Method for providing a pad to support heavy equipment

Abstract

A method for supporting heavy equipment at a site is provided. The method includes constructing a plurality of pre-formed reinforced concrete blocks. Each of the concrete blocks is constructed by: providing a concrete form having internal dimensions of at least 1½ feet by 3 feet by 3 feet, inserting a plurality of reinforcing members within the form, pouring concrete into the form over the reinforcing members, allowing the concrete to cure to form a concrete block, and removing the concrete block from the form. The method further includes excavating the site to form an excavated area and placing the plurality of pre-formed reinforced concrete blocks on the excavated area. The present invention also provides a concrete pad which can be formed by the above-described method.

Description

CROSS REFERENCE TO RELATED APPLICATION(S)

This application claims the benefit of U.S. Provisional Patent Application No. 60/677,560, filed May 4, 2005, which is incorporated by reference as if fully set forth.

BACKGROUND

Poured concrete pads are typically used under loading, unloading, parking, and storage areas for trucks and other heavy equipment. The loads associated with commercial and industrial equipment require that the poured concrete pads be substantial in size and sometimes reinforced with steel to carry loads of several thousand psi. Such concrete pads can have a thickness of approximately two feet +/− and are cast on-site over reinforcing bars in order to provide the necessary strength to handle heavy equipment traffic.

Known on-site concrete pad installation can be problematic because the thicker the pad, the longer the curing time. Many pads take approximately thirty days to cure. Further, since concrete may not cure properly in cold temperatures or in the presence of excess moisture, installation schedules are often affected by weather conditions.

It would be desirable to provide a concrete pad for heavy commercial and industrial vehicle traffic which may be easily and quickly installed in all temperatures, and which is not subject to an extended curing time.

SUMMARY

The present invention provides a method for supporting heavy equipment at a site. The method includes constructing a plurality of pre-formed reinforced concrete blocks. Each of the concrete blocks is constructed in accordance with the following method by: providing a concrete form having internal dimensions of at least 1½ feet by 3 feet by 3 feet, inserting a plurality of reinforcing members within the form, pouring concrete into the form over the reinforcing members, allowing the concrete to cure to form a concrete block, and removing the concrete block from the form. Preferably, the blocks include an interlocking feature to allow load transfer and distribution between the blocks. The method further includes excavating the site to form an excavated area and placing the plurality of pre-formed reinforced concrete blocks on the excavated area. The present invention also provides a concrete pad which can be formed by the above-described method.

BRIEF DESCRIPTION OF THE DRAWING(S)

The foregoing Summary as well as the following detailed description will be readily understood in conjunction with the appended drawings which illustrate preferred embodiments of the invention. In the drawings:

FIG. 1 shows a perspective view of a heavy equipment support pad according to a preferred embodiment of the present invention.

FIG. 2 shows a perspective view of a preformed reinforced concrete block of the support pad of FIG. 1 with a cutaway window showing a reinforcing skeleton.

FIG. 3 shows a perspective view of the reinforcing skeleton of the concrete block of FIG. 2.

FIG. 4 shows a perspective view of a form, including the reinforcing skeleton of FIG. 3, for forming the concrete block of FIG. 2.

FIG. 5 shows a perspective view of a heavy equipment support pad according to an alternative preferred embodiment of the present invention.

FIG. 6 shows a perspective view of a preformed reinforced concrete block of the support pad of FIG. 5.

FIG. 7 shows a flowchart depicting a method for providing a heavy equipment support pad.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Certain terminology is used in the following description for convenience only and is not considered limiting. Words such as “front”, “back”, “top” and “bottom” designate directions in the drawings to which reference is made. This terminology includes the words specifically noted above, derivatives thereof and words of similar import. Additionally, the terms “a” and “one” are defined as including one or more of the referenced item unless specifically noted.

The preferred embodiments of the present invention are described below with reference to the drawing figures where like numerals represent like elements throughout.

Referring to FIGS. 1-4, a heavy equipment support pad 10 according to a preferred embodiment of the present invention is shown. The pad 10 includes a plurality of adjacent preformed reinforced concrete blocks 20. The blocks 20 are preferably laid over a layer of leveling material 12 in an excavated area 14 surrounded by a footer 16.

Each reinforced block 20 is preferably at least 1½ feet by 3 feet by 3 feet in size. The block 20 shown in FIGS. 1 and 2 is a generally rectangular prism. Alternatively, a block can be provided having a non-rectangular shape so long as the block is at least 1½ feet thick and maintains a substantially flat bottom surface for contact with an excavated area. For example, the block can be a hexagonal prism or triangular prism, or any other suitable shape that can be placed in adjoining contact with other blocks for 100% area coverage. The block 20 can alternatively be dimensioned slightly smaller than 1½ feet by 3 feet by 3 feet, for example 1 foot by 3 feet by 3 feet, depending on application requirements.

