US20160305140A1 - Method and apparatus for repairing post-tensioned concrete - Google Patents
Method and apparatus for repairing post-tensioned concrete Download PDFInfo
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- US20160305140A1 US20160305140A1 US15/196,575 US201615196575A US2016305140A1 US 20160305140 A1 US20160305140 A1 US 20160305140A1 US 201615196575 A US201615196575 A US 201615196575A US 2016305140 A1 US2016305140 A1 US 2016305140A1
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- segment
- tubular member
- end cap
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- 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
- E04G23/00—Working measures on existing buildings
- E04G23/02—Repairing, e.g. filling cracks; Restoring; Altering; Enlarging
- E04G23/0218—Increasing or restoring the load-bearing capacity of building construction elements
- E04G23/0237—Increasing or restoring the load-bearing capacity of building construction elements of storey floors
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
- E04C2/06—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres reinforced
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
- E04C5/08—Members specially adapted to be used in prestressed constructions
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
- E04C5/16—Auxiliary parts for reinforcements, e.g. connectors, spacers, stirrups
- E04C5/162—Connectors or means for connecting parts for reinforcements
- E04C5/163—Connectors or means for connecting parts for reinforcements the reinforcements running in one single direction
- E04C5/165—Coaxial connection by means of sleeves
-
- 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
- E04G23/00—Working measures on existing buildings
- E04G23/02—Repairing, e.g. filling cracks; Restoring; Altering; Enlarging
- E04G23/0218—Increasing or restoring the load-bearing capacity of building construction elements
-
- 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
- E04G23/00—Working measures on existing buildings
- E04G23/02—Repairing, e.g. filling cracks; Restoring; Altering; Enlarging
- E04G23/0218—Increasing or restoring the load-bearing capacity of building construction elements
- E04G23/024—Increasing or restoring the load-bearing capacity of building construction elements of basement floors
Definitions
- the invention broadly relates to a method and apparatus for repairing post-tensioned concrete, and more particularly, to an end cap secured to a tubular member used during the splicing and coupling of post-tensioned concrete repairs.
- Post-tensioned concrete is widely used in building structures as it provides a light, structurally efficient, durable solution for the construction of commercial office buildings, residential apartments, high-rise condominiums, and mixed-use facilities such as hotels and casinos.
- Post-tensioned concrete is also utilized frequently in the elevated concrete decks and sometimes in the ground floor slabs of condominium structures, including the associated parking garages. Longer, thinner slabs result in greater design flexibility and require less reinforcing steel to achieve the same strength as other methods of construction.
- post-tensioned concrete greatly reduces the floor-to-floor height when compared to structural steel options, which results in significant savings in the façade, HVAC, electrical, plumbing, and vertical transportation systems.
- post-tension concrete was introduced into residential high-rise construction as a means to reduce the thickness of the elevated concrete decks, to widen spans between column supports, and to speed up the construction process.
- post-tension reinforcement includes stranded cables, also referred to as “tendons” or a “strand,” that are contained typically in a plastic sheath and are positioned in the forms before the concrete is poured. Afterwards, once the concrete has gained strength but before the service loads are applied, the cables are pulled tight, or “tensioned”, and anchored against the outer edges of the concrete. Concrete has a very high compressive strength, typically 3,000 to over 10,000 psi, but very low tensile strength, typically 300 to 400 psi. Post-tension cables provide tensile strength to the concrete. This increase in tensile strength is achieved when the cables are stressed under significant tension loads following the pouring of the concrete.
- a post-tension slab was typically constructed with cables laid out in two directions, typically at 90 degrees to one another.
- the cables are enclosed in a plastic sheathing to separate them from, and allow for movement within, the surrounding concrete.
- Each cable is anchored at one end of the slab and then placed loosely across the slab to another steel anchor located at the opposite end of the slab.
- Two steel reinforcing bars are placed behind the anchors to help distribute the high tensions forces from the anchors.
- Repair of a damaged post-tension cable is performed by typically exposing one or both ends of the damaged cable at the edges and at one or multiple locations where the cable breeched the concrete. A new cable or portion of a cable is used to replace the damaged cable. If the entire cable is replaced, the old cable is removed from the plastic sheathing within the concrete and a new cable is installed through the sheathing. The affected sheathing and the concrete are then repaired, and allowed to cure. The cable is then tensioned and the ends patched. If only a portion of a cable is replaced, the connection of the new cable to the older cable is accomplished with a post-tension cable splice and then repaired in the same fashion as replacing the entire cable mentioned above.
- the cables are usually encased in a flexible plastic protective hose, typically called a sheath or duct, to prevent the cable from bonding to the concrete during placement and curing of the concrete.
- the protective sheathing remains in the structure. In some cases, the void between the cable and the sheath is filled with grout. In this manner, the cable becomes bonded to the concrete section and corrosion of the steel cable is prevented. In other cases, the cable is coated with grease prior to placement into a protective sheathing. Cables of this type are not pressure grouted after stressing.
- This type of post-tensioning is usually referred to as an un-bonded post-tensioning system.
- concrete is poured and allowed to cure.
- a segment of polyvinyl chloride (PVC), polyethylene, etc. is used to cover the splice coupler.
- devices such as pocket formers are used as caps on each end of the PVC to hold the cable in place inside the PVC.
- PVC polyvinyl chloride
- pocket formers are used as caps on each end of the PVC to hold the cable in place inside the PVC.
- the present invention broadly comprises a combination end cap and tubular member for use in repairing post-tensioned concrete, where the end cap includes a first segment, a second segment, and a third segment.
- the first segment has a first end and a first opening, where the first segment is substantially cylindrical in shape.
