US20200200297A1 - Concrete Reinforcement Elements and Structures - Google Patents
Concrete Reinforcement Elements and Structures Download PDFInfo
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- US20200200297A1 US20200200297A1 US16/805,000 US202016805000A US2020200297A1 US 20200200297 A1 US20200200297 A1 US 20200200297A1 US 202016805000 A US202016805000 A US 202016805000A US 2020200297 A1 US2020200297 A1 US 2020200297A1
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- Prior art keywords
- prong
- tie wire
- concrete reinforcement
- legs
- prongs
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L9/00—Rigid pipes
- F16L9/08—Rigid pipes of concrete, cement, or asbestos cement, with or without reinforcement
- F16L9/085—Reinforced pipes
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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
- E04C5/01—Reinforcing elements of metal, e.g. with non-structural coatings
- E04C5/06—Reinforcing elements of metal, e.g. with non-structural coatings of high bending resistance, i.e. of essentially three-dimensional extent, e.g. lattice girders
- E04C5/0627—Three-dimensional reinforcements composed of a prefabricated reinforcing mat combined with reinforcing elements protruding out of the plane of the mat
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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
- E04C5/16—Auxiliary parts for reinforcements, e.g. connectors, spacers, stirrups
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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
- E04C5/01—Reinforcing elements of metal, e.g. with non-structural coatings
- E04C5/06—Reinforcing elements of metal, e.g. with non-structural coatings of high bending resistance, i.e. of essentially three-dimensional extent, e.g. lattice girders
- E04C5/0645—Shear reinforcements, e.g. shearheads for floor slabs
Definitions
- the present invention generally relates to reinforcement structures for reinforcing concrete and other brittle materials, and more specifically, to reinforcement elements that include a number of prongs that can be formed into a mat or other connected structure and embedded within the concrete.
- Certain structural materials such as concrete, are very strong in compression, but relatively weak in tension and/or shear, and can behave in a brittle manner when cracks form.
- Various reinforcement structures can be used to address these issues, such as metal bars, wires, and similar structures.
- reinforcing structures made of steel or other metals are typically embedded within the concrete to absorb tensile and/or shear loads and to resist brittle fracture and crack propagation. This can increase strength and durability and decrease the potential failure rate of the material.
- Concrete pipe structures can benefit from such embedded reinforcement structures.
- circular concrete pipe may experience shear and tensile forces when a radial force is exerted on the pipe, which can occur frequently in use.
- Square or rectangular concrete pipe also known as box culvert
- box culvert can experience similar tensile and shear loads when a force is exerted on one of the side walls of the pipe, as well as shear loads at the corners of the pipe.
- significant reinforcement structures are often provided at the points where these stresses are most frequently concentrated in the use of the concrete pipe.
- Such reinforcement structures can be provided in the form of a mat or other interconnected structure, which provides increased reinforcement over a large area.
- existing reinforcement structures for concrete pipe have certain disadvantages.
- one type of existing reinforcement structure utilizes stirrups or prongs that are welded in place. In this configuration, the weld forms a weak point, such that the tensile strength of the structure is often limited by the strength of the weld (which can be significantly lower than the wire's tensile strength in some cases).
- Another type of existing reinforcement structure utilizes long oscillating reinforcement elements that are arranged roughly parallel to each other. Reinforcement structures of this type can provide increased tensile strength, however, these structures provide limited options for spacing, alignment, and orientation of the reinforcement elements relative to each other. This, in turn, can limit the number of applications in which these reinforcement structures can be used.
- a prong configured for use with a concrete reinforcement element, including a first leg positioned on a first side of the prong and a second leg positioned on a second side of the prong opposite the first side, and a bridge portion connecting distal ends the first leg and the second leg, where the bridge portion forms a first end of the prong.
- the first and second legs extend from the bridge portion to a second end of the prong opposite the first end, and each of the first and second legs has a proximal end at the second end of the prong.
- the proximal end of the first leg is bent toward the second leg, and the proximal end of the second leg is bent toward the first leg, such that the proximal ends of the first and second legs overlap each other.
- inner surfaces of the proximal ends of the first and second legs define engagement surfaces configured to engage a tie wire, enabling the proximal ends to be connected to the tie wire.
- the bridge portion has a bend of at least 180° and a radius of curvature of about 0.5 inch.
- the first leg forms a left side of the prong
- the second leg forms a right side of the prong.
- the proximal end of the first leg may be bent to the right to extend past the proximal end of the second leg
- the proximal end of the second leg may be bent to the left to extend past the proximal end of the first leg.
- the proximal ends of the first and second legs may each be bent at an angle of at least 90°.
- the engagement surfaces may be defined by curved portions of the inner surfaces of the proximal ends of the first and second legs.
- the first and second legs may be configured to be in the same general plane at the first end of the prong, and the proximal ends of the first and second legs are in different planes.
- the proximal ends of the first and second legs each have a bend portion, and the bend portion of each of the first and second legs has a radius of curvature of about 0.09′′ to about 0.11′′.
- a concrete reinforcement element including a tie wire having a length and a plurality of prongs connected along the length of the tie wire, each of the prongs being spaced from adjacent prongs.
- Each of the prongs may be configured according to aspects described herein.
- the proximal end of the first leg extends on a first side of the tie wire and is bent toward the second leg to extend at least partially around an underside of the tie wire, and the proximal end of the second leg extends on a second side of the tie wire opposite the first side and is bent toward the first side to extend at least partially around the underside of the tie wire.
- the second ends of each prong are connected to the tie wire by welding, such that at least a portion of each of the proximal ends of the first and second legs is welded to the underside of the tie wire.
- the element is configured such that an applied load sufficient to cause failure of one of the prongs when exerted on the bridge portion of the prong in a direction away from the tie wire is higher than a bond strength of the welding.
- the element is configured such that an applied load sufficient to cause failure of one of the prongs when exerted on the bridge portion of the prong in a direction away from the tie wire is approximately equal to an applied load sufficient to cause fracture of the prong.
- the proximal ends of the first and second legs overlap each other, and wherein confronting surfaces of the proximal ends of the first and second legs contact each other while overlapping.
- each of the proximal ends of the first and second legs is welded to the underside of the tie wire defines a curved surface that is welded to the tie wire.
- FIG. 1 A perspective view of an exemplary concrete reinforcement mat.
- FIG. 1 A perspective view of an exemplary concrete reinforcement mat.
- FIG. 1 A perspective view of an exemplary concrete reinforcement mat.
- a plurality of cross-wires are connected to the plurality of concrete reinforcement elements by connection to the tie wires, such that the concrete reinforcement elements are all positioned in spaced relation and extending along a first direction, and the cross-wires are connected between the concrete reinforcement elements in spaced relation to each other and extend along a second direction transverse to the first direction.
- the prongs on each reinforcement element may be aligned or may not be aligned with the prongs on adjacent reinforcement elements. Additionally, the prong spacing on adjacent reinforcement elements may be substantially equal in one embodiment.
- the mat is configured such that an applied load sufficient to cause failure of one of the prongs when exerted on the bridge portion of the prong in a direction away from the tie wire is higher than a bond strength of the welding.
- the mat is configured such that an applied load sufficient to cause failure of one of the prongs when exerted on the bridge portion of the prong in a direction away from the tie wire is approximately equal to an applied load sufficient to cause fracture of the prong.
