Patent Grant
9745763
The application relates to methods and apparatus (systems) for restoring, repairing, reinforcing, protecting, insulating and/or cladding a variety of structures. Some embodiments provide formworks (or portions thereof) for containing concrete or other curable material(s) until such curable materials are permitted to cure. Some embodiments provide claddings (or portions thereof) which line interior surfaces of other supportive formworks and which are anchored to curable materials as they are permitted to cure.
Concrete is used to construct a variety of structures, such as building walls and floors, bridge supports, dams, columns, raised platforms and the like. Typically, concrete structures are formed using embedded reinforcement bars (often referred to as rebar) or similar steel reinforcement material, which provides the resultant structure with increased strength. Over time, corrosion of the embedded reinforcement material can impair the integrity of the embedded reinforcement material, the surrounding concrete and the overall structure. Similar degradation of structural integrity can occur with or without corrosion over sufficiently long periods of time, in structures subject to large forces, in structures deployed in harsh environments, in structures coming into contact with destructive materials or the like.
There is a desire for methods and apparatus for repairing and/or restoring existing structures (or portions thereof) which have been degraded or which are otherwise in need of repair and/or restoration.
Some structures have been fabricated with inferior or sub-standard structural integrity. By way of non-limiting example, some older structures may have been fabricated in accordance with seismic engineering specifications that are lower than, or otherwise lack conformity with, current structural (e.g. seismic) engineering standards. There is a desire to reinforce existing structures (or portions thereof) to upgrade their structural integrity or other aspects thereof.
There is also a desire to protect existing structures from damage which may be caused by, or related to, the environments in which the existing structures are deployed and/or the materials which come into contact with the existing structures. By way of non-limiting example, structures fabricated from metal or concrete can be damaged when they are deployed in environments that are in or near salt water or in environments where the structures are exposed to salt or other chemicals used to de-ice roads.
There is also a desire to insulate existing structures (or portions thereof)—e.g. to minimize heat transfer across (and/or into and out of) the structure. There is also a general desire to clad existing structures (or portions thereof) using suitable cladding materials. Such cladding materials may help to repair, restore, reinforce, protect and/or insulate the existing structure.
Previously known techniques for repairing, restoring, reinforcing, protecting, insulating and/or cladding existing structures often use excessive amounts of material and are correspondingly expensive to implement. In some previously known techniques, unduly large amounts of material are used to provide standoff components and/or anchoring components, causing corresponding expense. There is a general desire to repair, restore, reinforce, protect, insulate and/or clad existing structures (or portions thereof) using a suitably small amount of material, so as to minimize expense.
The desire to repair, restore, reinforce, protect, insulate and/or clad existing structures (or portions thereof) is not limited to concrete structures. There are similar desires for existing structures fabricated from other materials.
The foregoing examples of the related art and limitations related thereto are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.
One aspect of the invention provides an apparatus for repairing an existing structure to cover at least a portion of a surface of the existing structure with a repair structure. The apparatus comprises: a plurality of longitudinally and transversely extending panels connected to one another in edge-adjacent relationship; and a plurality of standoffs connected to the panels and extending from the panels toward the existing structure. Each panel comprises an exterior surface and an opposing interior surface on a side of the panel closer to the existing structure. Each panel comprises a panel connector component which extends longitudinally along the panel and from the interior surface toward the existing structure. Each standoff comprises a standoff connector component which is complementary to the panel connector components. The panel connector components and standoff connector components are shaped such that a connection formed between each panel connector component and each corresponding standoff connector component involves deformation of at least one of the connector components and the creation of restorative deformation forces such that the restorative deformation forces prevent relative movement between the panels and the standoffs under the force of gravity. Curable material is introduced into a space between the interior surface of the panels and the existing structure and permitted to cure to provide a repair structure cladded at least in part by the panels. Extension of the standoffs into the space into which the curable material is introduced anchors the panels to the curable material as it cures to provide the cladding.
Another aspect of the invention provides a method for repairing an existing structure to cover at least a portion of a surface of the existing structure with a repair structure. The method comprises: connecting a plurality of longitudinally and transversely extending panels to one another in edge-adjacent relationship; connecting a plurality of standoffs to the panels such that the standoffs extend from the panels toward the existing structure; and introducing a curable material into a space between the panels and the existing structure and permitting the curable material to cure to provide a repair structure cladded at least in part by the panels. Connecting the plurality of standoffs to the panels comprises making a connection between a panel connector component of each panel and a corresponding standoff connector component of each standoff which involves deforming at least one of the connector components and creating restorative deformation forces such that the restorative deformation forces prevent relative movement between the panels and the standoffs under the force of gravity. Extension of the standoffs into the space into which the curable material is introduced anchors the panels to the curable material as it cures to provide the cladding.
