EP4606963A1 - Connection system and stiffening template - Google Patents

Connection system and stiffening template

Info

Publication number
EP4606963A1
EP4606963A1 EP25160083.9A EP25160083A EP4606963A1 EP 4606963 A1 EP4606963 A1 EP 4606963A1 EP 25160083 A EP25160083 A EP 25160083A EP 4606963 A1 EP4606963 A1 EP 4606963A1
Authority
EP
European Patent Office
Prior art keywords
connection system
rebate
stiffening
template
backing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP25160083.9A
Other languages
German (de)
French (fr)
Inventor
Greg Stephen MASON
Andrew Mcfarland
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Illinois Tool Works Inc
Original Assignee
Illinois Tool Works Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2024900474A external-priority patent/AU2024900474A0/en
Priority claimed from AU2025201046A external-priority patent/AU2025201046A1/en
Application filed by Illinois Tool Works Inc filed Critical Illinois Tool Works Inc
Publication of EP4606963A1 publication Critical patent/EP4606963A1/en
Pending legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/16—Load-carrying floor structures wholly or partly cast or similarly formed in situ
    • E04B5/32—Floor structures wholly cast in situ with or without form units or reinforcements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38—Connections for building structures in general
    • E04B1/41—Connecting devices specially adapted for embedding in concrete or masonry
    • E04B1/4107—Longitudinal elements having an open profile, with the opening parallel to the concrete or masonry surface, i.e. anchoring rails
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38—Connections for building structures in general
    • E04B1/48—Dowels, i.e. members adapted to penetrate the surfaces of two parts and to take the shear stresses
    • E04B1/483—Shear dowels to be embedded in concrete
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G21/00—Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
    • E04G21/12—Mounting of reinforcing inserts; Prestressing
    • E04G21/125—Reinforcement continuity box
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/16—Load-carrying floor structures wholly or partly cast or similarly formed in situ
    • E04B5/17—Floor structures partly formed in situ
    • E04B2005/176—Floor structures partly formed in situ with peripheral anchors or supports
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/16—Load-carrying floor structures wholly or partly cast or similarly formed in situ
    • E04B5/32—Floor structures wholly cast in situ with or without form units or reinforcements
    • E04B2005/324—Floor structures wholly cast in situ with or without form units or reinforcements with peripheral anchors or supports

