U.S. patent application number 11/390545 was filed with the patent office on 2007-08-23 for apparatus for forming concrete and transferring loads between concrete slabs.
Invention is credited to Michael E. Carroll, Richard D. Jordan, Stephen F. McDonald.
Application Number | 20070196170 11/390545 |
Document ID | / |
Family ID | 38428335 |
Filed Date | 2007-08-23 |
United States Patent
Application |
20070196170 |
Kind Code |
A1 |
McDonald; Stephen F. ; et
al. |
August 23, 2007 |
Apparatus for forming concrete and transferring loads between
concrete slabs
Abstract
An embodiment configured according to principles of the
invention of an apparatus for forming concrete includes a form
having a slot configured to closely receive a plate in only one
direction. An embodiment configured according to principles of the
invention of an apparatus for transferring a load between a first
concrete slab and a second concrete slab, defining a joint,
includes a plate having a first portion and a second portion,
wherein the second portion has a first segment and a second segment
that is larger than the first segment.
Inventors: |
McDonald; Stephen F.;
(Loganville, GA) ; Carroll; Michael E.;
(Loganville, GA) ; Jordan; Richard D.;
(Lawrenceville, GA) |
Correspondence
Address: |
EMERGING STRATEGIES, PLLC
5440 31ST STREET, N.W.
WASHINGTON
DC
20015-1346
US
|
Family ID: |
38428335 |
Appl. No.: |
11/390545 |
Filed: |
March 24, 2006 |
Current U.S.
Class: |
404/37 |
Current CPC
Class: |
E01C 11/14 20130101 |
Class at
Publication: |
404/037 |
International
Class: |
E01C 5/00 20060101
E01C005/00 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 9, 2006 |
US |
PCT/US06/04487 |
Claims
1. Apparatus for forming concrete comprising a form having a slot
configured to closely receive a plate in only one direction.
2. Apparatus of claim 1, wherein said slot has a first section and
a second section that is larger than said first section.
3. Apparatus of claim 2, wherein at least one of said first section
and said second section has cooperating surfaces that correspond to
a direction in which said slot receives the plate.
4. Apparatus of claim 2, wherein said first section and said second
section define a shoulder for contacting a part of the plate and
preventing passage through said slot.
5. Apparatus of claim 2, wherein said second section defines a
radius that promotes ready removal of a plate therefrom.
6. Apparatus of claim 2, wherein said form has a surface for
receiving concrete and said second section is interposed between
said first section and said surface.
7. Apparatus of claim 1, further comprising a release layer on said
form.
8. Apparatus of claim 7, wherein said release layer is constructed
of phenolic paper, kraft paper, acrylic, latex, melamine,
Formica.RTM., foil, oil, high density overlay, metal, wood veneer
or combinations thereof.
9. Apparatus of claim 1, wherein said form is constructed of
oriented strand board, dimensional lumber, particle board, metal,
plastic, cardboard, fiber board, polyurethane foam, Styrofoam.RTM.
or combinations thereof.
10. Apparatus of claim 1, further comprising a plate configured to
be closely received in said slot.
11. Apparatus of claim 2, further comprising a plate configured to
be closely received in said slot wherein said plate has a first
portion and a second portion, wherein said second portion has a
first segment configured to be received in said first section and a
second segment configured to be received in said second
section.
12. Apparatus of claim 11, wherein said second segment defines a
radius that promotes ready removal of said plate from said
form.
13. Apparatus of claim 11, wherein said second section defines a
radius that promotes ready removal of said plate therefrom.
14. Apparatus of claim 12, wherein said second section defines a
second radius complementary of said radius.
15. Apparatus for transferring a load between a first concrete slab
and a second concrete slab, defining a joint, comprising a plate
having a first portion and a second portion, wherein said second
portion has a first segment and a second segment that is larger
than said first segment.
16. Apparatus for transferring a load between a first concrete slab
and a second concrete slab, defining a joint, comprising: a plate
having a surface; and edge banding disposed on said surface that is
compressible and/or resilient; wherein an amount that said edge
banding is compressible and/or resilient in a direction normal to
said surface differs according to location on said surface.
17. Apparatus of claim 16, wherein said edge banding has a
thickness in a direction normal to said surface that differs
according to location on said surface.
18. Apparatus of claim 16, wherein said surface is not
predominantly normal to the joint.
19. Apparatus of claim 16, wherein said edge banding is configured
to provide an amount of resilience, whereby the first concrete
slab, when cured, may move a distance relative to the plate.
20. Apparatus of claim 19, wherein said amount of resilience
results in the distance being sufficient to prevent compression
between the first concrete slab and said apparatus from achieving
an amount sufficient to cause local failure in the first concrete
slab.
21. Apparatus of claim 19, wherein said surface is not
predominantly normal to the joint and has a configuration such
that, when the first concrete slab cures, the first concrete slab
shrinks away from said apparatus by a second distance normal to
said surface, whereby the first concrete slab, when cured, may move
relative to the plate along the joint by a third distance; and said
configuration of said surface and said amount of resilience of said
edge banding are coordinated to result in a sum of the distance and
the third distance being sufficient to prevent compression between
the first concrete slab and said apparatus from achieving an amount
sufficient to cause local failure in the first concrete slab.
Description
REFERENCE TO EARLIER APPLICATION
[0001] This Application incorporates by reference and is a National
Phase of International Patent Application No. PCT/US06/004487,
filed Feb. 9, 2006.
BACKGROUND OF THE INVENTION
[0002] Conventional concrete pavement installation involves
preparing then positioning forms around an area intended for
pavement. The forms have vertical inner surfaces to receive and
contain poured concrete. The forms have horizontal top surfaces,
which typically are level with the surface of the poured concrete,
or, once cured, pavement surface. The forms have back surfaces that
rest against appropriately-spaced stakes for holding the forms in
place. To provide clearance for finish troweling, concrete workers
often field cut chamfers between the top and back surfaces of the
forms.
[0003] Very large pavements require substantial form preparation
and positioning. This is especially true if stock materials for
forms are short and/or flexible. Short and flexible forms require
more staking than longer, more rigid forms to ensure true, unwavy
pavement edges. Short forms also require more setup time for
chamferring. Regardless of whether the forms are long or short,
field chamferring requires considerable time for large pavement
areas.
[0004] Ideally, the forms used for receiving poured concrete should
have a true height for providing a true slab thickness.
Unfortunately, forms in the field typically have a height that is
less than a true height for an appropriate slab thickness. These
forms of inadequate height typically may be positioned so that the
top surfaces are at an appropriate height relative to the desired
pavement surface height, but present bottom surfaces that do not
contact, thus admit gaps through which poured concrete leaks. This
wastes concrete and requires additional work to remove the excess
portions.
[0005] Concrete leakage from the forms, especially at the butt
joints, leaves depressions in a finished slab surface causing poor
aesthetics. The depressions also impair surface coverings, such as
tile, because the uneven surface promotes uneven or incomplete
covering layout and adhesion. Cured leaked concrete also impinges
on adjacent slabs causing voids and/or increasing the chances of
obtaining a locked construction, which leads to cracks and joint
failures. Finally, removing the cured excess typically damages the
slab from which the excess is chiseled. Thus, avoiding form leaks
is highly desirable.
[0006] Unfortunately, none of the foregoing provides a method of
forming concrete and an apparatus for same that includes stiff,
infinitely long, pre-chamferred forms with predetermined true
height.
[0007] In construction of concrete pavements for highways, airport
runways, large warehouse buildings and the like, preventing random
cracking of the concrete necessitates dividing the pavement into
convenient slab sections. To this end, concrete workers pour a
monolithic concrete slab that is allowed to set for a short period.
