The present disclosure relates to elements for use as embedded in layered structures. More particularly, the present disclosure relates to lift and brace inserts for installation in layered concrete structures during fabrication without forming thermal bridges.
Large modern building and structures are often constructed, at least in par, using tilt-up construction, which involves pouring layered concreted walls horizontally on the buildings floor slab at the job site. A crane hoists the cured walls into a place where steel braces and welding can be applied to secure the walls in their final vertical positions. temporarily secure the panels until workers can weld permanent fasteners into the panel's joints, footings, and roofline. The layered walls typically have a thermally insulting core layer. Any elements of the construction, such reinforcing bars that connect the concrete layers sandwiching the core, that conduct thermal energy between interior and exterior walls serve as thermal bridges. Such thermal bridges are to kept at a minimum to conserve energy and costs of heating an cooling a building.
Lifting anchors are commonly embedded or cast in the precast concrete structures to facilitate handling, since these structures can be difficult to hoist and handle due to their weight. Brace inserts are also typically embedded to provide attachments points along a wall to mount other structural elements. Typical lifting anchors and brace inserts form thermal bridges.
Improvements are needed in anchors and brace elements to minimize or prevent thermal bridging in layered concrete structures such as tilt-up walls.
This summary is provided to briefly introduce concepts that are further described in the following detailed descriptions. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it to be construed as limiting the scope of the claimed subject matter.
According to at least one embodiment, an anchor assembly is configured to be embedded in a layered structure. The anchor assembly includes a base plate comprising a first side and a second side opposite the first side, an anchor member connected to the first side of the base plate, and a thermally insulating panel attached to the second side of the base plate.
An adhesive layer may be provided between the thermally insulating panel and the second side of the base plate, the adhesive layer attaching the thermally insulating panel to the second side of the base plate.
The adhesive layer may include epoxy, glue, double-sided tape, and/or an adhesive pad.
The anchor member may define, at least in part, a loop for attachment to a lift device for lifting the layered structure.
The anchor member may include an arch and two legs extending from the arch to the base plate, the two legs attached to the base plate. The two legs, arch, and base plate may cooperatively define the loop.
The assembly may include at least one connector bar for attaching the anchor assembly to a mesh in a layered structure, the connector bar having a first section connected to the first side of the base plate and opposing end sections connected to the first section, the end sections for tying to the mesh.
The anchor member may include a post connected to the base plate, the post having an upper end defining a ferrule with a threaded interior.
The assembly may include at least one connector bar for attaching the anchor assembly to a mesh in a layered structure, the connector bar connected to the post spaced from the base plate.
The thermally insulating panel may include foam.
In at least one embodiment, a layered structure includes: a first layer of cementitious material; an insulation layer positioned on the first layer of cementitious material, the insulating layer having an opening defining a receiving space; and an anchor assembly positioned in part in the receiving space. The anchor assembly includes a base plate having a first side and a second side opposite the first side, an anchor member connected to the first side of the base plate, and a thermally insulating panel attached to the second side of the base plate. The thermally insulating panel is positioned on the first layer of cementitious material within the receiving space.
In at least one embodiment, the insulating panel has a snug fit or interference fit with the opening through the insulation layer.
The insulating panel and opening may be matched with regard to shape such that the insulating panel covers a surface of the cementitious layer within the receiving space.
A second cementitious layer may be positioned on the insulation layer, and a plug of cementitious material may fill a remainder of the receiving space not filled by the anchor assembly.
The layered structure may define a tilt-up wall.
The insulating pad prevents the plug of cementitious material from reaching the first cementitious layer thus preventing a thermal bridge from forming between the first cementitious layer and second cementitious layer.
The second cementitious layer may have a surface below which the anchor member is sunken.
The above summary is to be understood as cumulative and inclusive. The above described embodiments and features are combined in various combinations in whole or in part in one or more other embodiments.
The previous summary and the following detailed descriptions are to be read in view of the drawings, which illustrate some, but not all, embodiments and features as briefly described below. The summary and detailed descriptions, however, are not limited to only those embodiments and features explicitly illustrated.
These descriptions are presented with sufficient details to provide an understanding of one or more particular embodiments of broader inventive subject matters. These descriptions expound upon and exemplify particular features of those particular embodiments without limiting the inventive subject matters to the explicitly described embodiments and features. Considerations in view of these descriptions will likely give rise to additional and similar embodiments and features without departing from the scope of the inventive subject matters. Although steps may be expressly described or implied relating to features of processes or methods, no implication is made of any particular order or sequence among such expressed or implied steps unless an order or sequence is explicitly stated.
Any dimensions expressed or implied in the drawings and these descriptions are provided for exemplary purposes. Thus, not all embodiments within the scope of the drawings and these descriptions are made according to such exemplary dimensions. The drawings are not made necessarily to scale. Thus, not all embodiments within the scope of the drawings and these descriptions are made according to the apparent scale of the drawings with regard to relative dimensions in the drawings. However, for each drawing, at least one embodiment is made according to the apparent relative scale of the drawing.
Like reference numbers used throughout the drawings depict like or similar elements. Unless described or implied as exclusive alternatives, features throughout the drawings and descriptions should be taken as cumulative, such that features expressly associated with some particular embodiments can be combined with other embodiments.
Unless defined otherwise, technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which the presently disclosed subject matter pertains. Although any methods, devices, and materials similar or equivalent to those described herein can be used in the practice or testing of the presently disclosed subject matter, representative methods, devices, and materials are now described.