Definitions

  • connection system for providing a structural connection between concrete components, which addresses one or more of the disadvantages of existing connection systems.
  • the rebate former is formed of sheet metal. More preferably, the backing is in the form of an elongated backing, the elongated backing having folded edges to a predefined depth.
  • each of the anchors has an internal thread for receiving an external thread of a reinforcing bar for reinforcing a second concrete component. More preferably, each of the anchors has a foot for providing anchorage in the first concrete component. The foot may be in the form of a tapered foot.
  • Each of the anchors may be in the form of a threaded insert.
  • the rebate former has folded ends to provide additional structural rigidity.
  • connection system includes a lid for covering an internal cavity of the rebate former defined by the elongated backing and the folded edges.
  • the rebate former includes a row of anchors mounted longitudinally of the rebate former.
  • a stiffening template for reinforcing a rebate former in a construction joint between a first concrete component and a second concrete component, the stiffening template comprising a plate having opposed folded edges to provide rigidity, and the stiffening template further including at least one aperture for accommodating an anchor coupled to the rebate former.
  • a method of providing a construction joint between a first concrete component and a second concrete component including the steps of:
  • connection system 10 has been developed by the applicant to facilitate improved rigidity, ease-of-use, efficiency and improved load-bearing capacity.
  • connection system 10 for providing a construction joint 12 between a first concrete component 14 and a second concrete component 16.
  • the connection system 10 includes a rebate former 18 for forming a rebate 20 (see Figure 17 ) in the first concrete component 14.
  • the rebate former 18 is formed of sheet metal, the rebate former 18 including an elongated backing 22, the elongated backing 22 having folded edges 24 to a predefined depth.
  • the rebate former 18 may have one or more folded ends 38 to provide structural rigidity.
  • connection system 10 may include a lid 40 for covering an internal cavity 42 of the rebate former 18 defined by the elongated backing 22 and the folded edges 24.
  • the connection system 10 may include at least one strap 44 extending around the rebate former 18 and the lid 40 to secure the lid 40 to the rebate former 18.
  • straps 44 may instead be used around the rebate former 18 without the lid 40 fitted.
  • the rebate former 18 may include a row of anchors 26 mounted longitudinally of the rebate former 18 (see, for example, Figure 12 ). In another form, the rebate former 18 may include a plurality of parallel rows of anchors 26 mounted longitudinally of the rebate former 18 (see, for example, Figure 13 ).
  • connection system 10 may include a plurality of parallel rebate formers 18 joined by an intermediate section 46, as shown in Figure 4 .
  • Each rebate former 18 may have a plurality of rows of anchors 26 mounted thereto, as shown in Figure 5 .
  • the rebate former 18 may include a cross strut 48 extending across a width of the internal cavity 42 of the rebate former 18.
  • the cross strut 48 may be in the form of a brace which is movable along a length of the rebate former 18.
  • each anchor 26 may be provided with a securing plug 50, the securing plug 50 having an external thread 52 for threading into the internal thread 28 of the anchor 26.
  • the securing plug 50 may have an external thread 52 having the same pitch as the external thread 30 of a reinforcing bar 32 for threading into the internal thread 28 of the anchor 26. This may be advantageous as the external thread 52 is therefore a coarse thread and is much quicker to thread in and thread out the securing plug 50 when compared with a metric thread.
  • the securing plug 50 may be arranged with an enlarged base 54 (see Figure 29 ) to facilitate threading manually by hand.
  • the securing plug 50 is formed of plastic material.
  • connection system 10 may include a resilient washer 56 (see Figure 31 and Figure 32 ) located between the securing plug 50 and the respective anchor 26 to facilitate a seal of the internal thread 28 of the anchor 26 against ingress of concrete.
  • the rebate former 18 may be dimpled on the backing 22 and on the folded edges 24 to facilitate retention of the rebate former 18 within surrounding concrete.
  • connection system 10 After casting of the first concrete component 14 and removal of the securing plugs 50, the connection system 10 includes a threaded reinforcing bar 32 threaded into each anchor 26, with an external thread 30 of the threaded reinforcing bar 32 mating with an internal thread 28 of the anchor 26 (see Figure 18 ).
  • the anchors 26 provided with a coarse thread for threaded insertion of externally threaded reinforcing bar 32, this facilitates direct insertion of the reinforcing bar 32 into the internal thread 28 of each anchor 26 rather than requiring a metric thread to be tapped on to an end of the reinforcing bar 32.
  • This may be advantageous as it may facilitate cutting on-site of a reinforcing bar 32 to size, then threading of the cup and of the reinforcing bar 32 directly into the anchor 26 without needing to form a metric thread on an end portion of the reinforcing bar 32.
  • connection system 10 for providing a construction joint 12 between a first concrete component 14 and a second concrete component 16, the connection system 10 including a rebate former 18 for forming a rebate 20 in a first concrete component 14, wherein the rebate former 18 has a backing 22, and the connection system 10 further includes a plurality of anchors 26 coupled to the backing 22 and at least one stiffening template 58 mounted to the backing 22 to prevent or at least reduce sag of the rebate former 18.
