METHODS OF FORMING CONNECTIONS BETWEEN CONCRETE ARTICLES

Description

REFERENCE TO CORRELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/625,129, filed on Jan. 25, 2024, the contents of which are incorporated in its entirety.

BACKGROUND

Field connection of two or more pieces of concrete can be carried out, but it is not possible to be used in many applications. Conventional field connection requires very specific placement of reinforcement bar (rebar) during the casting process. For example, rebar may extend out of the concrete element to allow it to connect to other concrete in a separate pour. However, any field connection requires the placement of rebar during the casting process, which requires considerable planning and prevents on-site adjustments of the connection.

Thus, there exists a need for alternate methods of field connection of concrete. This need and others are at least partially satisfied by the present disclosure.

SUMMARY

In one aspect, provided is a method of forming a connection between concrete articles, the method including: affixing one or more first fasteners to a first concrete article; affixing one or more second fasteners to a second concrete article; and forming one or more concrete patches around the one or more first fasteners and the one or more second fasteners and spanning between the first concrete article and the second concrete article, thereby forming a connection that substantially prevents movement of the first concrete article relative to the second concrete article.

In another aspect, provided is a method of forming a connection between concrete articles, the method including: affixing one or more first fasteners to a first concrete article; affixing one or more second fasteners to a second concrete article; and affixing one or more connecting elements between the one or more first fasteners and the one or more second fasteners, thereby connecting the first concrete article to the second concrete article; wherein the first concrete article and/or the second concrete article includes a nailable concrete composition including a cement in an amount of about 25 wt % to about 70 wt %, a rubber in an amount of about 15 wt % to about 35 wt %, and fine aggregates in an amount of about 10 wt % to about 35 wt % based on a total mass of dry material.

In yet another aspect, provided is a method of forming a connection between concrete articles, the method including: affixing one or more first fasteners to a first concrete article; affixing one or more second fasteners to a second concrete article; affixing one or more connecting elements between the one or more first fasteners and the one or more second fasteners, thereby connecting the first concrete article to the second concrete article; and forming one or more concrete patches around the one or more connecting elements and spanning between the first concrete article and the second concrete article; wherein the first concrete article and/or the second concrete article includes a nailable concrete composition including a cement in an amount of about 25 wt % to about 70 wt % and a rubber in an amount of about 15 wt % to about 35 wt %.

In yet another aspect, provided is an article formed by any of the disclosed methods.

In yet another aspect, provided is a construction including any of the disclosed articles.

Other systems, methods, features and/or advantages will be or may become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features and/or advantages be included within this description and be protected by the accompanying claims.

BRIEF DESCRIPTION OF DRAWINGS

FIGS. 1A-1B depict a comparison of shear studs (FIG. 1A) and various screws (FIG. 1B). Note that both have a wide head, aiding in the transfer of load from one section of concrete to another. It is understood that in certain aspects, these studs and various screws can serve as anchors that are holding the concrete patch in place and ensure the stability of the connecting patch.

FIGS. 2A-2F depict an example method of creating a screw-wire-patch (SWP) connection into the existing nailable concrete members. FIG. 2A shows the connection to be reinforced. FIG. 2B shows that screws are installed into the nailable concrete. FIG. 2C shows that wire is tied at the connection by first looping around to secure the wire. FIG. 2D shows that the wire is looped back and forth several times, using the screw heads as a method of securing. FIG. 2E shows that a patching concrete is mixed and applied at the connection. FIG. 2F shows that, after curing, the patch can withstand substantial load.

FIGS. 3A-3C show various connection alternatives according to some aspects of the disclosure.

DETAILED DESCRIPTION

It is appreciated that certain features of the disclosure, which are, for clarity, described in the context of separate aspects, can also be provided in combination with a single aspect. Conversely, various features of the disclosure, which are, for brevity, described in the context of a single aspect, can also be provided separately or in any suitable subcombination. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. Methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present disclosure.

Definitions

In this specification and in the claims that follow, reference will be made to a number of terms, which shall be defined to have the following meanings:

As used herein, the terms “optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur and that the description includes instances where said event or circumstance occurs and instances where it does not.

It is appreciated that certain features of the disclosure, which are, for clarity, described in the context of separate aspects, can also be provided in combination in a single aspect. Conversely, various features of the disclosure, which are, for brevity, described in the context of a single aspect, can also be provided separately or in any suitable subcombination.

As used in the description and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. As used in the specification and in the claims, the term “comprising” can include the aspects “consisting of” and “consisting essentially of” Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. In this specification and in the claims which follow, reference will be made to a number of terms that shall be defined herein.

For the terms “for example” and “such as” and grammatical equivalences thereof, the phrase “and without limitation” is understood to follow unless explicitly stated otherwise. It is further understood that these phrases are used for explanatory purposes only. It is further understood that the term “exemplary,” as used herein, means “an example of” and is not intended to convey an indication of a preferred or ideal aspect.

All disclosed values also include values that fall within ±10% variation from the disclosed value unless otherwise indicated or inferred. In other words, if a range of 1 to 10 is disclosed, then a range of about 1 to about 10 is disclosed. In such aspects, it is understood that the amount or value in question can be the exact value or a value that provides equivalent results or effects as recited in the claims or taught herein. That is, amounts, sizes, formulations, parameters, and other quantities and characteristics include both exact values but also approximate, larger or smaller values as desired, reflecting tolerances, conversion factors, rounding, measurement error, and the like, and other factors known to those of skill in the art such that equivalent results or effects are obtained. In some circumstances, the value that provides equivalent results or effects cannot be reasonably determined. In general, an amount, size, formulation, parameter, or other quantity or characteristic is “about,” “approximate,” or “at or about,” whether or not expressly stated to be such. Where “about,” “approximate,” or “at or about” is used before a quantitative value, the parameter also includes the specific quantitative value itself unless expressly stated otherwise.

When a range is expressed, a further aspect includes from the one particular value and to the other particular value. For example, where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the disclosure, e.g., the phrase “x to y” includes the range from ‘x’ to ‘y’ as well as the range greater than ‘x’ and less than ‘y’. The range can also be expressed as an upper limit, e.g., ‘x, y, z, or less' and should be interpreted to include the specific ranges of ‘x,’ ‘y,’ ‘z,’ ‘about x,’ ‘about y,’ and ‘about z’ as well as the ranges of ‘less than x,’ ‘less than y, or ‘less than z,’ or ‘less than about x,’ ‘less than about y, and ‘less than about z.’ Likewise, the phrase’ x, y, z, or greater’ should be interpreted to include the specific ranges of ‘x,’ ‘y,’ ‘z,’ ‘about x,’ ‘about y,’ and ‘about z’ as well as the ranges of ‘greater than x,’ greater than y,’ ‘greater than z,’ or ‘greater than about x,’ greater than about y,’ ‘greater than about z.’ In addition, the phrase” ‘x’ to ‘y’,” where ‘x’ and y′ are numerical values, also includes “about x′ to about y′.”

Such a range format is used for convenience and brevity and, thus, should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. To illustrate, a numerical range of “0.1% to 5%” should be interpreted to include not only the explicitly recited values of 0.1% to 5% but also include individual values (e.g., 1%, 2%, 3%, and 4%) and the sub-ranges (e.g., 0.5% to 1.1%; 5% to 2.4%; 0.5% to 3.2%, and 0.5% to 4.4%, and other possible sub-ranges) within the indicated range. In still further aspects, when the specific values are disclosed between two end values, it is understood that these end values can also be included.

Throughout this disclosure, various aspects of the invention can be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, a description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6, etc., as well as individual numbers within that range, for example, 1, 2, 2.7, 3, 4, 5, 5.3, 6 and any whole and partial increments therebetween. This applies regardless of the breadth of the range.

In still further aspects, when the specific values are disclosed between two end values, it is understood that these end values can also be included.