- each of the proximal ends of the first and second legs is welded to the underside of the tie wire defines a curved surface that is welded to the tie wire.
- Still further aspects of the disclosure relate to a reinforced concrete pipe that includes a concrete wall defining a central passage, the concrete wall having an internal reinforcement structure that includes a plurality of concrete reinforcement elements according to aspects described herein embedded within the concrete wall.
- the concrete reinforcement elements may include prongs configured according to aspects described herein.
- the concrete wall has a circular shape in cross-section, and the internal reinforcement structure extends around an arc of approximately 45° on a top portion and a bottom portion of the concrete wall.
- FIG. 1 is a front view of one embodiment of a prong forming a portion of a reinforcement element according to aspects of the present disclosure
- FIG. 2 is a side view of the prong of FIG. 1 ;
- FIG. 3 is a perspective view of the prong of FIG. 1 ;
- FIG. 4 is a perspective view of one embodiment of a reinforcement mat including a plurality of reinforcement elements according to aspects of the present disclosure
- FIG. 5 is a perspective view of one embodiment of a reinforcement element according to aspects of the present disclosure.
- FIG. 6 is a perspective view of another embodiment of a reinforcement element according to aspects of the present disclosure.
- FIG. 7 is a top view of another embodiment of a reinforcement mat including a plurality of reinforcement elements according to aspects of the present disclosure
- FIG. 8 is a perspective view of one embodiment of a concrete pipe according to aspects of the present disclosure.
- FIG. 9 is a cross-sectional view of the concrete pipe of FIG. 8 .
- the term “plurality,” as used herein, indicates any number greater than one, either disjunctively or conjunctively, as necessary, up to an infinite number. None in this specification should be construed as requiring a specific three dimensional orientation of structures in order to fall within the scope of this invention. Also, the reader is advised that the attached drawings are not necessarily drawn to scale.
- FIGS. 1-3 illustrate one embodiment of a prong that is usable in connection with aspects described herein, generally designated with the reference numeral 10 .
- the prong 10 is configured to function as a portion of a reinforcement structure that is partially or completely embedded within a structural material (e.g., concrete), to provide structural reinforcement to the material.
- the prong 10 generally includes a connecting portion 20 for connecting the prong 10 to a reinforcement structure and a protruding portion 21 configured to protrude from the reinforcement structure into the material to reinforce the material and anchor the prong 10 within the material.
- the prong 10 is formed of a metal wire, which may have a circular cross-section or a different cross-section, that is bent or otherwise formed into an appropriate shape in one embodiment.
- the prong 10 may be partially or completely formed of a different material and/or using a different technique in another embodiment.
- the prong 10 may be formed of a wire having a diameter of 0.120′′ to 0.209′′ (e.g., 11 ga to 5 ga), or possibly to 0.243′′, which results in an average stirrup prong steel area A V of 0.011 to 0.034, or possibly to 0.045.
- the prong 10 is made of a smooth wire, with a generally smooth outer surface.
- the prong 10 may be made from “deformed wire,” which has intentional deformations or other structural features (e.g., ridges, recesses, etc.) on the outer surface to enhance bonding with the structural matrix material (e.g., concrete).
- This deformed wire could be positively deformed or negatively deformed, in various embodiments. It is understood that the use of deformed wire could alter the calculation of the average prong steel area A V , due to the non-constant cross-section of deformed wire.
- the embodiment of the prong 10 illustrated in FIGS. 1-3 has first and second legs 11 on the first and second sides 12 , 13 (i.e., the left and right sides from the perspective shown in FIG. 1 ), respectively.
- the legs 11 are connected to each other at first or distal ends 14 thereof, such as by the use of a bridge portion or connecting portion 16 that connects the two legs 11 .
- the legs 11 are further configured for engagement with and/or connection to a portion of a reinforcement element, such as a tie wire 30 , at their second or proximal ends 15 .
- the bridge portion 16 forms a first or distal end 17 of the prong 10
- the proximal ends 15 of the legs 11 form a proximal end 18 of the prong 10 .
- the bridge portion 16 in the embodiment of FIGS. 1-3 has a smoothly curved shape that arcs at least 180° to connect the distal ends 14 of the legs 11 together.
- the legs 11 are closer together at their proximal ends 15 , and the distance between the legs 11 increases toward their distal ends 14 .
- the legs 11 are angled away from each other at their distal ends 14 , such that the bridge portion 16 forms an arc of greater than 180°.
- the bridge portion 16 is semi-circular and has a radius of curvature of approximately 0.5 inch, but may have a different size in another embodiment.
- the bridge portion 16 may also have a different shape in another embodiment, such as a polygonal shape (e.g., square, triangular, etc.), a semi-elliptical shape, or an irregular shape. It is understood that the shapes and sizes of the legs 11 and the bridge portion 16 may be dictated by the intended use or application of the prong 10 .
- the legs 11 and the bridge portion 16 in the embodiment illustrated in FIGS. 1-3 form the protruding portion 21 of the prong 10 .
- the proximal end 15 of each leg 11 is configured for engagement with a portion of a reinforcement structure, such as a tie wire 30 , and thereby form the connecting portion 20 of the prong 10 .
- a reinforcement structure such as a tie wire 30
- the proximal end 15 of each leg 11 is bent to wrap around a portion of the tie wire 30 , which provides an engagement surface 22 for engaging and/or connecting to the tie wire 30 .
- the engagement surfaces 22 may be considered to engage an underside of the tie wire 30 in this configuration, and it is understood that the term “underside” does not refer to any particular arrangement or orientation, but rather, that the “underside” of the tie wire 30 is the side opposite the distal end 17 of the prong 10 .
- the proximal ends 15 of the legs 11 in this configuration may therefore be considered to have a hook-like shape.
- the proximal end 15 of each leg 11 has a bend portion 23 that is bent toward the tie wire 30 and/or toward the opposite side 12 , 13 of the prong 10 .
- the bend portion 23 of the leg 11 on the first side 12 of the prong 10 is bent toward the second side 13
- the bend portion 23 of the leg 11 on the second side 13 of the prong 10 is bent toward the first side 12 .
- the bend portion 23 of each leg 11 may be bent at an angle of at least 90° or at least 100°, and in another embodiment, the bend portion 23 of each leg 11 may be bent at an angle of at least 120°. In a further embodiment, the bend portion 23 of each leg 11 may be bent to an angle that does not exceed 125°, or that does not exceed 135°. It is understood that the aforementioned upper and lower limits may be considered in conjunction with each other. Additionally, in one embodiment, the bend portion 23 of each leg 11 may be bent around the tie wire. In one embodiment, the minimum radius of curvature of the bend portion 23 may be from about 0.09′′ to about 0.11′′, depending on wire size and application.
- the minimum radius of curvature of the bend portion 23 is 0.089′′, which may be used, e.g., for a prong 10 made from 11, 10, 9, 8, or 7 gauge wire around a 7 gage tie wire.
- the minimum radius of curvature of the bend portion 23 is 0.096′′, which may be used, e.g., for a prong 10 made from 6 gage wire around a 6 gage tie wire.
- the minimum radius of curvature of the bend portion 23 is 0.104′′, which may be used, e.g., for a prong 10 made from for 5 gage wire around a 5 gage tie wire.
- the legs 11 have engagement surfaces 22 that are configured for engaging and/or connecting to the tie wire 30 .