  • the rebate former 18 is formed of sheet metal and the backing 22 is in the form of an elongated backing 22, the elongated backing 22 having folded edges 24 to a predefined depth.
  • the stiffening template 58 includes an aperture 60 to enable one of the anchors 26 to pass through the stiffening template 58.
  • the stiffening plates 58 may have a single aperture 60 for compatibility with single row rebate formers 18 as shown in Figure 36 , and alternatively may have dual apertures 60 for compatibility with dual row rebate formers 18 as shown in Figure 37 .
  • the stiffening templates 58 light across and transverse to the rebate former 18, across a full width of the rebate former 18, such that shorter stiffening templates 58 are used for narrower rebate formers 18 and longer stiffening templates 58 are used for wider rebate formers 18.
  • the narrow rebate former 18 shown in Figure 36 may use a shorter stiffening template 58 as shown in Figure 35 (outer left), whereas the wider rebate former 18 shown in Figure 38 may use a longer stiffening template 58 as shown in Figure 35 (inner left).
  • the narrow dual row rebate former 18 shown in Figure 37 may use a shorter stiffening template 58 as shown in Figure 35 (inner right), whereas the wider dual row rebate former 18 shown in Figure 39 may use a longer stiffening template 58 as shown in Figure 35 (outer right).
  • the aperture 60 may be round as shown in figures 44 to 51 , or alternatively, may be square as shown in Figures 35 and 43 .
  • the stiffening template 58 is arranged to be clamped to the backing by the anchor 26.
  • the stiffening template 58 may be clamped to the backing 22 by the anchor 26 and the securing plug 50, in particular by treading tightly the securing plug 50 into the anchor 26.
  • the stiffening plate 58 adds rigidity to the rebate former 18 and controls or at least minimises sag of threaded insert anchors 26 due to gravity and concrete weight (when poured) when the rebate former 18 is positioned in a vertical orientation.
  • the stiffening template 58 may be easily installed under fixing nailing plates (securing plugs 50) inside the rebate box (rebate former 18).
  • the forces due to gravity and concrete weight are depicted by the blue arrows in Figure 40 and Figure 41 , whereas the reaction force of the concrete against the rebate former 18 is depicted by the green parallel arrows.
  • each anchor 26 may be provided with its own stiffening plate 58 for a single row rebate former 18.
  • each opposite pair of anchors 26 may be provided with their own stiffening plate 58.
  • each of the stiffening templates 58 extends transversely across the elongated backing 22, tightened in place against the backing 22 by the anchors 26 and threaded securing plugs 50, thereby strengthening the rebate former 18 and minimising sag of the anchors 26.
  • the stiffening templates 58 are held in place by the threaded securing plugs 50, they are easily removed from the shear box once poured into the wall to facilitate placement of lap bars before the floor pour (second pour).
  • Each of the stiffening templates 58 is folded along opposite edges 62 to improve rigidity.
  • the folds at the opposite edges 62 are preferably perpendicular to a central surface of the stiffening template 58 so as to form strengthening flanges 64.
  • these flanges 64 are parallel and extend along the full length of the stiffening template 58.
  • the folded edges (flanges 64) of the stiffening template 58 are oriented transversely to the elongated backing 22.
  • a stiffening template 58 for reinforcing a rebate former 18 in a construction joint 12 between a first concrete component 14 and a second concrete component 16, the stiffening template 58 comprising a plate 66 having opposed folded edges 64 to provide rigidity, and the stiffening template 58 further includes at least one aperture 60 for accommodating an anchor 26 coupled to the rebate former 18.
  • FIG 52 there is shown a detailed view of a stiffening template 58 in place in a connection system 10 in accordance with another example of the present invention, similar to Figure 42 , but with the stiffening template 58 in an inverted configuration relative to the elongated backing 22.
  • the stiffening template 58 is inverted so that flanges 64 face the elongated backing 22. This results in the securing plugs 50 being seated further from the elongated backing 22, as the plate 66 is spaced relative to the elongated backing by virtue of the flanges 64.
  • the plate 66 of each stiffening template 58 rests against the elongated backing 22, and the flanges 64 face outward and away from the elongated backing 22.
  • stiffening template 58 in the same functional scenario, it can sometimes be more advantageous to position it in an inverted direction (with the folded flanges 64 to the base) to ensure better function.
  • the stiffening templates 58 can be placed in either direction, as may be deemed more appropriate for a particular situation, within the scope of the invention.
  • Figures 35 to 53 relate to the connection system including the stiffening template
  • Figures 1 to 34 relate to the connection system without the stiffening template.
  • various of Figures 1 to 34 show the use of a rubber washer 56 on the inside of the box between the securing plug 50 and the base (elongated backing 22). Due to design changes in the connection system shown in Figures 35 to 53 , the washer is now placed on the outside of the box between the anchor 26 and the base (elongated backing 22).
  • connection system 10 Construction joint 12 First concrete component 14 Second concrete component 16 Rebate former 18 Rebate 20 Elongated backing 22 Folded edges 24 Anchors 26 Internal thread 28 External thread 30 Reinforcing bar 32 Foot 34 External ribs 36 Folded end 38 Lid 40 Internal cavity 42 Strap 44 Intermediate section 46 Cross strut 48 Securing plug 50 External thread 52 Enlarged base 54 Resilient washer 56 Stiffening template 58 Aperture 60 Opposite edges 62 Flanges 64 Plate 66