In still further aspects, when the range is given, and exemplary values are provided, it is understood that any ranges can be formed between any exemplary values within the broadest range. For example, if individual numbers 1, 2, 3, 4, 5, 6, 7, etc. are disclosed, then the ranges 1-7, 2-7, 3-7, 4-7, 5-7, 6-7, 1-6, 1-5, 1-4, 1-3, 1-2, 2-6, 2-5, etc. are also disclosed.

The term “nailability” refers to the material's ability to function such that nails can be driven, by hand using a hammer, into the material without damaging the material excessively and with adequate withdrawal (pullout) strength to allow the material to be installed for structural applications. The penetration and withdrawal (pullout) force should be similar to the values of these variables for commonly used structural lumber species, such as Douglas fir, white pine, southern yellow pine, etc. A material is referred to as being nailable if it has attained the properties necessary to meet a nailability requirement. It is understood that if nails can be driven by hand using a hammer, then nails will drive appropriately using a pneumatic or cordless nailer or nail gun. Similarly, the term “screwability” refers to the material's ability to function such that screws, such as wood screws, for example, can be driven, by hand using a screwdriver, into the material without damaging the material excessively and with adequate withdrawal (pullout) strength to allow the material to be installed for structural applications.

It is understood that the terms “withdrawal” and “pullout,” as referred to herein, can be used interchangeably.

As used herein, the term “recycled” refers to leftovers of materials that are not in use anymore.

Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Furthermore, when numerical ranges of varying scope are set forth herein, it is contemplated that any combination of these values, inclusive of the recited values, may be used. Further, ranges can be expressed herein as from “about” one particular value and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value.

Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint and independently of the other endpoint. Unless stated otherwise, the term “about” means within 5% (e.g., within 2% or 1%) of the particular value modified by the term “about.”

As used herein, the term “composition” is intended to encompass a product comprising the specified ingredients in the specified amounts, as well as any product which results, directly or indirectly, from a combination of the specified ingredients in the specified amounts.

References in the specification and concluding claims to parts by weight of a particular element or component in a composition denotes the weight relationship between the element or component and any other elements or components in the composition or article for which a part by weight is expressed. Thus, in a mixture containing 2 parts by weight of component X and 5 parts by weight, components Y, X, and Y are present at a weight ratio of 2:5 and are present in such a ratio regardless of whether additional components are contained in the mixture.

A weight percent (wt. %) of a component, unless specifically stated to the contrary, is based on the total weight of the formulation or composition in which the component is included.

It will be understood that although the terms “first,” “second,” etc., may be used herein to describe various elements, components, regions, layers, and/or sections. These elements, components, regions, layers, and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, or section from another element, component, region, layer, or section. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of example embodiments.

As used herein, the term “substantially” means that the subsequently described event or circumstance completely occurs or that the subsequently described event or circumstance generally, typically, or approximately occurs.

Still further, the term “substantially” can, in some aspects, refer to at least about 80 at least about 85%, at least about 90%, at least about 91%, at least about 92%, at least about 93%, at least about 94%, at least about 95%, at least about 96%, at least about 97%, at least about 98%, at least about 99%, or about 100% of the stated property, component, composition, or other condition for which substantially is used to characterize or otherwise quantify an amount.

In other aspects, as used herein, the term “substantially free,” when used in the context of a composition or component of a composition that is substantially absent, is intended to refer to an amount that is then about 1% by weight, e.g., less than about 0.5% by weight, less than about 0.1% by weight, less than about 0.05% by weight, or less than about 0.01% by weight of the stated material, based on the total weight of the composition or based on any other calculations as disclosed.

As used herein, the term “substantially,” in, for example, the context “substantially identical” or “substantially similar,” refers to a method or a system, or a component that is at least about 90%, at least about 91%, at least about 92%, at least about 93%, at least about 94%, at least about 95%, at least about 96%, at least about 97%, at least about 98%, at least about 99%, or about 100% by similar to the method, system, or the component it is compared to.

As used herein, the terms “substantially identical reference composition” and “substantially identical reference article” refer to a reference composition or article comprising substantially identical components in the absence of an inventive component. In another exemplary aspect, the term “substantially,” in, for example, the context “substantially identical reference composition” or “substantially identical reference article,” refers to a reference composition or an article comprising substantially identical components and wherein an inventive component is absent or is substituted with a common in the art component.

Methods

In one aspect, provided is a method of forming a connection between concrete articles, the method including: affixing one or more first fasteners to a first concrete article; affixing one or more second fasteners to a second concrete article; and forming one or more concrete patches around the one or more first fasteners and the one or more second fasteners and spanning between the first concrete article and the second concrete article, thereby forming a connection that substantially prevents movement of the first concrete article relative to the second concrete article. In some aspects, the method can further include affixing one or more connecting elements between the one or more first fasteners and the one or more second fasteners before forming the one or more concrete patches; and the one or more concrete patches can be formed around the one or more first fasteners, the one or more second fasteners, and the one or more connecting elements.

In another aspect, provided is a method of forming a connection between concrete articles, the method including: affixing one or more first fasteners to a first concrete article; affixing one or more second fasteners to a second concrete article; and affixing one or more connecting elements between the one or more first fasteners and the one or more second fasteners, thereby connecting the first concrete article to the second concrete article; wherein the first concrete article and/or the second concrete article includes a nailable concrete composition including a cement in an amount of about 25 wt % to about 70 wt %, a rubber in an amount of about 15 wt % to about 35 wt %, and fine aggregates in an amount of about 10 wt % to about 35 wt % based on a total mass of dry material. In some aspects, the method can further include forming one or more concrete patches around the one or more connecting elements and spanning between the first concrete article and the second concrete article.

In yet another aspect, provided is a method of forming a connection between concrete articles, the method including: affixing one or more first fasteners to a first concrete article; affixing one or more second fasteners to a second concrete article; affixing one or more connecting elements between the one or more first fasteners and the one or more second fasteners, thereby connecting the first concrete article to the second concrete article; and forming one or more concrete patches around the one or more connecting elements and spanning between the first concrete article and the second concrete article; wherein the first concrete article and/or the second concrete article includes a nailable concrete composition including a cement in an amount of about 25 wt % to about 70 wt % and a rubber in an amount of about 15 wt % to about 35 wt %.

It is understood that in certain aspects, the one or more first and/or second fasteners are disposed in immediate distance to each other. In yet still further aspects, the one or more first fasteners and/or the one or more second fasteners can be disposed such that some of the first fasteners are affixed to one side of the first concrete article, while the others of the first fasteners are affixed to a different or opposing side of the first concrete article. Similarly, the one or more second fasteners can be affixed to the second concrete article.

In certain aspects, the first concrete article can further be affixed to the second concrete article with one or more additional fasteners. In such aspects, the one or more additional fasteners can protrude, for example through the first concrete article in the predetermined location and a protruding portion of the one or more additional fasteners are then connected with a body of the second concrete article. It is understood that this can be done also when the one or more additional fasteners protrude through the second concrete article in the predetermined location and the protruding portion connects with the first concrete article.

These configurations are shown in FIG. 3A-3C. For example, in FIG. 3A the first concrete article 302 is affixed to the second concrete article 304 with the one or more additional fasteners 312 that protrude form the first concrete article and connect with the second concrete article. Still further one or more first fasteners 308 are affixed to the first concrete article of 302 and one or more second fasteners 310 are affixed to the second concrete article 304 and one concrete patch 306 is formed in between to further connect these articles. In such connection, for example, the rotation (around the axis shown with an arrow) of the second concrete article 304 would be substantially minimized relative to the article 302.

A different aspect is shown in FIG. 3B. In this unlimited example, one or more first fasteners 308a and 308b are affixed to the first concrete article 302 at different locations relative to the article 304. Similarly, the one or more second fasteners 310a and 310b are affixed on different sides of the second concrete article 304 and two concrete patches 306a and 306b are formed.

An additional aspect of the disclosure is also shown in FIG. 3 C. In this case, for example the one or more additional fasteners 312 are affixed for example to the first concrete article 302 below the second concrete article 304. It is understood however, that this description is only exemplary and these fasteners can be affixed to the second concrete article and not to the first concrete article or they can be affixed to both articles at any location and two patches 306a and 306b are also formed.