- the second segment is substantially frustoconical in shape.
- the third segment has a second end and a second opening and is substantially cylindrical in shape.
- the second segment is disposed between and integral with the first segment and the third segment.
- a cavity is formed by the first, second, and third segments, where the first end is arranged to be secured to a tubular member and at least one cable is disposed longitudinally within the cavity.
- the end cap has an outer surface and an inner surface and the tubular member has an outer surface, an inner surface, a first end, and a second end, and the first end of the first segment is secured to the first end of the tubular member such that the inner surface of the end cap contacts the outer surface of the tubular member.
- a second end cap is secured to the second end of the tubular member.
- the first segment has a first diameter (D 1 ) and the third segment has a second diameter (D 2 ), and the first diameter is larger than the second diameter.
- the first diameter (D 1 ) is approximately 2.375 inches and the second diameter (D 2 ) is approximately 0.67 inches.
- the first end of the tubular member has a third diameter (D 3 ) and the third diameter (D 3 ) of the first end of the tubular member is slightly smaller than the first diameter (D 1 ) of the first segment.
- the tubular member has at least one splice coupler disposed therein and secured to at least one cable and the at least one cable is disposed longitudinally within the cavity.
- the invention further includes at least one sealing member, having a first end, a second end, and a throughbore disposed therein. The second end of the third segment of the end cap is secured to the first end of the sealing member, such that preferably, the sealing member and the end cap form a watertight seal.
- the end cap is made of plastic, such as polypropylene.
- the end cap may be made of metal, plastic, rubber, wood, etc., or any suitable material known in the art.
- the present invention also includes a method of installing an end cap during the repair of a post-tension concrete structure, where the end cap includes a first segment, a second segment, and a third segment, the first segment having a first end, and the second segment having a second end.
- the method includes the following steps: (1) cutting an opening in a slab of concrete, (2) installing a temporary anchor device to transfer the load of at least one cable to the temporary anchor device, (3) cutting a section of the at least one cable, (3) removing a section of the at least one cable, (4) replacing the section of the at least one cable with a second section of at least one cable, (5) installing an encapsulated anchorage, (6) affixing a splice coupler to secure an end of the remaining at least one cable to an end of the second section of at least one cable and where the remaining at least one cable and the second section of the at least one cable are disposed within the splice coupler, (7) installing a tubular member, having a first end and a second end, to cover the splice coupler, (8) securing the first end of at least one end cap to the first end of the tubular member, (9) pouring concrete to fill the opening, (10) stressing the at least one cable after the concrete has cured and reached a specified compressive strength, and
- FIG. 1 is a top plan view depicting two pocket formers disposed at opposite ends of a tubular member and a plurality of cables disposed therein;
- FIG. 2 is a top plan view of two end caps disposed at opposite ends of a tubular member and a plurality of cables disposed therein;
- FIG. 3 is a top plan view of the first end cap of FIG. 2 secured to the tubular member, shown with the plurality of cables removed;
- FIG. 4 is a perspective view of the end cap and the tubular member of FIG. 3 ;
- FIG. 5 is an exploded view of the end cap and the tubular member of FIG. 3 ;
- FIG. 6 is a perspective view of the end cap of FIG. 3 ;
- FIG. 7 is a front elevational view of the end cap of FIG. 3 ;
- FIG. 8 is a right side elevational view of the end cap of FIG. 3 ;
- FIG. 9 is a left side elevational view of the end cap of FIG. 3 ;
- FIG. 10 is a cross-sectional view of the end cap and the tubular member taken generally along the line 10 - 10 of FIG. 2 .
- FIG. 11 is a top plan view, similar to FIG. 2 , illustrating two end caps disposed at opposite ends of a tubular member and a plurality of cables disposed therein, and additionally, two sealing members are included, disposed at opposite ends, and a portion of the plurality cables is shown enclosed in sheathing.
- FIG. 12 is a cross-sectional view of the end cap and the tubular member taken generally along the line 12 - 12 of FIG. 11 .
- FIG. 13 is a detailed cross-sectional view of the end cap and the tubular member taken generally along the line 13 - 13 of FIG. 12 .
- FIG. 2 is a top plan view of two end caps 10 , 10 b disposed at opposite ends of tubular member 90 and plurality of cables 92 disposed therein and disposed in concrete 91 .
- FIG. 3 is a top plan view of first end cap 10 secured to tubular member 90 , shown with plurality of cables removed 92 removed.
- end cap 10 includes first end 11 , second end 12 , first segment 13 , second segment 14 , and third segment 15 .
- end cap 10 includes first end 11 , second end 12 , first segment 13 , second segment 14 , and third segment 15
- FIG. 4 is a perspective view of end cap 10 and tubular member 90 of FIG. 3 .
- FIG. 5 is an exploded view of end cap 10 and tubular member 90 of FIG. 3 .
- FIG. 6 is a perspective view of end cap 10 of FIG. 3 .
- FIG. 7 is a front elevational view of end cap 10 of FIG. 3 .
- FIG. 8 is a right side elevational view of end cap 10 of FIG. 3 .
- FIG. 9 is a left side elevational view of end cap 10 of FIG. 3 .
- FIG. 10 is a cross-sectional view of end cap 10 and tubular member 90 taken generally along the line 10 - 10 of FIG. 2 .
- first segment 13 includes first end 11 and first opening 23 .
- first segment 13 is substantially cylindrical in shape.
- Second segment 14 is substantially frustoconical in shape.
- Third segment 15 includes second end 12 and second opening 24 .
- third segment 15 is substantially cylindrical in shape.
