U.S. patent application number 13/943374 was filed with the patent office on 2014-01-23 for leave-in-place concrete formwork combining plate dowels, divider plates, and/or finishing, armoring and/or sealing molding.
The applicant listed for this patent is Russell Boxall, Nigel K. Parkes. Invention is credited to Russell Boxall, Nigel K. Parkes.
Application Number | 20140020320 13/943374 |
Document ID | / |
Family ID | 49945377 |
Filed Date | 2014-01-23 |
United States Patent
Application |
20140020320 |
Kind Code |
A1 |
Parkes; Nigel K. ; et
al. |
January 23, 2014 |
Leave-in-Place Concrete Formwork Combining Plate Dowels, Divider
Plates, and/or Finishing, Armoring and/or Sealing Molding
Abstract
A leave-in-place forming system is for concrete slabs and
pavements. It comprises a number of components that can include two
or more of the following but is not limited to two or more of the
following: a plate dowel for load transfer between adjacent
concrete panels (joint stability), a divider plate (which could be
sheet metal, plastic or other rigid material), and an assembly or
molding to finish the concrete to, that armors the joint and/or
provides a water-tight seal to the joint. The joint assembly could
incorporate an integral setting assembly or bracket, or could be
used with a re-usable setting bracket. The integral assembly or
bracket is most suitable when it is desirable to place concrete to
both sides of the joint assembly at the same time. The re-usable
setting bracket is most suitable where concrete is placed to just
one side of the assembly and it is desirable to re-use the setting
assembly.
Inventors: |
Parkes; Nigel K.; (Atlanta,
GA) ; Boxall; Russell; (Charlotte, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Parkes; Nigel K.
Boxall; Russell |
Atlanta
Charlotte |
GA
NC |
US
US |
|
|
Family ID: |
49945377 |
Appl. No.: |
13/943374 |
Filed: |
July 16, 2013 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61673061 |
Jul 18, 2012 |
|
|
|
Current U.S.
Class: |
52/396.05 |
Current CPC
Class: |
E04B 1/483 20130101;
E04G 17/06 20130101; E01C 11/14 20130101; E01C 11/04 20130101; E04B
1/4114 20130101; E04F 15/142 20130101; E04G 17/0644 20130101 |
Class at
Publication: |
52/396.05 |
International
Class: |
E04G 17/06 20060101
E04G017/06; E04B 1/41 20060101 E04B001/41 |
Claims
1. A concrete flatwork joint product for the advantages of both
load transfer and joint sealing in an assembly for simplified use
of a contractor, comprising: a plate dowel; at least one among the
group comprising an armored joint assembly and a joint sealing
assembly; and at least one among the group comprising a
leave-in-place formwork assembly and a reusable formwork assembly;
whereby the product is useful in isolation joints, expansion
joints, construction joints and contraction joints, provides the
joint stability, joint protection/armoring and/or joint sealing
required in a single assembly with a leave-in-place and/or reusable
form, tends to overcome the drawbacks of isolation joints that do
not provide for positive load transfer between adjacent panels and
other building components, expansion joints that are prone to both
joint spalling, such as damage to the joint edges, from wheeled
traffic or other objects crossing and impacting the joint, and the
intrusion of liquids, construction joints that are prone to joint
spalling under traffic, and contraction joints that are prone to
dominant joint activation, leading to the loss of load transfer
through aggregate interlock, and provides the opportunity for the
contractor to place multiple panels at one time and negate the need
for subsequent processes.
2. A concrete flatwork joint product as in claim 1, in which a
divider plate defines the upright edges of slabs at a joint where
the slabs are adjacent each other.
3. A concrete flatwork joint product as in claim 2 in which the
divider plate includes a vertically oriented extension, which
extends from the subgrade or base to the top of the slabs.
4. A concrete flatwork joint product as in claim 3 in which the
extension incorporates a setting bracket and at least one among the
group of a finishing structure and an armoring structure.
5. A concrete flatwork joint product as in claim 2 in which the
divider plate includes a vertically oriented extension, which
extends from the subgrade or base to below the top of the slabs,
for saw cutting of a top portion of the joint.
6. A concrete flatwork joint product as in claim 2 in which the
divider plate includes a plate support and a top structure.
7. A concrete flatwork joint product as in claim 6 in which the
plate support includes a setting bracket.
8. A concrete flatwork joint product as in claim 6 in which the top
structure includes a finishing structure.