Then, the workers cut transverse grooves, having a depth on the
order of one-fourth of the slab thickness, across the slab, with
spacing between cuts selected in accordance with the application
and design. Spacings from 12 to 40 feet are common for highway
pavements.
[0008] As the concrete of the slab cures, forces derived from the
exothermal curing reactions cause generally vertical cracks to
develop through the slab thickness at the reduced cross-sections
below each groove. This controlled cracking effectively divides the
slab into predetermined separate slab sections.
[0009] The vertical cracks or joints define adjacent and
interlocking faces formed by the cement and aggregates in the
concrete. The interlocking faces transfer vertical shear stresses
among adjacent slab sections, a phenomenon commonly referred to as
"aggregate interlock," as heavy objects, such as motor vehicles,
pass over the joint.
[0010] Aggregate interlock causes wear among slab intersections
with increasing use of the pavement. Additionally, cyclical and
extreme temperature changes decrease slab volumes. Thus, over time,
as traffic continuously passes over a joint, the intersections wear
and become smooth, then fail altogether, resulting in relative
vertical displacement of adjacent slab sections, hence a rough
pavement surface. Joint failure also becomes increasingly
susceptible to water intrusion, which may freeze and cause damage
among adjacent slabs.
[0011] To discourage relative vertical displacement among adjacent
slabs, prior art techniques provide for implanting dowels in
concrete extending across the joint intersections. Some dowels are
smooth steel rods with diameters on the order of one inch and
lengths of two feet. Each rod is coated or otherwise treated so
that it will not bond to concrete along its length or at least on
one end thereof. Thus, as a slab expands and contracts during
curing and subsequently with temperature changes, the dowel is free
to move horizontally relative to, yet maintain vertical alignment
of adjacent slabs, augmenting the aggregate interlock to transfer
vertical shear stresses across the joints. See, for example, U.S.
Pat. No. 3,397,626, issued Aug. 20, 1968, to J. B. Kornick et al.
for Plastic Coated Dowel Bar for Concrete and U.S. Pat. No.
4,449,844, issued May 22, 1984, to T. J. Larsen for Dowel for
Pavement Joints.
[0012] Among other problems, the foregoing techniques involve
significant time and labor to produce and place the dowels.
[0013] Another technique to discourage relative vertical
displacement among adjacent slabs involves embedding square-shaped
load plates in adjacent slabs with opposed corners of the load
plate aligned with the joint. To avoid shrink- or thermally-induced
stress creation between the plate and a slab, concrete workers
first embed a blockout sheath in one vertical joint face for
receiving a load plate. To this end, the workers nail onto a form a
mounting plate, from which a blockout sheath extends, then position
the form to receive poured concrete. Once the concrete is cured and
bonded to the blockout sheath, the workers remove the form board
and leave the blockout sheath in place. Then the workers insert a
load plate into the blockout sheath. Finally, the workers pour an
adjacent slab, which bonds to the exposed portion of the load
plate. See, for example, U.S. Pat. No. 6,354,760 ('760 patent),
issued Mar. 12, 2002, to Boxall et aL, for System for Transferring
Loads Between Cast-in-Place Slabs, which is incorporated by
reference herein.
[0014] Drawbacks of the foregoing include the cost and labor
associated with producing separate mounting and load plates, then
assembling same following curing of a first concrete slab.
[0015] Referring to FIG. 13, a concrete floor 1100 typically is
made up of a series of individual blocks or slabs 1102-1 through
1102-6 (collectively 1102). The same is true for sidewalks,
driveways, roads and the like. Blocks 1102 provide several
advantages, including relief of internal stress due to drying
shrinkage and thermal movement. Adjacent blocks 1102 meet at joints
1104-1 through 1104-7 (collectively 1104). Joints 1104 typically
are spaced so that each block 1102 has enough strength to overcome
internal stresses that otherwise would cause random stress relief
cracks. In practice, blocks 1102 should be allowed to move
individually, but also should be able to transfer loads from one
block to another block.
[0016] Transferring loads between blocks 1102 usually is
accomplished with smooth steel rods, also referred to as dowels,
embedded in two blocks 1102 defining joint 1104. For instance, FIG.
14 shows a side view of dowel 1200 between slabs 1102-4 and 1102-5.
FIG. 15 shows a cross-sectional view along line XV-XV in FIG. 14 of
several dowels 1200 spanning joints 1104 between slabs 1102.
Typically, a dowel or bar 1200 is approximately 14 to 24 inches
long, has either a circular or square cross-sectional shape, and a
thickness of approximately 0.5-2 inches. Such circular or square
dowels are capable of transferring loads between adjacent slabs
1102, but have several shortcomings.
[0017] U.S. Pat. Nos. 5,005,331, 5,216,862 and 5,487,249, issued to
Shaw et aL., which are incorporated by reference herein, disclose
tubular dowels receiving sheaths for use with dowel bars having
circular cross-sections.
[0018] Referring to FIG. 16, a shortcoming of circular or square
dowels is that if dowels 1200 are misaligned, or not perpendicular
to joint 1104, they can undesirably lock the joint together causing
unwanted stresses that could lead to slab failure in the form of
cracking. Such misaligned dowels can restrict movement in the
directions 1400-1 and 1400-2.
[0019] Another shortcoming of square and round dowels is that they
typically allow slabs to move only along the longitudinal axis of
the dowel. As shown in FIG. 17, movement is allowed in direction
1500, parallel to dowels 1200, while movement in other directions
1502-1 and 1502-2, and directions into and out from the page is
restrained. Such restraint of movement in directions other than
parallel to the longitudinal axes of dowels 1200 could result in
slab failure in the form of cracking.
[0020] U.S. Pat. No. 4,733,513 ('513 patent) issued to Shrader et
al.., which is incorporated by reference herein, discloses a dowel
bar having a rectangular cross-section and resilient facings
attached to the sides of the bar. As disclosed in column 5, at
lines 47-49 of the '513 patent, such bars, when used for typical
concrete paving slabs, would have a cross-section on the order of
1/2 to 2-inch square and a length on the order of 2 to 4 feet.
[0021] Referring to FIGS. 18 and 19, yet another shortcoming of
prior art dowel bars is that, under a load, only the first 3-4
inches of each dowel bar transfers the load. This creates very high
loadings per square inch at the edge of slab 1102-2, which can
result in failure 1600 of the concrete below dowel 1200, as shown
in FIGS. 18 and 19. Such a failure also could occur above dowel
1200.
[0022] Unfortunately, none of the foregoing provide a method of
forming concrete and an apparatus for same that includes partially
coated load plates carried in slotted forms.
[0023] What are needed, and not taught or suggested in the art, are
a method of forming concrete and an apparatus for same that provide
partially coated load plates carried in pre-slotted, stiff,
infinitely long, pre-chamferred forms with predetermined true
height that: (1) increase relative movement between slabs in a true
direction parallel to the longitudinal axis of the joint; (2)
reduce loadings per square inch close to the joint; (3) maximize
material at the joint for transferring loads between adjacent
cast-in-place slabs efficiently; (4) minimize raw materials needed
in a load plate; and (5) promote exact load plate positioning to
foster better perpendicular and parallel alignment with the joint
and upper concrete surface.
SUMMARY OF THE INVENTION
[0024] The invention overcomes the disadvantages noted above by
providing a method of forming concrete and an apparatus for same
that provide partially coated load plates carried in pre-slotted,
stiff, infinitely long, pre-chamferred forms with predetermined
true height. An embodiment configured according to principles of
the invention of an apparatus for forming concrete includes a form
having a slot configured to closely receive a plate in only one
direction.
