BULKHEAD ASSEMBLY FOR USE WITH A CONCRETE FORM
A bulkhead assembly for use with a concrete form and a first reinforcement bar is disclosed. The concrete form may have first and second spaced form sides; and the first reinforcement bar may be disposed between and may extend longitudinally of the spaced form sides. The bulkhead assembly may have a first pair of channel assemblies, each including a channel member and an elastomeric member. The elastomeric member may be positioned longitudinally in the channel member, with a portion of the elastomeric member extending outward transversely from the channel member. The portion may include an outer end that extends longitudinally of the channel member. The channel assemblies may be positioned on opposite sides of the reinforcement bar, with the elastomeric member outer ends facing one another and contacting the reinforcement bar, thereby inhibiting uncured concrete from passing between the channel assemblies when uncured concrete is poured into the concrete form.
This patent document claims the benefit of the filing date of Provisional Application No. 62/483,186, entitled “Adjustable Concrete Bulkhead” and filed on Apr. 7, 2017. The entire disclosure of Provisional Application No. 62/483,186 is incorporated into this patent document by reference.
FIELD OF THE INVENTIONThis invention relates to bulkhead assemblies for use with concrete forms, and more particularly, to bulkhead assemblies for use with concrete forms in making a variety of concrete structures (e.g., walls and slabs that have a single mat of rebar, and walls and slabs that have multiple mats of rebar).
BACKGROUND OF THE INVENTIONThe construction of a concrete wall or slab often requires the wall or slab to be poured in multiple sections. This is usually dictated by the Engineer of Record (EOR) within the project specifications or by the contractor based on availability of forming materials or placement restrictions. In order for the wall or slab to be built in sections and retain its structural integrity, reinforcement bars (rebar) must connect one section to the next. To accomplish this, the rebar of a given section must penetrate the bulkhead so that once the concrete section is cured and the bulkhead is removed, the rebar will extend into the next section to be placed. In addition, the size and spacing of the rebar as well as the thickness of the concrete wall or slab varies by the design and use requirements set forth by the EOR.
Current industry practice is to construct the bulkheads with ¾ inch thick wood boards. Holes are drilled through the boards to accommodate the size and spacing of the rebar. The boards are then attached to the sides of the wall forms with nails or screws and additional support lumber. This piecemeal approach to bulkhead construction is time consuming and labor intensive. Each board must be cut and drilled to fit. Also, the space constraints for the craftsman are often inhibited by the narrow space between the wall forms and the temporarily secured rebar he or she is trying to form around. Removal of this system after placement is also challenging due to the aforementioned space constraints and the hardened concrete that has locked boards in place. The boards are often removed in splintered pieces by means of claw hammer and pry bar.
SUMMARY OF THE INVENTIONThe invention is directed to a bulkhead assembly for use with: a concrete form that includes first and second spaced form sides; and a first reinforcement bar disposed between and extending longitudinally of the first and second spaced form sides.
In one aspect, the bulkhead assembly may include a first pair of channel assemblies that may be positioned between the first and second spaced form sides. Each of the first pair of channel assemblies may include a channel member and an elastomeric member that may be positioned longitudinally in the channel member. The elastomeric member may be constructed and arranged so that when it is positioned longitudinally in the channel member, a portion of the elastomeric member extends outward transversely from the channel member. The outwardly extending portion may include an outer end that extends longitudinally of the channel member. The first pair of channel assemblies may be positioned on opposite sides of the first reinforcement bar, with the elastomeric member outer ends facing one another and contacting the first reinforcement bar, thereby inhibiting uncured concrete from passing between the first pair of channel assemblies when uncured concrete is poured into the concrete form.
In another aspect, the bulkhead assembly may include a second pair of channel assemblies that may be positioned between the first and second spaced form sides, substantially coplanar with the first pair of channel assemblies. Each of the second pair of channel assemblies may include a channel member and an elastomeric member that may be positioned longitudinally in the channel member. The elastomeric member may be constructed and arranged so that when it is positioned longitudinally in the channel member, a portion of the elastomeric member extends outward transversely from the channel member. The outwardly extending portion may include an outer end that extends longitudinally of the channel member. The second pair of channel assemblies may be positioned on opposite sides of a second reinforcement bar disposed between and extending longitudinally of the first and second spaced form sides, with the elastomeric member outer ends facing one another and contacting the second reinforcement bar, thereby inhibiting uncured concrete from passing between the second pair of channel assemblies when uncured concrete is poured into the concrete form.
In a further aspect, the bulkhead assembly may include a bulkhead wall segment, or member, that may be positioned between the first and second pairs of channel assemblies, substantially coplanar with the first and second pairs of channel assemblies. If desired, a first angle member may be positioned between a bulkhead wall segment first end and the first pair of channel assemblies; and a second angle member may be positioned between a bulkhead wall segment second end and the second pair of channel assemblies. The first and second angle members may assist in supporting the bulkhead wall segment.