- Second segment 14 is disposed between and integral with first segment 13 and third segment 15 .
- first segment 13 transitions into second segment 14 at first transition 19
- second segment 14 transitions into third segment 15 at second transition 21 .
- first segment 13 extends longitudinally towards first transition 19 and at first transition 19 second segment 14 begins to taper as second segment 14 extends towards second transition 21 .
- third segment 15 continues to extend longitudinally towards second end 12 .
- Cavity 22 is formed by first segment 13 , second segment 14 , and third segment 15 , where first end 11 is arranged to be secured to tubular member 90 and at least one cable, but preferably plurality of cables 92 , is disposed longitudinally within cavity 22 .
- plurality of cables 92 enter through second opening 24 of end cap 10 , run longitudinally through first opening 23 of end cap 10 , are spliced and secured via coupler 96 , run longitudinally through a first opening of end cap 10 b and exit through a second opening of end cap 10 b , or vice versa, as the order can be transposed starting with plurality of cables entering through the second opening of end cap 10 b.
- Second end cap 10 b has substantially the same configuration as first end cap 10 .
- first segment 13 b includes first end 11 b .
- first segment 13 b is substantially cylindrical in shape.
- Second segment 14 b is substantially frustoconical in shape.
- Third segment 15 b includes second end 12 b .
- third segment 15 b is substantially cylindrical in shape.
- Second segment 14 b is disposed between and integral with first segment 13 b and third segment 15 b .
- first segment 13 b transitions into second segment 14 b at first transition 19 b
- second segment 14 b transitions into third segment 15 b at second transition 21 b .
- first segment 13 b extends longitudinally towards first transition 19 b and at first transition 19 b second segment 14 b begins to taper as second segment 14 b extends towards second transition 21 b .
- third segment 15 b continues to extend longitudinally towards second end 12 b .
- Cavity 22 b is formed by first segment 13 b , second segment 14 b , and third segment 15 b , where first end 11 b is arranged to be secured to tubular member 90 and at least one cable, but preferably plurality of cables 92 , is disposed longitudinally within cavity 22 b.
- end cap 10 further includes outer surface 16 and inner surface 18 .
- tubular member 90 has outer surface 93 and inner surface 94 .
- Tubular member 90 further includes first end 95 a and second end 95 b .
- first end 11 of first segment 13 is secured to first end 95 a of tubular member 90 such that inner surface 18 of end cap 10 contacts outer surface 93 of the tubular member 90 .
- second end cap 10 b is secured to second end 95 b of tubular member 90 .
- first segment 13 has diameter D 1 and third segment 15 has diameter D 2 .
- First diameter D 1 is larger than second diameter D 2 .
- first diameter D 1 is approximately 2.375 inches and second diameter D 2 is approximately 0.67 inches.
- first end 95 a of tubular member 90 has third diameter D 3 (not shown in the figures) and third diameter D 3 is slightly smaller than first diameter D 1 of first segment 13 .
- third diameter D 3 of tubular member 90 is slightly smaller than first diameter D 1 in order to secure end cap 10 to tubular member 90 via an interference or friction fit.
- any of the elements of the end cap can be various sizes, shapes, and configurations suitable in the art.
- end caps 10 , 10 b are made of plastic, such as polypropylene.
- the end cap may be made of metal, plastic, rubber, wood, etc., or any suitable material known in the art.
- FIG. 11 is a top plan view, similar to FIG. 2 , illustrating is a top plan view of two end caps 10 , 10 b disposed at opposite ends of tubular member 90 and plurality of cables 92 disposed therein and disposed in concrete 91 . Additionally, FIG. 2 shows two sealing members 25 , 25 b disposed at opposite ends and at least a portion of plurality of cables 92 is shown wrapped in sheathing 97 a , 97 b.
- FIG. 12 is a cross-sectional view of end cap 10 and tubular member 90 taken generally along the line 12 - 12 of FIG. 11 .
- FIG. 13 is a detailed cross-sectional view of end cap 10 and tubular member 90 taken generally along the line 13 - 13 of FIG. 12 .
- the invention further includes sealing members 25 , 25 b .
- Sealing member 25 has first end 26 , second end 28 , and throughbore 29 disposed therein.
- sealing member 25 b has first end 26 b , second end 28 b , and throughbore 29 b disposed therein.
- second end 12 of third segment 15 of end cap 10 is secured to first end 26 of sealing member 25 , such that preferably, sealing member 25 and end cap 10 form a watertight seal.
- second end 12 b of third segment 15 b of end cap 10 b is secured to first end 26 b of sealing member 25 b , such that preferably, sealing member 25 b and end cap 10 b form a watertight seal.
- plurality of cables 92 is shown where at least a portion is enclosed in sheathing 97 a , 97 b .
- sheathing 97 a continues longitudinally partway through end cap 10 and ceases prior to reaching coupler 96 .
- sheathing 97 b continues longitudinally partway through end cap 10 b and ceases prior to reaching coupler 96 .
- Unbonded post-tensioned concrete differs from bonded post-tensioning by providing each individual cable permanent freedom of movement relative to the concrete. To allow this movement, each individual cable or tendon of the plurality of cables is coated with a lubricant and covered by sheathing formed in an extrusion process.
- the sheathing is made of plastic but can be made of any material known in the art.
- the present invention is a method of installing end cap 10 during the repair of a post-tension concrete structure, where end cap 10 includes first segment 13 , second segment 14 , and third segment 15 .
- First segment 13 has first end 11 and third segment 15 has second end 12 .