Another aspect of the invention provides an apparatus for cladding a structure to cover at least a portion of a surface of the structure with a cladding. The apparatus comprises: a plurality of longitudinally and transversely extending panels connected to one another in edge-adjacent relationship and positioned such that the exterior surfaces of the edge-adjacent panels line at least a portion of an interior surface of a removable formwork; and a plurality of standoffs connected to the panels and extending from the panels toward an interior of the formwork. Each panel comprises a panel connector component which extends longitudinally along the panel and from the interior surface of the panel toward an interior of the formwork. Each standoff comprises a standoff connector component which is complementary to the panel connector components. The panel connector components and standoff connector components are shaped such that a connection formed between each panel connector component and each corresponding standoff connector component involves deformation of at least one of the connector components and the creation of restorative deformation forces such that the restorative deformation forces prevent relative movement between the panels and the standoffs under the force of gravity. Curable material is introduced into an interior of the formwork and permitted to cure to provide the structure cladded at least in part by the panels. Extension of the standoffs into the interior of the formwork where the curable material is introduced anchors the panels to the curable material as it cures to provide the cladding.
Another aspect of the invention provides a method for cladding a structure to cover at least a portion of a surface of the structure with a cladding. The method comprises: connecting a plurality of longitudinally and transversely extending panels to one another in edge-adjacent relationship; positioning the panels such that the exterior surfaces of the edge-adjacent panels line at least a portion of an interior surface of a removable formwork; connecting a plurality of standoffs to the panels such that the standoffs extend from the panels toward an interior of the formwork; introducing a curable material into the interior of the formwork; and permitting the curable material to cure to provide a repair structure cladded at least in part by the panels. Connecting the plurality of standoffs to the panels comprises making a connection between a panel connector component of each panel and a corresponding standoff connector component of each standoff which involves deforming at least one of the connector components and creating restorative deformation forces such that the restorative deformation forces prevent relative movement between the panels and the standoffs under the force of gravity. Extension of the standoffs into the interior of the formwork where the curable material is introduced anchors the panels to the curable material as it cures to provide the cladding.
Another aspect of the invention provides a standoff comprising an elongated shaft and a resiliently deformable connector component coupled to a connector end of the elongated shaft. The connector component is for creating restorative deformation forces between the connector component and a corresponding panel connector on the panel, the deformation forces preventing relative movement between the standoff and the panel due to gravity.
Aspects of the invention also provide repair structures and cladded structures fabricated using the methods and apparatus (systems) described herein. Kits may also be provided in accordance with some aspects of the invention. Such kits may comprise portions of the apparatus according to various embodiments and may facilitate effecting one or more methods according to various embodiments.
Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive.
In drawings which illustrate non-limiting embodiments:
Throughout the following description specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well known elements may not have been shown or described in detail to avoid unnecessarily obscuring the disclosure. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense.
Apparatus and methods according to various embodiments may be used to repair, restore, reinforce, protect, insulate and/or clad existing structures. Some embodiments provide stay-in-place formworks (or portions thereof) or the like for containing concrete and/or similar curable materials until such curable materials are permitted to cure. Such formworks may optionally be reinforced by suitable bracing. Some embodiments provide claddings (or portions thereof) which line interior surfaces of other supportive and/or removable formworks and which are anchored to curable materials as such curable materials are permitted to cure. For brevity, in this disclosure (including any accompanying claims), apparatus and methods according to various embodiments may be described as being used to “repair” existing structures. In this context, the verb “to repair” and its various derivatives should be understood to have a broad meaning which may include, without limitation, to restore, to reinforce and/or to protect the existing structure. In some applications, which will be evident to those skilled in the art, the verb “to repair” and its various derivatives may additionally or alternatively be understood to include, without limitation, to insulate and/or to clad the existing structure.
Similarly, structures added to existing structures in accordance with particular embodiments of the invention may be referred to in this description (and any accompanying aspects or claims, if present) as “repair structures”. However, such “repair structures” should be understood in a broad context to include additive structures which may, without limitation, repair, restore, reinforce and/or protect existing structures. In some applications, which will be evident to those skilled in the art, such “repair structures” may be understood to include structures which may, without limitation, insulate and/or clad existing structures. Further, some of the existing structures shown and described herein exhibit damaged regions which may be repaired in accordance with particular embodiments of the invention. In general, however, it is not necessary that existing structures be damaged and the methods and apparatus of particular aspects of the invention may be used to repair, restore, reinforce or protect existing structures which may be damaged or undamaged. Similarly, in some applications, which will be evident to those skilled in the art, methods and apparatus of particular aspects of the invention may be understood to insulate and/or clad existing structures which may be damaged or undamaged.
While not shown in the illustrated embodiment, repair structure 202 may comprise rebar which may be placed in space 212 prior to the introduction of curable material. In some embodiments, panels 204 provide at least a portion of the formwork needed to contain the curable material in space 212 until it cures. In some embodiments, panels 204 may optionally be braced by external bracing (not shown) which may assist panels 204 to contain the curable material in space 212. In some embodiments, panels 204 may provide a cladding which lines the interior of an external formwork (not shown) and the external formwork may provide the strength to contain the curable material in space 212 until it cures.