[0025] An embodiment configured according to principles of the
invention of an apparatus for transferring a load between a first
concrete slab and a second concrete slab, defining a joint,
includes a plate having a first portion and a second portion,
wherein the second portion has a first segment and a second segment
that is larger than the first segment.
[0026] The invention provides improved elements and arrangements
thereof, for the purposes described, which are inexpensive,
dependable and effective in accomplishing intended purposes of the
invention.
[0027] Other features and advantages of the invention will become
apparent from the following description of the preferred
embodiments, which refers to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The invention is described in detail below with reference to
the following figures, throughout which similar reference
characters denote corresponding features consistently, wherein:
[0029] FIG. 1 is an environmental perspective view of an embodiment
of an apparatus for forming concrete configured according to
principles of the invention shown adjacent to concrete;
[0030] FIG. 2 is a top front right side elevational view of another
embodiment of an apparatus for forming concrete and transferring
loads between concrete slabs configured according to principles of
the invention;
[0031] FIG. 3 is cross-sectional detail view, drawn along line 3-3
in FIG. 2;
[0032] FIG. 4 is a plan view of a plate of the embodiment of FIG.
2;
[0033] FIG. 5 is a schematic view of an embodiment of a method of
making an apparatus configured according to principles of the
invention;
[0034] FIG. 6 is a schematic view of an embodiment of a method of
forming concrete configured according to principles of the
invention;
[0035] FIG. 7 is a plan view of an embodiment of an apparatus for
forming concrete and transferring loads between concrete slabs
configured according to principles of the invention, shown
partially in cross-section;
[0036] FIG. 8 is a plan view of another embodiment of an apparatus
for transferring loads between concrete slabs configured according
to principles of the invention;
[0037] FIG. 9 is a plan view of a portion of the embodiment of FIG.
8 received in a concrete slab, a dashed-line outline of a
diamond-shaped plate being superimposed thereon;
[0038] FIGS. 10 and 11 are perspective views of the embodiment of
FIG. 1 receiving the embodiment of FIG. 8;
[0039] FIG. 12 is a top view of the embodiment of FIG. 1 receiving
the embodiment of FIG. 8, shown partially in cross section;
[0040] FIG. 13 is a plan view of a plurality of concrete slabs
defining a pavement;
[0041] FIG. 14 is a vertical cross-sectional detail view of
adjacent concrete slabs and an interposed prior art dowel;
[0042] FIG. 15 is cross-sectional detail view drawn along line
XV-XV in FIG. 14;
[0043] FIG. 16 is an enlarged horizontal cross-sectional detail
view of a plurality of concrete slabs with interposed prior art
dowels that are misaligned;
[0044] FIG. 17 is an enlarged horizontal cross-sectional detail
view of a plurality of concrete slabs with interposed prior art
dowels;
[0045] FIG. 18 is a vertical cross-sectional detail view of
adjacent concrete slabs and an interposed prior art dowel wherein
one slab exhibits a failure;
[0046] FIG. 19 is a cross-sectional detail view drawn along line
XVIV-XVIV in FIG. 18;
[0047] FIG. 20 is a plan view of a further embodiment of an
apparatus configured according to principles of the invention;
[0048] FIG. 21 is a cross-sectional detail view drawn along line
XXI-XXI in FIG. 20;
[0049] FIG. 22 is an environmental perspective view, shown
partially in cross-section, of yet another embodiment of an
apparatus for transferring loads between concrete slabs configured
according to principles of the invention and a concrete slab
prepared for receiving same;
[0050] FIG. 23 is a cross-sectional detail view of yet a further
embodiment of an apparatus for transferring loads between concrete
slabs configured according to principles of the invention received
in a concrete slab;
[0051] FIG. 24 is a schematic view of an embodiment of a method of
forming concrete configured according to principles of the
invention;
[0052] FIG. 25 is a schematic view of an embodiment of a method of
installing a load transfer apparatus configured according to
principles of the invention.
[0053] FIG. 26 is a top front right side elevational view of
another embodiment of an apparatus for forming concrete and
transferring loads between concrete slabs configured according to
principles of the invention;
[0054] FIG. 27 is a top front right side elevational view of
another embodiment of an apparatus for forming concrete and
transferring loads between concrete slabs configured according to
principles of the invention;
[0055] FIG. 28 is a schematic view of an embodiment of a method of
forming concrete configured according to principles of the
invention;
[0056] FIG. 29 is a schematic view of an embodiment of a method of
forming concrete configured according to principles of the
invention;
[0057] FIG. 30 is a top front right side elevational view of
another embodiment of an apparatus for forming concrete and
transferring loads between concrete slabs configured according to
principles of the invention;
[0058] FIG. 31 is an enlarged side elevational view of a form of
the embodiment of FIG. 30;
[0059] FIG. 32 is a top front right side elevational view of
another embodiment of an apparatus for forming concrete and
transferring loads between concrete slabs configured according to
principles of the invention;
[0060] FIGS. 33 and 34 are plan views, partially in cross-section,
of another embodiment of an apparatus for forming concrete and
transferring loads between concrete slabs configured according to
principles of the invention, respectively before and after proper
assembly;
[0061] FIG. 35 is a plan view of the embodiment of FIGS. 33 and 34
improperly assembled; and
[0062] FIGS. 36-67 are successive plan and side elevational views
of additional embodiments an apparatus for transferring loads
between concrete slabs configured according to principles of the
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0063] The invention includes an apparatus for and method of
forming concrete and transferring loads between concrete slabs that
provide partially coated load plates carried in pre-slotted, stiff,
infinitely long, pre-chamferred forms with predetermined true
height.
[0064] Referring to FIG. 1, an embodiment of an apparatus for
forming concrete configured according to principles of the
invention includes a form 100. Form 100 has a side surface 105, a
top surface 110, a back surface 115 and a bottom surface 120. Side
surface 105 and back surface 115 define a width 125 ranging from
0.875 to 2.500 inches. Top surface 110 and bottom surface 120
define a height 130 ranging from 3 to 18 inches or more, depending
on the thickness required for pavement.
[0065] Form 100 has a chamfer 135 between top surface 110 and back
surface 115. Chamfer 135 defines an angle 140 relative to top
surface 110 ranging from 10.degree. to 89.degree., preferably
22.5.degree. to 45.degree.. Side surface 105 and chamfer 135 define
a top surface width 143 ranging from 0.125 to 0.875 inch. Chamfer
135 provides clearance for trowels and other finishing tools and
allows for faster concrete finishing.
[0066] Width 125, height 130, angle 140 and top surface width 143
vary as needed to provide a desired overall stiffness of form 100.
Form stiffness dictates the amount of staking required to maintain
form 100 in place against the great weight of poured concrete 155.
Stiffer forms 100 require less staking, thus less labor to place
forms 100 where needed.
[0067] More importantly, form stiffness impacts the trueness of an
edge 145 defined by side surface 105 and top surface 110, which
forms a corresponding edge in concrete 155 when cured. Good
trueness is important to the overall appearance of a pavement
defined by multiple slabs having adjacent edges. For example, if an
edge of one slab has poor trueness and is adjacent to another slab
edge that has poor trueness, the gap defined between the un-true
edges will exhibit unsightly non-uniformity, or portions of the gap
that may be too narrow followed by portions that may be too wide.
This gap non-uniformity contributes to an overall non-professional
image of the area and associated business.
[0068] Preferably, form 100 is constructed of oriented strand board
(OSB). OSB stock may be manufactured to assume virtually any
dimension, which may be machined, as described below, to define
forms 100 of virtually any length. As the invention is intended for
constructing large-scale pavements, forms 100 with very large
lengths are desirable because fewer abutting forms 100 are needed
to define a continuous side surface 105 and edge 145, hence slab
side. This reduces the labor needed to limit and/or treat
discontinuities that may occur in the slab side. OSB stock also is
preferred because it may be machined to define a desired height
130. This eliminates the occurrence of concrete leaks between the
bottom surface of prior art forms of inadequate height and the
supporting surface underlying the concrete.