Each block 20 preferably includes reinforcing members. The reinforcing members preferably include internal longitudinal and transverse steel reinforcing bars (re-bar) 24, 26 in the form of a reinforcing skeleton 22. As shown, fourteen (14) longitudinal bars 24 are substantially perpendicular to two (2) transverse reinforcing bars 26. The reinforcing bars 24, 26 can alternatively be provided in any suitable quantity and arrangement depending on strength and size requirements. Further, in alternative preferred embodiments, the reinforcing members can include fibers, such as glass, steel, carbon or polymer fibers, or can include plates, tubes, or any other suitable material.

During manufacture of the block 20, the reinforcing members are preferably arranged in a form 28 into which the concrete is poured and cured. The reinforcing members, such as the reinforcing bars 24, 26, are preferably prefabricated, for example by welding, in the form of a stable frame, such as the reinforcing skeleton 22, prior to insertion into the form 28. Alternatively, the reinforcing members can be located within the form with the assistance of supporting structure on or in the form 28. The form 28 is preferably made of wood, steel, plastic, or any suitable material and can be fixed in size or adjustable. While the form 28 is in the shape of a rectangular prism, one skilled in the art will recognize that the interior shape of the form is dependent on a desired shape of the block to be created by the form. The block 20 is removed from the form 28 after the concrete has cured.

The excavated area 14 is preferably 1½-2½ feet deep. The layer of leveling material 12 preferably includes gravel and/or sand spread over the base of the excavated area 14 to a thickness of 4-8 inches. Preferably a footer 16 is provided around the perimeter of the excavated area 14 to prevent shifting of the blocks 20. The footer 16 can be constructed from materials such as poured concrete, stone, concrete block or other suitable stabilizing materials. The footer 16 may be installed new prior to the installation of the blocks 20, or alternatively, the footer 16 can be salvaged from a pre-existing pad or other pre-existing structure surrounding the excavated area 14. The blocks 20 are preferably placed over the leveling material flush with grade, or alternatively, slightly above grade to permit some settling.

Referring to FIGS. 5 and 6, an alternative preferred embodiment of the present invention is shown. A heavy equipment support pad 110 is provided which includes preformed reinforced concrete blocks 120 having interlocking portions. The blocks 120 include reinforcing members such as the reinforcing bars 24, 26 described above. The interlocking portions are preferably in the form of key projections 130 and key slots 132. During assembly of the heavy equipment support pad 110, adjacent concrete blocks 120 are connected by connecting their respective key projections 130 and key slots 132. For example, key projections 130 of a first concrete block 120 are slid over key slots 132 of a second concrete block 120, to join the first and second concrete blocks 120. Preferably, the key projections and slots allow some load transferring capability to distribute loads to adjacent blocks. While the keying feature is shown as requiring vertical alignment for installation, it can also be in the form of projections and recesses in the sides of the blocks for horizontal interlocking during placement of the blocks. Also, while a single key feature is shown per side, more than one can be utilized. Further, it is possible to have the reinforcing members extending into the key projections 130, as shown in FIG. 6, for better load distribution and transfer.

Now referring to FIG. 7, a flow chart depicting a method 200 for providing a pad to support heavy equipment, such as the heavy equipment support pads 10, 110, is shown. In the method 200, a concrete form having overall internal dimensions of least 1½ feet by 3 feet by 3 feet (step 202) is provided. In one preferred embodiment, the providing of the form includes providing a form having a structure suitable for forming a block with interlocking portions. A plurality of reinforcing members are inserted within the form (step 204). Concrete is poured into the form over the reinforcing members (step 206) and allowed to cure (step 208) forming a reinforced concrete block, such as the blocks 20,120. In a step 210, the block is removed from the form. Preferably, the concrete is allowed to cure for at least 30 days prior to installation. Steps 202-210 are repeated to form a plurality of reinforced concrete blocks.

In a step 212, a site is excavated to provide an excavated area at least 1½ feet deep to the appropriate desired pad size. Preferably, a layer of leveling material 4-8 inches thick is placed over the excavated area (step 214). Also, a stable footer is preferably provided within the excavated area around the perimeter of the excavated area. The plurality of pre-formed reinforced concrete blocks are placed on the excavated area over the leveling material (step 216). Preferably, the blocks are located using a crane, a front end loader or other equipment suitable for positioning large and heavy loads. Preferably, each of the blocks is placed adjacent to and in contact with at least one other of the blocks, and settling of the blocks is induced using a vibration leveling device. In the case where the blocks include interlocking portions, the placing of the concrete blocks includes connecting the interlocking portions of the adjacent blocks.

