EXPANSION JOINT SPLICING DEVICE AND METHOD

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 18/658,123, filed May 8, 2024, which claims the benefit of U.S. provisional application 63/464,824, filed on May 8, 2023, each of which are herein incorporated by reference in entirety. This application claims the benefit of U.S. provisional patent application 63/778,783, filed on Mar. 27, 2025; which is herein incorporated by reference in entirety.

FIELD

This disclosure relates generally to concrete floor constructions. More particularly, this disclosure relates to concrete floor constructions using, for example, post-tensioned concrete or reinforced concrete slabs.

BACKGROUND

A process for new floor construction using post-tensioned concrete or reinforced concrete slabs on either concrete frames or structural steel frames may include an expansion joint that separates adjacent concrete slabs (also known as pours or castings). The expansion joint or gap in the two slabs, with each slab supported by a separate beam often supported by columns of material like the beams. Generally, the gap is an inch to two feet or more in length. That is, an inch to several feet in distance separates the two ends of the concrete slabs, with the parallel supporting frames typically having a similar separation.

SUMMARY

In some embodiments, a device including: a body extending along a first longitudinal axis between a first end and a second end, the body including: a first opening, the first opening including a first bore at the first end, and the first bore being configured to receive a first rebar of a first concrete slab; a second opening, the second opening including a second bore at the second end, and the second bore being configured to receive a second rebar of a second concrete slab; an inlet, the inlet being at a second longitudinal axis, the second longitudinal axis extending in a first direction substantially perpendicular to the first longitudinal axis; an outlet, the outlet being at a third longitudinal axis, the third longitudinal axis extending in a second direction substantially perpendicular to the first longitudinal axis; and a cavity, the cavity extending along the first longitudinal axis and the cavity being in fluid communication with the first opening, the second opening, the inlet, and the outlet.

In some embodiments, the first bore including one or more threads on an inner surface, the one or more threads being configured to engage corresponding threads on the first rebar in response to installing the first rebar into the first bore so as to connect the device to the first rebar.

In some embodiments, the device is configured to receive a portion of the second rebar in the cavity of the body, the second bore permitting the second rebar to extend therethrough into the cavity and towards the first end of the body.

In some embodiments, the device is configured to receive a portion of a second rebar extending into the cavity and towards the first end. The end of the rebar is held back from the first end an amount of one to four inches. This gap amount allows for the second rebar to expand into the cavity not interfering with (i.e., not contacting) the end of the cavity (i.e., the first end of the body).

This movement has two components, both related to thermal expansion caused by ambient air temperature increasing in the environment. The first element of expansion is the first slab, which normally includes the device. This first slab expands toward the second slab. The second element of expansion is the movement of the second slab, including the second rebar toward the first slab. These movements, caused by thermal expansion, of both slabs cause the end of the second rebar to move closer to the end of the cavity (i.e., the first end of the body).

The initial gap is of sufficient length to accommodate this expansion movement so that the end of the bar second rebar in the cavity does not interfere with or reach the end of the cavity in the device at the threaded side.

In addition, the device is used in combination with a method in which the temporary gap is left open between the first and second slabs. The preferred gap location is at the end of the device, where the second rebar enters the device cavity. The direction of the gap is from end of the device opposite the treaded part toward the second end. The length of the gap is similar to the gap lengths of the end of the second rebar back from the end of the cavity near the end with threaded rebar part.

For the case where the gap is located further toward the second slab as part of the method, the rebar between the gap edge closest to the device is debonded from the concrete in slab from the gap edge closest to the device by tape or other such debonding device.

The method of replacing open expansion joints with coupler technology also applies to devices that are grouted on both ends. In some embodiments, the device being configured to receive a fill material in the cavity through one of the inlets and the outlet, and, in response to the fill material curing in the cavity, the fill material and the portion of the second rebar are secured in the cavity and connect the device to the second rebar. This may be done once the building thermal envelope is complete and the interior temperature of the building is stabilized and no longer subject to exterior temperature fluctuations.

In some embodiments, the second bore including a slot, the slot having a width that is greater than a height to permit a lateral movement of the second rebar. In some embodiments, the second bore being rectangular in geometry with arcuate ends.

In some embodiments, the cylindrical body including: a first cylindrical portion including: a first sidewall, the first sidewall including the third bore and the fourth bore extending therethrough, a second cylindrical portion including: a second sidewall, the second cylindrical portion including the first bore axially extending therethrough, and an end wall, the end wall including the second bore axially extending therethrough.

In some embodiments, the first bore being a conical bore extending from the first opening having a first diameter to an opening to the cavity having a second diameter, the first diameter being wider than the second diameter.

In some embodiments, the body being made of stainless steel.

In some embodiments, an apparatus for splicing together rebar of concrete slabs, the apparatus including: a splice device including: a cylindrical body including: a first end, a second end, and at least one sidewall; a first bore extending through the cylindrical body at the first end, the first bore including: one or more threads on an inner surface, the one or more threads configured to engage corresponding threads on a first rebar of a first post-tensioned concrete slab in response to installing the first rebar into the first bore; a second bore extending through the cylindrical body at the second end, the second bore including: a slot, the slot configured to permit a portion of a second rebar of a second post-tensioned concrete slab to extend therethrough; a third bore extending through the at least one sidewall; a fourth bore extending through the at least one sidewall; and a cavity, the cavity being in fluid communication with the first bore, the second bore, the third bore, and the fourth bore.

In some embodiments, the splice device being configured to receive a grout material in the cavity through one of the third bore and the fourth bore; and, in response to the grout material curing in the cavity, the grout material and the portion of the second rebar are retained in the cavity and connects the splice device to the second rebar.

In some embodiments, the second bore being rectangular in geometry with arcuate ends, the slot having a width that is greater than a height to permit a lateral movement of the second rebar.

In some embodiments, the cylindrical body including: a first cylindrical portion including: a first sidewall, the first sidewall including the third bore and the fourth bore extending therethrough, a second cylindrical portion including: a second sidewall, the second cylindrical portion including the first bore axially extending therethrough, and an end wall, the end wall including the second bore axially extending therethrough.

In some embodiments, the first bore being a conical bore extending from a first opening having a first diameter to an opening to the cavity having a second diameter, the first diameter being wider than the second diameter.

In some embodiments, the splice device being made of stainless steel; and the splice device further including a coating material coating an exterior surface of the splice device to resist corrosion.