- the method includes the following steps: (1) cutting an opening in slab of concrete 91 , (2) installing a temporary anchor device to transfer the load of at least one cable, but preferably plurality of cables 92 to the temporary anchor device, (3) cutting a section of plurality of cables 92 , (3) removing a section of plurality of cables 92 , (4) replacing the section of plurality of cables 92 with a second section of plurality of cables 92 , (5) installing an encapsulated anchorage, (6) affixing a splice coupler, i.e., coupler 96 , to secure an end of the remaining plurality of cables 92 to an end of the second section of plurality of cables 92 and where the remaining plurality of cables 92 and the second section of plurality of cables 92 are disposed within coupler 96 , (7) installing tubular member 90 , having first end 95 a and second end 95 b , to cover coupler 96 , (8) securing first end 11 of end cap 10 to first end 95 a of tubular
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Abstract
A combination end cap and tubular member for use in repairing post-tensioned concrete, including a first segment, a second segment, and a third segment. The first segment has a first end and a first opening, where the first segment is substantially cylindrical in shape. The second segment is substantially frustoconical in shape. The third segment has a second end and a second opening and is substantially cylindrical in shape. The second segment is disposed between and integral with the first segment and the third segment. A cavity is formed by the first, second, and third segments, where the first end is arranged to be secured to a tubular member and at least one cable is disposed longitudinally within the cavity.
Description
- This application is a Continuation-in-Part patent application under 35 U.S.C. §120 of U.S. patent application Ser. No. 14/599,085 filed Jan. 16, 2015, which application is incorporated herein by reference.
- The invention broadly relates to a method and apparatus for repairing post-tensioned concrete, and more particularly, to an end cap secured to a tubular member used during the splicing and coupling of post-tensioned concrete repairs.
- Post-tensioned concrete is widely used in building structures as it provides a light, structurally efficient, durable solution for the construction of commercial office buildings, residential apartments, high-rise condominiums, and mixed-use facilities such as hotels and casinos. Post-tensioned concrete is also utilized frequently in the elevated concrete decks and sometimes in the ground floor slabs of condominium structures, including the associated parking garages. Longer, thinner slabs result in greater design flexibility and require less reinforcing steel to achieve the same strength as other methods of construction. Additionally, post-tensioned concrete greatly reduces the floor-to-floor height when compared to structural steel options, which results in significant savings in the façade, HVAC, electrical, plumbing, and vertical transportation systems. As such, post-tension concrete was introduced into residential high-rise construction as a means to reduce the thickness of the elevated concrete decks, to widen spans between column supports, and to speed up the construction process.
- Generally, post-tension reinforcement includes stranded cables, also referred to as “tendons” or a “strand,” that are contained typically in a plastic sheath and are positioned in the forms before the concrete is poured. Afterwards, once the concrete has gained strength but before the service loads are applied, the cables are pulled tight, or “tensioned”, and anchored against the outer edges of the concrete. Concrete has a very high compressive strength, typically 3,000 to over 10,000 psi, but very low tensile strength, typically 300 to 400 psi. Post-tension cables provide tensile strength to the concrete. This increase in tensile strength is achieved when the cables are stressed under significant tension loads following the pouring of the concrete.
- In the past, a post-tension slab was typically constructed with cables laid out in two directions, typically at 90 degrees to one another. The cables are enclosed in a plastic sheathing to separate them from, and allow for movement within, the surrounding concrete. Each cable is anchored at one end of the slab and then placed loosely across the slab to another steel anchor located at the opposite end of the slab. Two steel reinforcing bars are placed behind the anchors to help distribute the high tensions forces from the anchors. Once the steel, cables, and anchors are installed, the concrete is poured. After the concrete has reached an acceptable strength, the cable is tensioned within the concrete slab, which is achieved by pulling the cable to a force of approximately 33,000 pounds. Two steel wedges are placed around the cable and within the anchor to lock the cable at the applied tension load.
- One example of a tendon anchorage system for use in prestressing concrete is found in U.S. Pat. No. 3,936,256 (Howlett et al.) In the invention of Howlett et al., the tendon anchorage is placed prior to the original concrete structure being poured into the form and is located in a recess in the end of the concrete structure, such that the tendons can be easily accessed and tensioned after the form is removed. One problem is that while this type of anchorage system can be used in the initial concrete structure, it cannot be used for concrete repairs, as there is no way to splice and couple the cable with this anchorage system.
- Many early post-tension installations did not include corrosion protection of the steel anchorage and cable ends. As a result, penetration of moisture through the concrete often results in the corrosion of the post-tension cable, anchor, and wedges. The presence of corrosion can have a substantial impact on the structural integrity of the post-tension system. Additionally, a post-tension cable can be compromised when types of restoration, renovation, or remedial work are being performed on a post-tensioned reinforced structure. Moreover, post-tension cables can also be compromised when the original construction was performed poorly or maintenance of the exterior of a building is not performed on a regular basis. In any of these situations, the ends of the cables at the edges of concrete are allowed to corrode, and without proper maintenance, the corrosion can advance to the point where cables or end anchors fail.
- Repair of a damaged post-tension cable is performed by typically exposing one or both ends of the damaged cable at the edges and at one or multiple locations where the cable breeched the concrete. A new cable or portion of a cable is used to replace the damaged cable. If the entire cable is replaced, the old cable is removed from the plastic sheathing within the concrete and a new cable is installed through the sheathing. The affected sheathing and the concrete are then repaired, and allowed to cure. The cable is then tensioned and the ends patched. If only a portion of a cable is replaced, the connection of the new cable to the older cable is accomplished with a post-tension cable splice and then repaired in the same fashion as replacing the entire cable mentioned above.