In some aspects, the one or more connecting elements can be wire, cord, fiber, rods (e.g., optionally welded together), plates, rope, a hook-and-eye connector, or any combination thereof. For example, in some aspects, the one or more connecting elements can be made from natural fibers (e.g., hemp, jute, flax, cotton, coir, ramie, abaca), synthetic fibers (e.g., acrylic, aramid, basalt, carbon, cellulose acetate, cellulose triacetate, rayon, glass, nylon, polyphenylene sulfide, polyacrylonitrile, polybenzimidazole, polydioxanone, polyester, polylactic acid, polyethylene, ultra-high-molecular-weight polyethylene), and/or metals (e.g., steel, iron, copper, galvanized steel, brass, bronze, stainless steel, epoxy coated metals, etc.).

In some aspects, some or all of the one or more connecting elements can be affixed after the one or more first fasteners and the one or more second fasteners are affixed to the first concrete article and second concrete article, respectively. In other aspects, some or all of the one or more connecting elements can be affixed after the one or more first fasteners and/or the one or more second fasteners are only partially affixed to the first concrete article and/or the second concrete article, respectively, and the one or more first fasteners and/or the one or more second fasteners can subsequently be fully affixed (e.g., driven into the concrete article further, tightening the fastener, etc.) to the first concrete article and/or the second concrete article, respectively, to add tension to the one or more connecting elements.

In some aspects, under load, the one or more connecting elements can confer tensile strength to the connection and the one or more concrete patches can confer compressive strength to the connection; and the one or more connecting elements can enable flexing of the connection under load. For example, in some aspects, the one or more connecting elements can enable about 20° or less of flexing of the connection under load (e.g., 19° or less, 18° or less, 17° or less, 160 or less, 150 or less, 140 or less, 130 or less, 120 or less, 110 or less, 100 or less, 9° or less, 8° or less, 7° or less, 6° or less, 5° or less, 4.5° or less, 4° or less, 3.5° or less, 3° or less, 2.5° or less, 2° or less, 1.5° or less, 10 or less, 0.5° or less).

In some aspects, together, the one or more connecting elements and the one or more concrete patches can minimize rotation of the first concrete article and/or the second concrete article about the connection.

In some aspects, the method can further include applying a bonding agent to the first concrete article and/or the second concrete article before forming the one or more concrete patches. For example, in some aspects, the bonding agent can be acrylic-based, epoxy-based, latex-based, water-based, cementitious-based, or any combination thereof.

In some aspects, forming each of the one or more concrete patches can include: providing a wet concrete mixture around the one or more first fasteners and the one or more second fasteners and spanning between the first concrete article and the second concrete article; and curing the wet concrete mixture. In some aspects, some or all of the one or more concrete patches can include a nailable concrete composition. In other aspects, some or all of the one or more concrete patches can include a non-nailable concrete composition.

In some aspects, the first concrete article and/or the second concrete article can include a nailable concrete composition. In other aspects, the first concrete article and/or the second concrete article can include a non-nailable concrete composition. In yet other aspects, the first concrete article can include a nailable concrete composition, and the second concrete article can include a non-nailable concrete composition.

In some aspects, the first concrete article and the second concrete article can have a same or different composition; and each of the one or more concrete patches can independently have a same or different composition as the first concrete article and/or the second concrete article.

In some aspects, the first concrete article and the second concrete article can be coplanar and spaced apart, and the connection can span a coplanar space between the first concrete article and the second concrete article; and the first concrete article and the second concrete can be spaced apart by from about 1.5 inches to about 6 feet. For example, in some aspects, the first concrete article and the second concrete article can be spaced apart by about 1.5 inches or more (e.g., about 2 inches or more, about 2.5 inches or more, about 3 inches or more, about 4 inches or more, about 5 inches or more, about 6 inches or more, about 7 inches or more, about 8 inches or more, about 9 inches or more, about 10 inches or more, about 11 inches or more, about 1 foot or more, about 1.5 feet or more, about 2 feet or more, about 2.5 feet or more, about 3 feet or more, about 3.5 feet or more, about 4 feet or more, about 4.5 feet or more, about 5 feet or more, about 5.5 feet or more, about 6 feet or more). In some aspects, the first concrete article and the second concrete article can be spaced apart by about 6 feet or less (e.g., about 5.5 feet or less, about 5 feet or less, about 4.5 feet or less, about 4 feet or less, about 3.5 feet or less, about 3 feet or less, about 2.5 feet or less, about 2 feet or less, about 1.5 feet or less, about 1 foot or less, about 11 inches or less, about 10 inches or less, about 9 inches or less, about 8 inches or less, about 7 inches or less, about 6 inches or less, about 5 inches or less, about 4 inches or less, about 3 inches or less, about 2.5 inches or less, about 2 inches or less, about 1.5 inches or less).

It is considered that the first concrete article and the second concrete article can be spaced apart by a distance ranging from any of the minimum values described above to any of the maximum values described above. For example, in some aspects, the first concrete article and the second concrete article can be spaced apart by from about 1.5 inches to about 6 feet (e.g., from about 2 inches to about 5.5 feet, from about 2.5 inches to about 5 feet, from about 3 inches to about 4.5 feet, from about 4 inches to about 4 feet, from about 5 inches to about 3.5 feet, from about 6 inches to about 3 feet, from about 7 inches to about 2.5 feet, from about 8 inches to about 2 feet, from about 9 inches to about 1.5 feet, from about 10 inches to about 1 foot, from about 1.5 inches to about 1 foot, from about 2 inches to about 11 inches, from about 2.5 inches to about 10 inches, from about 3 inches to about 9 inches, from about 4 inches to about 8 inches, from about 5 inches to about 7 inches, from about 10 inches to about 6 feet, from about 11 inches to about 5.5 feet, from about 1 foot to about 5 feet, from about 1.5 feet to about 4.5 feet, from about 2 feet to about 4 feet, from about 2.5 feet to about 3.5 feet). In some aspects, for example, if the first concrete article and the second concrete article are spaced apart by about 6 inches or more, additional reinforcement may be added between the first concrete article and the second concrete article before some or all of the one or more concrete patches are formed.

In some aspects, the first concrete article and the second concrete article can be immediately adjacent and positioned at an angle, and wherein the connection spans diagonally between the first concrete article and the second concrete article; and the first concrete article and the second concrete article can be positioned at an angle of from about 5° to about 175°. For example, in some aspects, the first concrete article and the second concrete article can be positioned at an angle of about 5° or more (e.g., about 10° or more, about 15° or more, about 200 or more, about 250 or more, about 300 or more, about 350 or more, about 400 or more, about 450 or more, about 500 or more, about 550 or more, about 600 or more, about 650 or more, about 700 or more, about 750 or more, about 800 or more, about 850 or more, about 900 or more, about 950 or more, about 1000 or more, about 1050 or more, about 1100 or more, about 1150 or more, about 1200 or more, about 1250 or more, about 1300 or more, about 1350 or more, about 1400 or more, about 1450 or more, about 1500 or more, about 1550 or more, about 1600 or more, about 1650 or more, about 1700 or more, about 1750 or more). In some aspects, the first concrete article and the second concrete article can be positioned at an angle of about 1750 or less (e.g., about 1700 or less, about 1650 or less, about 1600 or less, about 1550 or less, about 1500 or less, about 1450 or less, about 1400 or less, about 1350 or less, about 1300 or less, about 1250 or less, about 1200 or less, about 1150 or less, about 1100 or less, about 1050 or less, about 1000 or less, about 950 or less, about 900 or less, about 850 or less, about 800 or less, about 750 or less, about 700 or less, about 650 or less, about 600 or less, about 550 or less, about 500 or less, about 450 or less, about 400 or less, about 350 or less, about 300 or less, about 250 or less, about 200 or less, about 150 or less, about 100 or less, about 5° or less).