[0069] Form 100 also may be constructed of dimensional lumber,
particle board, metal, plastic, cardboard, fiber board,
polyurethane foam, Styrofoam.RTM., or other rigid synthetic or
other suitable materials commensurate with the purposes described
herein.
[0070] A release overlay 160 is disposed on side surface 105.
Release overlay 160 is constructed of phenolic paper, kraft paper,
acrylic, latex, melamine, Formica.RTM., foil, oil, high density
overlay, metal, wood veneer or other suitable material that
provides a smooth, closed-celled surface, substantially free of
pores for retaining poured concrete without adhering to or marring
the finished surface thereof when cured and separated from form
100. The foregoing materials may be combined to define release
overlay 160, such as a wood veneer that normally would be
oiled.
[0071] Referring to FIG. 2, another embodiment of an apparatus for
forming concrete configured according to principles of the
invention includes a form 200 and one or more load transfer
apparatuses or plates 300 for transferring loads that are received
in form 200. Form 200 is constructed similarly to form 100 and has
slots 260 for receiving plates 300. Slots 260 have a spacing 261 of
about two feet, or other dimension suitable for purposes described
herein.
[0072] Referring to FIG. 3, each slot 260, preferably, is formed by
plunge cutting with a rotary saw blade (not shown). Slot 260 is
defined by annular surfaces 263, each having curvatures
corresponding to the radius of the plunge-cutting saw blade.
Annular surfaces 263 and side surface 205 (comparable to side
surface 105 of form 100) define opposed proximal intersections 265.
Annular surfaces 263 and back surface 215 (comparable to back
surface 115 of form 100) define opposed distal intersections
270.
[0073] Referring to FIG. 4, each plate 300, preferably, is
constructed of steel or any material, metallic or non-metallic,
that is suitable for a load transfer device between adjacent
concrete slabs in a pavement. To economize production costs, plate
300 may be shear-cut. Plate 300 has a preferred thickness ranging
from 0.1875 through 0.375 inches and side dimensions 303 of
approximately 4.5 inches, or other dimension suitable for purposes
described herein. Preferably, plate 300 has a length 305 that is
greater than or equal to a width 310. Thus, plate 300, in plan
view, assumes the shape of a rhombus or square.
[0074] Plate 300 has a first portion 315 and a second portion 320,
delineated by a plane 321, defined by the intersections of sides
322 and 323, that is aligned with side surface 205. First portion
315 may be untreated. Second portion 320 has an elastomer coating
325 configured to adhere to plate 300 only enough to prevent
elastomer coating 325 from separating from plate, for example
during shipping, but when emplaced, may adhere to concrete, but not
to plate 300. Elastomer coating 325 is constructed of polymers,
grease or other materials suitable for the purposes described
herein.
[0075] In practice, when a first concrete slab adheres to elastomer
coating 325 on second portion 320 and a second concrete slab
adheres to first portion 315, lateral movement among the slabs, due
to shrinkage, etc., will not cause localized stresses because the
first and second slabs are not fixed to plate 300, rather, one slab
is permitted to move relative to plate 300 because it is adhered to
elastomer coating 325. While elastomer coating 325 originally
adheres to plate 300 when plate 300 is manufactured, curing
concrete exerts forces on elastomer coating 325 which urges
elastomer coating 325 to slide relative to plate 300 once
installed.
[0076] Alternative embodiments of elastomer coating 325: (1) adhere
to plate 300, but not to concrete, thereby allowing concrete to
slide relative to the coating; or (2) do not adhere to plate 300 or
concrete, thereby allowing concrete to slide relative to plate 300
and/or the coating.
[0077] Referring again to FIG. 2, first portion 315 is received in
slot 260. Preferably, slot 260 has a tolerance of 0.03125 inch
among horizontal surfaces of slot 260 and first portion 315. This
close tolerancing promotes closely receiving first portion 315 in
slot 260. This provides for maintaining plate 300 at a desired
attitude. Elastomer coating 325 is likely to have a thickness
exceeding this tolerance that would prevent slot 260 from receiving
second portion 320.
[0078] Referring to FIGS. 3 and 4, plate 300 is configured such
that intersections of sides 322 and 323 at the widest extremes of
plate 300 mate with proximal intersections 265 of form 200. This
configuration promotes a gap-free junction between plate 300 and
form 200 that discourages concrete from seeping therethrough. This
ensures that concrete only contacts elastomer coating 325 and not
plate 300.
[0079] Plate 300 also is configured, and the radius of a saw (not
shown) used for plunge cutting slot 260 is selected, such that
distal intersections 270 in form 200 firmly cradle first portion
315. This configuration prevents plate 300 from undesired rotation
or movement relative to form 200 despite significant forces exerted
on plate 300 by concrete when poured on form 200 and plate 300.
[0080] Referring to FIG. 7, another embodiment of an apparatus for
transferring loads between concrete slabs configured according to
principles of the invention is a plate 700 that has a first portion
715 and a second portion 720 delineated by a plane 721. First
portion 715 may be untreated. Second portion 720 has an elastomer
coating 725 that is similar to elastomer coating 325.
[0081] In practice, first portion 715 is received in a slot 860 in
a form 800 in a direction aligned with a side 730 extending along
first portion 715 and second portion 720. Coating 725, having a
preferred thickness of about 0.03 inches, or a thickness sufficient
to prevent second portion 720 from passing through slot 860.
Coating 725 may be compressible to allow a cured slab (not shown)
adhered thereto to move somewhat relative to second portion 720
along a joint between adjacent slabs (not shown).
[0082] Referring to FIG. 8, another embodiment of an apparatus for
transferring loads between concrete slabs configured according to
principles of the invention is a plate 900 that has a hexagonal
shape. Plate 900 has elongated bases 930, each with adjacent sides
935. Preferably, each base 930 and side 935 define an angle 940 of
about 100.degree.. Angle 940 may exceed 100.degree. in any amount
that maximizes the material and/or stress dissipation nearest the
joint between concrete slabs.
[0083] As with the embodiments described above, plate 900 has a
first portion 915 and a second portion 920 delineated by a plane
921. First portion 915 may be untreated. Second portion 920 has an
elastomer coating 925 that is similar to elastomer coating 325.
[0084] In practice, when a first concrete slab adheres to elastomer
coating 925 on second portion 920 and a second concrete slab
adheres to first portion 915, lateral movement among the slabs will
not cause localized stresses because the first and second slabs are
not fixed to plate 900, rather, one slab is permitted to move
relative to plate 900 because it is adhered to elastomer coating
925.
[0085] Referring to FIG. 9, plate 900 is shown received in the
vertical face of a concrete slab. The hexagonal geometry of plate
900, as compared with a diamond-shaped plate D, as shown in dashed
lines in FIG. 9, provides more support material 945 at a joint
between concrete slabs. This is due to the preferred 1000 angle
between base 930 and side 935, which provides nearly 18% additional
support material over that provided by a diamond-shaped plate
D.
[0086] Hexagonally-shaped plate 900 allows for faster and more
efficient stress dissipation at the joint. This is because a
hexagonal plate presents more perimeter in areas of high stress
concentration in a cement slab. This allows for reducing the
material thickness needed in a load plate, which saves material
costs and machine wear. For example, a plate 900 interposed between
four-inch slabs having a compressive strength of 3000
pounds-per-square-inch need only have a 3/16-inch thickness,
whereas a diamond-shaped plate must have at least a 1/4-inch
thickness. Reduced plate thickness also promotes plate yield before
concrete failure. An advantage of this is that, under great
loading, plate 900 yields, rather than causing failure in the
adjacent concrete slabs plate 900 ties together. Thus, the vertical
relationship of slabs still is contained, without catastrophic
concrete failures that would require slab replacement.