The accompanying drawings, which are incorporated into this patent document and constitute a part of this specification, illustrate embodiments of the invention and, together with the general description of the invention given above, and the detailed description of the drawings given below, serve to explain the principles of the invention. The drawings are schematic in nature and are not necessarily to scale. Where possible, like reference numbers are used for like components in describing various embodiments.
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An optional key and water stop assembly 50 is shown attached to the bulkhead assembly 10. In further detail, the optional key and water stop assembly 50 is fastened to the bulkhead wall segment 28; and the assembly 50 extends outward from the segment 28 in a direction generally perpendicular to the bulkhead assembly 10. The particular key and water stop assembly 50 shown includes a pair of beveled key members 51a, 51b and a water stop 53, with a portion of the water stop positioned between the key members, and another portion of the water stop extending outward from the key members in a direction generally perpendicular to the bulkhead assembly 10.
The key and water stop assembly 50 forms a keyway in an end of a section of concrete being placed. After the section has been placed, the bulkhead assembly 10 and the key and water stop assembly 50 may be removed (e.g., in preparation for placing an adjoining concrete section). Then when an adjoining section of concrete is placed, the keyway is filled with concrete from the adjoining section. Key and water stop assemblies can be especially useful in forming joints between adjacent concrete sections when the resulting concrete structure is used to retain water. If desired, the key members may be made of wood; and the water stop may be made of a pliable material that includes ribbed contours. The ribbed contours of the water stop impede the movement of water through the joint.
As will be appreciated, a bulkhead assembly in accordance with the principles of the invention may be used with any suitable formwork system. With reference to
A bulkhead assembly in accordance with the principles of the invention may be formed using any suitable materials. For example, if desired, the channel assembly channel members may be strut channel (e.g., Unistrut® strut channel from Atkore International, Inc.). The channel assembly elastomeric members may, if desired, be formed of rubber (e.g., a neoprene rubber). And the angle members may, if desired, be formed of any suitable metal. Also, the bulkhead wall segment may, if desired, be formed of wood; and if desired, the wood may include one or more panels of plywood (e.g., two panels of plywood overlaid one against the other).
The components of a bulkhead assembly in accordance with the principles of the invention may be fastened together and to the formwork system in any suitable fashion and with any suitable fasteners or fastening materials. With regard to an elastomeric member and a channel member of the invention, if desired, a channel assembly may be formed (of these two components) and maintained without the use of any fastening materials or substances (e.g., without the use of screws, nails, bolts, adhesives, and the like). For example, a portion of the elastomeric member may be positioned longitudinally in the channel member; and the elastomeric member portion may remain in, or be kept in, the channel member (e.g., not fall out of the channel member) without the use of any fastening materials or substances (e.g., without the use of screws, nails, bolts, adhesives, and the like).
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The bulkhead assembly 130 includes a first pair of channel assemblies 142, a second pair of channel assemblies 144, and a bulkhead wall segment 146 positioned between the pairs of channel assemblies. The first pair of channel assemblies 142 is positioned on opposite sides of the longitudinally extending bars of the first mat 134, with the elastomeric member outer ends (as at 44 in
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A bulkhead assembly, in accordance with the principles of the invention, has many benefits and advantages. For example, the assembly can be modified to fit a variety of wall, slab, and rebar configurations. Also, the assembly may be installed more efficiently. For example, the components can be sub-assembled and slid into place.
In addition, because the rebar passes between the elastomeric members of adjacent channel assemblies, and the rebar is not constrained by other materials, the removal of the formwork requires much less force than conventional methods. Once the concrete has cured and the support structure or formwork structure has been removed from behind the bulkhead assembly, an entire channel assembly may be removed from the concrete section in one piece. The pair(s) of channel assemblies can be quickly scraped clean and immediately ready for reuse on the subsequent pour.
Also, after placement of a concrete wall- or slab-section, none of the bulkhead assembly components is constrained by cured concrete on more than one side, which makes removal much easier.
While the present invention has been illustrated by a description of embodiments, and while the illustrative embodiments have been described in considerable detail, it is not the intention of the inventors to restrict or in any way limit the scope of the following claims to such detail. Additional advantages and modifications readily will appear to those skilled in the art upon a reading of this patent document. The invention, in its broader aspects, is therefore not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described in this patent document. Accordingly, departures may be made from such details without departing from the spirit or scope of the inventors' general inventive concept.