- the engagement surfaces 22 are at least partially defined by curved portions of the inner surfaces (or curved inner surfaces) 24 of the proximal ends 15 of the legs 11 . These curved inner surfaces 24 are formed by the bend portions 23 of the legs 11 .
- each leg 11 has a straight or relatively straight tail portion 25 extending from the bend portion 23 to the tip of the leg 11 .
- These straight tail portions 25 also partially define the engagement surfaces 22 in one embodiment, or the engagement surfaces 22 may be completely defined by the bend portions 23 in another embodiment.
- the bend portions 23 may extend all the way to the tips of the legs 11 in a further embodiment, such that no straight tail portions 25 are present.
- the proximal ends 15 of the legs 11 overlap each other and are positioned adjacent each other when configured for connection to the tie wire 30 .
- the proximal end 15 of the right leg 11 is positioned in front of the proximal end 15 of the left leg 11 in one embodiment, although this configuration can be reversed.
- This overlapping configuration gives the prong 10 a shape such that the distal ends 14 of the legs 11 are generally aligned with each other and/or in the same general plane as each other, while the proximal ends 15 of the legs 11 are in different planes from each other.
- the overlapping and confronting surfaces of the proximal ends 15 of the legs 11 may engage or contact each other in one embodiment, such that the engagement surfaces 22 generally form a single platform for engaging the tie wire 30 .
- the proximal ends 15 of the legs 11 may have sufficient length that they extend past each other as they overlap. In other words, the proximal end 15 of the leg 11 on the first side 12 (the left side in FIG. 1 ) extends beyond the second side 13 of the prong defined by the opposite leg 11 , and the proximal end 15 of the opposite leg 11 on the second side 12 (the right side in FIG. 1 ) extends beyond the first side 12 of the prong defined by the first leg 11 .
- the legs 11 may have lengths and/or bent configurations such that no portion of the proximal end 15 of each leg 11 extends beyond the opposite side 12 , 13 .
- the prong 10 may be connected to a tie wire 30 or other component of a reinforcement structure by use of the legs 11 with the proximal ends 15 bent around the tie wire 30 , as described herein.
- the prong 10 may initially be provided in a pre-bent configuration, which is then bent to the final shape.
- the pre-bent prong 10 may be a straight piece of wire in one embodiment.
- the pre-bent prong 10 is then bent to the final shape to place the engagement surfaces 22 of the legs 11 into engagement with the tie wire 30 , including further bending the bend portions 23 around the tie wire 30 .
- the legs 11 are welded to the tie wire 30 to secure the connection. In one embodiment, as shown in FIGS.
- each of the engagement surfaces 22 of the prong 10 are welded to the tie wire 30 at a single weld point 26 on the underside of the tie wire 30 .
- These weld points 26 may be along the same side of the tie wire 30 and generally aligned with each other in the axial direction of the tie wire 30 . In other embodiments, a different number and/or location of weld points 26 may be used. For example, weld points may additionally or alternately be placed along the sides (left and right in FIG. 1 ) of the tie wire 30 .
- the prong 10 When connected to a tie wire 30 as shown in FIGS. 1-3 , the prong 10 has increased strength relative to a reinforcement component that is connected by welding without the use of the bend portions 23 .
- the applied load sufficient to cause failure of the prong 10 when exerted on the bridge portion 16 in a direction away from the tie wire 30 i.e., the “pull force”
- the applied load sufficient to cause failure of the prong 10 when exerted on the bridge portion 16 in a direction away from the tie wire 30 i.e., the “pull force”
- the applied load sufficient to cause failure of the prong 10 when exerted on the bridge portion 16 in a direction away from the tie wire 30 i.e., the “pull force”
- the applied load sufficient to cause fracture of the prong itself i.e., the fracture of any portion of the prong wire.
- the prong 10 has its maximum possible failure resistance, because only forces near or at the force sufficient to fracture the prong 10 itself will cause failure. This increases the maximum reinforcement strength provided by the prong 10 to the concrete in which it is embedded. It is understood that the prong 10 may be used in reinforcement applications and configurations different from those shown and described herein by way of example. For example, the prong 10 may be configured for connection to a structure other than a tie wire 30 , in the same or a similar configuration to that described herein.
- the prong 10 may be used in connection with various reinforcement structures for concrete reinforcement, as illustrated in FIGS. 4-7 .
- a plurality of prongs 10 may be connected to a single tie wire 30 to create a reinforcement element 31 , as illustrated in FIG. 5 .
- the prongs 10 may be connected to the tie wire 30 at locations spaced along the length of the tie wire 30 .
- the prongs 10 may be connected to the tie wire 30 at constant spacing intervals. Any spacing intervals can be used, including variable spacing intervals, and the prongs 10 configured as shown in FIGS. 1-3 provide the advantage of permitting any spacing interval to be used.
- the prongs 10 may all be oriented in generally the same direction in one embodiment, such as in FIG.
- the reinforcement element 31 may include a lock rod 32 , such as shown in FIG. 6 , which may be useful or required for certain applications.
- the lock rod 32 if used, may be secured to the distal end 17 of the prong 10 , such as by use of a wire tie or welding to the inner side of the bridge portion 16 , as shown in FIG. 6 .
- the lock rod 32 may not be secured to the prong 10 , in an alternate configuration.
- the prong 10 may have various different sizes, including different heights, as measured in the direction between the distal and proximal ends 17 , 18 of the prong 10 , which creates different prong amplitudes when the prong 10 is connected to the tie wire 30 .
- the prong 10 may be configured to provide an amplitude of from 1.75′′ to 20′′ in one embodiment, or from 2′′ to 18′′ in another embodiment.
- the spacing of the prongs 10 may be adjusted to nearly any desired spacing.
- a plurality of reinforcement elements 31 as shown in FIG. 5 may be connected together to form a reinforcement mat 33 as shown in FIG. 4 .
- the reinforcement mat 33 shown in FIG. 4 includes a plurality of reinforcement elements 31 positioned to extend parallel to each other, with cross-wires 34 connecting the reinforcement elements 31 to each other. More specifically, as shown in FIG. 4 , a plurality of cross-wires 34 are connected to the reinforcement elements 31 by connection to the tie wires 30 , such that the reinforcement elements 31 are all positioned in spaced relation to each other and extending along a first direction, and the cross-wires 34 are connected between the reinforcement elements 31 in spaced relation to each other and extend along a second direction transverse to the first direction. As shown in FIG.
- the mat 33 may have a slight curvature, such that it is configured for use in a curved structure.
- the mat 33 in FIG. 4 is depicted, for example, in a configuration as may be installed in a curved component, such as a pipe 40 as in FIGS. 8-9 .
- the tie wires 30 and/or cross-wires 34 may be produced in a straight configuration and bent as desired. It is also understood that some or all of the bending of the tie wires 30 and/or cross-wires 34 may be non-permanent or non-plastic, and that the bent wires 30 , 34 may be held in bent shapes by other adjacent structures (e.g., cages 46 , 47 as shown in FIG. 9 ).
- the spacing of the reinforcement elements 31 and/or the cross-wires 34 may be constant in one embodiment, or may be variable in another embodiment. Additionally, different reinforcement elements 31 within the mat 33 can utilize the same or similar prong configurations (e.g., position, spacing, orientation, etc.) or may use varying prong configurations. For example, in one embodiment, all reinforcement elements within the mat 33 may have prongs 10 that are all configured with the same structure and spaced equal or substantially equal distances. The structure of the prong 10 enables such varying configurations.