In some embodiments, a method for making a concrete construction including a first concrete slab, a second concrete slab, the method including: installing a splice device onto an end of a first rebar for the first concrete slab, the splice device including a cylindrical body including a first bore at a first end, a second bore at a second end, an inlet, an outlet, and a cavity; positioning a portion of a second rebar of the second concrete slab into the cavity, the second rebar extending through the second bore; forming the first concrete slab, the first concrete slab including the first rebar; forming the second concrete slab, the second concrete slab including the second rebar; after forming the first concrete slab and the second concrete slab, filling a fill material into the cavity through one of the inlet and the outlet; and in response to the fill material curing in the cavity, the splice device securely fixes the second rebar in the cavity and couples the first rebar to the second rebar.

In some embodiments, the first bore including one or more threads formed on an inner surface of the first bore, the one or more threads being configured to engage corresponding threads on the first rebar in response to installing the first rebar into the first bore.

In some embodiments, the splice device being configured to receive the portion of the second rebar in the cavity, the second bore permitting the second rebar to extend therethrough into the cavity and towards the first end.

In some embodiments, forming the first concrete slab further including: pouring the first concrete slab so the first end of the splice device is embedded in the first concrete slab.

In some embodiments, wherein forming the second concrete slab further including: pouring the second concrete slab so the second end of the splice device is adjacent the gap between the first and second concrete slabs, the second concrete slab being formed with forming material to create a gap adjacent the first concrete slab to create a gap, in length similar to the gap length of the second rebar and the end of cavity at the first rebar threaded end, between the first concrete slab and the second concrete slab.

BRIEF DESCRIPTION OF THE DRAWINGS

References are made to the accompanying drawings that form a part of this disclosure and that illustrate embodiments in which the systems and methods described in this specification can be practiced.

FIG. 1 shows a schematic side view of a floor construction, according to some embodiments.

FIG. 2 is a sectional side view of the floor construction in FIG. 1, according to some embodiments.

FIG. 3 is a second sectional side view of the floor construction in FIG. 1, according to some embodiments.

FIG. 4 is a sectional side view of the splice device 104 FIG. 1, according to some embodiments.

FIG. 5 is a front view of the splice device, according to some embodiments.

FIG. 6 is a rear view of the splice device, according to some embodiments.

FIG. 7 is a top view of the splice device, according to some embodiments.

FIG. 8 is a second sectional side view of the splice device, according to some embodiments.

FIG. 9 is an exposed perspective view of the floor construction, according to some embodiments.

FIG. 10 is a sectional side view of the floor construction, according to some embodiments.

FIG. 11 is a method, according to some embodiments.

FIGS. 12A-12D show sectional side views of an embodiment of the floor construction system of FIG. 1.

FIG. 13 is a sectional side view of the splice device 1104 in FIGS. 12, according to some embodiments.

FIGS. 14A-14C are front plan views of the splice device 1104, according to various embodiments.

FIG. 15 is a rear plan view of the splice device 1104, according to some embodiments.

FIG. 16 is an exposed perspective view of the floor construction 1100, according to various embodiments.

FIG. 17 shows certain prior art embodiments of a traditional expansion joint made of structural steel framing using a traditional additional structural steel frame.

FIGS. 18A and 18B show schematic views of a floor construction system, according to various embodiments.

FIGS. 19A-19D shows certain prior art embodiments of traditional expansion joints.

FIGS. 20A and 20B show schematic views of a floor construction system, according to various embodiments.

FIG. 21 shows certain prior art embodiments of a traditional expansion joint made of structural concrete framing.

FIGS. 22A and 22B show schematic views of a floor construction system, according to various embodiments.

FIG. 23 is a flowchart showing a method of replacing an expansion joint according to various embodiments.

DETAILED DESCRIPTION

Prestressed concrete is a type of reinforced concrete which has been subjected to external compressive forces prior to the application of load. Prestressed concrete is categorized as either pre-tensioned or post-tensioned.

Pre-tensioned concrete is formed by a process including initial stressing of a wire strand system and then casting concrete around the stressed wire strand system. The stress from the wire strand system transfers to the concrete after the concrete has reached a specified strength (e.g., cured to a set specification).

Post-tensioned concrete is formed by a process of casting wet concrete around an unstressed wire strand system and then stressing the wire strand system after the concrete has reached specified strength (e.g., cured to a set specification). This can be accomplished via bonded or unbonded post tensioning. For example, in the bonded post tensioning process, post-tensioned concrete can have a wire strand system which has a wire enclosed in a duct (e.g., pipe, conduit, etc.). Concrete is formed around the duct and the concrete sets and cures. Then, the wire is stressed and grout material (e.g., a mixture of cement, sand, aggregate, and water) is pumped into the cavity surrounding the wire. The grout material bonds the wire to the duct, and the duct is bonded to the cured concrete. Thus, the stress applied to the wire can be transferred to the concrete. The applied stress (e.g., forces applied to the wire strand system) in the post-tensioning process causes a volume change (and/or a length change) to the concrete material. The volume change of the concrete material causes a change in the length of the concrete slab. The length change is a shortening in the direction parallel to applied stress (e.g., the post-tensioning force).

Reinforced concrete is formed by a process of casting wet concrete around a reinforcing bar system. The reinforcing bar system includes a plurality of steel rods or bars, or a mesh. The reinforcing bar system in a reinforced concrete structure resists tensile forces and the concrete material resists compressive forces. Accordingly, concrete that is not reinforced can develop cracking that limits the tensile forces that may be applied to the concrete structure. Thus, although certain compression structures (e.g., arches) can be formed without steel reinforcement, concrete that does not include some type of reinforcement is generally not suited for applications where various forces may be applied to the concrete structure. In reinforced concrete, the tensile strength of the reinforcing system and the compressive strength of concrete cooperate to allow the member to sustain these various stresses over considerable spans. Prior to the introduction of reinforcing bar systems, however, the spans of elevated concrete floors were shorter compared to modern structures and concrete members were primarily applied in compression structures (e.g., arches).

As used herein, the term “reinforced concrete” refers to concrete material in which steel is embedded in the concrete. The concrete and steel act together to resist both tensile forces and compressive forces after the concrete material has reached a specified strength (i.e., fully cured).

As used herein, the term “reinforcing steel,” or “reinforcing bar system,” refers to steel rods, bars, or mesh that is embedded in the concrete before the concrete has reached a specified strength. The reinforcing steel provides support to the concrete material and resists tensile forces.

Various embodiments of the present disclosure relate to systems, devices, apparatuses, and methods for splicing together rebar from adjacent concrete slabs in floor constructions. According to some embodiments, a splice device may be utilized to couple segments of rebar from the adjacent concrete slabs together. The splice device may also be referred to as a coupler, splice coupler, rebar coupler, and the like. The splice device is utilized for connecting, or splicing together, elongate segments of metal rods such as rebar, the rebar providing structural support to the floor constructions. The splice device is used in floor constructions to connect rebar from adjoining concrete slabs to provide improved structural support and stability to the floor construction. In some embodiments, the floor construction may include at least two separately formed concrete slab sections, and the splice device may be utilized to connect rebar from one concrete slab to the rebar from the other concrete slab. For example, one or more splice devices can be used to connect a rebar member from a first concrete slab to a second concrete slab, respectively. To build larger floor constructions, additional concrete slab sections may be constructed, and the adjoining concrete slab sections may be connected using additional splice devices. In some embodiments, the floor construction may include post-tensioned concrete slabs. In other embodiments, the floor construction may include reinforced concrete slabs.

