REINFORCING BAR CLIP

Description

CROSS REFERENCE TO RELATED APPLICATION

The present application claims priority to U.S. Provisional Application No. 63/643,538, filed May 7, 2024, the entire contents of which are herein incorporated by reference.

FIELD OF INVENTION

The present disclosure relates to a clip configured to support reinforcing bar proximate an induced crack.

SUMMARY

In some embodiments, the disclosure provides a crack control assembly for concrete. The assembly includes rebar that bonds to the concrete and extends along a rebar axis. A clip extends substantially parallel to the rebar axis. The clip includes a first end connected to the rebar at a first location along the rebar axis and a second end coupled to the rebar at a second location along the rebar axis, spaced from the first location. The clip extends generally parallel to the rebar and above the rebar to enhance the effective interlock of the concrete proximate the clip.

In some embodiments, the disclosure provides a method of enhancing the effective interlock strength of concrete in a concrete slab. The method includes positioning rebar at a height above the ground surface, so that the rebar extends along a rebar axis. The method further includes positioning the clip against the rebar, so that that a first end of the clip is positioned at a first location along the rebar axis and a second end of the clip is positioned at a second location along the rebar axis spaced from the first location. The method further includes moving the clip with respect to the rebar to thereby cause deformation of a portion of the clip. The method further includes at least partially surround the rebar with the clip to thereby couple the clip to the rebar, and pouring concrete over the rebar and the clip.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a rebar and bolster configuration.

FIG. 2 is a close up perspective view of a plurality of bolsters.

FIG. 3 is a close up perspective view of a bolster supporting a reinforcing bar.

FIG. 4 is a perspective view of a clip.

FIG. 5 is a side view of the clip coupled to the reinforcing bar.

FIG. 6 is a side view of the clip.

FIG. 7 is a side view of the clip, reinforcing bar and bolster.

FIG. 8 is a front view of the clip, reinforcing bar and bolster.

FIG. 9 is a front view of another reinforcing clip configuration.

FIG. 9A is a side view of the reinforcing clip from side A.

FIG. 9B is a side view of the reinforcing clip from side B.

DETAILED DESCRIPTION

Before any embodiments are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of supporting other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. Terms of degree, such as “substantially,” “about,” “approximately,” etc. are understood by those of ordinary skill to refer to reasonable ranges outside of the given value, for example, general tolerances associated with manufacturing, assembly, and use of the described embodiments.

FIG. 1 illustrates a grid of reinforcing bar (rebar) 10 supported by bolsters 14. The rebar 10 is positioned in spaced apart rows and columns. The rebar 10 can be spaced apart 16 inches, 24 inches or other suitable distance. The illustrated bolsters 14 are positioned in a square, such that each bolster 14 supports seven rebars 10. The bolsters 14 can be cut to length to allow for multiple sizes, shapes and configurations. In other configurations, more or fewer pieces of rebar 10 are supported by each bolster 14.

The illustrated rebar 10 is non-metallic and includes a fiber reinforced polymer. Some examples of fiber-reinforced polymer reinforcing bar are disclosed in U.S. Pat. Nos. 9,688,030; 10,682,818; and 11,919,254, the contents of which are herein incorporated by reference. The rebar 10 is cut to length and positioned in the bolsters 14 prior to concrete being poured.

FIGS. 2 and 3 illustrate the bolsters 14 in greater detail. The bolsters 14 include an elongate base 18 and a plurality of upwardly extending protrusions 22. The illustrated elongate base 18 includes a horizontal component 26 that is configured to rest on a ground surface and a vertical component 30 that extends upwardly from the horizontal component 26. In the illustrated embodiment, the vertical component 30 is positioned in the center of the horizontal component 26. In other embodiments, the vertical component 30 can be positioned closer to one side of the horizontal component 26 than to the other side of the horizontal component 26.

The horizontal component 26 includes a plurality of apertures 32 extending therethrough. FIGS. 2 and 3 illustrate the aperture 32 on one side of the vertical component 30. However, as shown in FIG. 8, the apertures 32 alternate between opposite sides of the vertical component 30 along the length of the bolster 14. In some embodiments, one of the apertures 32 is positioned 6″ from an end of the bolster 14 and the apertures 32 alternate sides every 24″ thereafter. The apertures 32 permit one or more fasteners to retain the bolster 14 in position while the cement is being poured. In some embodiments, a stake is pressed through one of the apertures 32 into a ground surface by an operator. In other embodiments, a nail, bolt or screw extends through the aperture 32 and into the surface below the bolster 14 to retain the bolster 14 in position.

