SLAB EDGE CASING AND METHOD THEREFOR
A slab edge casing for finishing a slab edge is provided. The casing comprises a face which defines a finished slab edge for an unfinished slab edge; and, a base which extends from the face. The base is connectable to one of a slab face that is adjacent the unfinished slab edge or is registerable with the unfinished slab edge. The face and base have respective inside surfaces that define a form into which concrete is poured and allowed to cure. One of the face and base also comprise a reinforcing element mount for receiving a reinforcing element that extends from the unfinished slab edge. A method for installing the casing is also provided.
The present invention relates to slab edges. In particular, the present invention relates to balcony edges.
BACKGROUND OF THE INVENTIONConcrete slabs, such as those found on balconies, have limited lifespans. They are built according to specifications which should provide a decades long life span. Unfortunately, often as a result of environmental conditions, the balconies must be replaced within 8-12 years. The process of re-finishing is labour, resource and time intensive for those re-furnishing the balconies. The re-furnishers must:
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- set up scaffolding in order to access the balconies;
- employ impact tools (e.g. jack hammers) to remove the damaged balcony portions while at the same time preserving any existing reinforcing bars within the slab structure; and
- set up form work to pour re-finishing concrete.
Also this process often times significantly inconveniences the individuals who use the balconies. The noise and dust created is often intolerable. The dust generated can sometimes permanently damage personal possessions.
The remains a need for a system and method for finishing a slab edge which mitigates or obviates at least some of the above-presented problems.
SUMMARYA slab edge casing for finishing a slab edge is provided. The casing comprises a face which defines a finished slab edge for an unfinished slab edge; and, a base which extends from the face. The base is connectable to one of a slab face that is adjacent the unfinished slab edge or is registerable with the unfinished slab edge. The face and base have respective inside surfaces that define a form into which concrete is poured and allowed to cure. One of the face and base also comprise a reinforcing element mount for receiving a reinforcing element that extends from the unfinished slab edge.
The slab edge may be a balcony edge.
A kit for finishing a slab edge is provided. The kit comprises a casing, which in turn comprises a face which defines a finished slab edge for an unfinished slab edge and a base that extends from the face. The base may be connectable to a slab face adjacent the unfinished slab edge or registerable with the unfinished slab edge. The face and base having respective inside surfaces that define a form into which concrete is poured and allowed to cure. One of the face and base comprises a reinforcing element mount for receiving a reinforcing element extending from the unfinished slab edge. The casing also comprises a brace mount positioned on one of the inside surfaces.
The kit also comprises a reinforcing element that is securable to the unfinished slab edge. The reinforcing element, when secured to the unfinished slab edge, extends from the unfinished slab edge to at least a terminal anchor point that corresponds to the finished slab edge. The reinforcing element also comprises a brace mount.
The kit also comprises a brace, which is extendable between the reinforcing element brace mount and the casing brace mount, and connectable to the respective mounts.
A method for installing a slab edge is also provided. The method comprises the steps of:
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- securing a reinforcing element into the unfinished slab edge. The reinforcing element extends from the unfinished slab edge to at least a terminal anchor point corresponding to the installed position of the finished slab edge.
- connecting a casing to the reinforcing element at the terminal anchor point. The casing defines the finished slab edge and defines a form into which concrete is poured and allowed to cure.
- and, pouring the concrete into the form and allowing the concrete to cure. The casing remaining in position after the concrete has cured.
Referring to
The finished slab edge 10 comprises a slab edge casing 11, which in turn comprises a face 13, the outside surface of which defines a finished slab edge 15 for an unfinished slab edge 17. The casing 11 also comprises a base 19, which extends from the casing face 13. The base 19 may be connectable to a slab face 21 adjacent the unfinished slab edge 17, as is illustrated in cross-section in
Referring again to
The casing 11 also preferably comprises a plurality of ribs 39, which extend from the inside surfaces 23. The ribs 39, which are preferably formed along with the casing 11 as a unitary structure, aid in securing the concrete in position within the form.
The finished slab edge 10 also comprises a reinforcing element 31, which is securable to the unfinished slab edge 17. The reinforcing element 31, when secured to the unfinished slab edge 17, extends from the unfinished slab edge 17 to a terminal end, which ends at a point that corresponds to at least the finished slab edge 15. Preferably, the reinforcing element 31 is securable within a hole (not shown) that has been drilled into the unfinished slab edge 17.