Panels 204 of the illustrated embodiment are generally planar in shape and may have generally uniform cross-sections in the direction of their longitudinal 214 dimensions, although this is not necessary. In some embodiments, the longitudinal 214 dimensions of panels 204 may be fabricated to have arbitrary lengths and then cut to desired lengths in situ. In other embodiments, the longitudinal 214 dimensions of panels 204 may be pre-fabricated to desired lengths.
Panels 204 also comprise one or more panel connector components 226 which are spaced apart from the transverse edges of panels 204 and which are complementary to standoff connector components 228 of standoffs 208 to provide connections 210 therebetween. Panel connector components 226 and their interaction with standoff connector components 228 to provide connections 210 are described in more detail below. With panel connector components 226 coupled to standoff connector components 228 at connections 210, panels 204 are positioned at locations spaced apart from existing structure 10 and from surface 14 thereof to provide space 212 (
In the illustrated embodiment of
System 200 also comprises standoffs 208. Standoffs 208 of the illustrated embodiment comprise generally planar shafts 229 which extend between standoff connector components 228 at one of their transverse edges and optional heads 232 at their opposing transverse edges. Standoffs 208 are also elongated in the longitudinal direction 214. In the illustrated embodiment of
Connections 210 between panel connector components 226 and standoff connector components 228 involve the creation of restorative deformation forces which tend to hold standoffs 208 in place relative to panels 204—i.e. to permit standoffs 208 to be “locatable” anywhere along the longitudinal 214 dimensions of panel connector components 226 and panels 204. For example, in cases where the longitudinal direction 214 is at least partially vertically oriented, the restorative deformation forces created in connections 210 may prevent standoffs 208 from moving (e.g. sliding) longitudinally along panel connector components 226 under the force of gravity. In some embodiments, these restorative deformation forces may be sufficient to support rebar against the force of gravity.
As shown best in
Panel connector components 226, standoff connector components 228 and the formation of connections 210 between panel connector components 226 and standoff connector components 228 are now described in more detail with reference to
As seen best from
The process of coupling panel connector component 226 to standoff connector component 228 involves forcing panel 204 and standoff 208 toward one another—e.g. forcing standoff 208 toward panel 204 in direction 260. In the
Under continued application of force (
More particularly, hooked arm 228A of standoff connector component 228 deforms in a direction 266A away from space 262, hooked arm 228B of standoff connector component 228 deforms in a direction 266B away from space 262, hooked arm 226A of panel connector component 226 deforms toward hooked arm 226B of panel connector component 226, and/or hooked arm 226B of panel connector component 226 deforms toward hooked arm 226A of panel connector component 226. This deformation permits panel connector component 226 to pass through transverse opening 262A and extend into space 262.
As panel connector component 226 and standoff connector component 228 continue to be forced toward one another (e.g. in direction 260), hooked arms 228A, 228B deform in directions 266A, 266B (and/or hooked arms 226A, 226B deform toward one another) until arms 228A, 228B fit past the edges of arms 226A, 226B (i.e. beveled surfaces 258A, 258B move past the edges of beveled surfaces 254A, 254B) and panel connector component 226 is inserted into space 262. At this point, restorative deformation forces (e.g. elastic forces which tend to restore connector components 226, 228 to their original (non-deformed) shapes) cause arms 228A, 228B to move back in directions 268A, 268B such that arms 228A, 228B extend into hook concavities 252A, 252B of panel connector component 226. Directions 268A, 268B may be respectively opposed to directions 266A, 266B. Similarly, restorative deformation forces cause arms 226A, 226B to move transversely away from one another and to extend into hook concavities 256A, 256B of standoff connector components 228. Connection 210 is thereby formed (
Hooked arms 226A, 226B, 228A and/or 228B are deformed during formation of connection 210, resulting in the creation of restorative deformation forces. Panel connector component 226 and standoff connector component 228 are shaped such that the restorative deformation forces associated with the deformation of hooked arms 226A, 226B, 228A and/or 228B are maintained after the formation of connection 210—i.e. after the formation of connection 210, hooked arms 226A, 226B, 228A and/or 228B are not restored all the way to their original non-deformed shapes, resulting in the existence of restorative deformation forces after the formation of connection 210. As discussed above, these restorative deformation forces allow standoffs 208 to be “located” anywhere along the longitudinal 214 dimension of panels 204. In other words, connection 210 is a form of press fit, where the friction caused by restorative deformation forces maintains the location of the standoffs 208 relative to panels 204. In particular embodiments, these restorative deformation forces are sufficient to permit standoffs 208 to be located without substantial movement under the force of gravity acting on standoffs 208. In some embodiments, these restorative deformation forces are sufficient to permit standoffs 208 to also support rebar without substantial movement under the force of gravity acting on standoffs 208 and the supported rebar.