9. A concrete flatwork joint product as in claim 8 in which the
finishing structure has extreme top surfaces which are
substantially equal in height to each other and provide guides for
concrete surface finishing tools and equipment such as screeds, so
as to permit accurate leveling, for example, of the tops of the
slabs.
10. A concrete flatwork joint product as in claim 9 in which the
finishing structure includes joint expansion and contraction
elements that are movable with their slabs as the slabs expand
and/or contract, with the top surfaces moving closer together and
farther apart as dictated by expansion and contraction.
11. A concrete flatwork joint product as in claim 6 in which the
top structure includes rails in the form of substantially
mirror-image components of greater height that width, and upper and
lower elements that extend toward each other in close vertical and
horizontal association.
12. A concrete flatwork joint product as in claim 11 in which the
upper elements constitute an overlapping pair of elements that by
turns of minimal space between them create a labyrinth of overlap
and effectively close the space below themselves by their
overlap.
13. A concrete flatwork joint product as in claim 11 in which the
rails of the top structure have laterally extending segments that
increase the thicknesses of portions of their upright elements and
provide channels for seal elements such as hydrophilic gaskets of
suitable rubber and the like.
14. A concrete flatwork joint product as in claim 13 in which
retaining elements exist within the interiors of the rails for
fitting against a portion of the divider plate in the area of the
top structure
15. A concrete flatwork joint product as in claim 14 in which the
rails are releasably fastened together at various locations to rest
atop the portion of the divider plate during slab formation.
16. A concrete flatwork joint product as in claim 14 in which the
rails are provided with fastening elements that place the rails in
association with the portion of the divider plate during slab
formation, the fastening elements releasing the rails from each
other and releasing the rails from the portion of the divider plate
upon the appropriate degree of hardening of the slabs.
17. A concrete flatwork joint product as in claim 1 in which the
load plates include load transfer plates in the form of plate
dowels which take on a shape from among the group including oval,
rectangular, alternating triangular and double triangular.
18. A method of forming a joint and pouring two adjacent slabs
simultaneously, comprising, in variable order: preparing one among
the group comprising a subgrade and a base; extending and securing
divider plates in series along intended joint locations for the
distances the intended joints are to cover, the divider plates
including load plate supports; installing load plates on the load
plate supports; doing at least one among the group of installing
top structures or sawcutting the intended joints; and pouring
concrete slabs.
19. The method of claim 18 wherein the placing of load plates
occurs last before pouring as among the installing of load plates
and the installing of top structures.
20. The method of claim 18 further comprising preparing the load
plates to break from being locked into poured concrete.
21. The method of claim 18 in which top structures are
installed.
22. The method of claim 18 comprising finishing concrete using top
surfaces of the top structure.
Description
[0001] This application claims priority to U.S. Provisional
Application Ser. No. 61/673,061, filed Jul. 18, 2012.
TECHNICAL FIELD
[0002] This invention relates to concrete flatwork such as slabs
and pavements, joints for such flatwork, and products for providing
improved concrete flatwork joint performance.
BACKGROUND OF THE INVENTION
[0003] There are generally four types of joints used in concrete
flatwork (slabs and pavements): isolation joints, expansion joints,
construction joints and contraction joints. Isolation joints are
used to create a separation between the concrete flatwork panel and
adjacent panels or other building components, such as walls,
columns, trenches, man-holes, bollards, etc. Expansion joints are
used in the same way as an isolation joint except that it contains
a compressible material or void space sufficient to accommodate
subsequent expansion of the concrete flatwork panel(s).
Construction joints are used at the termination of a single slab
placement and thus defines the joint between adjacent panels cast
independently. Construction joints are generally formed with
removable or leave in place forms, sawcut full depth, or slip
formed (temporary forms used with low slump concrete mixtures).
Contraction joints are used as means of allowing for the concrete
contraction by providing a plane of weakness. Contraction joints
are often induced cracks created with the use of a saw cut, crack
inducer, or tooled notch in the surface of the concrete.
[0004] Each joint type has its drawbacks and problems. Isolation
joints often do not provide for positive load transfer between
adjacent panels and other building components. Expansion joints are
wider than other joints and therefore more prone to both joint
spalling, such as damage to the joint edges, from wheeled traffic
or other objects crossing and impacting the joint, and the
intrusion of liquids. The intrusion of liquids can cause numerous
problems including the pumping of saturated subgrade materials and
faulting of pavement panels in exterior pavements, and subgrades
heaving due to frost in cold climates or areas where expansive
soils are found. Construction joints can also be prone to joint
spalling under traffic especially if sufficient load transfer is
not provided to create sufficient joint stability. Contraction
joints are prone to dominant joint activation where some joints
open wider than others, leading to the loss of load transfer
through aggregate interlock thus also increasing the likelihood of
joint spalling. There are additional issues as well.