- the mat 33 may be configured such that the prongs 10 in each element 31 are staggered with respect to the prongs 10 in one or more adjacent elements 31 , which can be referred to has having a “pitched” arrangement.
- FIG. 7 illustrates an embodiment of a mat 33 that uses prongs 10 having a pitched arrangement, in which the prongs 10 of adjacent elements 31 are progressively staggered in the same direction. This creates a corkscrew-like orientation of the prongs 10 with respect to each other.
- a mat 33 with prongs 10 in a pitched arrangement as shown in FIG. 7 may be configured for use with cages 46 , 47 having a “spiral” or “helical” configuration. Other varied and/or staggered configurations are possible, as the prongs 10 can be connected to the reinforcement structure in nearly any position or orientation.
- the reinforcement structures described herein, including the prongs 10 and the reinforcement elements 31 and mats 33 including the prongs 10 may be used to reinforce structural materials, such as concrete.
- a mat 33 as shown in FIG. 4 or FIG. 7 may be used to reinforce a concrete pipe 40 , as shown in FIGS. 8-9 .
- the pipe 40 illustrated in FIGS. 8-9 is a circular pipe segment that has a circular wall 41 having a tubular shape with cylindrical inner and outer walls and a circular central passage 42 .
- the pipe 40 has a spigot 43 extending around one end and a bell 44 extending around the other end.
- the spigot 43 can fit within the bell 44 of an adjacent pipe segment 40 to connect multiple segments to each other.
- the pipe 40 includes a reinforcement structure 45 that includes an inner cage 46 , an outer cage 47 , and a reinforcement mat 33 connected to at least one of the inner and outer cages 46 , 47 .
- the inner and outer cages 46 , 47 are both formed of a plurality of metal rods and/or wires interconnected together, such as in a cross-hatching pattern, to form a tubular structure.
- the reinforcement structure may also include spacers (not shown) between the cages 46 , 47 .
- One or more mats 33 can then be connected to the inner and/or outer cages 46 , 47 , such as by tie wires (not shown) or welding. In one embodiment, as shown in FIG.
- one or more mats 33 are connected to the inner cage 46 by tie wires (not shown) or welding.
- the prongs 10 of the mat(s) 33 extend from the inner cage 46 toward the outer cage 47 , but do not connect to or contact the outer cage 47 in this embodiment.
- the reinforcement structure, including the cages 46 , 47 and the mat(s) 33 are then placed in a form, mold, etc., and the concrete material is then formed (e.g., by pouring) around the reinforcement structure, such that the cages 46 , 47 and the mat(s) 33 are embedded within the concrete.
- only a single cage or a larger number of cages may be used, as well as additional reinforcement structures.
- the mat(s) 33 may be positioned only around a portion of the perimeter of the pipe 40 in some embodiments.
- the pipe 40 includes a top portion 48 , which includes top (outer) and crown (inner) surfaces, and a bottom portion 49 , which includes bottom (outer) and invert (inner) surfaces.
- the pipe 40 has mats 33 connected at the top portion 48 of the pipe 40 and the bottom portion 49 of the pipe 40 , which are the points of the pipe 40 that receive the greatest tensile and shear stresses (e.g., radial tension and diagonal shear), due to force exerted at these points in use.
- the mats 33 extend up to 90° around the top 48 and the bottom 49 of the pipe 40 . In another embodiment, the mats 33 extend 45° to 90° around the top portion 48 and the bottom portion 49 of the pipe 40 . In a further embodiment, the mats 33 extend 45° or 90° around the top portion 48 and the bottom portion 49 of the pipe 40 . In yet another embodiment, the mats 33 may extend around a greater portion of the perimeter of the pipe 40 , up to and including the entire perimeter. For example, a pipe 40 having mats 33 extending around the entire perimeter (e.g., 360°) may be used in an application where the exact orientation of the installed pipe 40 is not known or cannot be easily controlled (e.g., a jack pipe).
- the mats 33 may have a curved configuration in order to be connected to the cylindrical cage(s) 46 , 47 .
- this configuration is accomplished by bending the cross-wires 34 into curved shapes, such that the tie wires 30 of the individual reinforcement elements 31 are relatively straight.
- the tie wires 30 and the reinforcement elements 31 extend in a longitudinal or axial direction on the pipe 40
- the cross-wires 34 extend in a circumferential direction.
- the reinforcement structure may be differently configured, and it is understood that differently shaped pipes may utilize different structures.
- a square shaped pipe e.g., box culvert
- reinforcement structures including prongs 10 , reinforcement elements 31 , and reinforcement mats 33 , described herein provide benefits and advantages over existing designs.
- the configuration of the prong 10 with the proximal ends 15 bent around the tie wire 30 before welding increases the strength of the connection between the prong 10 and the reinforcement element 31 . Consequently, the pull force necessary to separate the prong 10 from the tie wire 30 is increased, particularly relative to prongs that are welded to opposite sides of the tie wire 30 and do not wrap around the tie wire 30 . In one embodiment, this pull force may be equal to the tensile strength of the prong 10 .
- the reinforcement capabilities of the prong 10 and the reinforcement structures with which it is used are thereby increased.
- the prongs 10 may be connected to the reinforcement structure (e.g., the tie wire 30 ) in a wide variety of configurations.
- the prongs 10 can be positioned to have any desired spacing interval and/or may be oriented in any desired direction, etc., including being arranged in a spiral configuration. Still other benefits and advantages are explicitly or implicitly described herein and/or recognized by those skilled in the art.
Abstract
Description
- This application is a continuation of co-pending U.S. patent application Ser. No. 15/910,609, filed Mar. 2, 2018, which is a continuation of U.S. patent application Ser. No. 14/632,821, filed Feb. 26, 2015, and issued as U.S. Pat. No. 9,909,693 on Mar. 6, 2018, and this application claims priority to both of these prior applications, which are incorporated by reference herein in their entireties and made parts hereof.
- The present invention generally relates to reinforcement structures for reinforcing concrete and other brittle materials, and more specifically, to reinforcement elements that include a number of prongs that can be formed into a mat or other connected structure and embedded within the concrete.
- Certain structural materials, such as concrete, are very strong in compression, but relatively weak in tension and/or shear, and can behave in a brittle manner when cracks form. Various reinforcement structures can be used to address these issues, such as metal bars, wires, and similar structures. For example, reinforcing structures made of steel or other metals are typically embedded within the concrete to absorb tensile and/or shear loads and to resist brittle fracture and crack propagation. This can increase strength and durability and decrease the potential failure rate of the material.
- Concrete pipe structures can benefit from such embedded reinforcement structures. For example, circular concrete pipe may experience shear and tensile forces when a radial force is exerted on the pipe, which can occur frequently in use. Square or rectangular concrete pipe (also known as box culvert) can experience similar tensile and shear loads when a force is exerted on one of the side walls of the pipe, as well as shear loads at the corners of the pipe. Thus, significant reinforcement structures are often provided at the points where these stresses are most frequently concentrated in the use of the concrete pipe. Such reinforcement structures can be provided in the form of a mat or other interconnected structure, which provides increased reinforcement over a large area. However, existing reinforcement structures for concrete pipe have certain disadvantages. For example, one type of existing reinforcement structure utilizes stirrups or prongs that are welded in place. In this configuration, the weld forms a weak point, such that the tensile strength of the structure is often limited by the strength of the weld (which can be significantly lower than the wire's tensile strength in some cases). Another type of existing reinforcement structure utilizes long oscillating reinforcement elements that are arranged roughly parallel to each other. Reinforcement structures of this type can provide increased tensile strength, however, these structures provide limited options for spacing, alignment, and orientation of the reinforcement elements relative to each other. This, in turn, can limit the number of applications in which these reinforcement structures can be used.