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Mechanical Engineering (AREA)
  • Reinforcement Elements For Buildings (AREA)

Abstract

A connection system for providing a construction joint between a first concrete component and a second concrete component, the connection system including a rebate former for forming a rebate in a first concrete component, wherein the rebate former has a backing, and the connection system further includes a plurality of anchors coupled to the backing and at least one stiffening template mounted to the backing to prevent or at least reduce sag of the rebate former.

Description

    FIELD OF THE INVENTION
  • The invention relates to construction and to a connection system, for example for connecting reinforcement of a floor to a wall prior to pouring concrete of the floor. The invention may also relate to a rebate former for construction. More particularly, but not exclusively, the invention relates to a rebate former for forming a rebate in a concrete component for floor and/or wall connections.
    • BACKGROUND OF THE INVENTION
  • It has been previously proposed to provide a connection system including a rebate box for providing a structural connection between concrete components. However, the applicant has identified that existing connection systems may be difficult to use, require a dense population of reinforcement anchorages and yet provide relatively low tensile capacity. Also, the applicant has identified that existing connection systems may be prone to sag, especially in relation to the anchors due to gravity and concrete weight.
  • The applicant has identified that it would be advantageous to provide an improved connection system for providing a structural connection between concrete components, which addresses one or more of the disadvantages of existing connection systems.
  • Examples of the invention seek to provide an improved connection system which obviates or at least alleviates one or more disadvantages of existing connection systems, or at least to provide a useful alternative.
    • SUMMARY OF THE INVENTION
  • In accordance with one aspect of the present invention, there is provided a connection system for providing a construction joint between a first concrete component and a second concrete component, the connection system including a rebate former for forming a rebate in a first concrete component, wherein the rebate former has a backing, and the connection system further includes a plurality of anchors coupled to the backing and at least one stiffening template mounted to the backing to prevent or at least reduce sag of the rebate former.
  • Preferably, the rebate former is formed of sheet metal. More preferably, the backing is in the form of an elongated backing, the elongated backing having folded edges to a predefined depth.
  • In a preferred form, the stiffening template includes an aperture to enable one of the anchors to pass through the stiffening template.
  • The aperture may be round, square, or a different shape.
  • Preferably, the stiffening template is arranged to be clamped to the backing by the securing plug.
  • In one form, the stiffening template extends transversely across the elongated backing.
  • The stiffening template may be folded along opposite edges to improve rigidity. More preferably, the folded edges of the stiffening template are oriented transversely to the elongated backing.
  • Preferably, the stiffening template has a plurality of apertures to allow passage of a plurality of anchors.
  • In a preferred form, each of the anchors has an internal thread for receiving an external thread of a reinforcing bar for reinforcing a second concrete component. More preferably, each of the anchors has a foot for providing anchorage in the first concrete component. The foot may be in the form of a tapered foot.
  • Preferably, each of the anchors has one or more external ribs along a length of the anchor for providing anchorage in the first concrete component.
  • Each of the anchors may be in the form of a threaded insert.
  • It is preferred that the rebate former has folded ends to provide additional structural rigidity.
  • Preferably, the connection system includes a lid for covering an internal cavity of the rebate former defined by the elongated backing and the folded edges.
  • In a preferred form, the rebate former includes a row of anchors mounted longitudinally of the rebate former.
  • In accordance with another aspect of the present invention, there is provided a stiffening template for reinforcing a rebate former in a construction joint between a first concrete component and a second concrete component, the stiffening template comprising a plate having opposed folded edges to provide rigidity, and the stiffening template further including at least one aperture for accommodating an anchor coupled to the rebate former.
  • In accordance with yet another aspect of the present invention, there is provided a method of providing a construction joint between a first concrete component and a second concrete component, the method including the steps of:
    • providing a connection system including a rebate former for forming a rebate in the first concrete component, wherein the rebate former includes a backing;
    • mounting at least one stiffening template to the backing to prevent or at least reduce sag of the rebate former;
    • providing a plurality of anchors coupled to the backing, each of the anchors having an internal thread;
    • providing a plurality of reinforcing bars, each of the reinforcing bars having an external thread along its length; and
    • threading one of the reinforcing bars into each of the anchors such that, for each anchor, an external thread of a reinforcing bar is threaded into the internal thread of the anchor to tighten the reinforcing bar relative to the anchor for providing reinforcement for the second concrete component.
    BRIEF DESCRIPTION OF THE DRAWINGS
  • The invention is further described by way of non-limiting example only, with reference to the accompanying drawings in which:
    • Figure 1 is a perspective view of a connection system, shown prior to embedment in concrete components;
    • Figure 2 is a cross-sectional view of a connection system, forming a structural connection between two concrete components;
    • Figure 3 is a cross-sectional view of a connection system having a rebate former with parallel rows of anchors;
    • Figure 4 is a cross-sectional view of a connection system having a pair of parallel rebate formers;
    • Figure 5 is a cross-sectional view of a connection system having a pair of parallel rebate formers, each with parallel rows of anchors;
    • Figure 6 is a perspective view of a connection system, showing an internal cavity beneath a lid;
    • Figure 7 is an end view of a connection system, depicted prior to connecting reinforcing bars to the anchors;
    • Figure 8 is a perspective view of a connection system having parallel rows of anchors;
    • Figure 9 is a perspective view of the connection system of Figure 8, shown fitted with threaded plugs; and
    • Figure 10 shows a detailed side view of an anchor of the connection system shown in Figure 9;
    • Figure 11 shows a range of different configurations of connection systems;
    • Figure 12 shows a pair of rebate formers, each with a single row of anchors;
    • Figure 13 shows a plurality of rebate formers, each with a pair of anchor rows;
    • Figure 14 shows a connection system having reinforcing bars connected to anchors thereof;
    • Figure 15 shows an end view of a rebate former embedded in a first concrete component;
    • Figure 16 shows the rebate former of Figure 15 shown with threaded plugs fitted;
    • Figure 17 shows the rebate former of Figure 16 with the plugs removed;