[0087] Another advantage of hexagonally-shaped plate 900 relative
to a diamond-shaped plate is that concrete tends to consolidate
better under plate 900 because plate 900 presents less area under
which concrete flows. This reduces the potential for pockets and
voids forming under plate 900, which could lead to joint failure or
ineffective load transfer.
[0088] A further advantage of plate 900 is that plate 900 presents
surfaces that are more stable, or less likely to move, during
pouring of concrete. This assures that the load plate will assume
proper placement and orientation relative to the joint, thus is
more likely to perform as intended.
[0089] Referring to FIGS. 10 and 11, as with plate 300, plate 900
is intended to be received in slot 260 in form 200.
[0090] Referring to FIG. 12, plate 900 is configured such that
intersections of sides 935 define a widest extreme of plate 900
that mate with proximal intersections 265 of form 200. This
configuration promotes a gap-free junction between plate 900 and
form 200 that discourages concrete from seeping therethrough. This
ensures that concrete only contacts elastomer coating 925 and not
plate 900.
[0091] Plate 900 also is configured, and the radius of a saw (not
shown) used for plunge cutting slot 260 is selected, such that
distal intersections 270 in form 200 firmly cradle first portion
915. This configuration prevents plate 900 from undesired rotation
or movement relative to form 200 despite significant forces exerted
on plate 900 by concrete when poured on form 200 and plate 900. The
hexagonal shape of plate 900 renders plate 900 more stable in, and
less prone to moving relative to form 200 than diamond-shaped
plates during pouring.
[0092] Referring to FIGS. 20 and 21, a further embodiment of an
apparatus for transferring loads between concrete slabs is a plate
1000 having edge banding 1005. While plate 1000 may assume any
geometry appropriate for an installation, preferably plate 1000 is
constructed similarly to plate 900, having a first portion 1015 and
a second portion 1020 delineated by a plane 1021. First portion
1015 may be untreated.
[0093] Edge banding 1005 preferably is disposed on vertical surface
1007 and/or vertical surface 1009 of second portion 1020 of plate
1000. Preferably, surfaces 1007 and 1009 are not parallel with
plane 1021, hence the joint between concrete slabs when emplaced.
While not excluded from the scope of the invention, in practice,
edge banding 1005 has not been found to be needed along surfaces
parallel to the joint. Abutting concrete slabs will compress each
other in a direction perpendicular to the joint, but, absent joint
failure, will not compress plate 1000 excessively or to the point
of joint failure. Thus, little benefit may be realized from
employing a plate that is compressive in a direction perpendicular
to the joint.
[0094] However, abutting concrete slabs do move relatively along
the joint. This imparts great shear forces on interslab load
plates. To reduce these shear forces and provide greater horizontal
relative slab mobility, edge banding 1005 is compressive and
resilient. Edge banding 1005 may be constructed of any material to
obtain these characteristics, but preferably is constructed of a
natural polymer and/or synthetic polymer.
[0095] Edge banding 1005 is configured so as to reduce interslab
shear forces, provide great horizontal relative slab mobility or
other desired functionality in consideration of slab sizing,
concrete composition, shrinkage expectations and other emplacement
considerations. In practice, edge banding 1005 with a thickness
1030 ranging from 0.025 to 0.25 inches has been found to perform
optimally.
[0096] Preferably, second portion 1020 has an elastomer coating
1025 that is similar to elastomer coating 325. Elastomer coating
1025 also coats edge banding 1005. Similar to elastomer coating
325, while edge banding 1005 originally adheres to plate 1000 when
plate 1000 is manufactured, curing concrete exerts forces on
elastomer coating 1025 and edge banding 1005 that urges sliding
among one or more of elastomer coating 1025, edge banding 1005 and
plate 1000 once installed.
[0097] Plate 1000 is well suited for very large concrete slab
installations in which the slabs require great degrees of
horizontal freedom. Without this added mobility, the slabs can
"lock up" and develop one or more cracks parallel to the joint
anywhere from a foot therefrom to the center of the slab.
[0098] As with plate 300, plate 1000 is intended to be received in
slot 260 in form 200.
[0099] Yet another embodiment of an apparatus for transferring
loads between concrete slabs configured according to principles of
the invention is a plate 1000 that includes independent edge
banding (not shown) disposed on surfaces 1011 and/or 1013 of first
portion 1015. Once installed in cured concrete, edge banding (not
shown) may slide relative to plate 1000 and/or the cured concrete
as needed.
[0100] Referring to FIGS. 22 and 23, yet a further embodiment of an
apparatus for transferring loads between concrete slabs configured
according to principles of the invention is a dowel 1100 that has
edge banding 1105 with or without an elastomer coating 1115, as
described above. Dowel 1100 may be constructed from 5/16-2-inch
square or round stock 1110 in 12-inch lengths.
[0101] While dowel 1100 is configured in accordance with industry
norms for retrofitting an existing concrete slab to receive a load
plate, the invention is not limited to square or round stock. The
invention also includes plunge-cutting or otherwise slotting an
existing concrete slab for receiving epoxy and any of the plates
described herein, with or without edge banding or an elastomer
coating.
[0102] Referring to FIG. 5, an embodiment of a method 400 of making
an apparatus for forming concrete configured according to
principles of the invention includes: a step 405 of providing a
sheet; a step 410 of disposing a release overlay on the sheet; a
step 415 of cutting the sheet into a plurality of forms; and a step
420 of cutting a chamfer in each of the plurality of forms.
[0103] Step 405 of providing a sheet of material includes material
suitable for performing as a concrete form, preferably OSB stock
material. However, the material may be dimensioned lumber, particle
board, steel and other suitable materials if commensurate with the
purposes described herein. OSB material is preferred because it can
assume virtually any width, length or thickness that may be
machined into forms of appropriate, true dimensions for defining
the desired pavement. The length of the material, ideally, should
be as long as the longest side of the pavement desired. However,
manufacturing material that is, e.g. two miles long, is problematic
for contemporary manufacturers.
[0104] Step 410 of disposing a release overlay on the sheet
includes an overlay that is suitable for retaining poured concrete
without adhering thereto or marring the finished surface thereof
when the concrete cures and is separated from the form.
[0105] Step 415 of cutting the sheet into a plurality of forms ties
into step 405 in that the material to be cut should be selected to
maximize the number of forms machined and minimize any scrap not
suitable to be a form. The number of forms derived from the sheet
depends on the thickness of pavement desired, which dictates the
height of the forms needed. Ideally, the width of the sheet of
material provided in step 405 should be an even multiple of the
form height, plus some allowance for cutting.
[0106] Step 420 of cutting a chamfer in each of the plurality of
forms involves machining each form derived from step 415 with a
chamfer machine that cuts chamfers in board stock. The chamfer may
assume any angle suitable for purposes described herein, but
preferably ranges from 22.degree. to 45.degree.. Step 420 provides
tremendous labor savings over prior art techniques and materials.
Ordinarily, concrete workers field cut chamfers into concrete forms
on site, which consumes considerable time. Providing workers with
pre-chamfered forms eliminates this on-site step and allows for
faster completion of the paving job at hand.