- Thus, while certain reinforcement structures according to existing designs provide a number of advantageous features, they nevertheless have certain limitations. The present disclosure seeks to overcome certain of these limitations and other drawbacks of the prior art, and to provide new features not heretofore available.
- The following presents a general summary of aspects of the invention in order to provide a basic understanding of the invention. This summary is not an extensive overview of the invention. It is not intended to identify key or critical elements of the invention or to delineate the scope of the invention. The following summary merely presents some concepts of the invention in a general form as a prelude to the more detailed description provided below.
- Certain aspects of the disclosure relate to a prong configured for use with a concrete reinforcement element, including a first leg positioned on a first side of the prong and a second leg positioned on a second side of the prong opposite the first side, and a bridge portion connecting distal ends the first leg and the second leg, where the bridge portion forms a first end of the prong. The first and second legs extend from the bridge portion to a second end of the prong opposite the first end, and each of the first and second legs has a proximal end at the second end of the prong. The proximal end of the first leg is bent toward the second leg, and the proximal end of the second leg is bent toward the first leg, such that the proximal ends of the first and second legs overlap each other. Further, inner surfaces of the proximal ends of the first and second legs define engagement surfaces configured to engage a tie wire, enabling the proximal ends to be connected to the tie wire.
- According to one aspect, the bridge portion has a bend of at least 180° and a radius of curvature of about 0.5 inch.
- According to another aspect, the first leg forms a left side of the prong, and the second leg forms a right side of the prong. In this configuration, the proximal end of the first leg may be bent to the right to extend past the proximal end of the second leg, and the proximal end of the second leg may be bent to the left to extend past the proximal end of the first leg. Additionally, the proximal ends of the first and second legs may each be bent at an angle of at least 90°. Further, the engagement surfaces may be defined by curved portions of the inner surfaces of the proximal ends of the first and second legs. Still further, the first and second legs may be configured to be in the same general plane at the first end of the prong, and the proximal ends of the first and second legs are in different planes.
- According to a further aspect, the proximal ends of the first and second legs each have a bend portion, and the bend portion of each of the first and second legs has a radius of curvature of about 0.09″ to about 0.11″.
- Additional aspects of the disclosure relate to a concrete reinforcement element including a tie wire having a length and a plurality of prongs connected along the length of the tie wire, each of the prongs being spaced from adjacent prongs. Each of the prongs may be configured according to aspects described herein. The proximal end of the first leg extends on a first side of the tie wire and is bent toward the second leg to extend at least partially around an underside of the tie wire, and the proximal end of the second leg extends on a second side of the tie wire opposite the first side and is bent toward the first side to extend at least partially around the underside of the tie wire. The second ends of each prong are connected to the tie wire by welding, such that at least a portion of each of the proximal ends of the first and second legs is welded to the underside of the tie wire.
- According to one aspect, the element is configured such that an applied load sufficient to cause failure of one of the prongs when exerted on the bridge portion of the prong in a direction away from the tie wire is higher than a bond strength of the welding.
- According to another aspect, the element is configured such that an applied load sufficient to cause failure of one of the prongs when exerted on the bridge portion of the prong in a direction away from the tie wire is approximately equal to an applied load sufficient to cause fracture of the prong.
- According to a further aspect, the proximal ends of the first and second legs overlap each other, and wherein confronting surfaces of the proximal ends of the first and second legs contact each other while overlapping.
- According to yet another aspect, the at least a portion of each of the proximal ends of the first and second legs is welded to the underside of the tie wire defines a curved surface that is welded to the tie wire.
- Further aspects of the disclosure relate to a concrete reinforcement mat that includes a plurality of concrete reinforcement elements, each configured according to aspects described herein and having a prong according to aspects described herein. A plurality of cross-wires are connected to the plurality of concrete reinforcement elements by connection to the tie wires, such that the concrete reinforcement elements are all positioned in spaced relation and extending along a first direction, and the cross-wires are connected between the concrete reinforcement elements in spaced relation to each other and extend along a second direction transverse to the first direction.
- According to one aspect, the prongs on each reinforcement element may be aligned or may not be aligned with the prongs on adjacent reinforcement elements. Additionally, the prong spacing on adjacent reinforcement elements may be substantially equal in one embodiment.
- According to another aspect, the mat is configured such that an applied load sufficient to cause failure of one of the prongs when exerted on the bridge portion of the prong in a direction away from the tie wire is higher than a bond strength of the welding.
- According to a further aspect, the mat is configured such that an applied load sufficient to cause failure of one of the prongs when exerted on the bridge portion of the prong in a direction away from the tie wire is approximately equal to an applied load sufficient to cause fracture of the prong.
- According to yet another aspect, the at least a portion of each of the proximal ends of the first and second legs is welded to the underside of the tie wire defines a curved surface that is welded to the tie wire.
- Still further aspects of the disclosure relate to a reinforced concrete pipe that includes a concrete wall defining a central passage, the concrete wall having an internal reinforcement structure that includes a plurality of concrete reinforcement elements according to aspects described herein embedded within the concrete wall. The concrete reinforcement elements may include prongs configured according to aspects described herein.
- According to one aspect, the concrete wall has a circular shape in cross-section, and the internal reinforcement structure extends around an arc of approximately 45° on a top portion and a bottom portion of the concrete wall.
- Other features and advantages of the invention will be apparent from the following description taken in conjunction with the attached drawings.
- To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings in which:
-
FIG. 1 is a front view of one embodiment of a prong forming a portion of a reinforcement element according to aspects of the present disclosure; -
FIG. 2 is a side view of the prong ofFIG. 1 ; -
FIG. 3 is a perspective view of the prong ofFIG. 1 ; -
FIG. 4 is a perspective view of one embodiment of a reinforcement mat including a plurality of reinforcement elements according to aspects of the present disclosure; -
FIG. 5 is a perspective view of one embodiment of a reinforcement element according to aspects of the present disclosure; -
FIG. 6 is a perspective view of another embodiment of a reinforcement element according to aspects of the present disclosure; -
FIG. 7 is a top view of another embodiment of a reinforcement mat including a plurality of reinforcement elements according to aspects of the present disclosure; -
FIG. 8 is a perspective view of one embodiment of a concrete pipe according to aspects of the present disclosure; and -
FIG. 9 is a cross-sectional view of the concrete pipe ofFIG. 8 . - It is understood that certain components may be removed from the drawing figures in order to provide better views of internal components.
- In the following description of various example structures according to the invention, reference is made to the accompanying drawings, which form a part hereof, and in which are shown by way of illustration various example devices, systems, and environments in which aspects of the invention may be practiced. It is to be understood that other specific arrangements of parts, example devices, systems, and environments may be utilized and structural and functional modifications may be made without departing from the scope of the present invention. Also, while the terms “top,” “bottom,” “front,” “back,” “side,” “rear,” “primary,” “secondary,” and the like may be used in this specification to describe various example features and elements of the invention, these terms are used herein as a matter of convenience, e.g., based on the example orientations shown in the figures or the orientation during typical use. Additionally, the term “plurality,” as used herein, indicates any number greater than one, either disjunctively or conjunctively, as necessary, up to an infinite number. Nothing in this specification should be construed as requiring a specific three dimensional orientation of structures in order to fall within the scope of this invention. Also, the reader is advised that the attached drawings are not necessarily drawn to scale.