The upwardly extending protrusion 22 extends upward from the vertical component 30 and includes a first projection 34 and a second projection 38 that define a recess 42 therebetween. The recess 42 is sized to receive the rebar 10 therein. The first and second projections 34, 38 are configured to retain the rebar 10 in the recess 42. In some embodiments, the first and second projections 34, 38 form an interference fit with the rebar 10 so as to retain the rebar 10 within the recess 42. The recess 42 retains the rebar 10 at the desired height while the cement is being poured. The upwardly extending protrusion 22 has a height that corresponds with the desired position of the rebar 10 within the poured concrete.

The bolsters 14 can be made from a recycled material, such as one or more polymeric materials. The bolsters 14 may be provided in a variety of lengths and can be cut to length if desired. For example, the bolsters 14 may be available in 10 foot, 12 foot, 14 foot and 16 foot lengths. The illustrated bolsters 14 are shown by way of example. Other shapes, sizes and configurations of bolsters 14 can be utilized to support the rebar 10 at the desired height.

Concrete can form cracks upon expanding or contracting due to temperature changes. One way to address this challenge is to cut the concrete at set intervals to induce a crack. At each of those cut locations, some type of reinforcement can be utilized to ensure effective interlock between the two sides of the crack. For example, in a 6 inch thick concrete slab, a saw may cut 0.5-1 inch deep to induce a crack and the rebar 10 may be spaced apart 18 inches on center.

In some embodiments, the bolsters 14 are positioned every four feet to induce a crack every four feet. The upwardly extending protrusions 22 of the bolsters 14 can help to induce a crack because the concrete is not joined together proximate vertical component 30 of the bolster 14. Instead, the concrete is joined to either side of the upwardly extending protrusions 22 and above the upwardly extending protrusions 22. Above the bolster 14, the concrete is bonded for a lesser height than at locations spaced from the bolster 14. The bolster 14 effectively weakens the bond of the concrete, so a crack is more likely to form proximate the bolster 14. A saw cut may also be made above the bolsters 14 to further induce a crack.

FIGS. 4-6 illustrate a clip 50 that can be utilized to enhance the interlock across the induced cracks. The clip 50 includes a first end portion 54, a second end portion 58, and an elongate middle portion 62 between the first end portion 54 and the second end portion 58. The clip 50 can be made of a flexible wire that is bent to shape. The clip 50 is generally symmetrical such that the second end portion 58 is substantially a mirror-image of the first end portion 54. The side views FIGS. 5 and 6 illustrate the first end portion 54, but the description of the first end portion 54 equally applies to the second end portion 58.

The first end portion 54 includes a first bent portion 70, a first curved portion 74 and a first vertical portion 78. The first bent portion 70 includes a first end positioned a first distance X away from the first vertical portion 78 and a second end positioned a second distance Y away from the vertical portion 78. The first bent portion 70 extends toward the first vertical portion 78 such that the first distance X is greater than the second distance Y. The first distance X is greater than the diameter of the rebar 10 and the second distance Y is less than the diameter of rebar.

The first curved portion 74 includes a first end coupled to the second end of the first bent portion 70, a middle portion and a second end coupled to a lower end of the first vertical portion 78. The first end of the first curved portion 74 is spaced apart the second distance Y from the vertical portion 78. The middle portion is spaced apart a third distance Z from the vertical portion. The third distance Z is greater than the second distance Y. The third distance Z is equal to, slightly greater or slightly less than the diameter of the rebar 10. While the illustrated bends at the first end of the first curved portion 74 and the middle portion of the first curved portion 74 are exemplary. Other suitable angles can be utilized.

The first vertical portion 78 includes a first end coupled to the second end of the first curved portion 74 and a second end coupled to the elongate middle portion 62. The first vertical portion 78 extends along a first height H1. The second end of the first bent portion 70, which is spaced from the first vertical portion 78 the second distance Y, is positioned a second height H2 above the first end of the first vertical portion 78. The first height H1 is sufficient so that the elongate middle portion 62 is positioned at the desirable location within the poured concrete. In different applications, the first height H1 differs within a range of heights to properly position the elongate middle portion 62 at the desired height within the poured concrete.

The second height H2 is less than the first height H1. In some embodiments, the second height H2 is approximately half of the first height. The second height H2 is greater than the diameter of the rebar 10. In the illustrated embodiment, the second height H2 is between about two and three times the diameter of the rebar 10.

The elongate middle portion 62 extends along a length L between the first end portion 54 and the second end portion 58. In some embodiments, the length L is approximately 10 inches. In other embodiments, other lengths can be utilized.

As noted above, the second end portion 58 is substantially a mirror image of the first end portion 54. The second end portion 58 includes a second bent portion 82, a second curved portion 86 and second vertical portion 90. The second bent portion 82 includes a first end positioned the first distance X away from the second vertical portion 90 and a second end positioned the second distance Y from the second vertical portion 90. The second bent portion 82 extends toward the second vertical portion 90 such that the first distance X is greater than the second distance Y. The first distance X is greater than the diameter of the rebar 10 and the second distance Y is less than the diameter of rebar.

