support for metal reinforcements for use during a concrete pour. The chair is box shaped having grooves in the side walls of different width for supporting rebar of different diameter. Notches in the edge of the grooves on opposite sides of the chair support wire mesh of different diameter. The notches are shaped so that the wire mesh is snapped into the notch. Wall like braces extend across the inside of the chair and support the grooves from the opposite wall. The larger grooves are on the short sides of the chair to raise the rebar a longer distance off the underlying surface.
U.S. Pat. No. 6,629,393 to Pignataro (the '393 patent) describes a masonry reinforcing tie. The tie is formed of a pair of spaced apart, parallel elongated elements joined by a series of lateral cross members welded or otherwise affixed across the elongated members. The elongated members and cross members are preferably formed of heavy metal wire or rod. The elongated members each include a series of spaced apart joint spacing elements formed integrally therewith, with the spacing elements having a height equal to the standard mortar joint thickness. Use of the tie permits a person to lay multiple vertically stacked blocks or bricks neatly and evenly, assuring that the horizontal mortar joints are even and consistent.
U.S. Pat. No. 6,571,526 to Queen (the '526 patent) describes a concrete masonry unit vertical reinforcement and anchor bolt positioning device. The device positions reinforcement bar within a masonry block. The positioning device includes a core with a central opening and an openable seam, a support structure having support arms connected to the core and arranged and configured for holding the positioning device in a desired position in a cavity of the masonry block. The core is arranged such that a gap can be formed along the seam, the gap being configured to receive the reinforcement bar, and the core encloses the reinforcement bar within the central opening when the gap is closed.
U.S. Pat. No. 6,526,721 to Nash (the '721 patent) describes a fluid-impervious barrier/keyway form support apparatus, system and method. The support carries the barrier and a pair of spaced legs for attachment to a corresponding pair of stable mounting points, such as reinforcement members. The support is positioned such that the barrier is at least partially covered by concrete during the pouring of a first slab and then the remainder is covered when a second concrete slab is poured atop the first slab.
U.S. Des. Pat. No. D483,246 to McPherson (the '246 patent) describes a rebar chair. The patent covers an ornamental design of a rebar chair. The rebar chair includes support legs attached to rebar claps for holding the rebar a certain distance above the ground level.
U.S. Pat. No. 6,354,054 to Verelli et al. (the '054 patent) describes a rebar support system including a rebar chair with four legs between which there are defined two intersecting passages for receiving the intersecting portions of two rebars. The rebars are suspended by a fastening wire or supported by an auxiliary chair below the apparatus. The legs forming one of the passages have a uniform spacing and are adapted to closely straddle the rebar extending through the same. The legs of the second passage flare downwardly so that their spacing progressively increases from the body to the free ends from a spacing smaller than to a spacing greater than the uniform spacing between the legs of the first passage. A saddle is formed on the top of the body for supporting a third rebar.
U.S. Pat. No. 5,819,493 to LeMoignan (the '493 patent) describes a height adjustable rebar support system for supporting rebar at various elevations during pouring and curing of concrete with a single adjustable support member. The support includes a first panel having a first lower slot, a second panel pivotally attached to the first panel having a second lower slot, an aperture and a notch into the first panel near the first lower slot, and a beaded cord secured to the second panel. The end of the beaded cord opposite of the second panel selectively engages the first panel through the aperture thereby adjusting the separation of the first panel with respect to the second panel.
U.S. Pat. No. 5,664,390 to Sorkin (the '390 patent) describes a bolster for use in construction. The bolster includes a plurality of leg members arranged in parallel relationship and a beam integrally formed with the plurality of leg members and extending across the leg members. The beam includes connectors, which serve to connect adjacent bolsters.
U.S. Pat. No. 5,456,051 to Queen et al. (the '051 patent) describes a compression spacer for bar reinforcement. The spacer includes a support base and a receptacle welded together at interfitting angular flanges. A bearing plug includes a circular support plate covering the upper surfaces of the radial walls with a tapered stem projecting into a tapered center opening of the support base. The flexible engagement fingers allow one way movement of the rebar rod into the receptacle and the protrusions of the rod engage the ends of the fingers prohibiting separation of the spacer support and the rod.
U.S. Pat. No. 4,756,641 to Hartzheim (the '641 patent) describes a sand plate and concrete reinforcement support. A flat, disk-shaped sand plate is disposed in contact with the earthen bed and has a plurality of channels adapted to receive pedestal feel extending upwardly from its top surface and radially from its center toward the periphery. A pedestal is disposed atop the sand plate with feet wedged into the pedestal fool channels. The reinforcement bar is cradled atop the pedestal.
U.S. Pat. No. 4,644,727 to Hanson et al. (the '727 patent) describes a strand chair for supporting cable and cross-mesh in elongated precast concrete plank. The chairs include a lower chair portion for supporting multiple prestressing cables at the bottom of a plank and a narrow upper chair portion for supporting an upper prestressing cable located in the web between the hollow core of the prestressed plank. The upper chair portion can be inserted into the strand receiving cups of the lower portion to form a structurally sound support for accurately placing the top and bottom reinforcing strands in the plank as it is cast.
U.S. Pat. No. 4,598,523 to Tolliver (the '523 patent) describes a reinforcement support spacer for spacing one or more concrete reinforcement members from a surface on which concrete is poured. The spacer comprises a support which has at least one recess therein for receiving a reinforcement member. Barbs or tines formed integrally with the support project into the recesses. The barbs or tines on each recess are oriented so as to permit a reinforcement member to be forced past the barbs or tines into the recess, but substantially to prevent a reinforcement member from being forced passed the barbs or tines out of the recess once a reinforcement member has been inserted into the recess. The support spacers of the present invention permit reinforcement members to be preassembled in spaced relationship to each other.