    • Figure 18 shows the rebate former of Figure 17 with reinforcing bars inserted;
    • Figure 19 shows a rebate former cavity shown with a cross strut/brace;
    • Figure 20 shows a table with anchorage capacity results of different anchors;
    • Figure 21 shows a table of Design Capacity;
    • Figure 22 shows a rebate former used with a single row of anchors;
    • Figure 23 shows a rebate former used with a double row of anchors;
    • Figure 24 shows a pair of rebate formers used, each with a single row of anchors;
    • Figure 25 shows a pair of rebate formers used, each with a double row of anchors;
    • Figure 26 shows a side view of a rebate former, depicting anchorage;
    • Figure 27 shows a pair of rebate formers used, each with a single row of double ended anchors;
    • Figure 28 shows a range of example connections;
    • Figure 29 shows both sides of a threaded plug;
    • Figure 30 shows a side view of a connection system with a plug fitted to each anchor;
    • Figure 30a shows a cross sectional view of a plug fitted to each anchor;
    • Figure 31 shows a perspective view of a resilient washer/seal;
    • Figure 32 shows a perspective view of resilient washers is being used to seal beneath threaded plugs;
    • Figure 33 shows a side view of an anchor fitted to a dimpled rebate former;
    • Figure 34 shows a connection system embedded in a first concrete component prior to removal of threaded plugs;
    • Figure 35 shows a perspective view of a range of stiffening templates in accordance with examples of the present invention;
    • Figure 36 shows a perspective view of a single row connection system in accordance with an example of the present invention;
    • Figure 37 shows a perspective view of a dual row connection system in accordance with an example of the present invention;
    • Figure 38 shows a perspective view of another single row connection system in accordance with an example of the present invention;
    • Figure 39 shows a perspective view of another dual row connection system in accordance with an example of the present invention;
    • Figure 40 shows a force diagram of a single row connection system;
    • Figure 41 shows a force diagram of a dual row connection system;
    • Figure 42 shows a detailed view of a stiffening template in place in a connection system in accordance with an example of the present invention;
    • Figure 43 shows an exploded view of a connection system in accordance with an example of the present invention;
    • Figure 44 shows a perspective view of a single aperture stiffening template;
    • Figure 45 shows a perspective view of a dual aperture stiffening template;
    • Figure 46 shows a perspective view of another single aperture stiffening template;
    • Figure 47 shows a perspective view of another dual aperture stiffening template;
    • Figure 48 shows a perspective view of yet another single aperture stiffening template, having different proportions;
    • Figure 49 shows a perspective view of yet another dual aperture stiffening template, having different proportions;
    • Figure 50 shows a perspective view of another single aperture stiffening template;
    • Figure 51 shows a perspective view of another dual aperture stiffening template;
    • Figure 52 shows a detailed view of a stiffening template in place in a connection system in accordance with an example of the present invention, similar to Figure 42, but with the stiffening template in an inverted configuration; and
    • Figure 53 shows an exploded view of the arrangement of Figure 52.
    DETAILED DESCRIPTION
  • With reference to Figures 1 to 34, there is shown various examples of a connection system 10. Advantageously, the connection system 10 has been developed by the applicant to facilitate improved rigidity, ease-of-use, efficiency and improved load-bearing capacity.
  • More specifically, as shown in the drawings, an example provides a connection system 10 for providing a construction joint 12 between a first concrete component 14 and a second concrete component 16. The connection system 10 includes a rebate former 18 for forming a rebate 20 (see Figure 17) in the first concrete component 14. The rebate former 18 is formed of sheet metal, the rebate former 18 including an elongated backing 22, the elongated backing 22 having folded edges 24 to a predefined depth.
  • As shown clearly in Figures 8 and 9, the connection system 10 includes a plurality of anchors 26 coupled to the elongated backing 22. Each of the anchors 26 as an internal thread 28 (see Figure 30a) for receiving an external thread 30 of a reinforcing bar 32 for reinforcing the second concrete component 16.
  • Each of the anchors 26 has a foot 34 for providing anchorage in the first concrete component 14. The foot may be in the form of a tapered foot 34. Even more specifically, the foot may be in the form of a circular tapered foot 34.
  • As can be seen in Figure 7, each of the anchors 26 has one or more external ribs 36 along a length of the anchor 26 for providing anchorage in the first concrete component 14. Each of the external ribs 36 may be tapered outwardly toward a free end of the anchor 26. Each of the anchors 26 may be in the form of a threaded insert.
  • The rebate former 18 may have one or more folded ends 38 to provide structural rigidity.
  • The connection system 10 may include a lid 40 for covering an internal cavity 42 of the rebate former 18 defined by the elongated backing 22 and the folded edges 24. The connection system 10 may include at least one strap 44 extending around the rebate former 18 and the lid 40 to secure the lid 40 to the rebate former 18. Alternatively, with reference to Figure 6 and Figure 9, straps 44 may instead be used around the rebate former 18 without the lid 40 fitted.
  • The rebate former 18 may include a row of anchors 26 mounted longitudinally of the rebate former 18 (see, for example, Figure 12). In another form, the rebate former 18 may include a plurality of parallel rows of anchors 26 mounted longitudinally of the rebate former 18 (see, for example, Figure 13).
  • The connection system 10 may include a plurality of parallel rebate formers 18 joined by an intermediate section 46, as shown in Figure 4. Each rebate former 18 may have a plurality of rows of anchors 26 mounted thereto, as shown in Figure 5.
  • With reference to Figure 6, the rebate former 18 may include a cross strut 48 extending across a width of the internal cavity 42 of the rebate former 18. The cross strut 48 may be in the form of a brace which is movable along a length of the rebate former 18.
  • Also as shown in Figure 6, each anchor 26 may be provided with a securing plug 50, the securing plug 50 having an external thread 52 for threading into the internal thread 28 of the anchor 26. As shown in Figure 29, the securing plug 50 may have an external thread 52 having the same pitch as the external thread 30 of a reinforcing bar 32 for threading into the internal thread 28 of the anchor 26. This may be advantageous as the external thread 52 is therefore a coarse thread and is much quicker to thread in and thread out the securing plug 50 when compared with a metric thread. The securing plug 50 may be arranged with an enlarged base 54 (see Figure 29) to facilitate threading manually by hand. In one form, the securing plug 50 is formed of plastic material.
  • The connection system 10 may include a resilient washer 56 (see Figure 31 and Figure 32) located between the securing plug 50 and the respective anchor 26 to facilitate a seal of the internal thread 28 of the anchor 26 against ingress of concrete.
  • With reference to Figure 32, the rebate former 18 may be dimpled on the backing 22 and on the folded edges 24 to facilitate retention of the rebate former 18 within surrounding concrete.