According to some embodiments, the splice device may include a body having openings at both ends, a cavity, and one or more bores at a side of the body. In some embodiments, the openings are configured to receive rebar. The openings of the splice device thereby enables the body of the splice device to receive the rebar in the respective opening so as to enable the splice device to be arranged around the portions of the rebar from the respective concrete slabs during the pouring of the concrete slabs of the floor construction.

According to some embodiments, one of the openings of the splice device may include an elongated structure, the elongated structure allowing for movement of rebar extending therethrough in a radial direction relative a central longitudinal axis of the splice device. For example, prior to the splice device being fixedly attached to the rebar, the splice device opening allows for rebar movement in the radial direction. The movement may be due to any of a plurality of reasons including, but not limited to, stress, curing, volume loss, temperature changes, settling, shifting, compressive forces, tensile forces, other factors, or any combinations thereof. For example, the movement of the rebar and/or the splice device can be due to loss of volume in one of the adjoining concrete slabs during construction. In another example, prior to the splice device being fixedly attached to the rebar, the splice device opening allows for movement of the splice device or the rebar located in the body of the splice device through the opening due to thermal expansion of the steel frame construction including the concrete floor construction. In some embodiments, the elongated structure of the opening may include a width that is greater than a height.

According to some embodiments, one of the openings may include a structure that allows movement of the rebar in an axial direction relative to the central longitudinal axis of the splice device. In some embodiments, one of the openings may include a structure that allows movement of the rebar in the axial direction, the axial direction being substantially parallel to the central longitudinal axis of the splice device. In some embodiments, the splice device opening may include a cross-section that is larger than a cross-section of the rebar to allow for a portion of the rebar to extend into the body of the splice device through the opening and towards an opposite end of the splice device. As a result of the opening having a cross-section that is greater than the cross-section of the rebar, a portion of the rebar may be installed into the device through the opening and the splice device can accommodate for movement of the rebar and/or the splice device such as, but not limited to, due to stress, curing, volume loss, temperature changes, settling, shifting, compressive forces, tensile forces, other factors, or any combinations thereof. For example, prior to the splice device being fixedly connected to the rebar of the concrete slab extending through the opening, the rebar may move in an axial direction relative the splice device, or vice versa, in response to a change in volume of the concrete slab.

According to some embodiments, one of the openings of the splice device may include a structure configured to receive a rebar member therethrough to enable fixedly attaching the rebar to the splice device. In some embodiments, the opening may be formed by a bore extending through the body of the splice device from the splice device exterior and to the cavity. In some embodiments, the opening may include threads on an inner surface of the bore for engaging corresponding threads on the rebar and for fixedly attaching the rebar to the splice device. In some embodiments, the bore may include a conical shape, the bore including an opening diameter that is greater than a diameter of the bore that is closer to the splice device interior (e.g., adjacent the cavity). In some embodiments, the bore forming the opening may include a conical shape for improving engagement of the rebar when fixedly attaching the rebar to the splice device.

According to some embodiments, the splice device may include the cavity. In some embodiments, the cavity may be formed within the body. In some embodiments, the cavity may be in fluid communication with a region outside the splice device through the openings. In this regard, bores may extend through the body of the splice device and into the cavity, thereby forming the respective openings. In some embodiments, the cavity may be configured to receive rebar therein, the rebar being inserted into the cavity through one of the openings. In some embodiments, the cavity may be configured to receive a fill material in the cavity, the fill material being configured to cure to a hardened state in the cavity so as to retain the rebar in the cavity and fixedly attach the rebar to the splice device. In some embodiments, the fill material may act in cooperation with the splice device to retain the rebar in the cavity of the splice device, so that if the splice device is fixedly attached to the rebar from the adjoining concrete slab, the splice coupler thereby connects the rebar of the adjoining concrete slabs together, as will be further described herein.

According to some embodiments, the splice device may include an inlet. In some embodiments, the inlet may be located along a side of the body. In some embodiments, the inlet may be at a longitudinal side of the body between the respective ends that include the openings. In some embodiments, the inlet may be in fluid communication with the cavity. That is, in some embodiments, the inlet may include a bore extending through a sidewall of the body and into the cavity. In some embodiments, the inlet may be configured to allow the fill material to be directed into the cavity through the inlet.

According to some embodiments, the splice device may include an outlet. That is, in some embodiments, the splice device may include an inlet and an outlet, the outlet being offset from the inlet by a distance. In some embodiments, the outlet may be at a side of the body. In some embodiments, the outlet may be at a longitudinal side of the body between the ends that include the respective openings for the rebar, the outlet being offset from the inlet. In some embodiments, the outlet may be in fluid communication with the cavity. That is, in some embodiments, the splice device may include a bore extending through the body and into the cavity, the bore forming the outlet opening at the device exterior and another opening into the cavity.

According to some embodiments, the outlet may be located at a same side of the body as the inlet, both the inlet and the outlet being in fluid communication with the cavity. For example, in some embodiments, the bores of the inlet and the outlet may extend along respective axes that may be substantially parallel to each other, and the axes of the inlet and the outlet may also be perpendicular to the longitudinal axis of the body. In other embodiments, the outlet may be located on substantially the same side of the body as the inlet. In some embodiments, by being located on the same side of the body, the inlet and the outlet of the splice device may be oriented so as to be positioned at or near a top of the splice device and relative a top surface of the concrete slab. Accordingly, in some embodiments, the inlet and outlet being positioned near the top may facilitate filling, or substantially filling, the cavity with the fill material directed into the cavity through the inlet. In some embodiments, the inlet and outlet may also be located at opposite ends of the cavity relative the longitudinal direction of the body, the location of the inlet and outlet being configured to facilitate the fill material filling the cavity space.

According to some embodiments, the splice device may include the inlet and the outlet. In some embodiments, the inlet and the outlet may be located on a same side of the body, the inlet and outlet each in fluid communicable connection with the cavity. In some embodiments, the splice device may include the inlet and the outlet to allow filling the cavity of the splice device with the fill material. In this regard, by including the inlet and the outlet, the cavity of the splice device may be filled with fill material through the inlet and excess fill material may exit from the cavity through the outlet rather than allowing pressure to build up in the cavity. In some embodiments, the inlet and outlet may also allow air to vent or escape from inside of the cavity when filling the cavity with the fill material.