It is considered that the first concrete article and the second concrete article can be positioned at an angle ranging from any of the minimum values described above to any of the maximum values described above. For example, in some aspects, the first concrete article and the second concrete article can be positioned at an angle of from about 5° to about 1750 (e.g., from about 100 to about 170°, from about 150 to about 165°, from about 200 to about 160°, from about 250 to about 155°, from about 300 to about 150°, from about 350 to about 145°, from about 400 to about 140°, from about 450 to about 135°, from about 500 to about 130°, from about 55° to about 125°, from about 60° to about 120°, from about 65° to about 115°, from about 70° to about 110°, from about 75° to about 105°, from about 80° to about 100°, from about 85° to about 95°, from about 5° to about 90°, from about 10° to about 85°, from about 15° to about 80°, from about 20° to about 75°, from about 25° to about 70°, from about 30° to about 65°, from about 35° to about 60°, from about 40° to about 55°, from about 45° to about 50°, from about 90° to about 175°, from about 95° to about 170°, from about 100° to about 165°, from about 105° to about 160°, from about 110° to about 155°, from about 115° to about 150°, from about 120° to about 145°, from about 125° to about 140°, from about 130° to about 135°).

In some aspects, a first end of the first concrete article can be immediately adjacent to a first end of the second concrete article (i.e., the first concrete article and the second concrete article can be joined together at their ends). In other aspects, the first end of the first concrete article can be immediately adjacent to a region of the second concrete article that is spaced from the first end of the second concrete article (i.e., the first concrete article can “intersect” the second concrete article). In some such aspects, the connection can span one or both angular spaces on either side of the first concrete article. For example, if the first concrete article and the second concrete article are positioned at an angle of about 45°, the connection can be formed in the 450 angular space on one side of the first concrete article and/or in the 1350 angular space on the opposite side of the first concrete article.

In some aspects, a distance between the one or more first fasteners and the one or more second fasteners can be about 0.5 inches or more (e.g., about 1 inch or more, about 1.5 inches or more, about 2 inches or more, about 2.5 inches or more, about 3 inches or more, about 4 inches or more, about 5 inches or more, about 6 inches or more, about 7 inches or more, about 8 inches or more, about 9 inches or more, about 10 inches or more, about 11 inches or more, about 1 foot or more, about 1.5 feet or more, about 2 feet or more, about 2.5 feet or more, about 3 feet or more, about 3.5 feet or more, about 4 feet or more). In some aspects, a distance between the one or more first fasteners and the one or more second fasteners can be about 4 feet or less (e.g., about 3.5 feet or less, about 3 feet or less, about 2.5 feet or less, about 2 feet or less, about 1.5 feet or less, about 1 foot or less, about 11 inches or less, about 10 inches or less, about 9 inches or less, about 8 inches or less, about 7 inches or less, about 6 inches or less, about 5 inches or less, about 4 inches or less, about 3 inches or less, about 2.5 inches or less, about 2 inches or less, about 1.5 inches or less, about 1 inch or less, about 0.5 inches or less).

It is considered that a distance between the one or more first fasteners and the one or more second fasteners can range from any of the minimum values described above to any of the maximum values described above. For example, in some aspects, a distance between the one or more first fasteners and the second one or more fasteners can be from about 0.5 inches to about 4 feet (e.g., from about 1 inch to about 3.5 feet, from about 1.5 inches to about 3 feet, from about 2 inches to about 2.5 feet, from about 2.5 inches to about 2 feet, from about 3 inches to about 1.5 feet, from about 4 inches to about 1 foot, from about 5 inches to about 11 inches, from about 6 inches to about 10 inches, from about 7 inches to about 9 inches, from about 0.5 inches to about 8 inches, from about 1 inch to about 7 inches, from about 1.5 inches to about 6 inches, from about 2 inches to about 5 inches, from about 2.5 inches to about 4 inches, from about 8 inches to about 4 feet, from about 9 inches to about 3.5 feet, from about 10 inches to about 3 feet, from about 11 inches to about 2.5 feet, from about 1 foot to about 2 feet).

In some aspects, the first concrete article and/or the second concrete article comprises a nailable concrete composition comprising a cement in an amount of about 25 wt % to about 70 wt %, a rubber in an amount of about 15 wt % to about 35 wt %, and fine aggregates in an amount of about 10 wt % to about 35 wt % based on a total mass of dry material.

In such aspects, the cement can be present in an amount of about 25 wt % to about 70 wt %, including exemplary values of about 26 wt %, about 27 wt %, about 28 wt %, about 29 wt %, about 30 wt %, about 31 wt %, about 32 wt %, about 33 wt %, about 34 wt %, about 35 wt %, about 36 wt %, about 37 wt %, about 38 wt %, about 39 wt %, about 40 wt %, about 41 wt %, about 42 wt %, about 43 wt %, about 44 wt %, about 45 wt %, about 46 wt %, about 47 wt %, about 48 wt %, about 49 wt %, about 50 wt %, about 51 wt %, about 52 wt %, about 53 wt %, about 54 wt %, about 55 wt %, about 56 wt %, about 57 wt %, about 58 wt %, about 59 wt %, about 60 wt %, about 61 wt %, about 62 wt %, about 63 wt %, about 64 wt %, about 65 wt %, about 66 wt %, about 67 wt %, about 68 wt %, about 69 wt %, and about 69.9 wt %, based on a total mass of dry material.

In still further aspects, the cement can be any known in the art cementitious materials suitable for the desired application can be used. In some aspects, the cement can comprise portland cement, calcium aluminate cement, calcium silicate, magnesium silicate, calcium phosphate cement, calcium aluminate sulfonate cement, fly ash, silica fume, slaked lime, cement kiln dust, limestone fines, ground granulated blast furnace slag, recycled cement mixtures, cement waste, and combinations of thereof. In still further aspects, the cement is portland cement.

Yet still, any other known in the art cement can be utilized in this disclosure. For example, the cement can be chosen from portland cement, portland cement blends (portland blast-furnace slag cement, or blast furnace cement, portland-fly ash cement, portland pozzolan cement, portland silica fume cement, masonry cement, expansive cement, white blended cement, and very finely ground types of cement), pozzolan-lime cement, slag-lime cement, supersulfated cement, calcium sulfoaluminate cement, geopolymer cement, polymer cement, Sorel cement (named by the chemist Stanislas Sorel), limestone cement, and hydraulic cement and non-hydraulic cement.

In still further aspects, the rubber in an amount of about 10 wt % to about 60 wt %, including exemplary values of about 15 wt %, about 20 wt %, about 25 wt %, about 30 wt %, about 35 wt %, about 40 wt %, about 45 wt %, about 50 wt %, and about 55 wt % on a total mass of dry material. While in still further aspects, the rubber is present in an amount of about 15 wt % to about 35 wt %, including exemplary values of about 16 wt %, about 17 wt %, about 18 wt %, about 19 wt %, about 20 wt %, about 21 wt %, about 22 wt %, about 23 wt %, about 24 wt %, about 25 wt %, about 26 wt %, about 27 wt %, about 28 wt %, about 29 wt %, about 30 wt %, about 31 wt %, about 32 wt %, about 33 wt %, and about 34 wt % on a total mass of dry material.

Yet in still further aspects, the rubber can be present in an amount of about 20 wt % to about 140 wt % based on the weight of the cement, including exemplary values of about 30 wt %, about 40 wt %, about 50 wt %, about 60 wt %, about 70 wt %, about 80 wt %, about 90 wt %, about 100 wt %, about 110 wt %, about 120 wt %, and about 130 wt % based on the weight of the cement.

It is understood that the rubber can be used as is, or it can be pretreated prior to use in the concrete. Any known in the art methods of pretreatment can be utilized. For example, and without limitations, the rubber can be treated with cement (to increase adherence, for example), treated with acids (sulfuric, hydrochloric, nitric, etc.), and treated with bases (sodium hydroxide, potassium hydroxide, etc.). It is understood that the examples provided herein include pretreated and non-treated rubber.