The “locatability” of standoffs 208 at various locations along panels 204 can add versatility to the process of fabricating system 200. For example, in some applications, standoffs 208 may be connected to panels 204 using connections 210 at desired locations prior to connecting panels 204 to one another in edge-adjacent relationship at connections 206. In other applications, standoffs 208 may be connected to panels 204 using connections 210 at desired locations after connecting panels 204 to one another in edge-adjacent relationship at connections 206. The order of assembly of connections 210 and connections 206 may depend on the particular circumstances of a given application. It will be appreciated though that added versatility is advantageous, because spatial constraints of particular applications may make it difficult to assemble system 200 in one order versus the other. Another advantage of the locatability of standoffs 208 at various locations along panels 204 is that standoffs 208 need not be connected to existing structure 10 prior to or after making connections 210.
Since panel connector component 226 is forced into and extends into space 262 between arms 228A, 228B of standoff connector component 228, panel connector component 226 may be considered to be a “male” connector component corresponding to the “female” standoff connector component 228. In other embodiments, standoff connector components 228 may comprise male connector components and panel connector components 226 may comprise female connector components.
The illustrated embodiment of
Standoffs 208 may comprise optional heads 232 which may be located opposite standoff connector components 228 on shafts 229. Optional heads 232 may abut against existing structure 10. Optional heads 232 may extend longitudinally 214 and transversely 216 at the inner edges of standoffs 208. That is, optional heads 232 may have a surface area facing away from standoff connector components 228 that is greater than the surface area of shafts 229 facing away from standoff connector components 228. Optional heads 232 may thereby serve to anchor standoffs 208 (and thereby panels 204) in the curable material once it cures and to disperse some of the forces which may occur if and when standoffs 208 abut against existing structure 10. In the illustrated embodiment of
As shown best in
In the illustrated embodiment, standoffs 208 are solid (i.e. non-apertured). In other embodiments, generally planar shafts 229 of standoffs 208 may be apertured. Such apertures may extend in the longitudinal direction 214 and in a direction between standoff connector components 228 and standoff heads 232 so as to permit the flow of curable material through standoffs 208. In some embodiments, such apertures may also serve to support and locate transversely extending rebar in a manner similar to rebar-chair concavities 234.
In the illustrated embodiment of
The form of connector components 220A, 220B that form edge-adjacent panel connections 206 in the illustrated embodiment represents one particular and non-limiting type of connection between edge-adjacent panels. In other embodiments, other forms of connections (and other forms of corresponding connector components) may be provided between edge-adjacent panels. Non-limiting examples of suitable edge-adjacent panel connections and corresponding connector components are described in PCT patent publication Nos. WO2008/119178, WO2010/078645, WO2009/059410, and WO2010/094111 which are hereby incorporated herein by reference. In some of these exemplary connections between edge-adjacent panels, two edge-adjacent panels are connected directly to one another without the use of third connector components. This is the case, for example, in the connections 206 between edge-adjacent panels 204 of the illustrated embodiment of
System 200 of the
In the illustrated embodiment, only one of the standoff connector components 226 on each corner panel 304A is in use to connect to a standoff 208, but this is not necessary. In some embodiments, each standoff connector component 226 on corner panels 304A may be connected to standoffs 208 which may be “located” at different longitudinal positions or which may have less extension toward existing structure 10 so that they do not interfere with one another. Corner panels 304A of the
Panels 404 of system 400 are similar to panels 204 of system 200 in that panels 404 are generally planar and comprise connector components 420A, 420B at their respective transverse ends which connect to one another to provide edge-adjacent panel connections 406 which connect panels 404 in edge-adjacent relationship in a manner substantially identical to connector components 220A, 220B and edge-adjacent panel connections 206 described above. Connections 406 between edge-adjacent panels 404 may additionally or alternatively implemented according to any of the variations described above.
Panels 404 of system 400 differ from panels 204 of system 200 in that panels 404 comprise panel connector components 426 which are shaped differently and function differently than panel connector components 226. Like panel connector components 226, panel connector components 426 are complementary to standoff connector components 428 of standoffs 408 to provide connections 410 therebetween. Panel connector components 426 interact with standoff connector components 428 to provide connections 410, described in more detail below. Like panels 204 of system 200, panels 404 of system 400 comprise three panel connector components 426, although this is not necessary. In general, panels 404 of system 400 may be provided with any suitable transverse widths (including a variety of different transverse widths) and may be provided with any suitable number of panel connector components 426 which may depend on the transverse widths of the corresponding panel 404 and on the requirements and/or specifications of a particular application.