In a first embodiment, the reinforcing element 31 comprises an anchor bolt 33 that is securable within the hole; a rod 35, which extends from the anchor bolt 33 to the terminal anchor point; and, a coupler 37, which connects the anchor bolt 33 to the rod 35. Preferably, the rod 35 is a threaded rod, a portion of which extends beyond the casing 11. The rod 35 is preferably composed of a steel, such as stainless steel. Alternately, the rod 35 is composed of a plastic. As will be apparent, the rod 35 may comprise any suitable material that is substantially inert to the environmental conditions of the installation.
Referring now to
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In a preferred embodiment, the lock 47 is also composed of a polymer that is resistant to the deteriorating effects of the environmental conditions of the slab installation. For example, the lock 47 may be composed to a suitable plastic.
Referring again to
The face 13 of the casing 11 preferably has a length (l) corresponding to the height of the slab edge 10. In order to accommodate varying slab heights, the face 13 may be cut to the required height at any point during the installation process. Alternately, and preferably, the casing face 13 comprises a first face portion 41 and a second face portion 43. The first and second portions (41, 43) are positionable with respect to each other and securable to each other at a position having a face length (l) corresponding to the slab height. Preferably, the first and second portions (41, 43) are slidably moveable with respect to each other. For example, referring to
The face 13 also preferably comprises a reinforcing element mount 25. Alternately, the base 19 comprises the reinforcing element mount 25, not shown.
The reinforcing element mount 25 may comprise a passage extending through the face 13, the rod 35 (or rod 77 as is illustrated in
The slab edge casing 11 further comprises a base mount 27, which is configured to receive securing means for securing the base 19 to the adjacent slab face 21. In a preferred embodiment, the base mount 27 is a passage extending through the base 19 and the securing means is a screw 29 (preferably a self tapping screw), which passes through the base mount 27 and into the slab face 21, thereby securing the base 19 to the slab face 21. In installation, the adjacent slab face 21 is pre-treated prior to the base 19 being secured. For example, the slab face 21 may be sandblasted or otherwise abraded. The base 19 is then secured with screws 29. Preferably, the base 19 is also glued to the adjacent slab face 21.
Still referring to
Preferably, the slab edge casing 11 comprises a second brace mount 55, also positioned on one of the inside surfaces 23, but, separate and apart from the first brace mount 49. The second brace mount 55 is connectable to a second brace 57, which extends from the reinforcing element 31. As will be apparent, the casing brace mounts 49, 55 may alternately be configured to function as additional casing ribs 39.
Still referring to
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In this alternate embodiment, the mounts 49, 51 are configured to receive the bar element. For example, as is illustrated in
The casing 11, as has been described above, is preferably composed of a GFRP. In an alternate embodiment, the casing 11 may be composed of a PVC (polyvinyl chloride). The thickness of the PVC composed casing 11 compared to that of the GFRP composed casing 11 will preferably be adjusted (increased) to compensate to PVC's relatively lower modulus of elasticity. In either case, respective thicknesses of the GFRP and PVC casings 11 will be selected, taking in to account the materials' respective modulus of elasticity, to minimise any deflection of the casing 11 caused by the concrete. Deflection is kept at a minimum in order to maintain the visual presentation of the finished slab edge 15.
PVC, as a material for casing 11 construction, offers a number of advantages over GFRP. One advantage is that PVC can be welded on site (in addition to being glued or cemented, as may also be required). Welding permits on site customization of the casing 11. It also reduces the number of welding plates that are required to connect casing pieces together, as in the corner portion of the finished slab edge, for example. An additional advantage of using PVC is that the face 13 and base 19 may be formed separately and welded on site to form the casing 11.
An embodiment of the present invention may alternately be characterized as a kit for finishing as unfinished slab edge. The kit comprises the casing 11, the reinforcing element 31 and a brace 53, as defined above, including the alternate embodiments. Preferably, the kit comprises a plurality of reinforcing elements 31 and a plurality of braces 53. For example, the kit may comprise an equal number of reinforcing elements 31 and braces 53.
Referring to
The corner casing 71 comprises adjacent faces 13, which define the finished slab edge 10. From each face 13, a respective base 19 extends. The bases 19 are either connectable to a slab face 21 adjacent the unfinished slab edge 17; or, registerable with the unfinished slab edge 17. The faces 13 and bases 19 have respective inside surfaces which define a form unto which concrete is poured and allowed to cure. Each face 13, base 19 pairing also comprises a reinforcing element mount 25 for receiving a respective reinforcing element 31 that extends from the unfinished slab edge 17. As stated previously, the casing 13 may further comprise base mounts 27 (not shown) for receiving securing means, such as self-tapping screws 29.