Depending on the application of the splice device, the position, size, shape, and dimensions of the various features on the splice device may vary, so long as the splice device may be capable of connecting a first rebar to a second rebar, in accordance with the present disclosure. It is to be appreciated by those having ordinary skill in the art that the bores forming the inlet and the outlet as described in the present disclosure and as labeled in the figures are for ease of discussion purposes and is not intended to limit the filling of the splice device with the fill material using only the inlet. In this regard, it is to be appreciated by those having ordinary skill in the art that the splice device may be filled using the inlet, the outlet, or both, during the floor construction.

According to some embodiments, the cavity may be filled with fill material. In some embodiments, the fill material may be configured to fill the unoccupied space in the cavity by being directed into the cavity through the inlet. In some embodiments, during the filling of the cavity, the fill material may also be configured to fill the unoccupied space in the cavity, thereby surrounding the rebar when arranged in the cavity. After a certain time period, the fill material in the cavity may then be configured to cure to a hardened state so as to retain the rebar in the cavity, thereby fixedly attaching the rebar to the splice device.

In this regard, the cavity may be filled using a fill material composed of one or more materials that may be configured to fixedly attach the rebar to the splice device when the fill material has cured to the hardened state, according to some embodiments. In some embodiments, after curing, the fill material may also be configured to restrict movement of the rebar in an axial or radial direction relative the splice device. In some embodiments, the fill material may include one or more materials that, when combined, may initially be in a liquid state capable of filling into the cavity. In addition, in response to the certain time period having elapsed, the fill material may cure from the liquid state to the hardened state, according to some embodiments.

In some embodiments, the fill material may include a cementitious material. In some embodiments, the fill material may include materials including, but not limited to, grout, concrete, epoxy, epoxy grout, other like structural materials, or any combinations thereof. For example, the fill material may include a grout material mixed with a volume of solution such as, but not limited to, water to form the fill material for filling the cavity of the splice device. In another example, the material may be a concrete material mixed with a volume of solution such as, but not limited to, water to form the fill material for filling the cavity of the splice device. In other examples, the cavity may be filled with a dry base material such as the grout material, and once the adjoining concrete slabs are ready for connecting, a volume of liquid may be directed into the splice device through the inlet to mix with the base material and surround the rebar in the cavity, which once cured hardens around the rebar and fixedly attaches the rebar to the splice device. In some embodiments, the fill material may also include one or more metallic materials.

In traditional floor constructions, adjacent concrete slab sections are poured so as to include a gap between the slabs, with frame supports (i.e., beam and columns) on either to support each edge of the slabs, this gap may commonly be referred to as an expansion joint. For example, the expansion joint can as little as one inch to as much as four feet in length. In some embodiments, the expansion joint is between about two inches and about two feet. Rebar from the concrete slabs located on either side of the gap can terminate at the slab edges and not continue in the area between the concrete slab sections. During the curing of the concrete slabs, the rebar can shift and move due to a plurality of different forces acting on the rebar as can be appreciated by those having ordinary skill in the art. When the expansion joint is complete the gap is simply surface covered with an expansion joint cover to conceal the gap for safety. The concrete slabs on opposing sides of the gap are never connected structurally to each other. The rebard are not connected between the slabs across the gap.

Various embodiments of the present disclosure improve upon floor constructions by enabling utilizing the splice device to pour and set adjacent concrete slab sections without necessitating including an expansion joint between the adjacent concrete slab sections. That is, in some embodiments, the splice device may be utilized by fixedly attaching a rebar of a first concrete slab to an opening at one end of the splice device and arranging a rebar of a second concrete slab into the cavity through an opening at an opposite end of the splice device. By accommodating a certain amount of movement in the axial and radial directions, the splice device enables the adjacent concrete slabs to be constructed without an expansion joint. In addition, the splice device may then be utilized for fixedly coupling the rebar of the first concrete slab to the rebar of the second concrete slab by filling the cavity with fill material and allowing the fill material to cure to the hardened state, according to some embodiments. In some embodiments, the splice device may be utilized in the space of the expansion joint to connect rebar from the concrete slabs on opposing sides of the expansion joint.

According to some embodiments, the embodiments of the present disclosure provide improvements for constructing adjacent concrete slabs compared with traditional floor constructions that include an expansion joint. By not including the expansion joint and thereby eliminating the need for an expansion joint and the traditional double frames. As such, the splice device simplifies the construction process for building floor constructions and reduces a total time needed to build the floor constructions.

Various embodiments of the present disclosure provide improvements for building floor constructions utilizing the splice device that can accommodate for thermal expansion and/or contraction until such a time as the adjoining concrete sections can be coupled together by filling the splice device with the fill material. Typically, a building may include a concrete frame construction and/or a metal frame construction, and the floor constructions may be built upon this structural frame. During the construction phase (e.g., before the building thermal envelope is complete), thermal loads may cause expansion and/or contraction of the structural frame. Historically, without limiting the length of the building, the structural frame of the building or its components may become damaged due to the thermal expansion and/or contraction. By accommodating for relative movement between the rebar from the adjacent concrete slabs, the splice device may thereby enable the structural frame of the building and its components to expand and contract with the thermal loads, thereby preventing the floor construction and/or the structural frame and/or other components from damage as a result of movement associated with the thermal expansion and/or contraction. Once the building is thermally controlled, the splice device may be utilized to structurally lock the building structural components by filling the cavity of the device and the gap between the slabs with the fill material. In this regard, the splice device may be utilized to eliminate or minimize expansion joints in both concrete frame constructions and steel frame constructions including the concrete floor constructions.

FIG. 1 shows a schematic side view of a floor construction 100, according to some embodiments. In the illustrated embodiment, the floor construction 100 includes a floor 102 formed including one or more concrete slabs. In the floor 102, adjacent concrete slabs may be connected to each other using one or more splice devices (e.g., couplers) such as splice device 104. In some embodiments, floor 102 includes concrete slab 108 and concrete slab 110 adjacent each other and the splice device 104 may be utilized to connect concrete slab 108 and concrete slab 110 together.

In some embodiments, the floor 102 may include a gap 112. The gap 112 may be formed between the concrete slab 108 and concrete slab 110. In some embodiments, the gap 112 is positioned at an end of the splice device 104. In some embodiments, the gap 112 may be formed as a result of individually forming concrete slab 108 and concrete slab 110. In some embodiments, the splice device 104 is positioned entirely within the concrete slab 108 or the concrete slab 110. Accordingly, in some embodiments, the splice device 104 is not within one of the concrete slabs 108, 110. In some embodiments, the gap 112 may allow for expansion or contraction of the respective slabs 108, 110. For example, the gap 112 may widen due to contraction from one of the concrete slab 108 or the concrete slab 110 decreasing in volume from post-tensioning. In another example, the gap 112 may narrow due to thermal expansion of the structural frame. In some embodiments, the gap 112 may be or an expansion joint, as will be further described herein. In some embodiments, the concrete slabs may be post-tensioned concrete slabs. In some embodiments, the concrete slabs may be reinforced concrete slabs.

