FOAM-CONCRETE REBAR TIE
A fastener is disclosed having a an extension portion configured to be inserted into a first construction material such as foam, and having a stirrup portion configured to retain portion of a second construction material, such as rebar at a distance from the first construction material. A third construction material such as concrete can then be inserted (poured) in contact with the first construction material and surrounding the second construction material such that the second construction material is not directly in contact with the first construction material.
Foam concrete structures are utilized in various capacities ranging from concrete stairs, drive ways, ramps, floating docks, precast walls, abutments, retaining walls with lightweight fill load distribution slabs, roadways and applications for concrete foam systems such as Geofoam™ and other applications for concrete foam structures. In general, a foam concrete structure has a central region comprised of foam material which may be expanded polystyrene (EPS) or extruded polystyrene (XEPS) with a perimeter portion of concrete therearound. Oftentimes, a tensile strength member such as rebar is positioned within the concrete. At present time, rebar, which is comprised of steel or other iron-based compositions, is a primary form of enhancing the strength of concrete to reinforce concrete structures. In general, concrete is very poor in tension, and having an insert therein, for example a metallic member such as a longitudinally extending piece of rebar, significantly enhances the strength of the concrete structure.
Now in the case of having a concrete block with a foam center portion, when a bending moment is placed upon the structure, there is a compressive force at its greatest magnitude in one portion of the block structure, whereas the opposing portion has a tensile stress imposed thereon. The concrete is used to encapsulate or provide a protective shell, for example: floatation, geofoam, floor systems, ICF's, poured-in-place and pre-cast concrete systems. The foam portion functions as floatation, lightweight fill, or insulation. Of course, the center portion has a shear force acting as welt pursuant to basic beam theory. Therefore, having a properly spaced tensile member such as rebar positioned in the foam concrete structure is important for properly positioning the rebar in the concrete to absorb the tensile stress placed thereon.
The prior art has failed to present a system, apparatus and method for properly positioning and orienting rebar at a proper depth within the outer concrete perimeter region. In some forms the rebar is positioned during a construction state in vertically and inverted orientated positions as well as a regular horizontal position. Therefore, in one form, having an apparatus to orientate the rebar in various orientations with respect to the flux field of gravity is desirable for constructing and forming a concrete/foam structure.
Further, having a proper anchoring system to attach to the foam material allows for proper positioning of the rebar holding unit. In one form, having a properly sized and dimensioned base portion allows for a sufficient amount of stability, without requiring excessive force to penetrate the foam to be mounted during production. These steps may be carried out in a manufacturing facility, or on a job site.
SUMMARY OF THE DISCLOSUREThe structure in one form described in this disclosure is a holding member having an extension portion, a base portion, and a stirrup portion. The extension portion is configured to be inserted into a rigid construction material such as a block of foam. The extension portion in one form comprises a plurality of base members with barbs which extend radially outward from the longitudinal axis of the extension portion. These barb members are constructed to add rigidity to the structure, and assist in proper positioning within the rigid construction material. These barb members are especially helpful in preventing rotational and longitudinal movement of the holding member in relation to the foam. In one form, a plurality of barb members extend from the barb members to further maintain the position of the extension within the first construction material. The extension portion may be directly coupled to or formed with the stirrup portion, or an intermediate base portion may be provided between the two. This base portion can provide a stop which will limit the depth to which the extension member can be inserted into the foam. All three elements may also be formed as a unitary structure, say of a polymer or metal.
In one form, after inserting the extension portion of the structure into the rigid construction material, a portion of an elongate construction material, such as a length of rebar, is coupled to the stirrup portion of the structure to hold the rebar a specified distance from the rigid construction material. After the rebar is positioned within the stirrup, another construction material such as concrete can be disposed in contact with the first construction material and substantially surrounding the second construction material. This will substantially encapsulate the construction materials and form a protective shell with the rebar adding support to the concrete (second material).
In one form, the barb members previously discussed also have a plurality of barb-like extensions which are configured to keep the structure from pulling out of the rigid construction.
As shown in
Therefore, it can be appreciated that the tensile stress member 26, which is most commonly rebar at the time of this writing, is positioned at a substantially center region 32 within the concrete perimeter 24. This positioning allows the rebar 26 to engage the surrounding concrete so as to transfer force thereto, so when for example the particular concrete perimeter wall section 34 is in tension, these tensile stresses are transferred to the rebar 26 properly, whereas the concrete aggregate itself is in general very poor at handling tension, and of course very strong in compressing as is well-known pursuant to conventional material science theory.
Therefore, as described in detail herein, the rebar holding member 28 provides utility in properly positioning the rebar during the production and manufacture of the foam concrete structure 20. Various attributes of one form of a rebar holding member will be described herein in detail with the understanding that other forms could be utilized without departing from the spirit and scope of the Applicant's broad concept.