- Referring now in detail to the Figures,
FIGS. 1-3 illustrate one embodiment of a prong that is usable in connection with aspects described herein, generally designated with thereference numeral 10. Theprong 10 is configured to function as a portion of a reinforcement structure that is partially or completely embedded within a structural material (e.g., concrete), to provide structural reinforcement to the material. Theprong 10 generally includes a connectingportion 20 for connecting theprong 10 to a reinforcement structure and a protrudingportion 21 configured to protrude from the reinforcement structure into the material to reinforce the material and anchor theprong 10 within the material. Theprong 10 is formed of a metal wire, which may have a circular cross-section or a different cross-section, that is bent or otherwise formed into an appropriate shape in one embodiment. Theprong 10 may be partially or completely formed of a different material and/or using a different technique in another embodiment. In one embodiment, theprong 10 may be formed of a wire having a diameter of 0.120″ to 0.209″ (e.g., 11 ga to 5 ga), or possibly to 0.243″, which results in an average stirrup prong steel area AV of 0.011 to 0.034, or possibly to 0.045. In the embodiment illustrated inFIGS. 1-3 , theprong 10 is made of a smooth wire, with a generally smooth outer surface. In another embodiment, theprong 10 may be made from “deformed wire,” which has intentional deformations or other structural features (e.g., ridges, recesses, etc.) on the outer surface to enhance bonding with the structural matrix material (e.g., concrete). This deformed wire could be positively deformed or negatively deformed, in various embodiments. It is understood that the use of deformed wire could alter the calculation of the average prong steel area AV, due to the non-constant cross-section of deformed wire. - The embodiment of the
prong 10 illustrated inFIGS. 1-3 has first andsecond legs 11 on the first andsecond sides 12, 13 (i.e., the left and right sides from the perspective shown inFIG. 1 ), respectively. Thelegs 11 are connected to each other at first or distal ends 14 thereof, such as by the use of a bridge portion or connectingportion 16 that connects the twolegs 11. Thelegs 11 are further configured for engagement with and/or connection to a portion of a reinforcement element, such as atie wire 30, at their second or proximal ends 15. In this configuration, thebridge portion 16 forms a first ordistal end 17 of theprong 10, and the proximal ends 15 of thelegs 11 form aproximal end 18 of theprong 10. - The
bridge portion 16 in the embodiment ofFIGS. 1-3 has a smoothly curved shape that arcs at least 180° to connect the distal ends 14 of thelegs 11 together. In one embodiment, thelegs 11 are closer together at their proximal ends 15, and the distance between thelegs 11 increases toward their distal ends 14. In this configuration, thelegs 11 are angled away from each other at theirdistal ends 14, such that thebridge portion 16 forms an arc of greater than 180°. In one embodiment, thebridge portion 16 is semi-circular and has a radius of curvature of approximately 0.5 inch, but may have a different size in another embodiment. Thebridge portion 16 may also have a different shape in another embodiment, such as a polygonal shape (e.g., square, triangular, etc.), a semi-elliptical shape, or an irregular shape. It is understood that the shapes and sizes of thelegs 11 and thebridge portion 16 may be dictated by the intended use or application of theprong 10. Thelegs 11 and thebridge portion 16 in the embodiment illustrated inFIGS. 1-3 form the protrudingportion 21 of theprong 10. - The
proximal end 15 of eachleg 11 is configured for engagement with a portion of a reinforcement structure, such as atie wire 30, and thereby form the connectingportion 20 of theprong 10. In the embodiment ofFIGS. 1-3 , theproximal end 15 of eachleg 11 is bent to wrap around a portion of thetie wire 30, which provides anengagement surface 22 for engaging and/or connecting to thetie wire 30. The engagement surfaces 22 may be considered to engage an underside of thetie wire 30 in this configuration, and it is understood that the term “underside” does not refer to any particular arrangement or orientation, but rather, that the “underside” of thetie wire 30 is the side opposite thedistal end 17 of theprong 10. The proximal ends 15 of thelegs 11 in this configuration may therefore be considered to have a hook-like shape. In this configuration, theproximal end 15 of eachleg 11 has abend portion 23 that is bent toward thetie wire 30 and/or toward theopposite side prong 10. For example, as shown inFIGS. 1-3 , thebend portion 23 of theleg 11 on thefirst side 12 of theprong 10 is bent toward thesecond side 13, and thebend portion 23 of theleg 11 on thesecond side 13 of theprong 10 is bent toward thefirst side 12. In some embodiments, thebend portion 23 of eachleg 11 may be bent at an angle of at least 90° or at least 100°, and in another embodiment, thebend portion 23 of eachleg 11 may be bent at an angle of at least 120°. In a further embodiment, thebend portion 23 of eachleg 11 may be bent to an angle that does not exceed 125°, or that does not exceed 135°. It is understood that the aforementioned upper and lower limits may be considered in conjunction with each other. Additionally, in one embodiment, thebend portion 23 of eachleg 11 may be bent around the tie wire. In one embodiment, the minimum radius of curvature of thebend portion 23 may be from about 0.09″ to about 0.11″, depending on wire size and application. For example, the minimum radius of curvature of thebend portion 23 is 0.089″, which may be used, e.g., for aprong 10 made from 11, 10, 9, 8, or 7 gauge wire around a 7 gage tie wire. As another example, the minimum radius of curvature of thebend portion 23 is 0.096″, which may be used, e.g., for aprong 10 made from 6 gage wire around a 6 gage tie wire. As a further example, the minimum radius of curvature of thebend portion 23 is 0.104″, which may be used, e.g., for aprong 10 made from for 5 gage wire around a 5 gage tie wire. - As shown in
FIGS. 1-3 , thelegs 11 haveengagement surfaces 22 that are configured for engaging and/or connecting to thetie wire 30. In one embodiment, the engagement surfaces 22 are at least partially defined by curved portions of the inner surfaces (or curved inner surfaces) 24 of the proximal ends 15 of thelegs 11. These curvedinner surfaces 24 are formed by thebend portions 23 of thelegs 11. In one embodiment, as shown inFIGS. 1-3 , eachleg 11 has a straight or relativelystraight tail portion 25 extending from thebend portion 23 to the tip of theleg 11. Thesestraight tail portions 25 also partially define the engagement surfaces 22 in one embodiment, or the engagement surfaces 22 may be completely defined by thebend portions 23 in another embodiment. Thebend portions 23 may extend all the way to the tips of thelegs 11 in a further embodiment, such that nostraight tail portions 25 are present. - As shown most clearly in
FIGS. 2 and 3 , the proximal ends 15 of thelegs 11 overlap each other and are positioned adjacent each other when configured for connection to thetie wire 30. As shown inFIG. 1 , theproximal end 15 of theright leg 11 is positioned in front of theproximal end 15 of theleft leg 11 in one embodiment, although this configuration can be reversed. This overlapping configuration gives the prong 10 a shape such that the distal ends 14 of thelegs 11 are generally aligned with each other and/or in the same general plane as each other, while the proximal ends 15 of thelegs 11 are in different planes from each other. Additionally, the overlapping and confronting surfaces of the proximal ends 15 of thelegs 11 may engage or contact each other in one embodiment, such that the engagement surfaces 22 generally form a single platform for engaging thetie wire 30. Further, in one embodiment, the proximal ends 15 of thelegs 11 may have sufficient length that they extend past each other as they overlap. In other words, theproximal end 15 of theleg 11 on the first side 12 (the left side inFIG. 1 ) extends beyond thesecond side 13 of the prong defined by theopposite leg 11, and theproximal end 15 of theopposite leg 11 on the second side 12 (the right side inFIG. 1 ) extends beyond thefirst side 12 of the prong defined by thefirst leg 11. In another embodiment, thelegs 11 may have lengths and/or bent configurations such that no portion of theproximal end 15 of eachleg 11 extends beyond theopposite side - The