The concrete slab 108, which may hereinafter be referred to as a first concrete slab 108, may include rebar 116. In some embodiments, the concrete slab 108 may include a plurality of the rebar 116. In some embodiments, rebar 116 may be located in the volume of the concrete material of concrete slab 108. In some embodiments, an end of rebar 116 may extend from a side of the concrete slab 108. For example, an end of rebar 116 may extend from concrete slab 108 and into concrete slab 110. In some embodiments, an end of rebar 116 may be located in the volume of the concrete material of concrete slab 108.

The concrete slab 110, which may hereinafter be referred to as a second concrete slab 110, may include rebar 118. In some embodiments, rebar 118 may be located in the volume of the concrete material of concrete slab 110. In some embodiments, an end of rebar 118 may extend from a side of the concrete slab 110. For example, an end of rebar 118 may extend from concrete slab 110 and into concrete slab 108. In some embodiments, an end of the rebar 118 may be located in the volume of the concrete material of concrete slab 110. For example, one end of rebar 118 may extend into concrete slab 108 and the opposite end of the rebar 118 may be located in a volume of the concrete material of concrete slab 110.

In some embodiments, the rebars 116 in concrete slab 108 may be aligned substantially parallel with each other. In some embodiments, the rebar 118 in concrete slab 110 may be aligned substantially parallel with each other. In some embodiments, rebar 116 from concrete slab 108 and rebar 118 from concrete slab 110 may be colinearly aligned with each other. In other embodiments, rebar 116 and rebar 118 may be in substantially colinear alignment with each other. In some embodiments, rebar 116 and rebar 118 may be aligned along a length of the floor 102 in an axial direction. Although not shown in the schematic view, it will be understood that the floor construction 100 may include the first concrete slab 108 including a plurality of rebars 116 and second concrete slab 110 including a plurality of rebars 118, and one or more of the rebars 116 may be fixedly coupled to rebars 118 using a respective splice device 104.

The splice device 104 includes a body 120. In some embodiments, the splice device 104 may fixedly attach to the rebar 116 and the rebar 118, as will be further described herein. In some embodiments, and as shown in FIG. 1, the splice device 104 may be arranged so the body 120 extends between the concrete slab 108 and concrete slab 110. In other embodiments, the body 120 of the splice device 104 may be arranged in concrete slab 108 or concrete slab 110. In some embodiments, the body 120 of the splice device 104 may fixedly attach to one of the rebar 116 and the rebar 118 by engaging threads located on an exterior of the rebar, and the body 120 of the splice device 104 may fixedly attach to the other of the rebar 116 and the rebar 118 using a fill material (see FIG. 2), as will be further described herein.

In some embodiments, the splice device 104 can be made of a material suitable for use in floor construction. In some embodiments, the splice device 104 can be manufactured by a casting process or the like. In some embodiments, the splice device 104 can be a cast metal such as, but not limited to, a cast steel, cast stainless steel, cast aluminum, or the like. In some embodiments, the splice device 104 may be formed using one or more materials including, but not limited to, iron, carbon, chromium, nickel, other materials, or any combinations thereof. In some embodiments, the splice device 104 may be formed of one or more metallic materials and may include a coating applied to an exterior surface. It is to be appreciated that the one or more materials of the splice device 104 are examples and that other materials suitable in the construction of floors are possible.

In some embodiments, the splice device 104 may further include an anti-corrosive coating applied to the exterior surfaces of the body 120 of splice device 104 to protect the splice device 104 from corrosion over time. In some embodiments, the coating may be applied using any of a plurality of methods including, but not limited to, spraying, painting, dipping, powder coating, electroplating, epoxy coating, enameling, electrocoating, other methods, or any combinations thereof.

FIG. 2 is a sectional side view of the floor construction 100 in FIG. 1, according to some embodiments. FIG. 3 is a second sectional side view of the floor construction 100 in FIG. 1, according to some embodiments. Unless specified otherwise, FIGS. 2 and 3 will be referenced collectively.

The splice device 104 includes body 120, the body 120 including a first end 122 and a second end 124 opposite the first end 122. The body 120 includes a cavity 128 (i.e., an internal chamber), opening 130, and opening 132. In some embodiments, the cavity 128 may be located within body 120 of splice device 104. In addition, in some embodiments, the cavity 128 may be in fluid communication with an exterior of the splice device 104 through opening 130 and opening 132. That is, in some embodiments, the opening 130 and opening 132 may be respective openings of bores extending through body 120 of the splice device 104.

In the floor 102, the splice device 104 may couple together rebar from respective concrete slabs such as, for example, from concrete slabs located adjacent each other. In some embodiments, the floor 102 includes concrete slab 108 including rebar 116 therein and concrete slab 110 including rebar 118 therein. Splice device 104 may fixedly couple together the rebar 116 of concrete slab 108 and the rebar 118 of concrete slab 110. In this regard, the splice device 104 may receive rebar 116 at opening 130 and may receive rebar 118 at opening 132. In some embodiments, the splice device 104 may fixedly attach to rebar 116 at opening 130 by engaging with the rebar 116. In addition, in some embodiments, the splice device 104 may fixedly attach to rebar 118 by positioning a portion of the rebar 118 in the cavity 128 and filling the cavity 128 with a fill material 140 and surrounding the rebar 118. In response to the fill material 140 surrounding the rebar 118 in the cavity 128 and the fill material 140 curing to a hardened state in the cavity 128, the rebar 118 is retained in the cavity 128 by the fill material 140, thereby fixedly attaching the rebar 118 to the splice device 104.

The splice device 104 may be arranged in concrete slab 108. The splice device 104 may be configured to fixedly couple the rebar 116 of concrete slab 108 to the rebar 118 of concrete slab 110. In this regard, the splice device 104 is configured receive the rebar 116 through opening 130, and the body 120 of splice device 104 is configured to engage with the rebar 116 to fixedly attach the rebar 116 to splice device 104. In addition, the body 120 of the splice device 104 is configured to receive rebar 118 in cavity 128 by extending the rebar 118 through opening 132. In addition, splice device 104 is configured to receive a fill material 140 for fixedly attaching the rebar 118 to the splice device 104, as will be further described herein.