- Due to the extremely high force in the cables, removal of the concrete behind the anchor and bars can cause a significant failure of the slab. As a result, replacement of deteriorated anchors requires de-tensioning of the affected cable. It should be noted that only the damaged portion of the cable is de-tensioned during repairs, as the remaining cable must retain post-tension force in order to maintain the structural integrity of the slab. The de-tensioning of the cable is accomplished by opening a small area of the concrete slab inward from the area to be repaired. Within this opening, a temporary cable “lock-off” device is installed. The lock-off location is generally two to three feet from the edge so that the cable forces can flow or be redirected around the opening with a risk of a concrete failure. The outer portion of the cable is then released, and repairs can begin.
- During concrete repairs, replacement anchors and cables are installed. To provide protection against corrosion, plastic sheathed anchorage systems that protect all the parts of the anchors and cables are used. The cables are usually encased in a flexible plastic protective hose, typically called a sheath or duct, to prevent the cable from bonding to the concrete during placement and curing of the concrete. The protective sheathing remains in the structure. In some cases, the void between the cable and the sheath is filled with grout. In this manner, the cable becomes bonded to the concrete section and corrosion of the steel cable is prevented. In other cases, the cable is coated with grease prior to placement into a protective sheathing. Cables of this type are not pressure grouted after stressing. This type of post-tensioning is usually referred to as an un-bonded post-tensioning system. Once installed, and the new cables spliced to the lock-off cable, concrete is poured and allowed to cure. As shown in
FIG. 1 , presently, a segment of polyvinyl chloride (PVC), polyethylene, etc., is used to cover the splice coupler. Then, devices such as pocket formers are used as caps on each end of the PVC to hold the cable in place inside the PVC. One problem with using a pocket former is that because pocket formers were not designed to be used as end caps, they do not tightly fit the PVC and can shift, allowing concrete to potentially enter the cavity. - Thus, there is a long felt need for an apparatus that tightly fits the ends of a tubular member, such as a PVC segment, when repairing concrete structures, to prevent concrete from entering the cavity of the PVC segment.
- The present invention broadly comprises a combination end cap and tubular member for use in repairing post-tensioned concrete, where the end cap includes a first segment, a second segment, and a third segment. The first segment has a first end and a first opening, where the first segment is substantially cylindrical in shape. The second segment is substantially frustoconical in shape. The third segment has a second end and a second opening and is substantially cylindrical in shape. The second segment is disposed between and integral with the first segment and the third segment. A cavity is formed by the first, second, and third segments, where the first end is arranged to be secured to a tubular member and at least one cable is disposed longitudinally within the cavity.
- In an embodiment, the end cap has an outer surface and an inner surface and the tubular member has an outer surface, an inner surface, a first end, and a second end, and the first end of the first segment is secured to the first end of the tubular member such that the inner surface of the end cap contacts the outer surface of the tubular member. Preferably, a second end cap is secured to the second end of the tubular member.
- In an embodiment, the first segment has a first diameter (D1) and the third segment has a second diameter (D2), and the first diameter is larger than the second diameter. Preferably, the first diameter (D1) is approximately 2.375 inches and the second diameter (D2) is approximately 0.67 inches. Additionally, the first end of the tubular member has a third diameter (D3) and the third diameter (D3) of the first end of the tubular member is slightly smaller than the first diameter (D1) of the first segment.
- In another embodiment, the tubular member has at least one splice coupler disposed therein and secured to at least one cable and the at least one cable is disposed longitudinally within the cavity. In yet another embodiment, the invention further includes at least one sealing member, having a first end, a second end, and a throughbore disposed therein. The second end of the third segment of the end cap is secured to the first end of the sealing member, such that preferably, the sealing member and the end cap form a watertight seal.
- Preferably, the end cap is made of plastic, such as polypropylene. However, it should be appreciated that the end cap may be made of metal, plastic, rubber, wood, etc., or any suitable material known in the art.
- The present invention also includes a method of installing an end cap during the repair of a post-tension concrete structure, where the end cap includes a first segment, a second segment, and a third segment, the first segment having a first end, and the second segment having a second end. The method includes the following steps: (1) cutting an opening in a slab of concrete, (2) installing a temporary anchor device to transfer the load of at least one cable to the temporary anchor device, (3) cutting a section of the at least one cable, (3) removing a section of the at least one cable, (4) replacing the section of the at least one cable with a second section of at least one cable, (5) installing an encapsulated anchorage, (6) affixing a splice coupler to secure an end of the remaining at least one cable to an end of the second section of at least one cable and where the remaining at least one cable and the second section of the at least one cable are disposed within the splice coupler, (7) installing a tubular member, having a first end and a second end, to cover the splice coupler, (8) securing the first end of at least one end cap to the first end of the tubular member, (9) pouring concrete to fill the opening, (10) stressing the at least one cable after the concrete has cured and reached a specified compressive strength, and (11) removing the temporary anchor device. Preferably, after securing the first end of the at least one end cap to the first end of the tubular member, the method further includes securing the first end of a second end cap to the second end of the tubular member.
- These and other objects and advantages of the present invention will be readily appreciable from the following description of preferred embodiments of the invention and from the accompanying drawings and claims.