System 400 also comprises standoffs 408 that are similar in many respects to standoffs 208 described above in that standoffs 408 connect to panels 404 at connections 410 and extend in longitudinal direction 414 and away from interior surfaces 407 of panels 404 toward existing structure 10. As is the case with standoffs 208 described above, the longitudinal 414 dimensions of standoffs 408 are less than the corresponding longitudinal dimensions of panels 404. The
Standoffs 408 are also similar to standoffs 208 in that generally planar shafts 429 of standoffs 408 comprise optional rebar-chair concavities 434 which may be substantially similar to optional rebar-chair concavities 234 of standoffs 208. In the illustrated embodiment, standoffs 408 are solid (i.e. non-apertured). In other embodiments, generally planar shafts 429 of standoffs 408 may be apertured in a manner similar to that discussed above for standoffs 208.
Standoffs 408 of the
Standoffs 408 also comprise standoff connector components 428 which are shaped differently, and which function differently, from standoff connector components 228 of standoffs 208. Like standoff connector components 228, standoff connector components 428 are complementary to panel connector components 426 of panels 404 to provide connections 410 therebetween. Connections 410 share a number of similarities to connections 210 described above. More particularly, connections 410 between panel connector components 426 and standoff connector components 428 involve the creation of restorative deformation forces which tend to hold standoffs 408 in place relative to panels 404—i.e. to permit standoffs 408 to be “locatable” anywhere along the longitudinal 414 dimensions of panel connector components 426 and panels 404. For example, in cases where the longitudinal direction 414 is at least partially vertically oriented, the restorative deformation forces created in connections 410 may prevent standoffs 408 from moving (e.g. sliding) longitudinally along panel connector components 426 under the force of gravity. In some embodiments, these restorative deformation forces created when forming connections 410 may be sufficient to support the weight of both standoffs 408 and rebar supported thereon.
As shown best in
Panel connector components 426, standoff connector components 428 and the formation of connections 410 between panel connector components 426 and standoff connector components 428 are now described in more detail with reference to
As can be seen best from
As seen best from
The process of coupling panel connector component 426 to standoff connector component 428 involves forcing relative pivotal motion between panel 404 and standoff 408—e.g. forcing standoff 408 to pivot relative to panel 404 in direction 460. Coupling panel connector component 426 to standoff connector component 428 involves initially aligning standoff 408 relative to panel 404 at a suitable initial angle θ (
Relative pivotal motion is then effected (e.g. in direction 460) between panel 404 and standoff 408 while primary hooked arm 428A remains extended into hook concavity 452A and hooked arm 426A remains extended into primary hook concavity 456A (
When secondary hooked arm 428B of standoff connector component 408 moves past the transversely outermost extent of hooked arm 426B, restorative deformation forces (e.g. elastic forces which tend to restore hooked arms 428A, 428B to their original (non-deformed) states) cause secondary hooked arm 428B to move back toward primary hooked arm 428A, such that secondary hooked arm 428B of standoff connector component 428 moves into hook concavity 452B of panel connector component 426 and hooked arm 426B of panel connector component 426 moves into secondary hook concavity 456B of standoff connector component 428. Connection 410 is thereby formed (
Hooked arms 428A and/or 428B are deformed during formation of connection 410, resulting in the creation of restorative deformation forces. Panel connector component 426 and standoff connector component 428 are shaped such that the restorative deformation forces associated with the deformation of hooked arms 428A and/or 428B are maintained after the formation of connection 410—i.e. after the formation of connection 410, hooked arms 428A and/or 428B are not restored to their original non-deformed state, resulting in the existence of restorative deformation forces after the formation of connection 410. As discussed above, these restorative deformation forces allow standoffs 408 to be “located” anywhere along the longitudinal 414 dimension of panels 404. In particular embodiments, these restorative deformation forces are sufficient to permit standoffs 408 to be located without substantial movement under the force of gravity acting on standoffs 408. In some embodiments, these restorative deformation forces are sufficient to permit standoffs 408 to also support rebar without substantial movement under the force of gravity acting on standoffs 408 and the supported rebar.
The “locatability” of standoffs 408 at various locations along panels 404 can add versatility to the process of fabricating system 400. For example, in some applications, standoffs 408 may be connected to panels 404 using connections 410 at desired locations prior to connecting panels 404 to one another in edge-adjacent relationship at connections 406. In other applications, standoffs 408 may be connected to panels 404 using connections 410 at desired locations after connecting panels 404 to one another in edge-adjacent relationship at connections 406. The order of assembly of connections 410 and connections 406 may depend on the particular circumstances of a given application. It will be appreciated though that added versatility is advantageous, because spatial constraints of particular applications may make it difficult to assemble system 400 in one order versus the other. Another advantage of the locatability of standoffs 408 at various locations along panels 404 is that standoffs 408 need not be connected to existing structure 10 prior to or after making connections 410.