Claims
1. A bulkhead assembly for use with a concrete form that includes first and second spaced form sides and with a first reinforcement bar disposed between and extending longitudinally of the first and second spaced form sides, the bulkhead assembly comprising:
- a first pair of channel assemblies positionable between the first and second spaced form sides, each of the first pair of channel assemblies including: a channel member; and an elastomeric member positionable longitudinally in the channel member, the elastomeric member constructed and arranged so that when it is positioned longitudinally in the channel member, a portion of the elastomeric member extends outward transversely from the channel member, the portion including an outer end that extends longitudinally of the channel member;
- the first pair of channel assemblies positionable on opposite sides of the first reinforcement bar, with the elastomeric member outer ends facing one another and contacting the first reinforcement bar, thereby inhibiting uncured concrete from passing between the first pair of channel assemblies when uncured concrete is poured into the concrete form.
2. The bulkhead assembly of claim 1 wherein the channel member of each of the first pair of channel assemblies includes a substantially U-shaped cross-section.
3. The bulkhead assembly of claim 2 wherein the channel member of each of the first pair of channel assemblies includes a base wall, a first sidewall, and a second sidewall, with the first and second sidewalls spaced from one another and extending outwardly from the base wall, and wherein the base wall, first sidewall, and second sidewall assist in forming the substantially U-shaped cross-section.
4. The bulkhead assembly of claim 3 wherein, for each of the first pair of channel assemblies, the elastomeric member contacts the channel member base wall when the elastomeric member is positioned longitudinally in the channel member.
5. The bulkhead assembly of claim 3 wherein, for each of the first pair of channel assemblies, the elastomeric member does not include a longitudinally-extending groove to assist in holding the elastomeric member in the channel member.
6. The bulkhead assembly of claim 3 wherein, for each of the first pair of channel assemblies, the channel member and the elastomeric member do not include longitudinally-extending complementary grooves that interact with one another to assist in holding the elastomeric member in the channel member.
7. The bulkhead assembly of claim 3 wherein each of the first and second sidewalls of the channel members of the first pair of channel assemblies includes a longitudinally extending outer end, and wherein each of the first and second sidewall longitudinally extending outer ends does not include a projection that extends laterally into a space between the sidewalls to assist in holding the elastomeric member in the channel member.
8. The bulkhead assembly of claim 1 wherein each of the first pair of channel assemblies does not include an adhesive for adhering the channel member and the elastomeric member to one another.
9. The bulkhead assembly of claim 3 further comprising a bulkhead wall segment, the bulkhead wall segment positionable between the first and second spaced form sides, substantially coplanar with the first pair of channel assemblies.
10. The bulkhead assembly of claim 9 further comprising an angle member positionable between the bulkhead wall segment and the first pair of channel assemblies, the angle member operable to assist in supporting the bulkhead wall segment.
11. The bulkhead assembly of claim 10 wherein the angle member includes a substantially L-shaped cross-section, a first longitudinal wall, and a second longitudinal wall adjacent the first longitudinal wall.
12. The bulkhead assembly of claim 11 wherein one of the angle member first and second longitudinal walls is fastenable longitudinally to the base wall of the channel member of one of the first pair of channel assemblies.
13. The bulkhead assembly of claim 1 further including a second pair of channel assemblies positionable between the first and second spaced form sides and substantially coplanar with the first pair of channel assemblies, each of the second pair of channel assemblies including:
- a channel member; and
- an elastomeric member positionable longitudinally in the channel member, the elastomeric member constructed and arranged so that when it is positioned longitudinally in the channel member, a portion of the elastomeric member extends outward transversely from the channel member, the portion including an outer end that extends longitudinally of the channel member;
- the second pair of channel assemblies positionable on opposite sides of a second reinforcement bar disposed between and extending longitudinally of the first and second spaced form sides, with the elastomeric member outer ends facing one another and contacting the second reinforcement bar, thereby inhibiting uncured concrete from passing between the second pair of channel assemblies when uncured concrete is poured into the concrete form.
14. The bulkhead assembly of claim 13 further comprising a bulkhead wall segment, the bulkhead wall segment positionable between the first and second spaced form sides, substantially coplanar with the first and second pairs of channel assemblies.
15. The bulkhead assembly of claim 14 wherein the bulkhead wall segment is positionable between the first and second pairs of channel assemblies, substantially coplanar with the first and second pairs of channel assemblies.
16. The bulkhead assembly of claim 15 further comprising a first angle member positionable between the bulkhead wall segment and the first pair of channel assemblies, and a second angle member positionable between the bulkhead wall segment and the second pair of channel assemblies, the first and second angle members operable to assist in supporting the bulkhead wall segment.
17. The bulkhead assembly of claim 16 wherein the first angle member is fastenable longitudinally to the base wall of the channel member of one of the first pair of channel assemblies, and the second angle member is fastenable longitudinally to the base wall of the channel member of one of the second pair of channel assemblies.
Type: Application
Filed: Apr 2, 2018
Publication Date: Dec 13, 2018
Inventors: J. Matthew Lash (Brazil, IN), Daniel A. Jones (Greensburg, IN)
Application Number: 15/942,586