[0005] All four joint types are generally filled or sealed after
their construction in an attempt to either protect the joint from
spalling under traffic or prevent the ingress of moisture, liquids,
contaminants, or bacteria. Load transfer with joint stability is
most often provided in any of these joints through the use of
either dowels, which are generally steel bars that are round or
square in section, or keyways, which are tongue and groove type
joints which can be formed with removable or leave in place
forms.
[0006] There are products on the market that provide improved joint
performance. Concerning load transfer, plate dowels are described
in U.S. Pat. Nos. 6,354,760 and 7,481,031, the disclosures of which
are incorporated by reference in their entireties. Concerning joint
sealing, an assembly designed to seal joints during the
construction stage and not afterwards is described in Patent
Co-operation Treaty document number PCT/AU2009/001376, the
disclosure of which is incorporated by reference in its
entirety.
SUMMARY OF THE INVENTION
[0007] Products have not previously existed that have all the
advantages of both load transfer and joint sealing according to the
products of the cited and incorporated patent and document as
opposed to the separate load transfer and joint sealing advantages
of the separate products in the cited and incorporated patent and
document. The envisioned products have never existed in an assembly
for simplified use of the contractor. The invention, which includes
both products and methods, combines a plate dowel and either an
armored joint assembly or a joint sealing assembly with a
leave-in-place and/or reusable formwork assembly. Unlike any other
joint product or system it is envisioned to be used in place of any
one of the four joint types described above and overcome the
various drawbacks of them listed above. By providing the joint
stability, joint protection (armoring) and/or joint sealing
required in a single assembly with a leave-in-place and/or reusable
form, the invention provides the opportunity for the contractor to
place multiple panels at one time and negate the need for
subsequent processes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a cross-section through two slabs of concrete on a
subgrade exposing in cross-section an embodiment of the joint
assembly according to the invention.
[0009] FIG. 2 is a detailed view of a portion of FIG. 1.
[0010] FIG. 3 is a set of perspective views of exemplary load
transfer plates of the type of plate dowel 62 in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0011] As in FIG. 1, two slabs of concrete 2 and 4 are seen in
cross-section when cut open or seen from their outer edges. The
concrete has the usual construction of binder and inclusions such
as aggregate 6. The slabs 2, 4 rest on a typical subgrade or base
material 8.
[0012] A divider plate 10 defines the upright edges 12, 14 of the
slabs 2, 4 at a joint 16 where the slabs are adjacent each other.
They "meet" at the joint 16 in the sense that they terminate at the
joint 16. They are also "separated" at the joint 16 in the sense
that the divider plate 10 lies between them. They also further
separate if the joint 16 between them is a construction and/or
contraction joint and they move back from each other, under the
action of concrete shrinkage or otherwise.
[0013] The divider plate 10 includes a vertically oriented
extension 18, which extends from the subgrade or base 8 to the top
of the slabs 2, 4. The extension 18 may have this extent by reason
of incorporating a setting bracket 20 and a finishing and/or
armoring structure 22 at set distances from each other equal to the
desired heights of the slabs 2, 4, or be the same heights with
exclusion of one or more of the setting bracket 20 and finishing
strip 22, or be other extents relative to the slabs 2, 4 such as an
extent shortened for saw cutting of the top portion of the joint
16.
[0014] As just expressed, the divider plate 10 as shown in FIG. 1
includes a plate support such as a setting bracket 20 and a top
structure such as a finishing structure 22. The setting bracket 20
includes a planar horizontal portion for resting and/or fastening
to the subgrade or base 8, or the plate support may include
features similar to the bracket 20 which equivalently provide
adequately for resting and/or fastening to the subgrade or base 8
and supporting the divider plate 10. Equivalents might, for
example, include wires that project feet to the subgrade or base 8.
They might include stakes driven into the subgrade or base 8 to
which the plate support may attach. The setting bracket 20 also may
be continuous along the joint 16 or intermittently project to the
subgrade or base 8. The divider plate 10 may be metal, such as
aluminum, or other materials as desired, such as plastic.