Connections 410 between standoff connector components 428 and panel connector components 426 have the additional advantage that if it is desired to disconnect a connection 410, force may be exerted on thumb 431 to exert torque that would tend to cause relative pivotal motion between standoff 408 and panel 404 (e.g. in a direction opposite direction 460). Such torque can deform one or both of connector components 426, 428 to thereby disconnect connection 410 and allow standoff 408 to be re-“located” at another desired location.
It will be appreciated that panel connector component 426 is symmetrical about its planar shaft 427. Consequently, standoff 408 may be reversed, so that standoff connector component 428 can be connected to panel connector component 426 by relative pivotal movement in the opposite direction to that shown in
Since panel connector component 426 is forced and extends into the space between arms 428A, 428B of standoff connector component 428, panel connector component 426 may be considered to be a “male” connector component corresponding to the “female” standoff connector component 428. In other embodiments, standoff connector components 428 may comprise male connector components and panel connector components 426 may comprise female connector components.
In other respects, system 400 may be similar to system 200, panels 404 may be similar to panels 204 and standoffs 408 may be similar to standoffs 208 described herein.
System 500 differs from system 400 principally in that system 500 is used to build a generally annular repair structure 502 around a generally cylindrical existing structure 110. Accordingly, system 500 does not use corner panels 404A. In the currently preferred embodiment, panels 404 of system 500 are the same as panels 404 of system 400, but are deformed when edge-adjacent connections 406 are made to provide the arcuate transverse shape of panels 404 in system 500. In some embodiments, panels may be fabricated to have an arcuate transverse shape and need not be deformed in this manner to provide the shape shown in
Concrete (or other curable material) is added to the space 512 between panels 404 and existing structure 110 to complete the fabrication of repair structure 502. While not shown in the illustrated embodiments, repair structure 502 may comprise rebar which may be placed in space 512 (e.g. in rebar-chair concavities of standoffs 408) prior to the introduction of curable material. Extension of standoffs 408 into space 512 anchors panels 404 to the curable material as it cures, thereby providing repair structure 502 with a cladding. In some embodiments, panels 404 may provide the formwork needed to contain the curable material in space 512 until it cures. In other embodiments, panels 404 may be braced by external bracing (not shown) which may assist panels 404 to contain the curable material in space 512. In still other embodiments, panels 404 may provide a cladding which lines the interior of an external formwork (not shown) and the external formwork may provide the strength to contain the curable material in space 512 until it cures.
In other respects, system 500 is similar to system 400.
Panels 604 of system 600 are similar to panels 204 of system 200 in that panels 604 are generally planar and comprise connector components 620A, 620B at their respective transverse ends which connect to one another to provide edge-adjacent panel connections 606 which connect panels 604 in edge-adjacent relationship in a manner substantially identical to connector components 220A, 220B and edge-adjacent panel connections 206 described above. Connections between edge-adjacent panels 604 may additionally or alternatively implemented according to any of the variations described above.
Panels 604 of system 600 differ from panels 204 of system 200 in that panels 604 comprise panel connector components 626 which are shaped differently and function differently than panel connector components 226. Like panel connector components 226, panel connector components 626 are complementary to standoff connector components 628 of standoffs 608 to provide connections 610 therebetween. Panel connector components 626, which interact with standoff connector components 628 to provide connections 610, are described in more detail below. Like panels 204 of system 200, panels 604 of system 600 comprise three panel connector components 626, although this is not necessary. In general, panels 604 of system 600 may be provided with any suitable transverse widths (including a variety of different transverse widths) and may be provided with any suitable number of panel connector components 626 which may depend on the transverse widths of the corresponding panel 604 and on the requirements and/or specifications of a particular application.
System 600 also comprises standoffs 608 that are similar in many respects to standoffs 208 described above in that standoffs 608 connect to panels 604 at connections 610 and extend in longitudinal direction 614 and away from interior surfaces 607 of panels 604 toward existing structure 10. As is the case with standoffs 208 described above, the longitudinal 614 dimensions of standoffs 608 may be less than the corresponding longitudinal dimensions of panels 604. Standoffs 608 having longitudinal dimensions less than those of panels 604 may be “located” relative to panels 604 in accordance with any of the patterns or arrangements discussed above for standoffs 208 relative to panels 204. In some embodiments, the longitudinal dimensions of standoffs may be coextensive with the longitudinal dimensions of panels.
Standoffs 608 of the
Standoffs 608 of the
Standoffs 608 also comprise standoff connector components 628 which are shaped differently and which function differently than standoff connector components 228 of standoffs 208. Like standoff connector components 228, standoff connector components 628 are complementary to panel connector components 626 of panels 604 to provide connections 610 therebetween. Connections 610 share a number of similarities with connections 210 described above. More particularly, connections 610 between panel connector components 626 and standoff connector components 628 involve the creation of restorative deformation forces which tend to hold standoffs 608 in place relative to panels 604—i.e. to permit standoffs 608 to be “locatable” anywhere along the longitudinal 614 dimensions of panel connector components 626 and panels 604. For example, in cases where the longitudinal direction 614 is at least partially vertically oriented, the restorative deformation forces created in connections 610 may prevent standoffs 608 from moving (e.g. sliding) longitudinally along panel connector components 626 under the force of gravity. In some embodiments, these restorative deformation forces created when forming connections 610 may be sufficient to support the weight of both standoffs 608 and rebar supported thereon.