In some embodiments, in use, the cavity 128 can be filled with fill material 140 for fixedly attaching (e.g., connecting) the splice device 104 to rebar 118. In some embodiments, the fill material 140 may be in a liquid state when filling the cavity 128 and may cure to a hardened state after a certain time period in the cavity 128. That is, the fill material 140 may be directed into the cavity 128 through inlet 134. In response to the fill material 140 sufficiently curing to a hardened state around the features of rebar 118 in cavity 128, the fill material 140 may fixedly attach rebar 118 to splice device 104 by restricting movement of the rebar 118. Similarly, if a portion of rebar 118 extends through the bore of opening 130 and into the cavity 128, the fill material 140 may also facilitate fixedly attaching the rebar 116 to splice device 104 by hardening around the features of the rebar 116 in the cavity 128. In some embodiments, the fill material 140 may be a cementitious material. In some embodiments, the fill material 140 may be a grout material. In some embodiments, the fill material 140 may include one or more materials including, but not limited to, water, cement, sand, epoxy, resin, binders, fillers, other like materials, or any combinations thereof.

The body 120 of the splice device 104 may be embedded in the concrete material of concrete slab 108. In some embodiments, the splice device 104 may be embedded in the concrete material of concrete slab 108 adjacent a side of the concrete slab 108 that is next to concrete slab 110. In some embodiments, the splice device 104 may be embedded in the concrete slab 108 so that the second end 124 of body 120 is adjacent the side of the concrete slab 108 facing the concrete slab 110 and the first end 122 may extend towards an opposite direction of the concrete slab 108. In this regard, the first end 122 of the body 120 of splice device 104 may receive the rebar 116 of concrete slab 108 at opening 130 and the second end 124 of the body 120 of splice device 104 may receive the rebar 118 at opening 132. In some embodiments, the splice device 104 may be embedded in the concrete slab 108 so that the second end 124 of the body 120 is exposed in the side of the concrete slab 108 so as to allow the rebar 118 of the concrete slab 110 to be positioned in the cavity 128 of the body 120. In some embodiments, the splice device 104 may be arranged in the concrete material of the concrete slab 108 so that the second end 124 of the body 120 is substantially flush with the side of the concrete slab 108. In other embodiments, the splice device 104 may be arranged in the concrete material of the concrete slab 108 so that the second end 124 of the body 120 is inset from the side of the concrete slab 108. In yet other embodiments, the splice device 104 may be arranged in the concrete material of the concrete slab 108 so that the second end 124 of the body 120 extends beyond the side of the concrete slab 108. It is to be appreciated by those having ordinary skill in the art that the splice device 104 is not limited to being embedded in the concrete slab 108 and may instead, for example, be embedded in the concrete slab 110 and receive in the cavity 128 the rebar 116 from the concrete slab 108.

It is to be appreciated by those having ordinary skill in the art that the location of the splice device 104 in concrete slab 108 is not intended to be limiting, and the splice device 104 may be arranged in concrete slab 108, concrete slab 110, and/or other locations depending on a particular application or use of the splice device 104.

FIG. 4 is a sectional side view of the splice device 104 in FIG. 1, according to some embodiments.

In some embodiments, the body 120 of splice device 104 may include a generally cylindrical shape. In some embodiments, the body 120 may be a cylindrical body extending in a longitudinal direction along an axis, L1. In some embodiments, the body 120 of splice device 104 may have an elongate shape with a geometric base. For example, the body 120 of splice device 104 may include a flat surface on one of its exterior sides, the flat surface extending in the longitudinal direction between first end 122 and second end 124. In other embodiments, the body 120 of splice device 104 may include a geometric shape (e.g., a circle, an ovoid, a triangle, a square, a rectangle, a hexagon, an octagon, or the like).

The body 120 of splice device 104 may include cavity 128, opening 130, opening 132, inlet 134, and outlet 136. In some embodiments, the body 120 may define each of the cavity 128, opening 130, opening 132, inlet 134, and outlet 136. In other embodiments, the body 120 may be formed so as to include each of the cavity 128, opening 130, opening 132, inlet 134, and outlet 136 extending therethrough. That is, in some embodiments, one or more bores may extend through body 120 and into cavity 128, thereby placing cavity 128 in fluid communication with an exterior region of the splice device 104 through the respective bores. In this regard, in some embodiments, opening 130, opening 132, inlet 134, and outlet 136 may be openings formed on an exterior surface 144 of body 120 and associated with respective bores extending through the body 120 and into the cavity 128.

The splice device 104 includes the cavity 128. The cavity 128 is formed within the body 120. The cavity 128 may be a cylindrical cavity extending along a longitudinal length of the body 120 and substantially parallel to axis, L1. The cavity 128 may be in fluid communication with the opening 130, opening 132, inlet 134, outlet 136, or any combinations thereof.

The cavity 128 may include ridges 156 circumferentially formed on the side of the cavity 128. That is, in some embodiments, the body 120 may be formed including the ridges 156 in the cavity 128. The ridges 156 may be configured to facilitate retaining the fill material 140 in the cavity 128. That is, the fill material 140 may fill the unoccupied space in the cavity 128 including the space formed by the ridges 156. When the fill material 140 cures to the hardened state, the fill material 140 thereby fills the space of the cavity 128 and the space of the ridges 156. Accordingly, the hardened material of the fill material 140 is formed around the eccentric features (e.g., threads) of the rebar 118 and is formed in the space of the ridges 156, thereby preventing movement of the fill material 140 in the cavity 128 and also restricting movement of the rebar 118 in the axial direction and the radial direction.

The rebar 116 may be connected to the body 120 of splice device 104 by installing the rebar 116 into the opening 130 so as to engage the threads 148 of bore 146 using the corresponding threads on rebar 116. In addition, to connect rebar 116 to rebar 118 using the splice device 104, the rebar 116 is positioned so that a portion of the rebar 116 is located in the cavity 128, and then fill material 140 is directed into cavity 128 using inlet 134 so as to fill the unoccupied space of the cavity 128 with the fill material 140. In response to the fill material 140 that is filling the cavity 128 curing to the hardened state, the fill material 140 hardens around the rebar 118 and retains the rebar 118 in the cavity 128 and in the splice device 104.

FIG. 5 is a front view of the splice device 104, according to some embodiments.

The splice device 104 includes opening 130. Opening 130 is located at the first end 122 of body 120. In addition, opening 132 is located at the second end 124 of body 120 opposite from the first end 122 along the longitudinal length of the body 120. Opening 130 and opening 132 may be in fluid communication with cavity 128. In this regard, in some embodiments, the opening 130 and opening 132 may be in fluid communication with each other through cavity 128.

