Patent Application
20240263452
The present disclosure relates to fabrication of concrete elements that include reinforcing bar cages. More specifically, the present disclosure relates to reinforcing bar cage connectors operable to secure reinforcing bar cages used in fabrication of concrete elements, and methods of constructing reinforcing bar cages used in fabrication of concrete elements.
Concrete is a building material made from the combination of aggregate and a cement binder. A common form of concrete consists of Portland cement, mineral aggregates (for example, gravel and sand) and water. After mixing, the water reacts with the cement in a chemical process known as hydration, during which the water is absorbed by the cement, which hardens, binding the aggregates together and eventually creating a stone-like material. Concrete is used, for example, in pavement, building structures, foundations, roads, and bases for gates, fences and poles. Concrete is also used, for example, in concrete columns used in construction known as footings.
Concrete has high compressive strength, but low tensile strength. In other words, concrete can withstand axially directed pushing forces, but cannot withstand axially directed pulling forces. As a result, concrete elements subjected to tensile stresses are often reinforced with steel bars, known as reinforcing bar or rebar, which can aid in carrying tensile loads. Rebar is often formed from mild steel, and given ridges for better frictional adhesion to the concrete.
In practice, a reinforcing cage can be constructed out of rebar. A reinforcing cage can be constructed out of multiple pieces of rebar that are maintained relative to each other in conjunction with specific design requirements. Some examples of items that can influence the design requirements of a reinforcing cage include: the type of structure that is being fabricated, the size and weight of the structure, and the bearing capacity of the soil upon which the structure will rest.
Once a reinforcing cage is constructed, it can be inserted into a mold that can receive concrete. In one example, a mold can be a tube made of cardboard or other fibrous material. Examples of such tubes are the Sonotube® made by Sonoco Products Company and the Quik-Tube® made by the QUIKRETE® Companies.
Once a reinforcing cage is constructed and inserted into a mold, mixed concrete can be poured into the tube and allowed to harden. The result is a concrete element that includes a reinforcing cage that, as described above, can aid in carrying tensile loads.
Unfortunately, constructing a reinforcing cage can be time-consuming and cumbersome. For example, one method used to construct reinforcing cages utilizes pieces of wire to connect pieces of rebar in a desired configuration. However, one problem with such a method is that the resulting reinforcing cage is not very durable and can fall apart or lose desired dimensions when being moved or inserted into a mold. In another example, pieces of rebar that make up a reinforcing guide can be welded together. Such reinforcing guides are more durable than the ones held together by wires, however, they can be costly in terms of materials and labor.
Further limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art, through comparison of such systems with some aspects of the present disclosure as set forth in the remainder of the present application.
Certain embodiments of the present technology provide reinforcing bar cage connectors and methods of constructing reinforcing bar cages, substantially as shown in and/or described in connection with at least one of the figures.
These and other advantages, aspects and novel features of the present disclosure, as well as details of an illustrated embodiment thereof, will be more fully understood from the following description and drawings.
Embodiments of the present technology provide reinforcing bar cage connectors that quickly and securely fasten reinforcing bar guides to reinforcing bar rods to construct a reinforcing bar cage.
The foregoing summary, as well as the following detailed description of certain embodiments will be better understood when read in conjunction with the appended drawings. It should be understood that the various embodiments are not limited to the arrangements and instrumentality shown in the drawings. It should also be understood that the embodiments may be combined, or that other embodiments may be utilized and that structural changes may be made without departing from the scope of the various embodiments of the present disclosure. The following detailed description is, therefore, not to be taken in a limiting sense.
As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding the plural of the elements or steps, unless such exclusion is explicitly stated. Furthermore, references to “an embodiment,” “one embodiment,” “a representative embodiment,” “an exemplary embodiment,” “various embodiments,” “certain embodiments,” and the like are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Moreover, unless explicitly stated to the contrary, embodiments “comprising,” “including,” or “having” an element or a plurality of elements having a particular property may include additional elements not having that property.
Referring to
Although the rebar rod 120 is shown connected on an outside of the rebar guide 110, in various embodiments, the rebar rod 120 may additionally or alternatively be coupled to an inside of the rebar guide 110. Although the rebar guide 110 is illustrated as having an oval shape, in various embodiments, the rebar guide 110 may be any suitable shape, such as circular, square, triangular, rectangular, trapezoidal, or the like. For example, in other embodiments, the rebar guide 110 can be a straight element or an element with any number of bends or curves. As an example, in other embodiments, the shape of the rebar guide 110 can vary depending on the design requirements of the rebar guide 110. Although the rebar guide 110 and rebar rod 120 are both preferably made of rebar (i.e., reinforcing bar), in other embodiments, one or both of the rebar guide 110 and rebar rod 120 may not be made of rebar. For example, the rebar guide 110 and/or rebar rod 120 may be made of any strong and durable material. In various embodiments, the rebar cage connector 130 may be made of high carbon steel and/or any suitable material. In an exemplary embodiment, the rebar cage connector 130 may be coated with a rust-resistant material to increase durability and lifespan.