  • After casting of the first concrete component 14 and removal of the securing plugs 50, the connection system 10 includes a threaded reinforcing bar 32 threaded into each anchor 26, with an external thread 30 of the threaded reinforcing bar 32 mating with an internal thread 28 of the anchor 26 (see Figure 18).
  • Advantageously, as the anchors 26 provided with a coarse thread for threaded insertion of externally threaded reinforcing bar 32, this facilitates direct insertion of the reinforcing bar 32 into the internal thread 28 of each anchor 26 rather than requiring a metric thread to be tapped on to an end of the reinforcing bar 32. This may be advantageous as it may facilitate cutting on-site of a reinforcing bar 32 to size, then threading of the cup and of the reinforcing bar 32 directly into the anchor 26 without needing to form a metric thread on an end portion of the reinforcing bar 32.
  • Accordingly, there is also provided a method of providing a construction joint 12 between a first concrete component 14 and a second concrete component 16. The method includes the steps of:
    • providing a connection system 10 including a rebate former 18 for forming a rebate 20 in the first concrete component 14, wherein the rebate former 18 is formed of sheet metal, the rebate former 18 including an elongated backing 22, the elongated backing 22 having folded edges 24 to a predefined depth;
    • providing a plurality of anchors 26 coupled to the elongated backing 22, each of the anchors 26 having an internal thread 28;
    • providing a plurality of reinforcing bars 32, each of the reinforcing bars 32 having an external thread 30 along its length; and
    • threading one of the reinforcing bars 32 into each of the anchors 26 such that, for each anchor 26, an external thread 30 of a reinforcing bar 32 is threaded into the internal thread 28 of the anchor 26 to tighten the reinforcing bar 32 relative to the anchor 26 for providing reinforcement for the second concrete component 16.
  • The following features and/or advantages may be present in examples, according to the following aspects:
    • Modular Unit Placement
    • Pre-assembled unit ready pick and place onsite installation directly to formwork.
    • Removes the requirement to drill through shuttering onsite.
    • Flexibility of placement onsite vertical and horizontally.
    • Standard single row configuration units to suit smaller slab sizes (140mm to 180mm) with centrally placed lap bars.
    • Standard double row configuration units to suit medium to large sized slabs (190mm to 500mm) with top and bottom lap bars.
    • Multiple row placement ability with single row configuration units to suit extra-large slab sizes (500mm plus). Rows placed at top and bottom of slab. Added ability to place different anchor sizes for top and bottom reinforcing.
    • Multiple row placement ability with double row configuration units to suit extra-large slab sizes (500mm plus). Rows placed at top and bottom of slab. Added ability to place different anchor sizes for top and bottom reinforcing.
    • Standard 1000mm unit length to facilitate simple take-off and ordering. The units can be cut onsite into infills to match specific length requirements. Internal supports can be moved to block cut ends.
    • Standardised predefined rebate depth of 30mm to suit unit placement before first lay of reinforcing in the wall.
    Modular Anchor Placement
    • Units use a perforated sheet metal base, punched as a template which accurately spaces and configures structural anchors or couplers at required centers laterally across the joint and spaces them at cover requirements for top and bottom reinforcing (on double row configurations).
    • Available in different anchor sizes (RB12, RBA16, RB20, RBA20, RB25 and RB32).
    • Optimised anchor/coupler centers to meet connection design parameters.
    • Unit base assembly restrains attached coupler/anchors perpendicular the rebated joint face.
    • The refined 30mm rebate positions the anchors at the optimal embedment depth in the wall to provide maximum shear cone efficiency.
    • Rebated channel provides added positive shear resistance.
    Threaded Lap Bars
    • Screw in structural 500 MPa lap bars for easy connection onsite.
    • Optional full-length lap bar connection to floor to wall continuality system through use of a full length threaded structural reinforcing bars or a screw on coupler connection system. This reduces lapping at lap bars giving reduced bars cost of overlapping bars and congestion in reinforcing.
    • Lap lengths are not limited by what can fit into the box lengths (i.e. bar laying in typical pull-out bar systems). This allows the standard 1000mm box length to be cut to any shorter infill length with easy and allows for fully developed lap lengths on these shorter lengths.
    • Reduction in weight of continuity systems during setup and transport.
    • Reduces exposure of tripping hazards created by pull-out bars systems.
    • Improves installer exposure to repetitive stress injuries caused by bending out multiple pull-out bars.
    Optimised Bar Anchorage
    • Headed anchorage rather than looped or cogged reo lap bars being tied into vertical reinforcing. The 30mm predefined rebates places the anchors at the correct embedment to maximise shear cone size and efficiency in the placed-in slab.
    • Cogged anchor of design development length for correct embedment when used with coupler fittings.
    • The structural anchors used are genuine Reidbar fittings optimised for use with structural Reidbar. They are manufactured to the highest quality and tolerance to match the connecting bar. When tested in concrete against theoretically calculated alternative systems they achieve up to a 30% increase in efficiency over the other systems allowing for a reduction in anchor quantities required for connections. This reduces cost of fittings and labour as well as reducing reinforcing congestion.
    • Anchors optimised in centers and layers in prefabricated units to give maximum anchorage performance with minimal in place anchors.
    • Standard anchor application suitable for all types rebated structural connections on multi-level projects:
      • floor to wall
      • wall to wall
      • precast panel to floor
      • precast panel to wall
      • wall to capping slab
      • crane penetrations
      • stair flights and landings
      • corbels
      • beam to wall/column
    Securing Nailing Plate and Washer
    • Secures couplers or anchors to the unit assembly with a bolt and nut functionality during setup with formwork and pouring of concrete.
    • Easy attachment during manufacturing and removal onsite of nailing plates from couplers/anchors using a ½" driver and cordless drill.
    • Nailing plate thread matches the thread of coupler/anchor and blocks void and thread profile during the concrete pour to prevent concrete slurry ingress into the fitting.
    • Sizes available in to suit RBA16, RB20, RBA20, RB25 and RB32 Reidbar couplers and anchors.
    • Rubber washer fits between coupler/anchor and nailing plate to create a secure seal to prevent slurry ingress into the rebate box unit during the concrete pour.
    • Washer acts as an anti-vibration device for the nailing plates to ensure coupler/anchor remains tight until pouring.
    Dimpled Unit Base
    • Dimpled finish on unit base helps anchors base component into the slab when stripping lid.
    • The dimpled finish maximises the contact surface area between connecting slabs by up to 5%.
    • Eliminates need for scabbling rebate.
    • Made of galvanised sheet metal to prevent corrosion in the rebate.
    Stiffening Template