Panel connector components 626, standoff connector components 628 and the formation of connections 610 between panel connector components 626 and standoff connector components 628 are now described in more detail with reference to
As seen best from
The process of coupling panel connector component 626 to standoff connector component 628 involves forcing relative pivotal motion between panel 604 and standoff 608—e.g. forcing standoff 608 to pivot relative to panel 604 in direction 660. Coupling panel connector component 626 to standoff connector component 628 involves initially aligning standoff 608 relative to panel 604 at a suitable initial angle θ (
Relative pivotal motion is then effected (e.g. in direction 660) between panel 604 and standoff 608 (
With further relative pivotal motion (e.g. in direction 660) between panel 604 and standoff 608, the connected configuration 610 of
The “locatability” of standoffs 608 at various locations along panels 604 can add versatility to the process of fabricating system 600. For example, in some applications, standoffs 608 may be connected to panels 604 using connections 610 at desired locations prior to connecting panels 604 to one another in edge-adjacent relationship at connections 606. In other applications, standoffs 608 may be connected to panels 604 using connections 610 at desired locations after connecting panels 604 to one another in edge-adjacent relationship at connections 606. The order of assembly of connections 610 and connections 606 may depend on the particular circumstances of a given application. It will be appreciated though that added versatility is advantageous, because spatial constraints of particular applications may make it difficult to assemble system 600 in one order versus the other. Another advantage of the locatability of standoffs 608 at various locations along panels 604 is that standoffs 608 need not be connected to existing structure 10 prior to or after making connections 610.
Connections 610 between standoff connector components 628 and panel connector components 626 have the additional advantage that if it is desired to disconnect a connection 610, force may be exerted on standoff 608 to exert torque that would tend to cause relative pivotal motion between standoff 608 and panel 604 (e.g. in a direction opposite direction 660). Such torque can deform one or both of connector components 626, 628 to thereby disconnect connection 610 and allow standoff 608 to be re-“located” at another desired location.
It will be appreciated that panel connector component 626 is symmetrical about its planar shaft 627. Consequently, standoff 608 may be reversed, so that standoff connector component 628 can be connected to panel connector component 626 by relative pivotal movement in the opposite direction to that shown in
In other respects, system 600 may be similar to system 200 (e.g. panels 604 may be similar to panels 204 and standoffs 608 may be similar to standoffs 208 described herein).
In the above described embodiments, systems for building repair structures are shown extending all of the way around an existing structure. For example, system 400 shown in
It will be appreciated that the use of cladding system 700 to clad a portion of a repair structure represents a sub-case of using cladding system 700 to clad a portion of a newly formed structure—i.e. a repair structure is merely an example of a newly formed structure. Cladding system 700 may also be used to clad the entirety of a new structure (including a repair structure). The
Standoff 808 differs from standoff 408 in that elongated shaft 829 comprises two transversely spaced apart stems 830A, 830B (transverse being the directions 816 in
In the illustrated embodiment, optional braces 833 extend between first stem 830A and second stem 830B. This configuration of braces 833 is not necessary. In other embodiments, braces 833 may extend between stems 830 at suitable angles—e.g. to form a plurality of triangles, such as in a truss. In still other embodiments, braces 833 may have other configurations, such as braces with varying widths, braces that extend only part way between stems 830, or the like. In some embodiments, braces 833 may not be present. In these embodiments, stems 830 may have a width such that a space is formed between stems 830 and stems 830 may be connected only at standoff connector 828 and an end opposite standoff connector 828 (such as optional head 832).
Stems 830 and braces 833 provide additional strength against shaft 829 being bent or deformed due to forces applied to shaft 829 by curable material (e.g. concrete) introduced into the system 800 or due to interaction between shaft 829 and an existing structure (not shown in
As mentioned, stems 830 extend from standoff connector component 828, which is connected to panel connector component 826. Panel connector component 826 differs from panel connector component 426 in that panel connector component 826 is coupled to panel 804 by way of two legs 827A, 827B (collectively, legs 827). In the illustrated embodiment, legs 827 are wider at their base where they connect to panel 808 than at their peak where they connect to hooked arms 826A, 826B. This provides a stable support for panel connector component 826 and still permits hooked arms 826A, 826B to form concavities 852A, 852B that are large enough to receive hooked arms 828A, 828B of standoff connector component 828.