In still further aspects, the concrete composition can comprise fine aggregates in an amount of about 10 wt % to about 35 wt %, including exemplary values of about 11 wt %, about 12 wt %, about 13 wt %, about 14 wt %, about 15 wt %, about 16 wt %, about 17 wt %, about 18 wt %, about 19 wt %, about 20 wt %, about 21 wt %, about 22 wt %, about 23 wt %, about 24 wt %, about 25 wt %, about 26 wt %, about 27 wt %, about 28 wt %, about 29 wt %, about 30 wt %, about 31 wt %, about 32 wt %, about 33 wt %, and about 34 wt % on a total mass of dry material.

It is understood that cement, rubber, and fine aggregates can be present in any ratio to each other.

In some exemplary and unlimiting aspects, the composition can comprise fine aggregates-to-cement-to-rubber in a ratio of 5:8:15 or 3:4:8 by volume. In other exemplary and unlimiting aspects, the composition can comprise fine aggregates-to-cement-to-rubber in a ratio of 5:18:26 or 1:3:4 by volume. In yet still further exemplary and unlimiting aspects, the composition can comprise fine aggregates-to-cement-to-rubber in a ratio of 1:1.6:3 based on volume or 1:3.6:5.2 based on volume. It is understood that, in some aspects, volumetric ratios can be used. The use of volumetric ratios can be useful when the mixture is prepared in the field during the mixing of the components. In such exemplary and unlimiting aspects, the shovels” or “shovel-fulls” can be used as measurement units.

In yet still further exemplary and unlimiting aspects, the composition can comprise fine aggregates-to-cement-to-rubber in a ratio of 7:11:5 by weight. In yet still further exemplary and unlimiting aspects, the composition can comprise fine aggregates-to-cement-to-rubber in a ratio of 20:68:25 by weight. In yet still further exemplary and unlimiting aspects, the composition can comprise fine aggregates-to-cement-to-rubber in a ratio of 1.4:2.2:1 based on weight or mass or 1:3.4:1.25 based on weight or mass.

In yet still further exemplary and unlimiting aspects, the composition can comprise fine aggregates-to-cement-to-rubber in a ratio of 3:14:12 or 7:8:1 by volume. In yet still further exemplary and unlimiting aspects, the composition can comprise fine aggregates-to-cement-to-rubber in a ratio of 2:11:28 or 7:6:28 by volume. In yet still further exemplary and unlimiting aspects, the composition can comprise fine aggregates-to-cement-to-rubber in a ratio of 7:10:12 by volume.

In still further aspects, the disclosed herein cement compositions are substantially free of coarse aggregates. It is understood that common cement compositions comprise aggregates that are fine aggregates having a diameter of less than about 9.5 mm and coarse aggregates having a diameter of about 9.5 mm to about 40 mm. The aggregates, in general, can comprise natural sand, silicone sand, crushed stone, recycled foundry sand, bottom ash, slag, gravel, recycled concrete, glass, limestone, granite, and the like, and any combination thereof.

In still further aspects, the fine aggregates present in the disclosed composition comprise any known aggregates having a size smaller than about 9.5 mm, smaller than about 9 mm, smaller than about 8.5 mm, smaller than about 8 mm, smaller than about 7.5 mm, smaller than about 7 mm, smaller than about 6.5 mm, smaller than about 6 mm, smaller than about 5.5 mm, smaller than about 5 mm, smaller than about 4.5 mm, smaller than about 4 mm, smaller than about 3.5 mm, smaller than about 3 mm, smaller than about 2.5 mm, smaller than about 2 mm, smaller than about 1.5 mm, smaller than about 1 mm, or smaller than about 0.5 mm. In still further aspects, the fine aggregates present in the disclosed composition can have a size greater than 0 to about 9.5 mm, including exemplary values of about 0.5 mm, about 1 mm, about 1.5 mm, about 2 mm, about 2.5 mm, about 3 mm, about 3.5 mm, about 4 mm, about 4.5 mm, about 5 mm, about 5.5 mm, about 6 mm, about 6.5 mm, about 7 mm, about 7.5 mm, about 8 mm, about 8.5 mm, and about 9 mm.

In still further aspects, the fine aggregates present in the disclosed herein compositions are sand. Again it is understood that sand can be natural sand, silicone sand, recycled foundry sand, and the like.

In aspects disclosed herein, the cement composition is substantially free of coarse aggregates a size larger than about 9 mm, larger than about 9.5 mm, larger than about 10 mm, larger than about 10.5 mm, larger than about 11 mm, larger than about 11.5 mm, larger than about 12 mm, larger than about 12.5 mm, larger than about 13 mm, larger than about 13.5 mm, larger than about 14 mm, larger than about 14.5 mm, larger than about 15 mm, larger than about 15.5 mm, larger than about 16 mm, larger than about 16.5 mm, larger than about 17 mm, larger than about 17.5 mm, larger than about 18 mm, larger than about 18.5 mm, larger than about 19 mm, larger than about 19.5, larger than about 20 mm, larger than about 20.5 mm, larger than about 21 mm, larger than about 21.5 mm, larger than about 22 mm, larger than about 22.5 mm, larger than about 23 mm, larger than about 23.5 mm, larger than about 24 mm, larger than about 24.5 mm, larger than about 25 mm, larger than about 25.5 mm, larger than about 26 mm, larger than about 26.5 mm, larger than about 27 mm, larger than about 27.5 mm, larger than about 28 mm, larger than about 28.5 mm, larger than about 29 mm, larger than about 29.5 mm, larger than about 30 mm, larger than about 30.5 mm, larger than about 31 mm, larger than about 31.5 mm, larger than about 32 mm, larger than about 32.5 mm, larger than about 33 mm, larger than about 33.5 mm, larger than about 34 mm, larger than about 34.5 mm, larger than about 35 mm, larger than about 35.5 mm, larger than about 36 mm, larger than about 36.5 mm, larger than about 37 mm, larger than about 37.5 mm, larger than about 38 mm, larger than about 38.5 mm, larger than about 39 mm, or larger than about 39.5 mm.

In yet other aspects, the concrete composition described herein is substantially free of coarse aggregates having a size of about 9.5 mm to about 40 mm, including exemplary values of about 10 mm, about 12 mm, about 15 mm, about 17 mm, about 20 mm, about 22 mm, about 25 mm, about 27 mm, about 30 mm, about 32 mm, about 35 mm, and about 37 mm.

In still further aspects, the coarse aggregates disclosed herein can comprise gravel, crushed rock, crushed limestone, crushed recycled concrete, crushed granite and the like. In still further aspects, the disclosed herein compositions are substantially free of rock aggregates.

In still further aspects, the rubber present in the concrete composition can be virgin. Yet, in other aspects, the rubber can be recycled. It is understood that the term “virgin” refers to rubbers as produced. In still further aspects, recycled rubber can be post-consumer recycled rubber or post-manufacturing recycled rubber. It is understood that post-manufacturing recycled rubber includes waste rubber, unused rubber, discarded good rubbers, unused rubber that does not pass quality control inspection and the like.

In still further aspects, recycled rubber can comprise recycled tires, tire buffing, recycled conveyor belts, rubber clothing, rubber gloves, rubber mats, rubber flooring, rubber seals, rubber gaskets, rubber hoses, or any combination thereof.

In still further aspects, the recycled rubber that is used in the concrete compositions disclosed herein does not have to be cleaned or purified. In such aspects, recycled rubber can comprise at least some amount of recycled material that is not rubber. For example, and without limitations, if the recycled rubber is recycled tires or conveyor belts, such rubber can contain recycled metals, nails, staples, other polymers, fabrics, and the like.

In still further aspects, the rubber present in the compositions disclosed herein has a particle size no greater than about 0.5 inches, no greater than about 0.45 inches, no greater than about 0.4 inches, no greater than about 0.35 inches, no greater than about 0.3 inches, no greater than about 0.25 inches, no greater than about 0.2 inches, no greater than about 0.15 inches, no greater than about 0.1 inches, or no greater than about 0.05 inches. In yet still further aspects, the rubber present in the compositions disclosed herein can have a particle size in microns or in millimeters. In still further aspects, the rubber present in the compositions disclosed herein has a particle size no smaller than about 0.00001 inches, no smaller than about 0.0001 inches, no smaller than about 0.001 inches, no smaller than about 0.01 inches, no smaller than about 0.1 inches, no smaller than about 0.15 inches, no smaller than about 0.2 inches, no smaller than about 0.25 inches, no smaller than about 0.3 inches, no smaller than about 0.35 inches, no smaller than about 0.4 inches, or no smaller than about 0.45 inches.