[0107] Referring to FIG. 6, an embodiment of a method 500 of
forming concrete configured according to principles of the
invention includes: a step 505 of providing a plate with a plate
coating disposed on a first portion thereof; a step 510 of
providing a form having a slot configured to receive a second
portion of the plate; a step 515 of inserting the second portion in
the slot; a step 520 of positioning the form to receive concrete; a
step 525 of pouring a volume of concrete against the form and the
first portion; a step 530 of curing the volume of concrete and
defining cured concrete; and a step 535 of removing the form from
the cured concrete, wherein the plate remains in the cured
concrete.
[0108] Step 505 of providing a plate with a plate coating disposed
on a first portion thereof involves preparing a plate 300 as
described above. An elastomer coating, configured to adhere to
concrete, but not to the plate, is disposed on the first portion of
a plate.
[0109] Step 510 of providing a form having a slot configured to
receive a second portion of the plate involves plunge cutting the
side surface of a form with a rotary blade having a pre-determined
radius selected according to the configuration of the plate
received in the slot, as described above.
[0110] Step 515 of inserting the second portion in the slot
represents a significant cost savings over prior load plate
installation apparatuses and methods. Rather than attaching to a
form a mounting plate and blockout sheath, then, after the slab has
cured, removing the form while breaking free the blockout sheath
followed by inserting a load plate in the blockout sheath, the
present method embeds a load plate directly into the concrete slab
as it cures. Once the concrete cures, the forms are removed with
the load plate already embedded in the concrete and no further
installation required.
[0111] Step 520 of positioning the form for receiving concrete also
represents an advance over many typical concrete pouring techniques
in use. Because the forms are precisely cut prior to being staked
around the desired pavement area, they present a true height from
support surface to pavement surface. This deters concrete from
leaking through any gap that often exists between the support
surface and the bottom surface of inadequately sized prior art
forms.
[0112] Step 525 of pouring a volume of concrete against the form
and the first portion and step 530 of curing the volume of concrete
and defining cured concrete are conventional, thus described no
further.
[0113] Step 535 of removing the form from the cured concrete
wherein the plate remains in the cured concrete, as described
above, represents a significant departure from current practices.
Once the concrete cures, the forms are removed with the load plate
already embedded in the concrete. Other methods require detaching a
form from a mounting plate previously attached thereto, then
installing a load plate in the pocket formed in the concrete.
[0114] Referring to FIGS. 22-24, an embodiment of another method
1200 of forming concrete configured according to principles of the
invention includes: a step 1205 of providing a plate having a first
portion and a second portion and edge banding disposed on a surface
of the first portion; a step 1210 of providing a form having a slot
configured to closely receive the second portion; a step 1215 of
inserting the second portion in the slot; a step 1220 of
positioning the form to receive concrete; a step 1225 of pouring a
volume of concrete on the form and the first portion; a step 1230
of curing the volume of concrete and defining cured concrete; and a
step 1235 of removing the form from the cured concrete.
[0115] Step 1205 of providing a plate having a first portion and a
second portion and edge banding disposed on a surface of the first
portion involves preparing a plate 1000 as described above. As
shown in FIGS. 20 and 21, edge banding 1005, with or without
elastomer coating 1025, is disposed on vertical surface 1007 and/or
vertical surface 1009 of plate 1000.
[0116] Steps 1210, 1215, 1220, 1225, 1230 and 1235 are similarto
steps 510, 515, 520, 525, 530 and 535 above.
[0117] Referring to FIG. 25, an embodiment of a method 1300 of
installing a load transfer apparatus configured according to
principles of the invention includes: a step 1305 of developing a
recess in a concrete slab; and a step 1310 of introducing a first
portion of a load transfer apparatus in the recess.
[0118] Step 1305 of developing a recess typically involves
developing a recess in an existing concrete slab adjacent to which
a second concrete slab is intended. As shown in FIGS. 22 and 23,
dowel 1100 represents an industry standard for retro-fitting an
existing concrete slab to receive a load plate. Thus, to
accommodate a square or round dowel 1100, step 1305 would involve
boring or reaming a hole in the concrete slab. However, method 1300
is not limited to dowel 1100, and may include any plates or dowels
described herein or not described, but appropriate for use in
retro-fitting an existing concrete slab to receive a load plate for
maintaining vertical alignment relative to a concrete slab to be
poured an adjacent thereto. Therefore, step 1305 may involve
plunge-cutting or otherwise developing a slot in the concrete for
receiving a plate.
[0119] Preferably, following step 1305, method 1300 includes
filling the recess sufficiently with an epoxy or suitable material
for bonding the dowel or plate to the concrete.
[0120] Step 1310 of introducing a first portion of a load transfer
apparatus in the recess preferably involves a dowel or plate that
has edge banding and/or an elastomer coating as described above.
The concrete worker would have to take care that the epoxy adheres
only to the edge banding and/or an elastomer coating and not to the
untreated portion of the dowel or plate. Once the epoxy cures, and
a second concrete slab may be poured so as to encapsulate the
untreated portion of the dowel or plate. The edge banding and/or
elastomer coating permits the slabs to move horizontally along and
perpendicularly to the joint therebetween.
[0121] An embodiment of a method 1400 of adapting existing and
freshly-poured concrete slabs for transferring a load therebetween
configured according to principles of the invention includes: a
step 1405 of installing a load transfer apparatus in an existing
concrete slab according to method 1300; and a step 1410 of pouring
a second volume of concrete on a second portion of the load
transfer apparatus.
[0122] Step 1405 of installing a load transfer apparatus in the
existing concrete slab is described above with respect to method
1300.
[0123] Step 1410 of pouring a second volume of concrete adjacent to
the cured concrete and on a second portion of the load transfer
apparatus involves encapsulating only the untreated end of dowel or
plate.
[0124] Referring to FIGS. 26 and 27, another embodiment of an
apparatus for forming concrete and transferring loads between
concrete slabs configured according to principles of the invention
includes a form 1500, one or more load transfer apparatuses or
plates 1600 for transferring loads between concrete slabs closely
received in form 1500, and a like number of sheaths 1700 closely
received on each plate 1600.
[0125] Preferably, form 1500 is constructed similarly to form 200
with slots 1560 comparable to slots 260 for receiving plate
1600.
[0126] Plate 1600 is constructed similarly to plate 300. However,
rather than having an elastomer coating 325, sheath 1700 is
selectably installable on plate 1600. Sheath 1700 may be
constructed similarly to the blockout sheath described in the '760
patent.
[0127] Alternatively, sheath 1700 may be constructed of material
and/or configured to allow: (1) concrete to slide relative thereto;
and/or (2) plate 1600 to slide relative thereto. Sheath 1700 should
have sufficient integrity to permit a concrete worker to handle and
install sheath 1700 on plate 1600 or form 1500, withstand pouring
concrete thereon, and perform the functions described above.
[0128] Sheath 1700 may include a mounting plate 1705, as shown in
FIG. 26, and as described more fully with respect to the blockout
sheath and mounting plate described in the '760 patent.
[0129] Referring to FIG. 28, an embodiment of another method 1800
of forming concrete configured according to principles of the
invention includes: a step 1805 of providing a plate configured to
transfer a load between concrete slabs; a step 1810 of providing a
form having a slot configured to closely receive a first portion of
the plate; a step 1815 of positioning the form to receive concrete;
a step 1820 of inserting the first portion in the slot wherein a
second portion of the plate is exposed; a step 1825 of pouring a
first volume of concrete on the form and the second portion; a step
1830 of curing the first volume of concrete and defining a first
slab; a step 1835 of removing the form from the first slab and
exposing the first portion; and a step 1840 of disposing a sheath
on the first portion.
[0130] Step 1805 of providing a plate configured to transfer a load
between concrete slabs involves preparing a plate 1600 as described
above. Plate 1600 may, but preferably does not, include an
elastomer coating and/or edge-banding as described above.