Opening 130 may include a bore 146 extending through the body 120 and into the cavity 128. The opening 130 includes a diameter that is larger than a diameter of the rebar extending therethrough. In addition, in some embodiments, bore 146 may include threads 148 formed on an inner surface of the bore 146, the threads 148 being configured to engage corresponding threads located on an outer surface of the rebar 116 for fixedly attaching the body 120 of splice device 104 to the rebar 116. In this regard, in some embodiments, splice device 104 may be installed into concrete slab 108 by installing the rebar 116 into the opening 130 of body 120 of splice device 104 so as to fixedly attach the rebar 116 to the splice device 104, and then the wet concrete material may be poured to form the concrete slab 108, the splice device 104 and rebar 116 being positioned in the concrete material so that the second end 124 of the splice device 104 is arranged on the side of the concrete slab 108 that is facing the concrete slab 110.

FIG. 6 is a rear view of the splice device 104, according to some embodiments.

The splice device 104 includes opening 132. Opening 132 may include a bore 150 extending through the body 120 and into cavity 128. The opening 132 and bore 150 including a diameter that is larger than a diameter of the rebar extending therethrough to permit the rebar 118 to extend through the opening 132 and into the cavity 128 towards the first end 122. In addition, the opening 132 may include a size and dimensions that allows the rebar 118 to move in an axial direction and a radial direction relative the splice device 104.

In some embodiments, the opening 132 may be a slot 142. The slot 142 having a width that is greater than a height to permit both an axial movement and a lateral movement of the rebar 118 extending through the slot 142 and into the cavity 128 prior to filling the cavity 128 with the fill material 140. In this regard, the splice device 104 may be fixedly attached to the rebar 116 at the bore 146 and the size of the slot 142 at the second end 124 may allow the rebar 118 extending therethrough to move in the axial and lateral direction to accommodate for movement of the rebar 118 relative the splice device 104 prior to filling the cavity 128 with the fill material 140. In some embodiments, the slot 142 may be rectangular in geometry with arcuate ends. That is, in some embodiments, the sides of the slot 142 may have an arcuate shape similar to a shape of the rebar 118 extending therethrough. In some embodiments, the slot 142 includes an upper surface configured to be able to contact a rebar's outer surface and provide sufficient strength to be a part of a self-supporting concrete slab (which uses rebars and splice devices) and/or be a part of a floor to a wall connection. In some embodiments, the slot 142 includes a lower surface configured to be able to contact a rebar's outer surface and provide sufficient strength to be a part of a self-supporting concrete slab (which uses rebars and splice devices) and/or be a part of a floor to a wall connection.

In some embodiments, the body 120 of splice device 104 may further include portions 160a, 160b. Each portion 160 may protrude from the body 120 at the second end 124 in a radial direction relative the axis, L1. In some embodiments, each portion 160a, 160b may further include an aperture 162a, 162b extending therethrough. The splice device 104 may receive one or more fasteners, each of the aperture 162a, 162b receiving a respective fastener therethrough for mounting the splice device 104 to a structural member such as a form work (e.g., made of wood) connected to the concrete slab 108 or concrete slab 110 during the floor construction process. In some embodiments, the splice device 104 may include one or more of the portions 160a, 160b. In some embodiments, the splice device 104 may include a first portion 160a and a second portion 160b arranged at opposite sides of the body 120 from each other, the first portion 160a including a first aperture 162a and the second portion 160b including a second aperture 162b for receiving a respective fastener therethrough.

FIG. 7 is a top view of the splice device 104, according to some embodiments.

In some embodiments, the splice device 104 includes inlet 134. In some embodiments, the splice device 104 includes outlet 136. Referring to FIG. 7, the splice device 104 includes inlet 134 and outlet 136. In some embodiments, the inlet 134 may be located adjacent the first end 122 and the outlet 136 may be located adjacent the second end 124 on the body 120 of splice device 104.

Inlet 134 includes bore 152 extending through the body 120 and into cavity 128 at a side of the body 120. The inlet 134 may extend in a radial direction along axis, L2. In some embodiments, the axis, L2, may be perpendicular to axis, L1. In other embodiments, the axis, L2, may be substantially perpendicular to axis, L1. The inlet 134 may include a diameter sufficient to allow fill material 140 to be directed into the cavity 128 through the inlet 134.

The splice device 104 includes outlet 136. Outlet 136 includes bore 154 extending through the body 120 and into cavity 128 at a side of the body 120. The outlet 136 may extend in a radial direction along axis, L3. In some embodiments, the axis, L3, may be perpendicular to axis, L1. In other embodiments, the axis, L3, may be substantially perpendicular to axis, L1. In some embodiments, the axis, L2, may be parallel to axis, L3. In other embodiments, the axis, L2, may be substantially parallel to the axis, L3, and the axis, L2, and the axis, L3, may be substantially perpendicular to the axis, L1. The outlet 136 may include a diameter sufficient to allow fill material 140 to exit the cavity 128 through outlet 136 in response to the cavity 128 being filled with the fill material 140.

In some embodiments, the inlet 134 and outlet 136 may be located at a same side of the body 120. In some embodiments, the inlet 134 may be in alignment with the outlet 136 on the side of body 120. In other embodiments, the inlet 134 and outlet 136 may be located at substantially the same side. In yet other embodiments, the inlet 134 and outlet 136 may be located at different sides of the body 120. For example, the axis, L2, of the inlet 134 and the axis, L3, of the outlet 136 may both be substantially perpendicular to the axis, L1, but the axis, L2, and the axis, L3, not be parallel to each other.

It is to be appreciated that the location of inlet 134 and outlet 136 along the side of the body 120 is not intended to be limiting, and the inlet 134 and outlet 136 may be located anywhere along a side of the body 120 between the first end 122 and second end 124 so long as they are in fluid communication with the cavity 128 and enables the cavity 128 to be filled with the fill material 140, in accordance with the present disclosure.

FIG. 8 is a second sectional side view of the splice device 104, according to some embodiments.

The splice device 104 includes the body 120, the body 120 including the opening 130 extending through the body 120 at the first end 122. In some embodiments, the body 120 may include a protrusion 170 distally extending from body 120 to the first end 122. The splice device 104 may include the bore 146 extending through the protrusion 170 from the first end 122 and towards the second end 124 to the cavity 128.

In some embodiments, the bore 146 may be a conical bore. In this regard, a diameter, D1, of opening 130 at the first end 122 may be wider (e.g., greater) than a diameter, D2, of opening 172 at the cavity 128. By including a varying diameter, the splice device 104 may receive rebar 116 in the bore 146 through the opening 130 at the first end 122 and the threads 148 at the inner surface of the bore 146 may engage the corresponding thread or threads on the rebar 116 to fixedly attach the rebar 116 to the splice device 104. In this regard, in some embodiments, an end of the rebar 116 may include a tapered end having dimensions that correspond to the dimensions of the bore 146 and to enable fixedly attaching the rebar 116 to the splice device 104 at the bore 146.