- The nature and mode of operation of the present invention will now be more fully described in the following detailed description of the invention taken with the accompanying drawing figures, in which:
-
FIG. 1 is a top plan view depicting two pocket formers disposed at opposite ends of a tubular member and a plurality of cables disposed therein; -
FIG. 2 is a top plan view of two end caps disposed at opposite ends of a tubular member and a plurality of cables disposed therein; -
FIG. 3 is a top plan view of the first end cap ofFIG. 2 secured to the tubular member, shown with the plurality of cables removed; -
FIG. 4 is a perspective view of the end cap and the tubular member ofFIG. 3 ; -
FIG. 5 is an exploded view of the end cap and the tubular member ofFIG. 3 ; -
FIG. 6 is a perspective view of the end cap ofFIG. 3 ; -
FIG. 7 is a front elevational view of the end cap ofFIG. 3 ; -
FIG. 8 is a right side elevational view of the end cap ofFIG. 3 ; -
FIG. 9 is a left side elevational view of the end cap ofFIG. 3 ; and, -
FIG. 10 is a cross-sectional view of the end cap and the tubular member taken generally along the line 10-10 ofFIG. 2 . -
FIG. 11 is a top plan view, similar toFIG. 2 , illustrating two end caps disposed at opposite ends of a tubular member and a plurality of cables disposed therein, and additionally, two sealing members are included, disposed at opposite ends, and a portion of the plurality cables is shown enclosed in sheathing. -
FIG. 12 is a cross-sectional view of the end cap and the tubular member taken generally along the line 12-12 ofFIG. 11 . -
FIG. 13 is a detailed cross-sectional view of the end cap and the tubular member taken generally along the line 13-13 ofFIG. 12 . - At the outset, it should be appreciated that like drawing numbers on different drawing views identify identical, or functionally similar, structural elements of the invention. While the present invention is described with respect to what is presently considered to be the preferred aspects, it is to be understood that the invention as claimed is not limited to the disclosed aspects.
- Furthermore, it is understood that this invention is not limited to the particular methodology, materials and modifications described and, as such, may, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to limit the scope of the present invention, which is limited only by the appended claims.
- Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs. It should be appreciated that the term “substantially” is synonymous with terms such as “nearly”, “very nearly”, “about”, “approximately”, “around”, “bordering on”, “close to”, “essentially”, “in the neighborhood of”, “in the vicinity of”, etc., and such terms may be used interchangeably as appearing in the specification and claims. Although any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the invention, the preferred methods, devices, and materials are now described.
- Adverting now to the figures,
FIG. 2 is a top plan view of twoend caps tubular member 90 and plurality ofcables 92 disposed therein and disposed inconcrete 91.FIG. 3 is a top plan view offirst end cap 10 secured totubular member 90, shown with plurality of cables removed 92 removed. Generally,end cap 10 includesfirst end 11,second end 12,first segment 13,second segment 14, andthird segment 15. Similarly,end cap 10 includesfirst end 11,second end 12,first segment 13,second segment 14, andthird segment 15 -
FIG. 4 is a perspective view ofend cap 10 andtubular member 90 ofFIG. 3 . -
FIG. 5 is an exploded view ofend cap 10 andtubular member 90 ofFIG. 3 . -
FIG. 6 is a perspective view ofend cap 10 ofFIG. 3 . -
FIG. 7 is a front elevational view ofend cap 10 ofFIG. 3 . -
FIG. 8 is a right side elevational view ofend cap 10 ofFIG. 3 . -
FIG. 9 is a left side elevational view ofend cap 10 ofFIG. 3 . -
FIG. 10 is a cross-sectional view ofend cap 10 andtubular member 90 taken generally along the line 10-10 ofFIG. 2 . - As shown in
FIGS. 2 through 10 ,first segment 13 includesfirst end 11 andfirst opening 23. Preferably,first segment 13 is substantially cylindrical in shape.Second segment 14 is substantially frustoconical in shape.Third segment 15 includessecond end 12 andsecond opening 24. Preferably,third segment 15 is substantially cylindrical in shape.Second segment 14 is disposed between and integral withfirst segment 13 andthird segment 15. In particular,first segment 13 transitions intosecond segment 14 atfirst transition 19, whereassecond segment 14 transitions intothird segment 15 atsecond transition 21. For example,first segment 13 extends longitudinally towardsfirst transition 19 and atfirst transition 19second segment 14 begins to taper assecond segment 14 extends towardssecond transition 21. Atsecond transition 21,third segment 15 continues to extend longitudinally towardssecond end 12.Cavity 22 is formed byfirst segment 13,second segment 14, andthird segment 15, wherefirst end 11 is arranged to be secured totubular member 90 and at least one cable, but preferably plurality ofcables 92, is disposed longitudinally withincavity 22. In particular, plurality ofcables 92 enter throughsecond opening 24 ofend cap 10, run longitudinally throughfirst opening 23 ofend cap 10, are spliced and secured viacoupler 96, run longitudinally through a first opening ofend cap 10 b and exit through a second opening ofend cap 10 b, or vice versa, as the order can be transposed starting with plurality of cables entering through the second opening ofend cap 10 b. -
Second end cap 10 b has substantially the same configuration asfirst end cap 10. For example,first segment 13 b includesfirst end 11 b. Preferably,first segment 13 b is substantially cylindrical in shape.Second segment 14 b is substantially frustoconical in shape.Third segment 15 b includessecond end 12 b. Preferably,third segment 15 b is substantially cylindrical in shape.Second segment 14 b is disposed between and integral withfirst segment 13 b andthird segment 15 b. In particular,first segment 13 b transitions intosecond segment 14 b atfirst transition 19 b, whereassecond segment 14 b transitions intothird segment 15 b atsecond transition 21 b. For example,first segment 13 b extends longitudinally towardsfirst transition 19 b and atfirst transition 19 bsecond segment 14 b begins to taper assecond segment 14 b extends towardssecond transition 21 b. Atsecond transition 21 b,third segment 15 b continues to extend longitudinally towardssecond end 12 b.Cavity 22 b is formed byfirst segment 13 b,second segment 14 b, andthird segment 15 b, wherefirst end 11 b is arranged to be secured totubular member 90 and at least one cable, but preferably plurality ofcables 92, is disposed longitudinally withincavity 22 b. - In an embodiment,
end cap 10 further includesouter surface 16 andinner surface 18. Similarly,tubular member 90 hasouter surface 93 andinner surface 94.Tubular member 90 further includesfirst end 95 a andsecond end 95 b. Additionally,first end 11 offirst segment 13 is secured tofirst end 95 a oftubular member 90 such thatinner surface 18 ofend cap 10 contactsouter surface 93 of thetubular member 90. Preferably,second end cap 10 b is secured tosecond end 95 b oftubular member 90. - In an embodiment,
first segment 13 has diameter D1 andthird segment 15 has diameter D2. First diameter D1 is larger than second diameter D2. Preferably, first diameter D1 is approximately 2.375 inches and second diameter D2 is approximately 0.67 inches. Additionally,first end 95 a oftubular member 90 has third diameter D3 (not shown in the figures) and third diameter D3 is slightly smaller than first diameter D1 offirst segment 13. It should be appreciated that third diameter D3 oftubular member 90 is slightly smaller than first diameter D1 in order to secureend cap 10 totubular member 90 via an interference or friction fit. It should also be appreciated that the above dimensions are preferred; however, any of the elements of the end cap can be various sizes, shapes, and configurations suitable in the art. - Preferably, end caps 10, 10 b are made of plastic, such as polypropylene. However, it should be appreciated that the end cap may be made of metal, plastic, rubber, wood, etc., or any suitable material known in the art.