prong 10 may be connected to atie wire 30 or other component of a reinforcement structure by use of thelegs 11 with the proximal ends 15 bent around thetie wire 30, as described herein. In one embodiment, theprong 10 may initially be provided in a pre-bent configuration, which is then bent to the final shape. Thepre-bent prong 10 may be a straight piece of wire in one embodiment. Thepre-bent prong 10 is then bent to the final shape to place the engagement surfaces 22 of thelegs 11 into engagement with thetie wire 30, including further bending thebend portions 23 around thetie wire 30. Once theprong 10 is in position, thelegs 11 are welded to thetie wire 30 to secure the connection. In one embodiment, as shown inFIGS. 1-3 , each of the engagement surfaces 22 of theprong 10 are welded to thetie wire 30 at asingle weld point 26 on the underside of thetie wire 30. These weld points 26 may be along the same side of thetie wire 30 and generally aligned with each other in the axial direction of thetie wire 30. In other embodiments, a different number and/or location of weld points 26 may be used. For example, weld points may additionally or alternately be placed along the sides (left and right inFIG. 1 ) of thetie wire 30. - When connected to a
tie wire 30 as shown inFIGS. 1-3 , theprong 10 has increased strength relative to a reinforcement component that is connected by welding without the use of thebend portions 23. For example, in one embodiment, the applied load sufficient to cause failure of theprong 10 when exerted on thebridge portion 16 in a direction away from the tie wire 30 (i.e., the “pull force”) is higher than the bond strength of the welding. As another example, in one embodiment, the applied load sufficient to cause failure of theprong 10 when exerted on thebridge portion 16 in a direction away from the tie wire 30 (i.e., the “pull force”) is approximately equal to the applied load sufficient to cause fracture the prong itself, i.e., the fracture of any portion of the prong wire. In this configuration, theprong 10 has its maximum possible failure resistance, because only forces near or at the force sufficient to fracture theprong 10 itself will cause failure. This increases the maximum reinforcement strength provided by theprong 10 to the concrete in which it is embedded. It is understood that theprong 10 may be used in reinforcement applications and configurations different from those shown and described herein by way of example. For example, theprong 10 may be configured for connection to a structure other than atie wire 30, in the same or a similar configuration to that described herein. - The
prong 10 may be used in connection with various reinforcement structures for concrete reinforcement, as illustrated inFIGS. 4-7 . A plurality ofprongs 10 may be connected to asingle tie wire 30 to create areinforcement element 31, as illustrated inFIG. 5 . Theprongs 10 may be connected to thetie wire 30 at locations spaced along the length of thetie wire 30. In one embodiment, theprongs 10 may be connected to thetie wire 30 at constant spacing intervals. Any spacing intervals can be used, including variable spacing intervals, and theprongs 10 configured as shown inFIGS. 1-3 provide the advantage of permitting any spacing interval to be used. Additionally, theprongs 10 may all be oriented in generally the same direction in one embodiment, such as inFIG. 5 , where all of theprongs 10 are extending upward from thetie wire 30. Different connection configurations and orientations may be used in other embodiments. Further, thereinforcement element 31 may include alock rod 32, such as shown inFIG. 6 , which may be useful or required for certain applications. Thelock rod 32, if used, may be secured to thedistal end 17 of theprong 10, such as by use of a wire tie or welding to the inner side of thebridge portion 16, as shown inFIG. 6 . Thelock rod 32 may not be secured to theprong 10, in an alternate configuration. - The
prong 10 may have various different sizes, including different heights, as measured in the direction between the distal and proximal ends 17, 18 of theprong 10, which creates different prong amplitudes when theprong 10 is connected to thetie wire 30. For example, theprong 10 may be configured to provide an amplitude of from 1.75″ to 20″ in one embodiment, or from 2″ to 18″ in another embodiment. Likewise, the spacing of theprongs 10 may be adjusted to nearly any desired spacing. - A plurality of
reinforcement elements 31 as shown inFIG. 5 may be connected together to form areinforcement mat 33 as shown inFIG. 4 . Thereinforcement mat 33 shown inFIG. 4 includes a plurality ofreinforcement elements 31 positioned to extend parallel to each other, with cross-wires 34 connecting thereinforcement elements 31 to each other. More specifically, as shown inFIG. 4 , a plurality ofcross-wires 34 are connected to thereinforcement elements 31 by connection to thetie wires 30, such that thereinforcement elements 31 are all positioned in spaced relation to each other and extending along a first direction, and the cross-wires 34 are connected between thereinforcement elements 31 in spaced relation to each other and extend along a second direction transverse to the first direction. As shown inFIG. 4 , themat 33 may have a slight curvature, such that it is configured for use in a curved structure. Themat 33 inFIG. 4 is depicted, for example, in a configuration as may be installed in a curved component, such as apipe 40 as inFIGS. 8-9 . It is understood that thetie wires 30 and/or cross-wires 34 may be produced in a straight configuration and bent as desired. It is also understood that some or all of the bending of thetie wires 30 and/or cross-wires 34 may be non-permanent or non-plastic, and that thebent wires cages FIG. 9 ). The spacing of thereinforcement elements 31 and/or the cross-wires 34 may be constant in one embodiment, or may be variable in another embodiment. Additionally,different reinforcement elements 31 within themat 33 can utilize the same or similar prong configurations (e.g., position, spacing, orientation, etc.) or may use varying prong configurations. For example, in one embodiment, all reinforcement elements within themat 33 may haveprongs 10 that are all configured with the same structure and spaced equal or substantially equal distances. The structure of theprong 10 enables such varying configurations. - In one embodiment, the
mat 33 may be configured such that theprongs 10 in eachelement 31 are staggered with respect to theprongs 10 in one or moreadjacent elements 31, which can be referred to has having a “pitched” arrangement. For example,FIG. 7 illustrates an embodiment of amat 33 that usesprongs 10 having a pitched arrangement, in which theprongs 10 ofadjacent elements 31 are progressively staggered in the same direction. This creates a corkscrew-like orientation of theprongs 10 with respect to each other. Amat 33 withprongs 10 in a pitched arrangement as shown inFIG. 7 may be configured for use withcages prongs 10 can be connected to the reinforcement structure in nearly any position or orientation. - The reinforcement structures described herein, including the