In some aspects, the aggregates present in the composition need to be a smaller diameter than the diameter of the nails intended for use. Without wishing to be bound by any theory, it is assumed that a small enough piece of aggregate may allow for nail deflection without detrimental effects.

In yet other aspects, the rubber can have a particle size of about 0.05 inches to about 0.45 inches, including exemplary values of about 0.1 inches, about 0.15 inches, about 0.2 inches, about 0.25 inches, about 0.3 inches, about 0.35 inches, about 0.4 inches, and about 0.45 inches. In yet other aspects, the rubber can have a particle size up to about 1 inch, including exemplary values of about 0.1 inches, about 0.15 inches, about 0.2 inches, about 0.25 inches, about 0.3 inches, about 0.35 inches, about 0.4 inches, about 0.45 inches, about 0.5 inches, about 0.55 inches, about 0.6 inches, about 0.65 inches, about 0.7 inches, about 0.75 inches, about 0.8 inches, about 0.85 inches, about 0.9 inches, and about 0.95 inches.

In still further aspects, the rubber comprises natural rubber, natural polyisoprene, synthetic polyisoprene, styrene-butadiene rubber, butadiene rubber, butyl rubber, halogenated butyl rubber, nitrile rubber, hydrogenated nitrile rubber, ethylene propylene diene rubber, ethylene propylene rubber, chloroprene, polychloroprene, neoprene, silicone rubber, fluorosilicone rubber, fluoroelastomers, perfluloroelasomers, polyether block amides, polysulfide rubber, ethylene-vinyl acetate, chlorusulfonated polyethylene, epichlorhydrin rubber, inorganic rubber, or any combination thereof. In yet still further aspects, the rubber can be substituted by an elastomer such as thermoplastic elastomers, proteins resilin, elastin, elastolefin, poly(dichlorophosphazene), and the like, and any combination thereof.

In still further aspects, the concrete composition disclosed herein can comprise water in an amount of about 20 wt % to about 40 wt %, including exemplary values of about 21 wt %, about 22 wt %, about 23 wt %, about 24 wt %, about 25 wt %, about 26 wt %, about 27 wt %, about 28 wt %, about 29 wt %, about 30 wt %, about 31 wt %, about 32 wt %, about 33 wt %, about 34 wt %, about 35 wt %, about 36 wt %, about 37 wt %, about 38 wt %, and about 39 wt %, based on the water-to-cement-ratio.

In still further aspects, the concrete composition disclosed herein can comprise one or more fillers, plasticizers, water-reducing agents, pumping agents, air entrainers, set retarders, fire retardants, water repellants, defoamers, antifreeze agents, expanding agents, curing agents, coloring additives, anti-dispersant agents, mold release agents, antimicrobial agents, fire-retardants, antifungal agents, insect- and animal-repellant agents, anti-corrosion additive, adhesive additives, or any combination thereof.

In some aspects, if plasticizers are present, they can be an amount of about 0.25 wt % to about 8 wt %, including exemplary values of about 1 wt %, about 1.5 wt %, about 2 wt %, about 2.5 wt %, about 3 wt %, about 3.5 wt %, about 4 wt %, about 4.5 wt %, about 5 wt %, about 5.5 wt %, about 6 wt %, about 6.5 wt %, about 7 wt %, and about 7.5 wt %, based on the weight of the cement.

In such exemplary aspects, the one or more plasticizers comprise lignosulfonates, naphthalene, sulfonated naphthalene formaldehyde (SNF), melamine sulfonate-based superplasticizer, polycarboxylate ether superplasticizer (PCE), just polycarboxylate (PC), polycarboxylate superplasticizer monomer in ether mode (TPEG-HPEG) or any combination thereof.

In still further aspects, the filler can be present from greater than 0 wt % to about 70 wt %, including exemplary values of about 0.1 wt %, about 0.5 wt %, about 1 wt %, about 5 wt %, about 10 wt %, about 15 wt %, about 20 wt %, about 25 wt %, about 30 wt %, about 35 wt %, about 40 wt %, about 45 wt %, about 50 wt %, about 55 wt %, about 60 wt %, about 65 wt %, and about 69 wt % based on the total concrete composition.

In yet still further aspects, the filler can be present up to about 300 wt % based on the weight of the cement, including exemplary values of about 1 wt %, 10 wt %, about 20 wt %, about 50 wt %, about 100 wt %, about 120 wt %, about 150 wt %, about 170 wt %, about 200 wt %, about 220 wt %, about 250 wt %, and about 280 wt %.

In such exemplary aspects, the filler comprises one or more of calcium carbonate, flyash, pozzolanic ash, calcium carbonate, aluminum trihydrate, talc, nano-clay, barium sulfate, barite, barite glass fiber, fiberglass glass powder, glass cullet, metal powder, alumina, hydrated alumina, clay, magnesium carbonate, calcium sulfate, silica, glass, fumed silica, carbon black, graphite, cement dust, feldspar, nepheline, magnesium oxide, zinc oxide, aluminum silicate, calcium silicate, titanium dioxide, titanates, glass microspheres, chalk, calcium oxide, and any combination thereof.

In certain aspects, the cement composition can comprise reinforcing materials, such as, for example, and without limitations fiberglass. It is understood, however, that other reinforcing materials can be utilized. In some aspects, the fiberglass can be present as it, or it can also be reinforced with the polymers, such as for example, polypropylene, nylon, or a combination thereof. In still further aspects, these reinforcing materials can be present in an amount of about 0.1 wt % to about 10 wt %, including exemplary values of about 0.2 wt %, about 0.5 wt %, about 0.7 wt %, about 1 wt %, about 2 wt %, about 3 wt %, about 4 wt %, about 5 wt %, about 6 wt %, about 7 wt %, about 8 wt %, and about 9 wt %, based on the weight of the cement present in the composition.

In still further exemplary and unlimiting aspects, the water-reducing agent can be sodium lignosulfonate or calcium lignosulfonate. Water-reducing agents can also comprise hydroxycarboxylic acids, hydroxylated polymers, and the like.

In still further exemplary and unlimiting aspects, the air entrainers can comprise wood-derived acid salts, such as vinsol resins and wood rosins, and synthetic resins. It is understood that these compounds are only exemplary, and any known in the art air entrainers suitable for the desired purpose can be utilized.

In still further aspects, the cement composition disclosed herein comprises fire-retardants. In such aspects, the fire-retardant can comprise aluminum trihydrate (ATH), chlorinated tris [tris(1,3-dichloro-2-propyl)phosphate, TDCPP, and TDCIPP], Pentabromodiphenyl ether (PentaBDE) mixture [DE-71 (technical grade)], Tetrabromobisphenol A (TBBPA), Tris(2-

In some aspects, the rubber is virgin and/or recycled and has a particle size no greater than about 0.5 inches.

In some aspects, the rubber comprises natural rubber, natural polyisoprene, synthetic polyisoprene, styrene-butadiene rubber, butadiene rubber, butyl rubber, halogenated butyl rubber, nitrile rubber, hydrogenated nitrile rubber ethylene propylene diene rubber, ethylene propylene rubber, chloroprene, polychloroprene, neoprene, silicone rubber, fluorosilicone rubber, fluoroelastomers, perfluloroelasomers, polyether block amides, polysulfide rubber, ethylene-vinyl acetate, chlorusulfonated polyethylene, epichlorhydrin rubber, inorganic rubber, or any combination thereof.

In some aspects, the nailable concrete composition further comprises water in an amount of about 20 wt % to about 40 wt % based on the water-to-cement ratio.