Still referring to
The second clamp portion 138 comprises a base 139, sides 140, 141, an opening 142, and punch grips 147. The sides 140, 141 extend from the base 139 and comprise inward facing side surfaces 140 and outward facing side surfaces 141. In various embodiments, the sides 140, 141 may include flared ends 143 opposite the base 139. The flared ends 143 may comprise tie wire guide slots 144 operable to guide the metal tie wire 148 into position for tightening. The sides 140, 141 comprise tie wire holes 145 adjacent the base 139 such that the metal tie wire 148 extends through the tie wire hole 145 on one of the sides 140, 141, along the surface of the base 139 where the metal tie wire 148 may be secured by a bridge tab (not shown), and extends through the tie wire hole 145 in the other of the sides 140, 141. The opening 142 is defined between the inward facing side surfaces 140. The inward facing side surfaces 140 may comprise punch grips 147. The punch grips 147 are protrusions (e.g., dimples, indents, or the like) configured to engage a deformation pattern 112, 122 on the rebar guide 110 or rebar rod 120 to provide a strong and stable connection. The deformation pattern 112, 122 is protrusions (e.g., ribs or the like) on the rebar 110, 120, which may be a helical pattern, V-shaped pattern, swirls, or any suitable pattern. The second clamp portion 138 is configured to receive the rebar rod 120 (as shown in
The back surface of the base 132, 139 of each of the first 131 and second 138 clamp portions are attached to or integrated with each other to form a single rebar cage connector 130. The first clamp portion 131 having the opening 135 formed by the base 132 and sides 133, 134 faces away from and is perpendicular to the second clamp portion 138 having the opening 142 formed by the base 139 and sides 140, 141. In this way and as shown in
Referring to
The base 132, 139 and/or inward facing surfaces 133, 140 of the first 131 and second 138 clamp portions may comprise punch grips 137, 147 operable to engage deformation patterns on received rebar. The punch grips 137, 147 hold onto the deformation pattern on the rebar, using its small, dimpled indentations to grasp the ribs or protrusions of the deformation pattern firmly. The punch grips 137, 147 are able to hold onto the deformation pattern with a strong and secure grip, helping to prevent the rebar from slipping or shifting within the clamps 131, 138. The dimpled indentations on the punch grips 137, 147 fit snugly around the ribs or protrusions of the deformation pattern, providing a secure and stable hold.
The outward facing surfaces 134, 141 of the first 131 and second 138 clamp portions may be configured to receive compressive forces by the metal tie wire 148 when the metal tie wire 148 is manipulated around the first 131 and second 138 clamp portions and tightened to secure rebar in the first 131 and second 138 clamp portions. The first clamp portion 131 may comprise an alignment guide 136 operable to guide the metal tie wire 148 along the outward facing surface 134 of the first clamp portion 131. The alignment guide 136 may be generally L-shaped and provided at a lateral edge of the outward facing surface 134 to prevent the tie wire 148 from sliding off of the outward facing surface 134 of the first clamp portion 131.
The second clamp portion 138 comprises tie wire guide slots 144, tie wire holes 145, and a bridge tab 146 operable to guide and securely hold the metal tie wire 148. The metal tie wire 148 extends through a tie wire hole 145 in each of the sides 140, 141 of the second clamp portion 138 adjacent the base 139 of the second clamp portion 138. The metal tie wire 148 extends across the base 139 and is securely held by the bridge tab 146, which holds the metal tie wire 148 against the base 139. Prior to use, a length of a first portion of the metal tie wire 148 extending from a first tie wire hole 145 on a first side 140, 141 of the second clamp portion 138 may be longer than a length of a second portion of the metal tie wire 148 extending from a second tie wire hole 145 on a second side 140, 141 of the second clamp portion 138. The shorter portion of the metal tie wire 148 extends across the outward facing side surface 141 on the second side and through the tie wire guide slot 144 at the flared end 143 of the second side. The longer portion of the metal tie wire 148 is manipulated against the alignment tab 136 of the first clamp portion 131, around the outward facing side surface 134 of the first clamp portion 131, back across the outward facing side surface 141 on the first side of the second clamp portion 138, and through the tie wire guide slot 144 at the flared end 143 of the first side of the second clamp portion 138 after the rebar has been received in the openings 135, 142 of the first 131 and second 138 clamp portions. The length of the initially longer portion of the metal tie wire 148 should be substantially a same length as the initially shorter portion of the metal tie wire 148 after the longer portion has been routed around the first clamp portion 131 and back through the tie wire guide slot 144 in the flared end 143 of the second clamp portion 138. The metal tie wire 148 may then be twisted to tighten the rebar cage connector 130 by providing compressive forces against the outward facing side surfaces 134, 141 of the first 131 and second 138 clamp portions.