-
FIG. 11 is a top plan view, similar toFIG. 2 , illustrating is a top plan view of twoend caps tubular member 90 and plurality ofcables 92 disposed therein and disposed inconcrete 91. Additionally,FIG. 2 shows two sealingmembers cables 92 is shown wrapped in sheathing 97 a, 97 b. -
FIG. 12 is a cross-sectional view ofend cap 10 andtubular member 90 taken generally along the line 12-12 ofFIG. 11 . -
FIG. 13 is a detailed cross-sectional view ofend cap 10 andtubular member 90 taken generally along the line 13-13 ofFIG. 12 . - As shown in
FIGS. 11 through 13 , the invention further includes sealingmembers member 25 hasfirst end 26,second end 28, and throughbore 29 disposed therein. Similarly, sealingmember 25 b hasfirst end 26 b,second end 28 b, and throughbore 29 b disposed therein. As shown,second end 12 ofthird segment 15 ofend cap 10 is secured tofirst end 26 of sealingmember 25, such that preferably, sealingmember 25 andend cap 10 form a watertight seal. Likewise,second end 12 b ofthird segment 15 b ofend cap 10 b is secured tofirst end 26 b of sealingmember 25 b, such that preferably, sealingmember 25 b andend cap 10 b form a watertight seal. - Additionally, plurality of
cables 92 is shown where at least a portion is enclosed in sheathing 97 a, 97 b. Particularly, sheathing 97 a continues longitudinally partway throughend cap 10 and ceases prior to reachingcoupler 96. Similarly, sheathing 97 b continues longitudinally partway throughend cap 10 b and ceases prior to reachingcoupler 96. Unbonded post-tensioned concrete differs from bonded post-tensioning by providing each individual cable permanent freedom of movement relative to the concrete. To allow this movement, each individual cable or tendon of the plurality of cables is coated with a lubricant and covered by sheathing formed in an extrusion process. Preferably, the sheathing is made of plastic but can be made of any material known in the art. - Moreover, the present invention is a method of installing
end cap 10 during the repair of a post-tension concrete structure, whereend cap 10 includesfirst segment 13,second segment 14, andthird segment 15.First segment 13 hasfirst end 11 andthird segment 15 hassecond end 12. The method includes the following steps: (1) cutting an opening in slab ofconcrete 91, (2) installing a temporary anchor device to transfer the load of at least one cable, but preferably plurality ofcables 92 to the temporary anchor device, (3) cutting a section of plurality ofcables 92, (3) removing a section of plurality ofcables 92, (4) replacing the section of plurality ofcables 92 with a second section of plurality ofcables 92, (5) installing an encapsulated anchorage, (6) affixing a splice coupler, i.e.,coupler 96, to secure an end of the remaining plurality ofcables 92 to an end of the second section of plurality ofcables 92 and where the remaining plurality ofcables 92 and the second section of plurality ofcables 92 are disposed withincoupler 96, (7) installingtubular member 90, having first end 95 a andsecond end 95 b, to covercoupler 96, (8) securingfirst end 11 ofend cap 10 tofirst end 95 a oftubular member 90, (9) pouring concrete to fill the opening, (10) stressing the plurality ofcables 92 after the concrete has cured and reached a specified compressive strength, and (11) removing the temporary anchor device. Preferably, after securingfirst end 11 offirst end cap 10 tofirst end 95 a oftubular member 90, the method further includes securingfirst end 11 b ofsecond end cap 10 b tosecond end 95 b oftubular member 90. - Thus, it is seen that the objects of the present invention are efficiently obtained, although modifications and changes to the invention should be readily apparent to those having ordinary skill in the art, which modifications are intended to be within the spirit and scope of the invention as claimed. It also is understood that the foregoing description is illustrative of the present invention and should not be considered as limiting. Therefore, other embodiments of the present invention are possible without departing from the spirit and scope of the present invention.