[0015] Again as just expressed, and as shown in larger size in FIG.
2, the divider plate includes a top structure such as a finishing
and armoring structure 22. The extreme top surfaces 21, 23 of the
structure 22 are substantially equal in height and provide guides
for concrete surface finishing tools and equipment such as screeds,
so as to permit accurate leveling, for example, of the tops of the
slabs 2, 4.
[0016] The structure 22 as in FIG. 2 and some embodiments of
invention also include(s) joint expansion and contraction elements
such as co-operating rails 24, 26, upon which the top surfaces 21,
23 are formed. These elements are movable with their slabs as the
slabs expand and/or contract, with the top surfaces 21, 23 moving
closer together and farther apart as dictated by expansion and
contraction.
[0017] Rails of the top structure may take various specific forms,
as for example the rails 24, 26 take the form of substantially
mirror-image components of greater height that width, and upper and
lower elements 28, 30 and 32, 34 that extend toward each other in
close vertical and horizontal association. The upper elements 32,
34 constitute as most preferred an overlapping pair of elements
that by the turns of the minimal space between them create a short
"labyrinth" of overlap and effectively "close" the space below
themselves by their overlap.
[0018] The rails of a top structure may as in rails 24, 26, also
have laterally extending segments 36, 38, 40, 42 that increase the
thicknesses of portions of their upright elements 44, 46 and
provide channels such as 51, 53, 55, 57 for seal elements such as
52, 54, 56, 58, such as hydrophilic gaskets of suitable rubber and
the like. Additional channels and seal elements such as channel 59
and seal element 60 may also be included, in the case of 59, 60,
for example, under upper element 32 of rail 24.
[0019] Retaining elements such as spring retaining elements 48, 49
may exist within the interiors of the rails such as rails 24, 26,
or equivalent structures for fitting against the portion 50 of the
divider plate 10 in the area of the top structure such as structure
22. The rails 24, 26 may be releasably fastened together at various
locations to rest atop portion 50 during slab formation, or
provided with structure that equivalently places rails 24, 26 in
association with portion 50 during slab formation, such as clips
and the like. The fastening elements should release the rails 24,
26 from each other and may release the rails 24, 26 from the
portion 50 upon the appropriate degree of hardening of the slabs
24, 26.
[0020] The rails 24, 26 and all structures shown in FIG. 2 may be
extended in longitudinal dimension (into the paper of FIG. 2) and
be continuous extrusions or be intermittent in longitudinal extent,
or otherwise, as for example, at various extents beyond their
length exchanging or varying locations or sizes of specific
structures. As most preferred, the rails and structures are
continuous extrusions for manufacturing simplicity.
[0021] Referring again to FIG. 1, the preferred embodiment may also
include and most desirably does include load transfer plates such
as for example plate dowel 62. As in the perspective views of FIG.
3, the plates may take on a variety of shapes, including oval 63,
rectangular 65, alternating triangular 67, 69 and double triangular
71. Load plate supports such as load plate support bracket 73 in
FIG. 1 are attached to and/or formed with or from divider plate 10.
The load plate supports support load plates relative to divider
plate 10 and assure or at least assist assuring proper orientations
of load support plates for best use of the load plates.
[0022] In use, as by now perceived, to form a joint and pour two
adjacent slabs simultaneously, the subgrade or base is prepared, as
in FIG. 1, divider plates are extended and secured in series along
the intended joint location for the distance the joint is to cover
(or more or less), as in FIG. 1, load plates are installed on their
supports, as in FIG. 1, top structures are installed, as in FIG. 1,
and concrete slabs are poured. The stated steps are carried out in
such orders as make sense, with some interchangeability of order,
such as placing load plates last before pouring, installing top
structures last before pouring, etc. To the extent appropriate,
additional steps are also taken such as preparing the load plates
to break from being locked into poured concrete at both ends, and
the like. Concrete finishing using the top surfaces of the top
structure may or may not occur, and indeed, more or less than all
the structures shown may be included or excluded from the method,
as for example, the top structures, which may or may not be
included in some situations, if and where saw cutting to create
joints is desired.
[0023] The invention and especially its preferred embodiment are
now described in such full, clear and concise and exact manner as
to enable a person of ordinary skill in the art to make and use the
same. All embodiments of invention that come with the scope of
claims to be appended on the preparation and filing of a
non-provisional patent application are to be deemed to be covered
by the claims.
* * * * *