The metal tie wire 148 may comprise metal tie wire loops 149 at the ends of the metal tie wire 148 to assist with manipulation of the metal tie wire 148. The metal tie wire 148 may be manipulated and tightened by hand or using metal tie wire tools, such as pliers, tie wire reels, rebar tie wire twisters, or any suitable tool.
Accordingly, the rebar cage connector 130 is a clamping device used for building a rebar cage 100, a structure used to reinforce concrete. The rebar cage connector 130 may be made of high carbon steel, or any suitable material, and coated with rust-resistant material to increase its durability and lifespan. The rebar cage connector 130 comprises two clamp portions 131, 138 that are joined together. Each clamp portion 131, 138 has punch grip 137, 147 features, which are dimpled or indented surfaces that are used to hold the rebar securely in place and provide a strong and stable connection.
At step 202, a rebar guide 110 is inserted in an opening 135 of a first clamp portion 131 of a rebar cage connector 130. At step 204, a rebar rod 120 is inserted in an opening 142 of a second clamp portion 138 of the rebar cage connector 130. At step 206, a long end of a metal tie wire 148 is manipulated against an alignment tab 136 of the first clamp portion 131, around outward facing side surfaces 134 of the first clamp portion 131, and through a guide slot 144 in a flared end 143 of the second clamp portion 138. At step 208, the ends of the metal tie wire 148 are twisted together to compress the first clamp portion 131 on the rebar guide 110 and the second clamp portion 138 on the rebar rod 120.
Steps 202 through 208 may be repeated using a rebar cage connector 130 for each connection point between the rebar guide(s) 110 and rebar rod(s) 120. For example, if the rebar cage 100 comprises three (3) rebar guides 110 and four (4) rebar rods 120, twelve (12) rebar cage connectors 130 may be implemented to build the rebar cage 100. Once a rebar cage 100 is constructed, it can be placed in a mold. The mold can then be filled with mixed concrete. After the concrete sets, the mold can be removed and a concrete element that contains a reinforcing guide can remain.
Aspects of the present disclosure provide reinforcing bar cage connectors 130 and methods 200 of constructing reinforcing bar cages 100. A reinforcing bar cage 100 may comprise a reinforcing bar guide 110, a reinforcing bar rod 120, and a reinforcing bar cage connector 130. The reinforcing bar cage connector 130 may comprise a first clamp portion 131 facing a first direction and configured to receive one of the reinforcing bar guide 110 or the reinforcing bar rod 120 in a first opening 135. The reinforcing bar cage connector 130 may comprise a second clamp portion 138 facing a second direction, opposite the first direction, and configured to receive an other one of the reinforcing bar guide 110 or the reinforcing bar rod 120 in a second opening 142. The first opening 135 is perpendicular to the second opening 142. The reinforcing bar cage connector 130 may comprise a metal tie wire 148 operable to be twisted to compress the first clamp portion 131 and the second clamp portion 138.
In an exemplary embodiment, the first clamp portion 131 of the reinforcing bar cage connector 130 comprises a first base 132 and first sides 133, 134 extending from the first base 132. The first sides 133, 134 comprise first inward facing side surfaces 133 and first outward facing side surfaces 134. The second clamp portion 138 of the reinforcing bar cage connector 130 comprises a second base 139 and second sides 140, 141 extending from the second base 139. The second sides 140, 141 comprise second inward facing side surfaces 140 and second outward facing side surfaces 141. In a representative embodiment, the first base 132 is integrated with or fixedly attached to the second base 139. In various embodiments, the first opening 135 is defined between the first inward facing side surfaces 133. The second opening 142 is defined between the second inward facing side surfaces 140. In certain embodiments, the first clamp portion 131 comprises an alignment tab 136 extending from a lateral edge of one of the first outward facing side surfaces 134. The alignment tab 136 is operable to guide the metal tie wire 148 along the first outward facing side surfaces 134. In an exemplary embodiment, the first sides 133, 134 extending from the first base 132 curl inwards to define the first inward facing side surfaces 133 of the first clamp portion 131. In a representative embodiment, ends 144 of the second sides 140, 141 are flared outward and comprise tie wire guide slots 144. The metal tie wire 148 extends through the tie wire guide slots 144. In various embodiments, the reinforcing bar guide 110 and/or the reinforcing bar rod 120 comprises a deformation pattern 112, 122. In certain embodiments, the first base 132, the first inward facing side surfaces 133, the second base 139, and/or the second inward facing side surfaces 140 comprise one or more punch grips 137, 147 configured to engage with the deformation pattern 112, 122. In an exemplary embodiment, each end of the metal tie wire 148 comprises a metal tie wire loop 149.