[0131] Step 1810 of providing a form having a slot configured to
closely receive a first portion of the plate, preferably, involves
plunge cutting the side surface of a form with a rotary blade
having a pre-determined radius selected according to the
configuration of the plate received in the slot, as described
above.
[0132] Step 1815 of positioning the form to receive concrete is
comparable to step 520 above.
[0133] Step 1820 of inserting the first portion in the slot wherein
a second portion of the plate is exposed is comparable to step 515
above in that it represents a significant cost savings over prior
load plate installation apparatuses and methods. While this
embodiment employs a blockout sheath, neither time nor accuracy are
sacrificed positioning then attaching the blockout sheath as in
prior applications. Rather, the blockout sheath is installed on a
plate that already is properly positioned in a cured concrete
slab.
[0134] Steps 1825 and 1830 are conventional and described no
further.
[0135] Step 1835 of removing the form from the first slab and
exposing the first portion is comparable to step 535 above.
[0136] Step 1840 of disposing a sheath on the first portion,
preferably, involves placing on the plate a blockout sheath as
described in the '760 patent. However, a sheath may assume any form
appropriate for the function desired, specifically, to allow the
concrete slab to move relative to, or prevent bonding with the
plate. To this end, the sheath simply may be a coating of grease or
other debonding agent known in the art. The sheath also could be
constructed of an elastomer coating, somewhat as described above,
but configured with sufficient integrity so as to allow for
installation on a plate without disintegration.
[0137] Referring to FIG. 29, an embodiment of another method 1900
of forming concrete configured according to principles of the
invention includes: a step 1905 of providing a plate configured to
transfer a load between concrete slabs; a step 1910 of providing a
form having a slot configured to closely receive a first portion of
the plate; a step 1915 of positioning the form to receive concrete;
a step 1920 of inserting the first portion in the slot wherein a
second portion of the plate is exposed; a step 1925 of disposing a
sheath on the second portion; step 1930 pouring a first volume of
concrete on the form and the sheath; and a step 1935 of curing the
first volume of concrete and defining a first slab.
[0138] Steps 1905, 1910, 1915 and 1920 are comparable to steps 1805
1810, 1815 and 1820 above.
[0139] Step 1925 of disposing a sheath on the second portion is
comparable to step 1840 above with the only difference being that,
in step 1840, the plate is in cured concrete, while in step 1925,
the plate is in a form.
[0140] Step 1930 pouring a first volume of concrete on the form and
the sheath is comparable to step 1825 above with the only
difference being that, in step 1825, concrete directly contacts the
plate, while in step 1930, the concrete directly contacts the
sheath.
[0141] Step 1935 is conventional and described no further.
[0142] Referring to FIGS. 30 and 31, another embodiment of an
apparatus for forming concrete and transferring loads between
concrete slabs configured according to principles of the invention
includes a form 2000 and one or more sheaths 2100, with or without
mounting plates 2105 as shown in FIG. 30, for mounting on form
2000, preferably at predetermined intervals. A like number of load
transfer apparatuses or plates (not shown) for transferring loads
between concrete slabs are configured to be closely received in
each sheath 2100 once disposed in cured concrete and form 2000 is
separated therefrom.
[0143] Sheath 2100 is similar to sheath 1700 and optional mounting
plate 2105 is similar to optional mounting plate 1705. Where sheath
2100 does not include mounting plate 2105, sheath 2100 defines a
proximal outer perimeter 2110. Where sheath 2100 includes mounting
plate 2105, mounting plate 2105 defines a proximal outer perimeter
2115.
[0144] Unlike form 200, form 2000 does not have slots comparable to
slots 260 for receiving plate 1600. Rather, form 2000 has slots
2060 configured to mate with or closely receive a portion of outer
perimeter 2110 when sheath 2100 is configured without optional
mounting plate 2105. When sheath 2100 is configured with optional
mounting plate 2105, slot 2060 is configured to mate with or
closely receive outer perimeter 2115 of mounting plate 2105.
[0145] Slots 2060 are spaced according to load conditions
anticipated for the load plates (not shown) ultimately installed in
adjacent concrete slabs. With either embodiment, form 2000 mates
with sheath 2100 (or mounting plate 2105) such that only the outer
surface thereof contacts concrete when poured thereon. Once the
concrete here's, and form 2000 is removed, sheath 2100 remains
embedded in the cured concrete with the interior exposed for
receiving a plate (not shown). Thereafter, another volume of
concrete may be poured adjacent to the previously cared slab
containing sheath 2100 and on the plate, thereby providing for load
transfer between the adjacent slabs.
[0146] The plate (not shown) intended for use with this embodiment
is configured similarly to plate 1600 and described no further.
[0147] Referring to FIG. 32, another embodiment of an apparatus for
forming concrete and transferring loads between concrete slabs
configured according to principles of the invention includes a form
2200 and one or more sheaths 2300 for mounting on form 2200,
preferably at predetermined intervals. A like number of load
transfer apparatuses or plates (not shown) for transferring loads
between concrete slabs are configured to be closely received in
each sheath 2300.
[0148] Form 2200 differs from previously described embodiments in
that form 2200 does not provide a slot for receiving a load plate.
Rather, as described below, form 2200 provides for mounting sheath
2300 thereon. Preferably, form 2200 has sets of pre-drilled holes
2205 for receiving fasteners for fixing sheaths 2300 on form 2200,
spaced according to where sheaths 2300 are desired. As with slots
2060, spacing of the sets of holes 2205 corresponds to loading
conditions anticipated for the load plates (not shown) ultimately
installed in adjacent concrete slabs.
[0149] Sheath 2300 has a mounting plate 2305 that provides for
fixing sheath to form 2200 so that the interior 2320, which is
configured to receive a load plate (not shown), is disposed toward
form 2200, preventing poured concrete from entering. To this end,
mounting plate 2305, preferably, has througbores 2310 that receive
threaded fasteners 2315 for engaging holes 2205. Mounting plate
2305 also may be configured to provide integral protrusions or pins
(not shown) for engaging holes 2205.
[0150] While form 2200 is described as having the "female"
components and sheath is described as having the "male" components
of whatever fixing convention is employed, such may be reversed.
Other mounting conventions may be used that are appropriate and
render fixation easy and inexpensive.
[0151] Referring to FIG. 33, an embodiment of another method 2400
of forming concrete configured according to principles of the
invention includes: a step 2405 providing a form configured to
secure a portion of the sheath thereto, thereby orienting an
exterior of the sheath for contacting concrete when poured thereon;
a step 2410 of positioning the form to receive concrete; a step
2415 of securing the sheath to the form; a step 2420 of pouring a
first volume of concrete on the form and the exterior; and a step
2425 of curing the first volume of concrete and defining a first
slab.
[0152] Referring also to FIG. 30, step 2405 of providing a form
2000 configured to secure a portion of the sheath thereto may
involve providing the form with slots 2060 for closely receiving
the outer perimeter at the opening or mouth of the sheath, or a
mounting plate defining same, such that the open end of sheath
interior 2120, which is configured to receive a load plate (not
shown), is disposed toward form 2000, preventing poured concrete
from entering. Thus, the poured concrete would contact and cure or
adhere to only the exterior of sheath 2100, leaving interior 2120
free of any concrete that could interfere with desired mobility of
a plate in sheath 2100.
[0153] Referring to FIG. 32, step 2405 of providing a form 2200
configured to secure a portion of the sheath thereto alternatively
may involve providing the form with pre-drilled holes for receiving
fasteners for fixing sheath thereto. Other affixation conventions
may be employed as appropriate, easy to use and economically
sensible.
[0154] Step 2410 of positioning the form to receive concrete is
conventional.