Claims (20)
1. A combination end cap and tubular member for use in repairing post-tensioned concrete, comprising:
the end cap including:
a first segment, having a first end and a first opening;
a second segment;
a third segment, having a second end and a second opening, wherein the second segment is disposed between the first segment and the third segment; and,
a cavity formed therein and bounded by the first, second, and third segments,
wherein the first end is secured to the tubular member, the tubular member having at least one splice coupler disposed therein and secured to at least one cable and the at least one cable disposed longitudinally within the cavity.
2. The combination end cap and tubular member of claim 1 , wherein the first segment is substantially cylindrical in shape, the second segment is substantially frustoconical in shape, and the third segment is substantially cylindrical in shape.
3. The combination end cap and tubular member of claim 2 , wherein the second segment is integral with the first segment and the third segment.
4. The combination end cap and tubular member of claim 1 , wherein the first segment has a first diameter (D1) and the third segment has a second diameter (D2), and the first diameter is larger than the second diameter.
5. The combination end cap and tubular member of claim 4 , wherein the first diameter (D1) is approximately 2.375 inches and the second diameter (D2) is approximately 0.67 inches.
6. The combination end cap and tubular member of claim 4 , wherein the end cap has an outer surface and an inner surface and the tubular member has an outer surface, an inner surface, a first end, and a second end, and the first end of the first segment is secured to the first end of the tubular member such that the inner surface of the end cap contacts the outer surface of the tubular member.
7. The combination end cap and tubular member of claim 6 , wherein the first end of the tubular member has a third diameter (D3) and the third diameter (D3) of the first end of the tubular member is smaller than the first diameter (D1) of the first segment.
8. The combination end cap and tubular member of claim 1 , wherein a second end cap is secured to a second end of the tubular member.
9. The combination end cap and tubular member of claim 1 , wherein the end cap is made of plastic.
10. The combination end cap and tubular member of claim 9 , wherein the end cap is made of polypropylene.
11. A combination end cap and tubular member for use in repairing post-tensioned concrete, comprising:
the end cap including:
a first segment, having a first end and a first opening;
a second segment;
a third segment, having a second end and a second opening, wherein the second segment is disposed between the first segment and the third segment; and,
a cavity formed therein and bounded by the first, second, and third segments,
wherein the first end of the first segment is secured to a first end of the tubular member, a second end cap is secured to a second end of the tubular member, and at least one cable is disposed longitudinally within the cavity.
12. The combination end cap and tubular member of claim 11 , wherein the first segment of each end cap is substantially cylindrical in shape, the second segment of each end cap is substantially frustoconical in shape, and the third segment of each end cap is substantially cylindrical in shape.
13. The combination end cap and tubular member of claim 11 , wherein the first segment of each end cap has a first diameter (D1) and the third segment of each end cap has a second diameter (D2), and the first diameter is larger than the second diameter.
14. The combination end cap and tubular member of claim 13 , wherein each end cap has an outer surface and an inner surface, the tubular member has an outer surface and an inner surface, the first end of the first segment of the first end cap is secured to the first end of the tubular member such that the inner surface of the first end cap contacts the outer surface of the tubular member, and the first end of the first segment of the second end cap is secured to the second end of the tubular member such that the inner surface of the second end cap contacts the outer surface of the tubular member.
15. The combination end cap and tubular member of claim 14 , wherein the first end of the tubular member has a third diameter (D3) and the third diameter (D3) of the first end of the tubular member is smaller than the first diameter (D1) of the first segment.
16. A combination end cap and tubular member for use in repairing post-tensioned concrete, comprising:
the end cap including:
a first segment, having a first end and a first opening;
a second segment;
a third segment, having a second end and a second opening, wherein the second segment is disposed between the first segment and the third segment; and,
a cavity formed therein and bounded by the first, second, and third segments,
wherein the first end is secured to the tubular member; and,
a sealing member, having a first end, a second end, and a throughbore disposed therein, wherein the second end of the third segment of the end cap is secured to the first end of the sealing member and at least one cable is disposed longitudinally within the cavity.
17. The combination end cap and tubular member of claim 16 , wherein the sealing member and the end cap form a watertight seal.
18. The combination end cap and tubular member of claim 16 , wherein the first segment has a first diameter (D1) and the third segment has a second diameter (D2), and the first diameter is larger than the second diameter.
19. The combination end cap and tubular member of claim 18 , wherein the end cap has an outer surface and an inner surface and the tubular member has an outer surface, an inner surface, a first end, and a second end, and the first end of the first segment is secured to the first end of the tubular member such that the inner surface of the end cap contacts the outer surface of the tubular member.
20. The combination end cap and tubular member of claim 19 , wherein the first end of the tubular member has a third diameter (D3) and the third diameter (D3) of the first end of the tubular member is smaller than the first diameter (D1) of the first segment.
Priority Applications (1)
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US15/196,575 US20160305140A1 (en) | 2015-01-16 | 2016-06-29 | Method and apparatus for repairing post-tensioned concrete |
Applications Claiming Priority (2)
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US14/599,085 US20160208490A1 (en) | 2015-01-16 | 2015-01-16 | Method and apparatus for repairing post-tensioned concrete |
US15/196,575 US20160305140A1 (en) | 2015-01-16 | 2016-06-29 | Method and apparatus for repairing post-tensioned concrete |
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US14/599,085 Continuation-In-Part US20160208490A1 (en) | 2015-01-16 | 2015-01-16 | Method and apparatus for repairing post-tensioned concrete |
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US20160305140A1 true US20160305140A1 (en) | 2016-10-20 |
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US15/196,575 Abandoned US20160305140A1 (en) | 2015-01-16 | 2016-06-29 | Method and apparatus for repairing post-tensioned concrete |
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