Various embodiments provide a reinforcing bar cage connector 130 comprising a first clamp portion 131, a second clamp portion 138, and a metal tie wire 148. The first clamp portion 131 faces a first direction and comprises a first base 132 and first sides 133, 134 extending from the first base 132. The first sides 133, 134 comprise first inward facing side surfaces 133 and first outward facing side surfaces 134. The second clamp portion 138 faces a second direction, opposite the first direction, and comprises a second base 139 and second sides 140, 141 extending from the second base 139. The second sides 140, 141 comprise second inward facing side surfaces 140 and second outward facing side surfaces 141. The first opening 135 is perpendicular to the second opening 142. The metal tie wire 148 is operable to be twisted to compress the first clamp portion 131 and the second clamp portion 138.
In a representative embodiment, the first base 132 is integrated with or fixedly attached to the second base 139. In various embodiments, the first opening 135 is defined between the first inward facing side surfaces 133 and the second opening 142 is defined between the second inward facing side surfaces 140. In certain embodiments, the first clamp portion 131 comprises an alignment tab 136 extending from a lateral edge of one of the first outward facing side surfaces 134. The alignment tab 136 is operable to guide the metal tie wire 148 along the first outward facing side surfaces 134. In an exemplary embodiment, the first sides 133, 134 extending from the first base 132 curl inwards to define the first inward facing side surfaces 133 of the first clamp portion 131. In a representative embodiment, ends 143 of the second sides 140, 141 are flared outward and comprise tie wire guide slots 144. The metal tie wire 148 extends through the tie wire guide slots 144. In various embodiments, the first base 132, the first inward facing side surfaces 133, the second base 139, and/or the second inward facing side surfaces 140 comprise one or more punch grips 137, 147 configured to engage with a deformation pattern 112, 122 on reinforcing bar 110, 120 received within the first opening 135 of the first clamp portion 131 and/or the second opening 142 of the second clamp portion 138. In certain embodiments, each end of the metal tie wire 148 comprises a metal tie wire loop 149. In an exemplary embodiment, the first clamp portion 131 and the second clamp portion 138 is made of high carbon steel and coated with rust-resistant material.
Certain embodiments provide a method 200 of constructing a reinforcing bar cage 100. The method 200 comprises inserting 202 a reinforcing bar guide 110 in a first opening 135 of a first clamp portion 131 of a reinforcing bar cage connector 130. The method 200 comprises inserting 204 a reinforcing bar rod 120 in a second opening 142 of a second clamp portion 138 of the reinforcing bar cage connector 130. The first opening 135 is perpendicular to the second opening 142. The first opening 135 and the second opening 142 face opposite directions. The method 200 comprises manipulating 206 a metal tie wire 148 around outward facing side surfaces 134 of the first clamp portion 131 and through a tie wire guide slot 144 in a flared end 143 of the second clamp portion 138. The method 200 comprises twisting 208 ends of the metal tie wire 148 together to compress the first clamp portion 131 on the reinforcing bar guide 110 and the second clamp portion 138 on the reinforcing bar rod 120.
As utilized herein, “and/or” means any one or more of the items in the list joined by “and/or”. As an example, “x and/or y” means any element of the three-element set {(x), (y), (x, y)}. As another example, “x, y, and/or z” means any element of the seven-element set {(x), (y), (z), (x, y), (x, z), (y, z), (x, y, z)}. As utilized herein, the term “exemplary” means serving as a non-limiting example, instance, or illustration. As utilized herein, the terms “e.g.,” and “for example” set off lists of one or more non-limiting examples, instances, or illustrations. As utilized herein, a component is “operable” or “configured” to perform a function whenever the component comprises the necessary structure to perform the function, regardless of whether the function is performed.
While the present disclosure has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed.