In some aspects, the nailable concrete composition further comprises one or more fillers, plasticizers, water-reducing agents, pumping agents, air entrainers, set retarders, fire retardants, water repellants, defoamers, antifreeze agents, expanding agents, curing agents, coloring additives, anti-dispersant agents, mold release agents, antimicrobial agents, fire-retardants, antifungal agents, insect- and animal-repellant agents, anti-corrosion additive, adhesive additives, or any combination thereof.

In still further aspects, the exemplary nailable compositions and the articles formed therefrom can be found in the US. Application No. 2024/0308914 that is incorporated herein by reference in its all entirety.

In some aspects, the first concrete article and/or the second concrete article can be precast. In some aspects, the first concrete article and/or the second concrete article can be cast in situ.

In some aspects, the one or more first fasteners and the one or more second fasteners can each independently include one or more nails, screws, studs, bolts, or a combination thereof; and the one or more first fasteners can be driven into the first concrete article and/or the one or more second fasteners can be driven into the second concrete article.

In some aspects, each of the first concrete article and the second concrete article can be selected from: a horizontal member (e.g., joists, beams, girders, rafters, decking, sheathing, block, rails, railing, trusses, lintels, purlins, spandrels, bracing, slabs, floors, gussets, fillets, chords, corbels, capping beams, toe boards, top boards, rings, ties, struts, crossties, cheeks, fascia, struts, ties, stiffeners, bolsters); a vertical member (e.g., columns, pillars, posts, studs, sheathing, pilings, piers, shear walls, walls, pedestals, pilasters, ridge poles, core walls, lattice towers); a foundational element (e.g., strip footings, slabs on grade, spread footings, mat or raft foundations, piles, caissons, grade beams, pier foundations, grillage foundations); an architectural element (e.g., cladding, curtain walls, facades, window frames, roof parapets, balconies, terraces, awnings, canopies, staircases, ramps, doors, entryways, pilasters, louvers, cornices, moldings, friezes, exposed beams, shutters, fencing, walls); or a fencing element (e.g., rails, pickets, posts, panels, caps, infill materials such as compacted soil, compacted gravel, soil cement, etc., gates, caps, finials, scrollwork, balusters, balustrades, fencing foundational elements).

In some aspects, the method can be used for: connecting any horizontal members to any horizontal members; connecting any horizontal members to any vertical members; connecting any horizontal members to any foundational elements; connecting any horizontal members to any architectural elements; connecting any horizontal members to any fencing elements; connecting any vertical members to any vertical members; connecting any vertical members to any foundational elements; connecting any vertical members to any architectural elements; connecting any vertical members to any fencing elements; connecting any foundational elements to any foundational elements; connecting any foundational elements to any architectural elements; connecting any foundational elements to any fencing elements; connecting any architectural elements to any architectural elements; connecting any architectural elements to any fencing elements; and/or connecting any fencing elements to any fencing elements.

In another aspect, provided is an article formed by any of the disclosed methods.

In yet another aspect, provided is a construction including any of the disclosed articles.

EXAMPLES

Example 1

Disclosed herein is a field connection technique that can be significantly improved through the use of nailable concrete. This in particular applies to nailable concretes, due to the fact that a nailable concrete allows for the connection to be installed extremely fast, however, any other type of concrete could be used.

This connection described herein is a connection into which two concrete elements can be joined, in the field, as though they are a single element and with minimal effort. This is, typically, a substantially stronger connection as well as longer lasting connection. This is possible as the strengthening elements (e.g., wire, in various forms) are covered and therefore protected from the elements. The connection is referred to as a screw-wire-patch (SWP) connection, though any type of fastener (e.g., screws, nails, bolts, etc.) and any type of connecting element (e.g., wire, hooks, etc.) could be used. Suitable fasteners for SWP connections are shown in FIGS. 1A-1B. In the SWP connection, a connection is formed between two fasteners on adjacent concrete articles, and the connection is coated with concrete to protect said connection. FIGS. 2A-2F show the method of installing the screws and wire for the connection.

The two concrete articles being connected could each be formed from a nailable concrete since the screws can be fastened into the nailable concrete quickly. This can include nailable rubber concrete or other nailable concretes incorporating aerated concrete, wood pulp concrete, and/or talc/mica concretes.

The concrete to cover the connection may be many different types of concrete. For example, if the connection may be nailed into, a nailable concrete could be used. Alternatively, a stronger patching concrete can be used, such as one that only requires a cement (portland or hydraulic) and sand as aggregate. Any combination is possible for patching the connection. See TABLE 1.

TABLE 1
Various combinations of patch are available. By using hydraulic
cement, the time to cure can be reduced to only a few minutes,
allowing for very fast connections with high strength. This is
possible by using a nailable concrete as the quick installation
of the necessary fasteners can be accomplished in the field.

Patching	5 Minute	24 Hour	Notes
Non-	✓	✓	Higher Strength,
Nailable			Non-Nailable
Nailable	✓	✓	Lower Strength,
			Lower Cost,
			Nailable
Notes	Higher Cost,	Lower Cost,
	Significantly	Slower Curing
	Faster Curing

This technology allows for strong, fast field connections using nailable concrete and leverages the fact that nailable concretes allow for installation of an equivalent shear stud (e.g., wood screw, other fasteners with a wide head). The head of the fastener can also be used to allow for looping wire around and creating a fast and strong connection. This can be accomplished in the field or in a precast concrete manufacturing setting; this may be necessary in a factory setting as some precast concrete elements may be too complex to cast in a single segment. This technique would allow for joining of said elements.

This method can be used to connect any two or more of the following (either within the same category or between multiple categories): horizontal members, vertical members, foundational elements, architectural elements, or fencing elements. Non-limiting examples of each are given below. This method can be used to connect any combination of existing structures and/or new construction. This process can be used in both a precast concrete plant or in the field.

Horizontal members: joists, beams, girders, rafters, decking, sheathing, block, rails, railing, trusses, lintels, purlins, spandrels, bracing, slabs, floors, gussets, fillets, chords, corbels, capping beams, toe boards, top boards, rings, ties, struts, crossties, cheeks, fascia, struts, ties, stiffeners, bolsters, etc.

Vertical members: columns, pillars, posts, studs, sheathing, pilings, piers, shear walls, walls, pedestals, pilasters, ridge poles, core walls, lattice towers, etc.

Foundational elements: strip footings, slabs on grade, spread footings, mat or raft foundations, piles, caissons, grade beams, pier foundations, grillage foundations, etc.

Architectural elements: cladding, curtain walls, facades, window frames, roof parapets, balconies, terraces, awnings, canopies, staircases, ramps, doors, entryways, pilasters, louvers, cornices, moldings, friezes, exposed beams, shutters, fencing, walls, etc.

Fencing elements: rails, pickets, posts, panels, caps, infill materials (such as compacted soil, compacted gravel, soil cement, etc.), gates, caps, finials, scrollwork, balusters, balustrades, fencing foundational elements (such as infill concrete), etc.

Non-limiting examples of connections: connecting any horizontal members to any horizontal members; connecting any horizontal members to any vertical members; connecting any horizontal members to any foundational elements; connecting any horizontal members to any architectural elements; connecting any horizontal members to any fencing elements; connecting any vertical members to any vertical members; connecting any vertical members to any foundational elements; connecting any vertical members to any architectural elements; connecting any vertical members to any fencing elements; connecting any foundational elements to any foundational elements; connecting any foundational elements to any architectural elements; connecting any foundational elements to any fencing elements; connecting any architectural elements to any architectural elements; connecting any architectural elements to any fencing elements; connecting any fencing elements to any fencing elements.

The following patents, applications and publications as listed below and throughout this document are hereby incorporated by reference in their entirety herein.

Exemplary Aspects

Example 1. A method of forming a connection between concrete articles, the method comprising: affixing one or more first fasteners to a first concrete article; affixing one or more second fasteners to a second concrete article; and forming one or more concrete patches around the one or more first fasteners and the one or more second fasteners and spanning between the first concrete article and the second concrete article, thereby forming a connection that substantially prevents movement of the first concrete article relative to the second concrete article.