prongs 10 and thereinforcement elements 31 andmats 33 including theprongs 10, may be used to reinforce structural materials, such as concrete. In one embodiment, amat 33 as shown inFIG. 4 orFIG. 7 may be used to reinforce aconcrete pipe 40, as shown inFIGS. 8-9 . Thepipe 40 illustrated inFIGS. 8-9 is a circular pipe segment that has acircular wall 41 having a tubular shape with cylindrical inner and outer walls and a circularcentral passage 42. Thepipe 40 has aspigot 43 extending around one end and abell 44 extending around the other end. Thespigot 43 can fit within thebell 44 of anadjacent pipe segment 40 to connect multiple segments to each other. As shown inFIG. 9 , thepipe 40 includes areinforcement structure 45 that includes aninner cage 46, anouter cage 47, and areinforcement mat 33 connected to at least one of the inner andouter cages outer cages cages more mats 33 can then be connected to the inner and/orouter cages FIG. 9 , one ormore mats 33 are connected to theinner cage 46 by tie wires (not shown) or welding. Theprongs 10 of the mat(s) 33 extend from theinner cage 46 toward theouter cage 47, but do not connect to or contact theouter cage 47 in this embodiment. The reinforcement structure, including thecages cages - The mat(s) 33 may be positioned only around a portion of the perimeter of the
pipe 40 in some embodiments. As a point of reference, thepipe 40 includes atop portion 48, which includes top (outer) and crown (inner) surfaces, and abottom portion 49, which includes bottom (outer) and invert (inner) surfaces. For example, as shown inFIG. 9 , thepipe 40 hasmats 33 connected at thetop portion 48 of thepipe 40 and thebottom portion 49 of thepipe 40, which are the points of thepipe 40 that receive the greatest tensile and shear stresses (e.g., radial tension and diagonal shear), due to force exerted at these points in use. In one embodiment, themats 33 extend up to 90° around the top 48 and the bottom 49 of thepipe 40. In another embodiment, themats 33 extend 45° to 90° around thetop portion 48 and thebottom portion 49 of thepipe 40. In a further embodiment, themats 33 extend 45° or 90° around thetop portion 48 and thebottom portion 49 of thepipe 40. In yet another embodiment, themats 33 may extend around a greater portion of the perimeter of thepipe 40, up to and including the entire perimeter. For example, apipe 40 havingmats 33 extending around the entire perimeter (e.g., 360°) may be used in an application where the exact orientation of the installedpipe 40 is not known or cannot be easily controlled (e.g., a jack pipe). It is noted that themats 33 may have a curved configuration in order to be connected to the cylindrical cage(s) 46, 47. In the embodiment shown inFIG. 4 , this configuration is accomplished by bending the cross-wires 34 into curved shapes, such that thetie wires 30 of theindividual reinforcement elements 31 are relatively straight. In this configuration, thetie wires 30 and thereinforcement elements 31 extend in a longitudinal or axial direction on thepipe 40, and the cross-wires 34 extend in a circumferential direction. In other embodiments, the reinforcement structure may be differently configured, and it is understood that differently shaped pipes may utilize different structures. For example, a square shaped pipe (e.g., box culvert) may be subjected to significant shear forces at the corners of the pipe, and may therefore be provided withreinforcement mats 33 at the corners, as well as potentially withlock rods 32. - The embodiments of reinforcement structures, including
prongs 10,reinforcement elements 31, andreinforcement mats 33, described herein provide benefits and advantages over existing designs. For example, as described above, the configuration of theprong 10 with the proximal ends 15 bent around thetie wire 30 before welding, increases the strength of the connection between theprong 10 and thereinforcement element 31. Consequently, the pull force necessary to separate theprong 10 from thetie wire 30 is increased, particularly relative to prongs that are welded to opposite sides of thetie wire 30 and do not wrap around thetie wire 30. In one embodiment, this pull force may be equal to the tensile strength of theprong 10. The reinforcement capabilities of theprong 10 and the reinforcement structures with which it is used are thereby increased. As another example, theprongs 10 may be connected to the reinforcement structure (e.g., the tie wire 30) in a wide variety of configurations. Theprongs 10 can be positioned to have any desired spacing interval and/or may be oriented in any desired direction, etc., including being arranged in a spiral configuration. Still other benefits and advantages are explicitly or implicitly described herein and/or recognized by those skilled in the art. - While the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying Claims.
Claims (20)
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KR20230114925A (en) * | 2022-01-26 | 2023-08-02 | 류승일 | A non-welded concrete reinforcement having a coil-type fixing head and a reinforcement method of a concrete member using the same |
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US20140068946A1 (en) * | 2012-09-13 | 2014-03-13 | Korea Institute Of Construction Technology | Fire-resistance enhancing method for the high strength concrete structure |
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US20160251856A1 (en) * | 2013-11-04 | 2016-09-01 | Samsung C&T Corporation | Solid reinforced concrete column based on arrangement of triangular reinforcing bar networks and method of constructing the same |
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US20170321421A9 (en) * | 2014-10-16 | 2017-11-09 | Emin Buzimkic | Prefabricated modular rebar modules and methods of using the same |
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2015
- 2015-02-26 US US14/632,821 patent/US9909693B2/en active Active
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2018
- 2018-03-02 US US15/910,609 patent/US20190040977A1/en not_active Abandoned
-
2020
- 2020-02-28 US US16/805,000 patent/US20200200297A1/en not_active Abandoned
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US5802802A (en) * | 1993-07-19 | 1998-09-08 | Resaro Ab | Arrangement at a beam or building element and a mould for making a beam or building element |
US5924458A (en) * | 1996-11-12 | 1999-07-20 | Kaines; John L. | Self-locking stirrup mat |
US6293071B1 (en) * | 1997-01-03 | 2001-09-25 | Apostolos Konstantinidis | Antiseismic spiral stirrups for reinforcement of load bearing structural elements |
US7421827B1 (en) * | 1997-11-05 | 2008-09-09 | Apostolos Konstantinidis | Cellular stirrups and ties for structural members |
US6247501B1 (en) * | 2000-09-29 | 2001-06-19 | John L. Kaines | Clip-on stirrup mat |
US9279246B2 (en) * | 2009-09-11 | 2016-03-08 | Joseph Bronner | Twist on wire tie wall connection system and method |
US20140068946A1 (en) * | 2012-09-13 | 2014-03-13 | Korea Institute Of Construction Technology | Fire-resistance enhancing method for the high strength concrete structure |
US20160251856A1 (en) * | 2013-11-04 | 2016-09-01 | Samsung C&T Corporation | Solid reinforced concrete column based on arrangement of triangular reinforcing bar networks and method of constructing the same |
US20170321421A9 (en) * | 2014-10-16 | 2017-11-09 | Emin Buzimkic | Prefabricated modular rebar modules and methods of using the same |
US9719245B1 (en) * | 2016-05-30 | 2017-08-01 | Indian Institute Technology | Lateral reinforcement system and method for concrete structures |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
KR20230114925A (en) * | 2022-01-26 | 2023-08-02 | 류승일 | A non-welded concrete reinforcement having a coil-type fixing head and a reinforcement method of a concrete member using the same |
KR102609710B1 (en) * | 2022-01-26 | 2023-12-04 | 류승일 | A non-welded concrete reinforcement having a coil-type fixing head and a reinforcement method of a concrete member using the same |
Also Published As
Publication number | Publication date |
---|---|
US9909693B2 (en) | 2018-03-06 |
US20190040977A1 (en) | 2019-02-07 |
US20160252198A1 (en) | 2016-09-01 |
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