Legs 827 provide panel connector component 826 with additional strength and stability relative to a single leg 827. This additional support facilitates standoffs 808 maintaining a desired alignment relative to panels 804. Legs 827 may increase the strength of panel connector component 826 by reducing the length of hooked arms 826A, 826B from legs 827 relative to the length of hooked arms 826A, 826B with a single leg. Shorter hooked arms 826A may result in relatively more resilient deformation of standoff connector component 828 (and less resilient deformation of panel connector component 826) when connection 810 between standoff connector component 828 and panel connector component 826 is formed.
Legs 827 may be configured differently than shown in
Those skilled in the art will appreciate that the hooked arms 826 of panel connector component 826 have the same shape as those of other panel connector components described herein (e.g. panel connector components 426) and that standoff connector component 828 and head 832 of standoff 808 have shapes similar to those of other standoff connector components and heads described herein (e.g. standoff connector components 408 and heads 432). Consequently, panels 804 incorporating panel connector components 826 may be used with other standoffs described herein (e.g. standoffs 408) and standoffs 808 may be used with other panels described herein (e.g. panels 404).
In currently preferred embodiments, system components such as panels 204, 404, etc., corner panels 204A, 404A etc., and standoffs 208, 408, etc. are fabricated from suitable plastic (e.g. polyvinyl chloride (PVC)) using an extrusion process. Standoffs 208, 408, etc. may optionally be punched to provide rebar-chair concavities 234, 434 and/or apertures. It will be understood, however, that system components could be fabricated from other suitable materials, such as, by way of non-limiting example, other suitable plastics, other suitable metals or metal alloys, polymeric materials, fibreglass, carbon fibre material or the like and that cladding system components described herein could be fabricated using any other suitable fabrication techniques, such as (by way of non-limiting example) injection molding, pultrusion.
Where a component is referred to above (e.g., a panel, a standoff and/or features of panels and/or standoffs), unless otherwise indicated, reference to that component (including a reference to a “means”) should be interpreted as including as equivalents of that component any component which performs the function of the described component (i.e., that is functionally equivalent), including components which are not structurally equivalent to the disclosed structure which performs the function in the illustrated exemplary embodiments of the invention.
Unless the context clearly requires otherwise, throughout the description, the aspects and the claims (if present), the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to.” Where the context permits, words in the above description using the singular or plural number may also include the plural or singular number respectively. The word “or,” in reference to a list of two or more items, covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list.
The above detailed description of example embodiments is not intended to be exhaustive or to limit this disclosure, aspects and claims (if present) to the precise forms disclosed above. While specific examples of, and examples for, embodiments are described above for illustrative purposes, various equivalent modifications are possible within the scope of the technology, as those skilled in the relevant art will recognize.
These and other changes can be made to the system in light of the above description. While the above description describes certain examples of the technology, and describes the best mode contemplated, no matter how detailed the above appears in text, the technology can be practiced in many ways. As noted above, particular terminology used when describing certain features or aspects of the system should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects of the system with which that terminology is associated. In general, the terms used in the following claims (if present) should not be construed to limit the system to the specific examples disclosed in the specification, unless the above description section explicitly and restrictively defines such terms. Accordingly, the actual scope of the technology encompasses not only the disclosed examples, but also all equivalent ways of practicing or implementing the technology under the claims (if present).
From the foregoing, it will be appreciated that specific examples of apparatus and methods have been described herein for purposes of illustration, but that various modifications, alterations, additions and permutations may be made without departing from the practice of the invention. The embodiments described herein are only examples. Those skilled in the art will appreciate that certain features of embodiments described herein may be used in combination with features of other embodiments described herein, and that embodiments described herein may be practised or implemented without all of the features ascribed to them herein. Such variations on described embodiments that would be apparent to the skilled addressee, including variations comprising mixing and matching of features from different embodiments, are within the scope of this invention.
As will be apparent to those skilled in the art in light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof. For example:
While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended aspects and aspects hereafter introduced should not be limited by the preferred embodiments and should be interpreted to include all such modifications, permutations, additions and sub-combinations as are within the broadest interpretation consistent with the description as a whole.
This application is a continuation of U.S. application Ser. No. 14/368,773 having a 371 date of 25 Jun. 2014 which in turn is a national entry of PCT application No. PCT/CA2013/050005 having an international filing date of 4 Jan. 2013, which in turn claims priority (and the benefit of 35 USC 119(e)) from U.S. application No. 61/583,589 filed 5 Jan. 2012 and U.S. application No. 61/703,169 filed 19 Sep. 2012. All of the applications and patents referred to in this paragraph are hereby incorporated herein by reference.
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| Number | Date | Country | |
|---|---|---|---|
| 20160186452 A1 | Jun 2016 | US |
| Number | Date | Country | |
|---|---|---|---|
| 61583589 | Jan 2012 | US | |
| 61703169 | Sep 2012 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 14368773 | US | |
| Child | 15063189 | US |