Example 2. The method of any one of the examples herein, particularly Example 1, further comprising affixing one or more connecting elements between the one or more first fasteners and the one or more second fasteners before forming the one or more concrete patches; and wherein the one or more concrete patches are formed around the one or more first fasteners, the one or more second fasteners, and the one or more connecting elements.

Example 3. The method of any one of the examples herein, particularly Example 1 or 2, wherein the one or more connecting elements is wire, cord, fiber, rods, plates, rope, a hook-and-eye connector, or any combination thereof.

Example 4. The method of any one of the examples herein, particularly any one of Examples 1-3, wherein, under load, the one or more connecting elements confers tensile strength to the connection and the one or more concrete patches confers compressive strength to the connection; and wherein the one or more connecting elements enables flexing of the connection under load.

Example 5. The method of any one of the examples herein, particularly any one of Examples 1-4, wherein, together, the one or more connecting elements and the one or more concrete patches minimize rotation of the first concrete article and/or the second concrete article about the connection, and wherein the connection is substantially moment resisting connection.

Example 6. The method of any one of the examples herein, particularly any one of Examples 1-5, further comprising applying a bonding agent to the first concrete article and/or the second concrete article before forming the one or more concrete patches.

Example 7. The method of any one of the examples herein, particularly Example 6, wherein the bonding agent is acrylic-based, epoxy-based, latex-based, water-based, cementitious-based, or any combination thereof.

Example 8. The method of any one of the examples herein, particularly any one of Examples 1-7, wherein forming each of the one or more concrete patches comprises: providing a wet concrete mixture around the one or more first fasteners and the one or more second fasteners and spanning between the first concrete article and the second concrete article; and curing the wet concrete mixture.

Example 9. The method of any one of the examples herein, particularly any one of Examples 1-8, wherein the first concrete article and the second concrete article have a same or different composition; and wherein each of the one or more concrete patches independently has a same or different composition as the first concrete article and/or the second concrete article.

Example 10. The method of any one of the examples herein, particularly any one of Examples 1-9, wherein the first concrete article and the second concrete article are coplanar and spaced apart, and wherein the connection spans a coplanar space between the first concrete article and the second concrete article; and wherein the first concrete article and the second concrete are spaced apart by from about 1.5 inches to about 6 feet.

Example 11. The method of any one of the examples herein, particularly any one of Examples 1-10, wherein the first concrete article and the second concrete article are immediately adjacent and/or positioned at an angle, and wherein the connection spans diagonally between the first concrete article and the second concrete article; and wherein when the first concrete article and the second concrete article are positioned at an angle, such an angle is from about 5° to about 1750.

Example 12. The method of any one of the examples herein, particularly Example 11, wherein a distance between the one or more first fasteners and the one or more second fasteners is from about 0.5 inches to about 4 feet.

Example 13. The method of any one of the examples herein, particularly any one of Examples 1-12, wherein the first concrete article and/or the second concrete article comprises a nailable concrete composition comprising a cement in an amount of about 25 wt % to about 70 wt %, a rubber in an amount of about 15 wt % to about 35 wt %, and fine aggregates in an amount of about 10 wt % to about 35 wt % based on a total mass of dry material.

Example 14. The method of any one of the examples herein, particularly Example 13, wherein the rubber is virgin and/or recycled and has a particle size no greater than about 0.5 inches

Example 15. The method of Example 13 or 14, wherein the rubber comprises natural rubber, natural polyisoprene, synthetic polyisoprene, styrene-butadiene rubber, butadiene rubber, butyl rubber, halogenated butyl rubber, nitrile rubber, hydrogenated nitrile rubber ethylene propylene diene rubber, ethylene propylene rubber, chloroprene, polychloroprene, neoprene, silicone rubber, fluorosilicone rubber, fluoroelastomers, perfluloroelasomers, polyether block amides, polysulfide rubber, ethylene-vinyl acetate, chlorusulfonated polyethylene, epichlorhydrin rubber, inorganic rubber, or any combination thereof.

Example 16. The method of any one of the examples herein, particularly any one of Examples 13-15, wherein the nailable concrete composition further comprises water in an amount of about 20 wt % to about 40 wt % based on the water-to-cement ratio.

Example 17. The method of any one of the examples herein, particularly any one of Examples 13-16, wherein the nailable concrete composition further comprises one or more fillers, plasticizers, water-reducing agents, pumping agents, air entrainers, set retarders, fire retardants, water repellants, defoamers, antifreeze agents, expanding agents, curing agents, coloring additives, anti-dispersant agents, mold release agents, antimicrobial agents, fire-retardants, antifungal agents, insect- and animal-repellant agents, anti-corrosion additive, adhesive additives, or any combination thereof.

Example 18. The method of any one of the examples herein, particularly any one of Examples 1-17, wherein the first concrete article and/or the second concrete article is precast.

Example 19. The method of any one of the examples herein, particularly any one of Examples 1-18, wherein the first concrete article and/or the second concrete article is cast in situ.

Example 20. The method of any one of the examples herein, particularly any one of Examples 1-19, wherein the one or more first fasteners and the one or more second fasteners each independently comprise one or more nails, screws, studs, bolts, or a combination thereof; and wherein the one or more first fasteners is driven into the first concrete article and/or the one or more second fasteners is driven into the second concrete article.

Example 21. The method of any one of the examples herein, particularly any one of Examples 1-20, wherein each of the first concrete article and the second concrete article is selected from: a horizontal member (e.g., joists, beams, girders, rafters, decking, sheathing, block, rails, railing, trusses, lintels, purlins, spandrels, bracing, slabs, floors, gussets, fillets, chords, corbels, capping beams, toe boards, top boards, rings, ties, struts, crossties, cheeks, fascia, struts, ties, stiffeners, bolsters); a vertical member (e.g., columns, pillars, posts, studs, sheathing, pilings, piers, shear walls, walls, pedestals, pilasters, ridge poles, core walls, lattice towers); a foundational element (e.g., strip footings, slabs on grade, spread footings, mat or raft foundations, piles, caissons, grade beams, pier foundations, grillage foundations); an architectural element (e.g., cladding, curtain walls, facades, window frames, roof parapets, balconies, terraces, awnings, canopies, staircases, ramps, doors, entryways, pilasters, louvers, cornices, moldings, friezes, exposed beams, shutters, fencing, walls); or a fencing element (e.g., rails, pickets, posts, panels, caps, infill materials such as compacted soil, compacted gravel, soil cement, etc., gates, caps, finials, scrollwork, balusters, balustrades, fencing foundational elements).

Example 22. A method of forming a connection between concrete articles, the method comprising: affixing one or more first fasteners to a first concrete article; affixing one or more second fasteners to a second concrete article; and affixing one or more connecting elements between the one or more first fasteners and the one or more second fasteners, thereby connecting the first concrete article to the second concrete article; wherein the first concrete article and/or the second concrete article comprises a nailable concrete composition comprising a cement in an amount of about 25 wt % to about 70 wt %, a rubber in an amount of about 15 wt % to about 35 wt %, and fine aggregates in an amount of about 10 wt % to about 35 wt % based on a total mass of dry material.

Example 23. The method of any one of the examples herein, particularly Example 22, further comprising forming one or more concrete patches around the one or more connecting elements and spanning between the first concrete article and the second concrete article.

Example 24. A method of forming a connection between concrete articles, the method comprising: affixing one or more first fasteners to a first concrete article; affixing one or more second fasteners to a second concrete article; and affixing one or more connecting elements between the one or more first fasteners and the one or more second fasteners, thereby connecting the first concrete article to the second concrete article; wherein the first concrete article and/or the second concrete article comprises a nailable concrete composition comprising a cement in an amount of about 25 wt % to about 70 wt % and a rubber in an amount of about 15 wt % to about 35 wt %.

Example 25. The method of any one of the examples herein, particularly Example 24, further comprising forming one or more concrete patches around the one or more connecting elements and spanning between the first concrete article and the second concrete article.

Example 26. An article formed by the method of any one of the examples herein, particularly any one of Example 1-21.

Example 27. A construction comprising the article of any one of the examples herein, particularly Example 26.