Also, as stated previously, the corner casing 71 may further comprise a brace mount 49 positioned on one of the inside surfaces 23 (not shown). The brace mount 49 is connectable to a brace 53 extending from the reinforcing element 31 (not shown). The corner casing 71 may additionally comprise a second brace mount 55 (not shown). As will be apparent, the corner casing 71 is comprised similarly to the casing 11. As such, it may comprise:
a plurality of ribs 39 extending from the inside surfaces 23 (not shown); and,
a polymer composition, preferably a glass-fibre reinforced polymer.
As with the casing 11, the face 13 of the corner casing 71 has a length corresponding to the slab height. Alternatively, the face 13 of the corner casing 71 may comprise the first face portion 41 and second face portion 43, as described above.
Referring to
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- (a) securing a reinforcing element 31 into the unfinished slab edge 17. (Step 100) The reinforcing element 31 extends from the unfinished slab edge 17 to a terminal end that extends to a point corresponding to the installed position of the finished slab edge 10;
- (b) connecting a casing 11 to the reinforcing element 31 at the terminal end. (Step 200) The casing defines the finished slab edge 10 and defines a form into which concrete is poured and allowed to cure; and,
- (c) pouring the concrete into the form and allowing the concrete to cure. (Step 300) The casing 11 remains in position after the concrete has cured.
Step (a) may further comprise any one or a combination of the steps of:
- (a) cutting the slab to remove an original deteriorated slab edge and expose the unfinished slab edge 17. (Step 100(a)). [As will be apparent, any suitable cutting tool, such as a circular or chain saw for concrete, may be employed. The use of the cutting tool contrasts with traditional methods, which involve the use of percussion or impact tools (commonly referred to as jack hammers) of varying sizes, which are used to remove the concrete and preserve the underlying reinforcing bars.]
- (b) drilling a plurality of holes into an unfinished slab edge 17 (Step 100(b)); and,
- (c) securing a reinforcing element 31 into each of the holes. (Step 100(c)). [The number of holes drilled, and the drilling depth of the holes are determined by the particular installation requirements. The reinforcing element 31 may be secured into its hole by any one or a combination of the action of an anchor bolt portion 33 of the reinforcing element 31, and a cement (such as an epoxy cement or glue).]
Step (b) may further comprise any one or a combination of the steps of:
- (a) securing a lock to a portion of the terminal end that extends beyond the finished edge 15. (Step 200(a));
- (b) connecting the casing 11 to a face 21 adjacent the unfinished slab edge. (Step 200 (b));
- (c) positioning reinforcing bars 59 between the finished and unfinished slab edges 15, 17 in an orientation orthogonal to a longitudinal axis 61 of the reinforcing element 31. (Step 200(c));
- (d) connecting a brace 53 to a casing brace mount 49 and a reinforcing element brace mount 51. (Step 200(d)); and,
- (e) connecting a second brace 57 to the reinforcing element brace mount 51 and a second casing brace mount 55. (Step 200(e)).
The above description is intended in an illustrative rather than restrictive sense. Variations may be apparent to those skilled in the art without departing from the spirit and scope of the invention as defined by the claims set out below.
Claims
1. A method for finishing an unfinished slab edge comprising the steps of:
- (a) securing a reinforcing element into the unfinished slab edge, the reinforcing element extending from the unfinished slab edge to at least a terminal anchor point corresponding to the installed position of the finished slab edge;
- (b) connecting a casing to the reinforcing element at the terminal anchor point, the casing defining the finished slab edge and defining a form into which concrete is poured and allowed to cure; and,
- (c) pouring the concrete into the form and allowing the concrete to cure, the casing remaining in position after the concrete has cured.
2. A method for finishing a slab edge according to claim 1, wherein step (b) further comprises connecting the casing to a face adjacent the unfinished slab edge.
3. A method for finishing a slab edge according to claim 1, wherein step (a) further comprises cutting the slab to remove an original slab edge and expose the unfinished slab edge.
4. A method for finishing a slab edge according to claim 1, wherein step (a) further comprises drilling a plurality of holes into an unfinished slab edge; and, securing a reinforcing element into each of the holes.
5. A method for finishing a slab edge according to claim 1, wherein the reinforcing element comprises a brace mount and the casing comprises a corresponding brace mount, and step (b) further comprises connecting a brace to the respective mounts.
6. A method for finishing a slab edge according to claim 5, wherein the casing further comprises a second brace mount and the reinforcing element is configured to receive a second brace, and step (b) further comprises connecting the second brace to the reinforcing element brace and the second brace.
7. A method for finishing a slab edge according to claim 1, wherein the terminal anchor point extends beyond the casing, the portion extending beyond being configured to receive a lock, and step (b) further comprises securing the lock to extended anchor portion.