In another embodiment, a section of tubing can be utilized instead of the tensile stress member 26. This would not only add rigidity to the material but would also add a channel for applying fluids, gases, or serve as a conduit for electrical or communication service. For example, once the structure is completed, hot water could be provided through the tubing which would heat the structure adjacent the tubing.
Referring now to
Referring now to
In general, the extension portion 36 is configured to be positioned in the foam material 22 in a manner as shown in
Therefore, it can be appreciated that the extension portion 36 must provide a reasonably stable platform when inserted within the foam. As shown in
Now referring to
With the foregoing description in place with regard to the extension portion 36, there will now be a discussion of the support portion (otherwise referred to as a stirrup portion) 38 with initial reference to
As further shown in
To further describe one form of the rebar holding member 28, the plurality of barbs 50 and 52 as shown in
Analysis upon the overall dimensions of the rebar holding member 20 will now be presented. As shown in
Therefore, as shown in
In general, the device can be utilized in various forms, such as concrete sandwich panels, which in one form are poured in place, or alternatively can be pre-cast. Further, the device can be utilized in other forms, such as insulated heated floors, or further, precast concrete joists, decking, floors, or roofs and various compositions thereof. For example, the device could be utilized similar to decking for insulated reinforced concrete floor such as Decklite™ from Benchmark Foam, Inc. and other similar products from other manufactures.
While the present invention is illustrated by description of several embodiments and while the illustrative embodiments are described in detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications within the scope of the appended claims will readily appear to those sufficed in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of Applicants' general concept.
Claims
1. A rebar holding member configured to be positioned in a foam material having an outer surface, the rebar holding member comprising:
- a. an extension portion having a longitudinal axis, the extension portion having a plurality of barb members extended radially outward from the longitudinal axis;
- b. a base portion having a base surface located in a forward longitudinal direction;
- c. a stirrup portion having a base region and a rebar holding region, the rebar holding region comprising first and second arms comprising an interior surface configured to hold a rebar member therein;
- d. whereas the base region maintains a minimum prescribed distance from the base surface which is configured to be placed adjacent to the foam material.
2. The rebar holding member as recited in claim 1 where the plurality of barb members are arranged such that a longitudinally rearward barb member extends radially further outward than a longitudinally forward barb member.
3. The rebar holding member as recited in claim 1 where the plurality of barb members comprise a first transverse axis and a second transverse axis where a first set of barbs are aligned substantially in the direction of the first transverse axis and a second set of barbs are aligned substantially in the second transverse axis direction.
4. The rebar holding member as recited in claim 3 where the first set of barbs are spaced so as to be longitudinally offset and interposed between the second set of barbs.
5. The rebar holding member as recited in claim 4 where the second set of barbs substantially extend in the second transverse direction and comprise a perimeter flange portion which extends in the first transverse direction.
6. The rebar holding member as recited in claim 1 where the interior surface of the rebar holding region has a plurality of radially inward extensions having a width sufficiently narrow so the extensions undergo plastic deformation when the rebar is placed between the first and second arms of the rebar holding region.
7. The rebar holding member as recited in claim 6 where the width of the radially inward extensions are less than one half the width of the first and second arms.
8. The rebar holding member as recited in claim 7 where the rebar holding member is configured to hold the rebar in an inverted manner.
9. The rebar holding member as recited in claim 1 where the first and second arms each provide an inward slanting surface defining a central open region configured to have a portion of rebar pass therethrough.
10. The rebar holding member as recited in claim 9 where the rebar is operatively configured to be held within the interior surface of the rebar holding region when the rebar holding region is positioned beneath the extension portion.
11. The rebar holding member as recited in claim 1 where the extension portion, base portion, and stirrup portion are formed a s a unitary structure.
12. The rebar holding member as recited in claim 11 where the unitary structure is substantially formed as a polymer.
13. A device comprising:
- a. an extension portion operatively configured to be inserted into a portion of resilient material wherein the extension portion further comprises; i. a plurality of orthogonally extending base members; and ii. a plurality of barb members;
- b. a base portion having a first side and a second side, the first side coupled to the extension portion;
- c. a stirrup portion coupled to the second side of the base portion, the stirrup portion operatively configured to hold a portion of construction material.
14. The device of claim 13 wherein the extension portion, base portion, and stirrup portion are formed as a unitary structure.
15. The device of claim 14 wherein the unitary structure is formed of a polymer.
16. The device of claim 13 wherein the resilient material is substantially a foam material.
17. The device of claim 13 wherein the portion of construction material is a length of rebar.
18. The device of claim 13 wherein the portion of construction material is a length of tubing.
Type: Application
Filed: Mar 12, 2008
Publication Date: Sep 17, 2009
Inventor: Steven J. Nelson (Bellingham, WA)
Application Number: 12/047,036
International Classification: E04C 5/16 (20060101);