The above-described heavy equipment support pads 10, 110 according to preferred embodiments of the present invention, provide many advantages over conventional on-site poured concrete pads. Preformed reinforced concrete blocks, such as the blocks 20, 120 of FIGS. 2 and 6, are rapidly installable and readily usable in high traffic areas. These blocks can be installed, as by the method 200, during facility downtimes or overnight, preventing interruption of work at a factory or other industrial or commercial facility. This method can be used to install complete pads or to repair sections of an existing pad within one week or less, and preferably in one or two days for pads up to 5000 square feet. Further, unlike poured pads, the installation of the blocks is not affected by temperature or adverse weather conditions.

Immediately after installation, the support pads 10, 110 including the reinforced blocks 20, 120 according to the above-described preferred embodiments can support heavy equipment such as trucks having a vehicle weight in excess of 50,000 pounds. A reinforced concrete block sized 1½ ft by 3 ft by 3 ft weighs approximately 2000 pounds, while a 2 ft by 4 ft by 4 ft block weighs approximately 4800 pounds. The size and weight of the blocks prevents them from shifting under the weight of large vehicles.

While the preferred embodiments of the invention have been described in detail above, the invention is not limited to the specific embodiments described above, which should be considered as merely exemplary. Further modifications and extensions of the present invention may be developed, and all such modifications are deemed to be within the scope of the present invention as defined by the appended claims.

Claims

1. A method of providing a pad for supporting heavy equipment at a site, the method comprising:

constructing a plurality of pre-formed reinforced concrete blocks using a method comprising: providing a concrete form having internal dimensions of at least 1½ feet by 3 feet by 3 feet; inserting a plurality of reinforcing members within the form; pouring concrete into the form over the reinforcing members; allowing the concrete to cure to form a concrete block; and removing the concrete block from the form;

excavating the site to form an excavated area; and

placing the plurality of pre-formed reinforced concrete blocks on the excavated area.

2. The method of claim 1, further comprising forming a footer around at least a portion of a perimeter of the excavated area.

3. The method of claim 1, further comprising excavating the site in proximity to a preexisting footer.

4. The method of claim 1, further comprising applying a layer of leveling material over the excavated area.

5. The method of claim 1, further comprising providing the concrete form with features for forming interlocking portions on each of the plurality of concrete blocks and connecting adjacent ones of the concrete blocks using the interlocking portions.

6. The method of claim 1, wherein the constructing the plurality of pre-formed concrete blocks further comprises:

providing the concrete form with features for forming interlocking portions on each of the plurality of concrete blocks, wherein at least one of the interlocking portions on each of the plurality of concrete blocks includes at least one projection; and

inserting the plurality of reinforcing members within the form such that at least one of the reinforcing members extends into the at least one projection;

wherein the method further comprises:

connecting adjacent ones of the concrete blocks using the interlocking portions.

7. The method of claim 1, further comprising:

providing each of the plurality of concrete blocks with at least one key projection and at least one key slot; and

connecting the key projection of at least a first one of the plurality of concrete blocks with the key slot of at least a second one of the plurality of concrete blocks adjacent to the at least the first one of the plurality of concrete blocks.

8. The method of claim 1, further comprising providing the concrete form with internal dimensions of at least 2 feet by 3 feet by 3 feet.

9. The method of claim 1, wherein the inserting the plurality of reinforcing members includes inserting a plurality of steel reinforcing bars.

10. The method of claim 1, further comprising positioning the plurality of concrete blocks on the excavated area using a crane.

11. The method of claim 1, further comprising vibrating the plurality of blocks on the excavated area to induce settling.

12. The method of claim 1, further comprising placing the plurality of pre-formed concrete blocks on the excavated area such that top surfaces of the plurality of blocks are substantially flush with grade.

13. A concrete pad for supporting heavy equipment at a site comprising:

an excavated area;

a plurality of pre-formed reinforced concrete blocks having dimensions of at least 1½ feet by 3 feet by 3 feet positioned within the excavated area.

14. The concrete pad of claim 13, further comprising a footer formed around at least a portion of a perimeter of the excavated area.

15. The concrete pad of claim 13, further comprising a layer of leveling material between the excavated area and the plurality of concrete blocks.

16. The concrete pad of claim 13, wherein each of the plurality of concrete blocks comprises interlocking portions and adjacent ones of the plurality of concrete blocks are connected together using the interlocking portions.

17. The concrete pad of claim 13, wherein each of the plurality of pre-formed reinforced concrete blocks have dimensions of at least 2 feet by 3 feet by 3 feet.

18. The concrete pad of claim 13, wherein each of the plurality of pre-formed reinforced concrete blocks includes reinforcing bars.

19. The concrete pad of claim 13, wherein each of the plurality of pre-formed reinforced concrete blocks comprises reinforcing members disposed therein and interlocking portions including at least one projection, wherein at least one of the reinforcing members extends into the at least one projection.

20. The concrete pad of claim 13, wherein a top surface of each of the plurality of pre-formed reinforced concrete blocks is substantially flush with grade.