The second curved portion 86 includes a first end coupled to the second end of the second bent portion 82, a middle portion and a second end coupled to a lower end of the second vertical portion 90. The first end of the second curved portion 86 is spaced apart the second distance Y from the second vertical portion 90. The middle portion is spaced apart a third distance Z from the vertical portion. The third distance Z is greater than the second distance Y. The third distance Z is equal to, slightly greater than or slightly less than the diameter of the rebar 10. The angles between the bends at the first end of the second curved portion 86 and the middle portion of the second curved portion 86 are exemplary. Other suitable angles can be utilized.

The second vertical portion 90 includes a first end coupled to the second end of the second curved portion 86 and a second end coupled to the elongate middle portion 62. The second vertical portion 90 extends along the first height H1. The second end of the second bent portion 82, which is spaced from the second vertical portion 90 the second distance Y, is positioned the second height H2 above the first end of the second vertical portion 90. The first height H1 can be adjusted so that the elongate middle portion 62 is positioned at the desirable location within the poured concrete.

FIGS. 7 and 8 illustrate an assembly including the rebar 10, the bolster 14 and the clip 50. The bolster 14 is positioned on a ground surface 94. In the exemplary embodiment of FIGS. 7 and 8, the ground surface 94 is denoted as zero inches and the concrete slab has an upper surface 98 about six inches above the ground surface 94. In other configurations, other thicknesses of slabs can be poured.

The illustrated elongate base 18 has an overall height of between one and two inches and the upwardly extending protrusion 22 extends to just over three inches. Other sizes, shapes and configurations of the bolster 14 are possible in other configurations. The rebar 10 is positioned in the recess 42 and such that the rebar 10 is positioned at approximately three inches above the ground surface. In the example of FIGS. 7 and 8, the rebar 10 is retained at a generally central location along the thickness of the concrete slab. In other configurations, the rebar 10 can be positioned closer to a lower surface or an upper surface of the slab if desired.

The horizontal component 26 includes apertures 32 that alternate on opposite sides of the vertical component 30 along the length of the bolster 14. The vertical component 30 in the illustrated configuration is substantially centered above the horizontal component 26.

After the rebar 10 is positioned in the recess 42, the clip 50 is connected to the rebar 10 on opposite sides of the bolster 14. The clip 50 is installed by positioning the clip 50 above and perpendicular to the bolster 14. The clip 50 is pressed against the rebar 10 such that the first and second vertical portions 78 and 90 contact the rebar 10. The clip 50 is then lifted upward such that the rebar 10 presses against the first and second bent portions 70 and 82 causing the first and second curved portions 74 and 86 to deform. The clip 50 continues to slide against the first and second vertical portions 78 and 90. After the rebar 10 has moved past the first ends of the first and second curved portions 74, 86 toward the middle portions of the first and second curved portions 74, 86, the first and second curved portions 74 and 86 move back to the undeformed position. The rebar 10 is thereby retained between the first and second curved portions 74 and 86 and the first and second vertical portions 78 and 90 as shown in FIGS. 7 and 8.

After the clips 50 are coupled to the rebar 10 at the desired spacing, the concrete is then poured. The clips 50 are sized to fit tightly onto the rebar 10 such that elongate middle portion 62 remains above the rebar 10 during the pour. The clips 50 are positioned such that the elongate middle portion 62 is positioned in the upper portion of the concrete slab. In the illustrated embodiment, the rebar is positioned in the upper one third of the concrete slab. Specifically, in the illustrated embodiment, the elongate middle portion 62 is positioned at about four and one half inches above the ground and about one and one half inches below the upper portion of the slab. Optionally, a saw cut between one half and one inch thick is cut above the bolster 14. The optional saw cut would be generally parallel to the bolster 14 to weaken the concrete proximate the bolster 14 and the optional saw cut. The clips 50 enhance the effective interlock of the concrete proximate the bolster 14 and the optional saw cut.

FIGS. 9, 9A and 9B illustrate an alternative clip 150 that can be utilized in place of clip 50. Only the differences between the clip 150 and the clip 50 will be discussed in detail. The remaining discussion of clip 50 is applicable to clip 150 unless noted otherwise. The illustrated clip 150 is coupled to rebar 10. Like the clip 50, the clip 150 enhances the interlock across the induced cracks. Also, like the clip 50, the length of the clip 150 is variable depending upon the desired application.