[0155] Referring again to FIG. 30, step 2415 of securing the
portion to the form, where form 2000 has slots 2060 for receiving
sheath 2100, involves inserting sheath 2100 in slot 2060. Where
sheath 2100 has a mounting plate 2105, step 2415 would involve
inserting mounting plate 2115 in slot 2060.
[0156] Steps 2420 and 2425 are conventional and described no
further.
[0157] Referring to FIGS. 33 and 34, another embodiment of an
apparatus for forming concrete configured according to principles
of the invention includes a form 2500. Like form 100, form 2500 has
a side surface 2505, a top surface (not shown), a back surface 2515
and a bottom surface (not shown). Form 2500 has a chamfer (not
shown) that is comparable to chamfer 135 between top surface (not
shown) and back surface 2515. Side surface 2505 and chamfer (not
shown) define a top surface width (not shown)that is comparable to
top surface width 143. Preferably, a release overlay 2560
comparable to release overlay 160 is disposed on side surface
2505.
[0158] Form 2500 has a slot 2510 that closely receives a plate,
such as plate 2600. Slot 2510 is constructed so as to encourage
proper assembly of form 2500 and plate 2600, as shown in FIG. 34.
Proper assembly promotes proper orientation of form 2500 so that
concrete is poured against release overlay 2560, not back surface
2515. Proper orientation of form 2505 relative to a concrete
pouring area facilitates ready release of form 2500 from the
concrete when sufficiently cured, and promotes a cleaner or more
finished joint surface.
[0159] Accordingly, slot 2510 is configured to enable or promote
complete insertion of plate 2600 therein along direction 2520, and
incomplete insertion when attempted in the opposite direction.
Thus, a concrete worker may readily observe upon insertion whether
plate 2600 is fully received in slot 2510 and confirm that form
2500 is properly oriented. To this end, slot 2510 may be configured
to have at least two sections, a first section 2523 and a second
section 2525. First section 2523 is proximate to back surface 2515,
defining a lip 2527 at the intersection therewith. Second section
2525 is proximate to side surface 2505 and, being larger than first
section 2523, defines a shoulder 2530 at the intersection
therewith.
[0160] FIGS. 33 and 34 also show another embodiment of an apparatus
for transferring loads between concrete slabs configured according
to principles of the invention including a plate 2600. Like plate
300, plate 2600 has a first portion 2615 and a second portion 2620,
delineated by a plane 2621. First portion 2615 may be untreated.
Second portion 2620 may have an elastomer coating 2625 that is
comparable to elastomer coating 325. Second portion 2620 also may
have one or more surfaces 2640 on which edge banding 2645,
comparable to edge banding 1005, may be disposed.
[0161] First portion 2615 is configured to be closely received in
slot 2510 and promote complete insertion of plate 2600 therein
along direction 2520, and incomplete insertion when attempted in
the opposite direction. To this end, first portion 2615 preferably
has a like number of corresponding segments as slot 2510 has
sections. Thus, first portion 2615 may have a first segment 2630
and a second segment 2635 that respectively correspond to first
section 2523 and second section 2525.
[0162] When inserted properly, first portion 2615 nests snugly in
slot 2510 and plate 2600 appears to be fully received, as shown in
FIG. 34. If plate 2600 is inserted into slot 2510 in an incorrect
direction 2521 opposite to direction 2520, first segment 2630 may
be received in first section 2523 of slot 2510, but second segment
2635 is not received in second section 2525 and plate 2600 does not
appear to be fully received, as shown in FIG. 35.
[0163] When plate 2600 is properly received in form 2500, as shown
in FIG. 34, second segment 2635 abuts shoulder 2530 preventing
passage of plate 2600 through form 2500. When incorrect insertion
of plate 2600 is attempted, as shown in FIG. 35, second segment
2635 abuts lip 2527 preventing complete reception of plate
2600.
[0164] Referring to FIG. 34, the positive stop provided by second
segment 2635 and shoulder 2530 also operates to prevent coating
2625 and/or edge banding 2645 from accidental dislocation from
plate 2600. While coating 2625 and/or edge banding 2645 are
dimensioned to prevent passage through slot 2510, the weak bond
between coating 2625 and/or edge banding 2645 and plate 2600 could
allow for separation if subjected to especially vigorous insertion.
The positive stop prevents even excessive insertion from stripping
off coating 2625 and/or edge banding 2645.
[0165] The sectioned slot 2510 and segmented first portion 5615
also promote ready form removal from a cured concrete slab. While a
concrete slab cures, form 2500 and plate 2600 are positioned as
shown in FIG. 34. Once cured, form 2500 must be removed. Plate
2600, having been snugly installed in form 2500, is not easy to
remove. Therefore, reducing the contact or interference fit between
first portion 2615 and slot 2510 reduces the force necessary to
remove form 2500 from the slab. To this end, rather than having to
pull first segment 2630 of first portion 5615 through an entire
form 2500, first segment 2630 only has to clear from first section
2523 of slot 2510, reducing the overall amount of effort needed to
remove form 2500 from the cured concrete slab.
[0166] To promote even greater ease of form removal, either or both
of second segment 2635 and second section 2525 may have curved or
radiused surfaces (not shown). Where both of the second segment
2635 and second section 2525 surfaces are radiused, such should be
complementary. The preferred radius is 18 inches.
[0167] FIGS. 36-67 show alternative embodiments of an apparatus for
transferring loads between concrete slabs configured according to
principles of the invention. In each figure, "A" generally
designates a plate and "B" generally designates an elastomeric
coating with or without edge banding, as described herein. As with
the embodiments described above, a first concrete slab is intended
to adhere to only the coating and/or edge banding, while a second
concrete slab is intended to adhere to only the portion of the
plate that is not coated or edge banded. Thus, the joint between
the first and second concrete slabs corresponds with line defined
by where coating and/or edge banding B discontinues on A.
[0168] As used herein, "normal" obtains its customary meaning,
perpendicular to a surface or the tangent of a curved surface.
"Predominating normal" or cognates thereof refers to an average of
the normals of a nonuniform surface.
[0169] Referring to FIGS. 38, 39, 40, 41, 52, 53, 60, 61 and 64-67,
some embodiments have coated portions of the plate A that have
surfaces that, when emplaced, are not predominantly normal to the
joint between concrete slabs. When the concrete cures, the concrete
shrinks away from the surface along that predominantly normal
direction. A void forms between the concrete and the apparatus
corresponding to the amount that the concrete shrunk. When the
first and second slabs move horizontally along the joint, the void
provides clearance for plate A to move therein, thus preventing
compressive forces from growing to an amount sufficient to cause
localized concrete failures. The amount that the slabs may move
relatively along the joint is a fraction of the amount that the
concrete shrinks away from the surface in the predominantly normal
direction, according to standard trigonometric principles.
[0170] Referring to FIGS. 36, 37, 46, 47, 50, 51, 54, 55, 58, 59,
62, 63, 64 and 65 some embodiments have coating and/or edge banding
having a thickness or resiliency that differs according to location
on surface on which the coating and/or edge banding is disposed. In
addition to any void that develops between the concrete and the
coating and/or edge banding, a moving concrete slab also may
compress the coating and/or edge banding without developing
compressive forces to an amount sufficient to cause localized
concrete failures. Similar to the above, the joint travel distance
may be tailored by fine tuning the coating and/or edge banding
thickness or resiliency.
[0171] Another embodiment provides for tailoring the joint travel
distance by coordinating both the surface, hence predominant
normal, and the coating and/or edge banding thickness or
resiliency.
[0172] The invention is not limited to the particular embodiments
described and depicted herein, rather only to the following
claims.
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