  • With reference to Figures 35 to 51, there is shown a connection system 10 for providing a construction joint 12 between a first concrete component 14 and a second concrete component 16, the connection system 10 including a rebate former 18 for forming a rebate 20 in a first concrete component 14, wherein the rebate former 18 has a backing 22, and the connection system 10 further includes a plurality of anchors 26 coupled to the backing 22 and at least one stiffening template 58 mounted to the backing 22 to prevent or at least reduce sag of the rebate former 18.
  • In the examples shown in the drawings, the rebate former 18 is formed of sheet metal and the backing 22 is in the form of an elongated backing 22, the elongated backing 22 having folded edges 24 to a predefined depth.
  • As can be seen clearly in Figure 35 and Figures 44 to 51, the stiffening template 58 includes an aperture 60 to enable one of the anchors 26 to pass through the stiffening template 58. In particular, as can be seen in Figure 35, the stiffening plates 58 may have a single aperture 60 for compatibility with single row rebate formers 18 as shown in Figure 36, and alternatively may have dual apertures 60 for compatibility with dual row rebate formers 18 as shown in Figure 37. In addition, the stiffening templates 58 light across and transverse to the rebate former 18, across a full width of the rebate former 18, such that shorter stiffening templates 58 are used for narrower rebate formers 18 and longer stiffening templates 58 are used for wider rebate formers 18. For example, the narrow rebate former 18 shown in Figure 36 may use a shorter stiffening template 58 as shown in Figure 35 (outer left), whereas the wider rebate former 18 shown in Figure 38 may use a longer stiffening template 58 as shown in Figure 35 (inner left). Similarly, the narrow dual row rebate former 18 shown in Figure 37 may use a shorter stiffening template 58 as shown in Figure 35 (inner right), whereas the wider dual row rebate former 18 shown in Figure 39 may use a longer stiffening template 58 as shown in Figure 35 (outer right).
  • The aperture 60 may be round as shown in figures 44 to 51, or alternatively, may be square as shown in Figures 35 and 43.
  • The stiffening template 58 is arranged to be clamped to the backing by the anchor 26. In particular, as shown in Figure 40 and Figure 41, the stiffening template 58 may be clamped to the backing 22 by the anchor 26 and the securing plug 50, in particular by treading tightly the securing plug 50 into the anchor 26. In this way, the stiffening plate 58 adds rigidity to the rebate former 18 and controls or at least minimises sag of threaded insert anchors 26 due to gravity and concrete weight (when poured) when the rebate former 18 is positioned in a vertical orientation. The stiffening template 58 may be easily installed under fixing nailing plates (securing plugs 50) inside the rebate box (rebate former 18). The forces due to gravity and concrete weight are depicted by the blue arrows in Figure 40 and Figure 41, whereas the reaction force of the concrete against the rebate former 18 is depicted by the green parallel arrows.
  • As shown in Figure 38, each anchor 26 may be provided with its own stiffening plate 58 for a single row rebate former 18. With reference to Figure 39, in the case of a dual row rebate former 18, each opposite pair of anchors 26 may be provided with their own stiffening plate 58.
  • With reference to Figures 36 to 39, each of the stiffening templates 58 extends transversely across the elongated backing 22, tightened in place against the backing 22 by the anchors 26 and threaded securing plugs 50, thereby strengthening the rebate former 18 and minimising sag of the anchors 26. As the stiffening templates 58 are held in place by the threaded securing plugs 50, they are easily removed from the shear box once poured into the wall to facilitate placement of lap bars before the floor pour (second pour).
  • Each of the stiffening templates 58 is folded along opposite edges 62 to improve rigidity. The folds at the opposite edges 62 are preferably perpendicular to a central surface of the stiffening template 58 so as to form strengthening flanges 64. In the examples shown, these flanges 64 are parallel and extend along the full length of the stiffening template 58. When in situ, as shown in detail in Figure 42 and Figure 43, the folded edges (flanges 64) of the stiffening template 58 are oriented transversely to the elongated backing 22.
  • Accordingly, as will be appreciated from the above, there is provided a stiffening template 58 for reinforcing a rebate former 18 in a construction joint 12 between a first concrete component 14 and a second concrete component 16, the stiffening template 58 comprising a plate 66 having opposed folded edges 64 to provide rigidity, and the stiffening template 58 further includes at least one aperture 60 for accommodating an anchor 26 coupled to the rebate former 18.
  • With reference to Figure 52, there is shown a detailed view of a stiffening template 58 in place in a connection system 10 in accordance with another example of the present invention, similar to Figure 42, but with the stiffening template 58 in an inverted configuration relative to the elongated backing 22. In particular, as can be seen clearly in the exploded view of Figure 52, the stiffening template 58 is inverted so that flanges 64 face the elongated backing 22. This results in the securing plugs 50 being seated further from the elongated backing 22, as the plate 66 is spaced relative to the elongated backing by virtue of the flanges 64. In contrast, in the arrangement shown in Figure 42 and Figure 43, the plate 66 of each stiffening template 58 rests against the elongated backing 22, and the flanges 64 face outward and away from the elongated backing 22.
  • Accordingly, with the stiffening template 58 in the same functional scenario, it can sometimes be more advantageous to position it in an inverted direction (with the folded flanges 64 to the base) to ensure better function. The stiffening templates 58 can be placed in either direction, as may be deemed more appropriate for a particular situation, within the scope of the invention.
  • With reference to Figures 35 to 53, these drawings relate to the connection system including the stiffening template, whereas Figures 1 to 34 relate to the connection system without the stiffening template. As can be seen in the drawings, various of Figures 1 to 34 show the use of a rubber washer 56 on the inside of the box between the securing plug 50 and the base (elongated backing 22). Due to design changes in the connection system shown in Figures 35 to 53, the washer is now placed on the outside of the box between the anchor 26 and the base (elongated backing 22).
  • While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not by way of limitation. It will be apparent to a person skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. Thus, the present invention should not be limited by any of the above described exemplary embodiments.
  • Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
  • The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge.
    • List of numbered features
  • Connection system 10
    Construction joint 12
    First concrete component 14
    Second concrete component 16
    Rebate former 18
    Rebate 20
    Elongated backing 22
    Folded edges 24
    Anchors 26
    Internal thread 28
    External thread 30
    Reinforcing bar 32
    Foot 34
    External ribs 36
    Folded end 38
    Lid 40
    Internal cavity 42
    Strap 44
    Intermediate section 46
    Cross strut 48
    Securing plug 50
    External thread 52
    Enlarged base 54
    Resilient washer 56
    Stiffening template 58
    Aperture 60
    Opposite edges 62
    Flanges 64
    Plate 66