8. A method for finishing a slab edge according to claim 1, wherein step (b) further comprises positioning reinforcing bars between the finished and unfinished slab edges in an orientation orthogonal to a longitudinal axis of the reinforcing element.
9. A method for finishing a slab edge according to claim 1, wherein the slab is a balcony.
10. A slab edge casing for finishing a slab edge, the casing comprising:
- a face defining a finished slab edge for an unfinished slab edge; and,
- a base extending from the face, the base being one of connectable to a slab face adjacent the unfinished slab edge and registerable with the unfinished slab edge, the face and base having respective inside surfaces defining a form into which concrete is poured and allowed to cure,
- one of the face and base comprising a reinforcing element mount for receiving a reinforcing element extending from the unfinished slab edge.
11. A slab edge casing for finishing a slab edge according to claim 10, wherein the casing further comprises a base mount for receiving securing means for securing the base to the adjacent slab face.
12. A slab edge casing for finishing a slab edge according to claim 11, wherein the securing means is a self tapping screw.
13. A slab edge casing for finishing a slab edge according to claim 10 further comprising a brace mount positioned on one of the inside surfaces, the brace mount being connectable to a brace extending from the reinforcing element.
14. A slab edge casing for finishing a slab edge according to claim 13 further comprising a second brace mount positioned on one of the inside surfaces, apart from the first brace mount, the second brace mount being connectable to a second brace extending from the reinforcing element.
15. A slab edge casing for finishing a slab edge according to claim 10, wherein the casing further comprises a plurality of ribs extending from the inside surfaces, the ribs aiding in securing the cured concrete in position.
16. A slab edge casing for finishing a slab edge according to claim 10, wherein the casing is composed of a polymer.
17. A slab edge casing for finishing a slab edge according to claim 16, wherein the polymer is one of a glass fibre reinforced polymer and a polyvinyl chloride.
18. A slab edge casing for finishing a slab edge according to claim 10, wherein the face has a length corresponding to the slab height.
19. A slab edge casing for finishing a slab edge according to claim 10, wherein the face comprises a first face portion, and a second face portion, the first and second face portions being moveable with respect to each other and securable to each other at position having a length corresponding to the slab height.
20. A kit for finishing an unfinished slab edge, the kit comprising:
- a casing comprising: a face defining a finished slab edge for an unfinished slab edge; and, a base extending from the face, the base being one of connectable to a slab face adjacent the unfinished slab edge and registerable with the unfinished slab edge, the face and base having respective inside surfaces defining a form into which concrete is poured and allowed to cure, one of the face and base comprising a reinforcing element mount for receiving a reinforcing element extending from the unfinished slab edge, and, a brace mount positioned on one of the inside surfaces;
- a reinforcing element securable to the unfinished slab edge, the reinforcing element, when secured to the unfinished slab edge, extending from the unfinished slab edge to at least a terminal anchor point corresponding to the finished slab edge, the reinforcing element comprising a brace mount; and,
- a brace, extendable between the reinforcing element brace mount and the casing brace mount, and connectable to the respective mounts.
21. A kit for finishing an unfinished slab edge according to claim 20, wherein the reinforcing element is securable within a hole drilled into the unfinished slab edge.
22. A kit for finishing an unfinished slab edge according to claim 21, wherein the reinforcing element further comprises:
- an anchor bolt securable within the hole;
- a rod extending from the anchor bolt to the terminal anchor point; and,
- a coupler connecting the anchor bolt to the rod.
23. A kit for finishing an unfinished slab edge according to claim 22, wherein the rod is a threaded rod.
24. A kit for finishing an unfinished slab edge according to claim 23, wherein the lock is a lock nut.
25. A kit for finishing an unfinished slab edge according to claim 24, wherein the lock nut is composed of a polymer.
26. A kit for finishing an unfinished slab edge according to claim 20, wherein the casing is composed of a polymer.
27. A kit for finishing an unfinished slab edge according to claim 26, wherein the polymer is one of a glass fibre reinforced polymer and a polyvinyl chloride.
28. A kit for finishing an unfinished slab edge according to claim 26, wherein when the polymer is a polyvinyl chloride, the face and base are welded together.
29. A kit for finishing an unfinished slab edge according to claim 21, wherein the reinforcing element further comprises a rod extending from the hole to the terminal anchor point.
Type: Application
Filed: May 18, 2007
Publication Date: Jul 31, 2008
Applicant: I & F ENGINEERING CORP. (Concord)
Inventor: Isaak FINKELSHTEYN (Concord)
Application Number: 11/750,788
International Classification: E02D 27/08 (20060101);