U.S. Pat. No. 3,728,836 to Gates (the '836 patent) describes a concrete form tie and rebar chair. The twisted wire concrete form tie is characterized by a lower single-wire strand joined to an upper double-wire twisted section by a pair of return bends at opposite ends, all of which cooperate with one another to define an elongated endless loop. The portions of the length of wire that are laid side by side and twisted together to form the twisted section terminate in free ends that are bent to form upstanding stops with upwardly opening generally U-shaped rebar saddles on the inside thereof. The section of the return bend projecting outwardly beyond the adjacent stop is slightly longer on one end than the other.
U.S. Pat. No. 1,268,887 to A. F. Schroeder (the '887 patent) describes a reinforcing device or a tie brace. The tie brace connects to and holds reinforcing rods in proper spaced relation during the pouring of concrete. The tie brace is |-shaped and adapted for use in the manufacture of concrete I-beams or trussed flooring, in which a plurality of extending rods are to be embedded.
It can thus be seen from the foregoing that many attempts have been made to provide improvements to structural reinforcements that use rebar to speed up construction. However clearly, the need exists for a modular prefabricated rebar component system which allows rebar to be installed faster on site. Modular prefabricated rebar components are capable of easy, fast, strong installation that can stably handle loads as well as tensile and compressive forces when combined with concrete.
None of the previous inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed. Hence, the inventor of the present invention proposes to resolve and surmount existent technical difficulties to eliminate the aforementioned shortcomings of prior art.
In light of the disadvantages of the prior art, the following summary is provided to facilitate an understanding of some of the innovative features unique to the present invention and is not intended to be a full description. A full appreciation of the various aspects of the invention can be gained by taking the entire specification, claims, drawings, and abstract as a whole.
The primary objective of this invention is to provide improvements in reinforced concrete with modular prefabricated rebar components.
It is a further object to reduce or eliminate the need for cranes to be used for installation on the construction site, as well as reduction or elimination of the use of hand labor to assemble rebar on the construction site as compared with the background art.
Still another important feature of this invention is in its simplicity of assembly, ease of installation, effectiveness in use and its generally inexpensive cost compared to delivering long rebar pieces and hand assembling them on the construction site.
Another important object of the present invention is to provide technology which can reduce construction cost and can save the time required for construction.
Another objective of the invention is to provide an assembly that allows lighter rebar components that weigh 100 to 500 pounds to be delivered and installed with light machinery and rapidly combined on the construction site using self-locking rebar couplings that are pre-welded onto the components during manufacturing.
Another objective of the invention is to provide the location of mechanical sleeves in the manufacturing process using Building Imaging Management (BIM) software so that no core drilling is required to be done on site.
It is also the objective of invention to provide the pour stop and rebar chairs during manufacturing so that formwork can readily be set up against the modular prefabricated rebar components and have the proper spacing to guarantee a continuous spacing on the concrete pour for curing
This Summary is provided merely for purposes of summarizing some example embodiments, so as to provide a basic understanding of some aspects of the subject matter described herein. Accordingly, it will be appreciated that the above-described features are merely examples and should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following Detailed Description, Figures, and Claims.
The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, together with the detailed description below, are incorporated in and form part of the specification, and serve to further illustrate embodiments of concepts that include the claimed invention, and explain various principles and advantages of those embodiments.
Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the present invention.
The apparatus and method components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
Detailed descriptions of the preferred embodiment are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner.
The present invention relates to an advancement in modular prefabricated rebar components. As used herein, the term “rebar” refers to a length of metal bar, often steel, which is placed into formwork before concrete is poured around it. It shall be understood that rebar is available in many grades and diameters.
The present invention as per its preferred embodiments provide a reinforcing bar component that combines rebar pieces during manufacturing that are significantly lighter than the rebar cages currently available, and are capable of easy, fast, strong installation that can stably handle loads as well as tensile and compressive forces. The present invention has the follow features for achieving the above object.
The present invention as per its additional embodiments eliminates the need for additional heavy equipment for delivering, bending, and installing reinforcing bars during manufacturing and on the construction site as compared with the background art, and can reduce construction cost and can save time required for construction.
The assembly as per its additional embodiments makes it possible to rapidly install rebar since the prefabricated rebar components are much lighter to move around a construction site than heavy crane delivered rebar cages, are fully pre-fabricated off site and then lock together using a self-locking rebar coupler.
The assembly as per its additional embodiments, make it possible to construct all foundation and superstructure elements by having all of the reinforcing bars delivered pre-fabricated to the construction site and able to be installed without requiring welding, tying, clamping, or lap splicing.
The assembly as per its additional embodiments allows all elements required for the concrete pour to be pre-fabricated in a modular way to reduce human error on site and ease speed with which concrete can be being poured onto the rebar for curing.
Having described the invention in detail, those skilled in the art will appreciate that modifications may be made to the invention without departing from its spirit. Therefore, it is not intended that the scope of the invention be limited to the specific embodiment illustrated and described. Rather, it is intended that the scope of this invention be determined by the appended claims and their equivalents.
The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in various embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter.
Having described the invention in detail, those skilled in the art will appreciate that modifications may be made to the invention without departing from its spirit. Therefore, it is not intended that the scope of the invention be limited to the specific embodiment illustrated and described. Rather, it is intended that the scope of this invention be determined by the appended claims and their equivalents.
The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in various embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter.