Claims (15)

  1. A connection system for providing a construction joint between a first concrete component and a second concrete component, the connection system including a rebate former for forming a rebate in a first concrete component, wherein the rebate former has a backing, and the connection system further includes a plurality of anchors coupled to the backing and at least one stiffening template mounted to the backing to prevent or at least reduce sag of the rebate former.
  2. A connection system as claimed in claim 1, wherein the rebate former is formed of sheet metal.
  3. A connection system as claimed in claim 2, wherein the backing is in the form of an elongated backing, the elongated backing having folded edges to a predefined depth.
  4. A connection system as claimed in any one of claims 1 to 3, wherein the stiffening template includes an aperture to enable one of said anchors to pass through the stiffening template.
  5. A connection system as claimed in any one of claims 1 to 4, wherein the stiffening template is arranged to be clamped to the backing by the anchor.
  6. A connection system as claimed in any one of claims 1 to 5, wherein the stiffening template extends transversely across the elongated backing.
  7. A connection system as claimed in any one of claims 1 to 6, wherein the stiffening template is folded along opposite edges to improve rigidity.
  8. A connection system as claimed in any one of claims 1 to 7, wherein each of the anchors has an internal thread for receiving an external thread of a reinforcing bar for reinforcing a second concrete component.
  9. A connection system as claimed in any one of claims 1 to 7, wherein the rebate former has folded ends to provide structural rigidity.
  10. A connection system as claimed in claim 1, wherein the connection system includes a lid for covering an internal cavity of the rebate former defined by the elongated backing and the folded edges.
  11. A connection system as claimed in any one of claims 1 to 7, including a plurality of parallel rebate formers joined by an intermediate section.
  12. A connection system as claimed in any one of claims 1 to 7, wherein the rebate former includes a cross strut extending across a width of the internal cavity of the rebate former.
  13. A connection system as claimed in any one of claims 1 to 7, wherein the rebate former is dimpled on the backing and on the folded edges to facilitate retention of the rebate former within surrounding concrete.
  14. A stiffening template for reinforcing a rebate former in a construction joint between a first concrete component and a second concrete component, the stiffening template comprising a plate having opposed folded edges to provide rigidity, and the stiffening template further including at least one aperture for accommodating an anchor coupled to the rebate former.
  15. A method of providing a construction joint between a first concrete component and a second concrete component, the method including the steps of:
    providing a connection system including a rebate former for forming a rebate in the first concrete component, wherein the rebate former includes a backing;
    mounting at least one stiffening template to the backing to prevent or at least reduce sag of the rebate former;
    providing a plurality of anchors coupled to the backing, each of the anchors having an internal thread;
    providing a plurality of reinforcing bars, each of the reinforcing bars having an external thread along its length; and
    threading one of the reinforcing bars into each of the anchors such that, for each anchor, an external thread of a reinforcing bar is threaded into the internal thread of the anchor to tighten the reinforcing bar relative to the anchor for providing reinforcement for the second concrete component.
EP25160083.9A 2024-02-26 2025-02-25 Connection system and stiffening template Pending EP4606963A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2024900474A AU2024900474A0 (en) 2024-02-26 Connection system and stiffening template
AU2025201046A AU2025201046A1 (en) 2024-02-26 2025-02-14 Connection system and stiffening template

Publications (1)

Publication Number Publication Date
EP4606963A1 true EP4606963A1 (en) 2025-08-27

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US (1) US20250270806A1 (en)
EP (1) EP4606963A1 (en)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2820201B1 (en) * 2012-02-29 2015-07-15 Permaban Limited Anti-spalling edging
EP4141181A1 (en) * 2021-08-25 2023-03-01 Illinois Tool Works, Inc. Connection system

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2820201B1 (en) * 2012-02-29 2015-07-15 Permaban Limited Anti-spalling edging
EP4141181A1 (en) * 2021-08-25 2023-03-01 Illinois Tool Works, Inc. Connection system

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