Clip 150 includes a first end portion 154, a first elongate middle portion 158, a first central portion 162, a second central portion 166, a second elongate middle portion 170 and a second end portion 174. The clip 150 can be made of a flexible wire that is bent to shape. In some embodiments, the clip 150 can be made from a wire having a smaller diameter than the clip 50. For example, the clip 50 can be made from ⅜″ diameter wire and the clip 150 can be made from ¼″ diameter wire. In other embodiments, other sizes of wire can be utilized.

The first end portion 154 includes a lower curved portion 178 sized to engage the rebar 10 and a generally vertical portion 182. The second end portion 174 is generally L-shaped and includes a free end portion 186 angled away from the rebar 10, a middle portion 190 extending toward the rebar and an upper end 194 extending away from the rebar 10. The first end portion 154 and the second end portion 174 cooperate to clip onto the rebar 10 and to maintain a tight interference fit with the rebar 10. The rebar 10 slides along the generally vertical portion 182 of the first end portion 154 until the rebar 10 abuts the middle portion 190 of the second end portion 174. Then, further movement causes the second end portion 174 to deflect away from the first end portion 154. While the rebar 10 is seated in the lower curved portion 178 of the first end portion 154, the second end portion 174 abuts the rebar 10 to maintain a tight engagement between the clip 150 and the rebar 10.

The first central portion 162 includes a substantially vertical portion 198 and a lower curved portion 202 that connects to the second central portion 166. The second central portion 166 includes an inwardly bent portion 206 and an outwardly extending portion 210. The lower curved portion 202 is sized to receive the rebar 10.

The first central portion 162 and the second central portion 166 cooperate to clip onto the rebar 10 and to maintain a tight interference fit with the rebar 10. The rebar 10 slides along the substantially vertical portion 198 of the first central portion 162 until the rebar 10 abuts the inwardly bent portion 206 of the second central portion 166. Further movement causes the second central portion 166 to deflect to permit the rebar 10 to move downward into the lower curved portion 202. The inwardly bent portion 206 retains the rebar 10 within the lower curved portion 202 to maintain a tight engagement between the clip 150 and the rebar 10.

The first elongate middle portion 158 extends along a first length L1 and the second elongate middle portion 170 extends along a second length L2. In the illustrated embodiment, the first length L1 is greater than the second length L2. One of both of the first length L1 and the second length L2 can be within a range of lengths in various embodiments. The first elongate middle portion 158 and the second elongate middle portion 170 are spaced apart a sufficient distance to permit free movement of the rebar 10 between the elongate middle portions 158, 170. The user can grasp the first elongate middle portion 158 with one hand and the second elongate middle portion 170 with the other hand and pull upwards to attach the clip 150 to the rebar 10. The tight engagement between the clip 150 and the rebar 10 maintains the clip 150 in position above the rebar 10 to enhance the effective interlock of the concrete.

In some configurations, a crack control assembly for concrete includes rebar that is configured to bond to the concrete. The rebar extends along a rebar axis. The assembly also includes a clip that extends substantially parallel to the rebar axis. The clip includes a first end coupled to the rebar at a first location along the rebar axis and a second end coupled to the rebar at a second location along the rebar axis, spaced from the first location. The clip extends generally parallel to the rebar and above the rebar. The clip enhances the effective interlock of the concrete proximate the clip.

In some configurations, the assembly also includes a bolster positioned on a ground surface. The bolster extends along an elongate axis and positions the rebar at a desired height above the ground surface.

In some configurations, the bolster is configured to weaken interlock in the concrete adjacent the bolster to thereby induce cracks to form in the concrete above the bolster.

In some configurations, the first end of the clip includes a first flexible portion, and the second end of the clip includes a second flexible portion. The first and second flexible portions are configured to deform to permit the clip to be coupled to the rebar.

In some configurations, the clip is configured to be coupled to the rebar without the use of tools.

In some configurations, a method of enhancing the effective interlock strength of concrete in a concrete slab includes positioning rebar at a height above a ground surface, such that the rebar extends along a rebar axis. The method also includes positioning a clip against the rebar, such that a first end of the clip is positioned at a first location along the rebar axis and a second end of the clip is positioned at a second location along the rebar axis spaced from the first location. The method further includes moving the clip with respect to the rebar to thereby cause deformation of a portion of the clip. The method additionally includes at least partially surround the rebar with the clip to thereby couple the clip to the rebar, and pouring concrete over the rebar and the clip.

In some configurations, the method includes positioning the rebar at a height above the ground surface includes coupling the rebar to a bolster on a ground surface.

In some configurations, the method includes, cutting the concrete above the bolster after the concrete has at least partially hardened.

In some configurations, the method includes cutting the concrete above the bolster after the concrete has at least partially hardened.

In some configurations, the method includes inducing a crack proximate the clip and the optional bolster with the optional bolster and the optional saw cut.