Following long-standing patent law convention, the terms “a,” “an,” and “the” refer to “one or more” when used in the subject specification, including the claims. Unless indicated to the contrary, the numerical parameters set forth in the instant specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained within the scope of these descriptions.
A thermally insulated lifting anchor assembly 10, according to at least one embodiment, is shown in
In at least one expected use, the inventive anchor assemblies described in the following are used in host structures such as tilt-up walls, which can typically be fabricated on-site as a building is constructed. Such host structures, when fabricated, typically have an expanded polystyrene (EPS) foam insulating core between two rebar reinforced cementitious layers, such as concrete.
In the illustrated embodiment, the anchor assembly 10 includes an anchor member 12 (
The anchor member 12 provides structural reinforcement and support to lift a layered structure. In a fabricated structure, the lifting anchor assembly 10 is embedded, with a loop 14 (
As a layered structure is fabricated around the anchor assembly 10, the anchor member 12 stands upright on the upper first side of the base plate 60, which is illustrated as rectangular, more particularly square, in the drawings. For stability and strength, the anchor member 12 is fixed to the base plate 60 in the illustrated example, for example by welding the end portions 22 of the legs 16 to the base plate 60. In such an example, the base plate 60 is made of material that is weld-compatible with the anchor member 12.
Similarly, the connector bars 80 stand upright on the upper first side 66 of the base plate 60 as a layered structure is fabricated around the anchor assembly 10. Each bar 80 has a lower linear section 82 having opposing ends, each of which is connected to a respective diagonal section 84, which is connected to a respective upper end section 86. For stability and strength, the connector bars 80 are fixed to the base plate 60 in the illustrated example, for example by welding the linear first section 82 to the base plate 60. In such an example, the connector bars 80 are made of material that is weld-compatible with the base plate 60. With reference to either bar 80, the diagonal sections 84 extend at angles to diverge from each other, and end sections 86 of the bars 80 are parallel to each other and collinear with each other, having respective termini 88 (
The void forming shell 44 is illustrated as having halves 44a and 44b, each engaged to the other. Each leg 16 of the anchor member 12 extends through a respective close-fitting opening 17 through the shell 44, the openings 17 defined cooperatively by aligned recesses in mutually facing edges of the halves 44a and 44b. The shell 44 and features thereof are further described in the referenced U.S. Patent (U.S. Pat. No. 10,837,185). The shell 44 includes a cover 46 that prevents cementitious material from spilling into the shell 44 during pouring stages of the fabrication of a structure. The illustrated cover 46 includes upwardly-extending protruding rods 48 that facilitate removal of the cover 46 after cementitious layers are poured and cured. The shell 44 thus forms a protected and essentially sealed enclosure around the loop 14 of the anchor member 12, preventing cementitious material from obstructing access to the loop 14 and thus assuring the loop 14 is accessible to receive a lift apparatus or device, such as a hook on a cable or chain, by which a fabricated layered structure can be lifted, transported, and tilted to desired position. As shown for example in
An adhesive layer 62 is shown in
Stages of fabrication of a layered structure 100, in which the anchor assembly 10 is embedded, are shown in
In
Other dimensions of the anchor assembly 10, insulation layer including its opening and depth, and prescribed depth of the pending pour of a second cementitious layer are mutually prescribed prior to fabrication of the structure to yield desired effects. For example, to provide internal reinforcement to a top cementitious layer, a mesh 120 can be positioned over the anchor assembly 10 as shown in
In
In
When both cementitious layers 102 and 130 are cured, including the plug 132 of cementitious material of the second layer 130 filling the remainder of the receiving space above the insulating pad 70, the fabricated structure can be lifted to a desired position. Typically this refers to a vertical disposition in which: the horizontal lower surface 104 of the first cementitious layer 102 in
A thermally insulated brace anchor assembly 210, according to at least one embodiment, is shown in
In the illustrated embodiment, the anchor assembly 210 includes an anchor member 212, a base plate 260 to which the anchor member 212 is attached, a thermally insulating panel 270, and connector bars 280 for connection to a mesh embedded in a cast top layer in a fabricated host structure. These referenced features and others are described in the following.
The anchor member 212 is illustrated as a cylindrical post 214, which may be hollow, having a lower end connected to the upper first side of the base plate 260, and an upper end extending away therefrom. The upper end of the post defines a ferrule 216 having an opening upper terminus and a threaded interior 218 (
The novel thermally insulated brace anchor assembly 210 further includes connector bars 280 for connection to a mesh embedded in a cast top layer in a fabricated host structure. The connector bars 280 are positioned above and spaced from the base plate 260 as a layered structure is fabricated around the anchor assembly 210. Each bar 280 has opposing ends defining a length therebetween, and a central portion connected to the post below the ferrule. The bars 280 may be attached to the post 214, for example, by tack welding. In such an example, the connector bars 280 are made of material that is weld-compatible with the anchor member 212. In the illustrated embodiment, bars are provided in pairs. A first pair includes two connector bars 282 that are parallel to each other, are attached to opposing sides of the post, and are thus spaced from each other by the diameter of the post. A second pair includes two connector bars 284 that are parallel to each other, are attached to opposing sides of the post, and are thus spaced from each other by the diameter of the post. In the illustrated embodiment, two connector bars 282 of the first pair are perpendicular to the two connector bars 284 of the second pair. As shown for example in
An adhesive layer, for example such as adhesive layer 62 shown in
As described above with reference to
Particular embodiments and features have been described with reference to the drawings. It is to be understood that these descriptions are not limited to any single embodiment or any particular set of features, and that similar embodiments and features may arise or modifications and additions may be made without departing from the scope of these descriptions and the spirit of the appended claims.