In some embodiments, the rebar configured to be inserted into the opening 130 and installed into the bore 146 may include a straight thread of substantially uniform diameter. In other embodiments, the corresponding rebar may include a tapered thread of narrowing diameter. In such embodiments, the threads 148 can receive the threads of the rebar and securely fix the rebar to the splice device 104. In the illustrated embodiment, the opening 130 has a varying diameter such that a diameter D1 at the opening 130 is relatively larger than a diameter D2 at the cavity 128. In some embodiments, the relative diameters could be reversed such that the diameter D1 is relatively smaller than the diameter D2. It is to be appreciated that the threaded rebar may have a corresponding shape to the shape of the bore 146 to enable engaging with the threads 148 at the opening 130. In some embodiments, the opening 130 may have a constant diameter. That is, in some embodiments, the diameter D1 and the diameter D2 can be the same.

The body 120 of splice device 104 may include portion 174 and portion 176. The portion 174 may be located adjacent the second end 124 and the portion 176 may be located adjacent the first end 122. In some embodiments, portion 174, portion 176, or both may include a cylindrical shape. In other embodiments, portion 174, portion 176, or both may include a geometric shape. In some embodiments, the portion 174 and the portion 176 may be contiguously formed from one piece.

In some embodiments, the body 120 may be formed including portion 174 and portion 176. In some embodiments, the portion 174 of body 120 may include the inlet 134 and the outlet 136 arranged thereon. That is, the bore 152 and the bore 154 may extend through the portion 174 of body 120 and to the cavity 128. In some embodiments, the portion 174 of body 120 may further include the opening 132 arranged thereon. In this regard, the bore 150 may extend through the portion 174 of body 120 and to the cavity 128.

In some embodiments, portion 176 of body 120 may include the opening 130 arranged thereon. That is, the bore 146 may extend through portion 176 of body 120 and to the cavity 128. As such, the cavity 128 may be formed by the portion 174 and the portion 176.

In some embodiments, the body 120 may further include an end wall 178, the end wall 178 located at the second end 124 of the body 120 and including the opening 132 extending therethrough. That is, in some embodiments, the bore 150 may extend through the end wall 178 into the cavity 128.

According to some embodiments, the splice device 104 may include a cap (not shown). In some embodiments, the splice device 104 may include a cap for each of the openings arranged in the body 120. In some embodiments, the splice device 104 may include a cap for the inlet 134. In some embodiments, the splice device 104 may include a cap for the outlet 136. In other embodiments, the splice device 104 may include a cap for each of the inlet 134 and the exterior surface 144. In some embodiments, the cap may be configured to prevent concrete material from entering into cavity 128 during pouring of the floor surrounding the splice device 104. For example, the splice device 104 may be fixedly attached to the rebar 116 and the other openings of the splice device 104 may include caps to cover the openings to prevent the concrete material from entering the cavity 128 and interfering with the splice device 104 being utilized to couple the rebar 116 to the rebar 118.

FIG. 9 is an exposed perspective view of the floor construction 100, according to some embodiments.

According to some embodiments, in floor construction 100, the floor 102 may include concrete slab 108 and concrete slab 110. In some embodiments, the concrete slab 108 may include a plurality of rebar 116 and concrete slab 110 may include a plurality of rebar 118. In addition, the concrete slab 108 and the concrete slab 110 may be connected to each other by coupling one or more of the plurality of rebar 116 to one or more of the plurality of rebar 118 using a respective splice device 104. In this regard, the splice device 104 may be utilized to connect one or more of the rebars of a concrete slab such as the rebar 116 of concrete slab 108 to one or more of the rebars of another concrete slab such as the rebar 118 of concrete slab 110.

The concrete slab 108 includes rebar 116 and rebar 116′, and the concrete slab 110 includes rebar 118 and rebar 118′. Splice device 104 may be utilized to fixedly couple the rebar 116 to the rebar 118 and the splice device 104′ may be utilized to fixedly couple the rebar 116′ to the rebar 118′.

FIG. 10 is a sectional side view of the floor construction 100, according to some embodiments.

In some embodiments, the floor 102 may include a pour strip 158 between concrete slab 108 and concrete slab 110. In some embodiments, the pour strip 158 may be 1 ft. to 5 ft. wide, or any range or subrange therebetween. In some embodiments, the pour strip 158 may be 3 ft. to 5 ft. wide. In other embodiments, the pour strip 158 may be greater than 5 ft. wide.

The splice device 104 may be located in the space corresponding to the pour strip 158, and the splice device 104 may be utilized to connect the rebar 116 from concrete slab 108 to the rebar 118 from concrete slab 110 in the pour strip 158. That is, the splice device 104 may be embedded in the concrete material of the pour strip 158 with the rebar 116 from concrete slab 108 being fixedly attached to the body 120 of splice device 104 at the bore of opening 130 and the rebar 118 from concrete slab 108 being fixedly attached to the body 120 of splice device 104 at the cavity 128 using the fill material 140 filling the cavity 128.

FIG. 11 is a method 200 for making a floor construction, according to some embodiments.

The method 200 may include, in some embodiments, a first concrete slab and a second concrete slab that may be connected together using one or more splice devices such as, for example, concrete slab 108 as shown in FIG. 1.

At 202, the method 200 includes installing the splice device onto an end of a first rebar of the first concrete slab. In some embodiments, the splice device includes a cylindrical body including a first opening at a first end, a second opening at a second end, an inlet, an outlet, and a cavity within the cylindrical body. In some embodiments, installing the splice device onto the end of the first rebar includes installing the first rebar into a first opening of the splice device.

In some embodiments, the first bore comprises one or more threads formed on an inner surface of the first bore, the one or more threads being configured to engage corresponding threads on the first rebar in response to installing the first rebar into the first bore. In this regard, in some embodiments, installing the splice device onto the end of the first rebar includes threading the first rebar into a first opening of the splice device, the first rebar including threads corresponding to one or more threads formed on an inner surface of a first bore of the first opening. The splice device is shown as splice device 104 in FIG. 4. The cylindrical body is shown as body 120, the first opening is shown as opening 130, the second opening is shown as opening 132, the inlet is shown as inlet 134, the outlet is shown as outlet 136, and the cavity is shown as cavity 128 in FIG. 4. In addition, the first bore is shown as bore 146, the threads of the first bore is shown as threads 148 in FIG. 4.

At 204, the method 200 includes positioning a portion of a second rebar of the second concrete slab into the cavity, the second rebar extending through the second opening. In some embodiments, the splice device is configured to receive the portion of the second rebar in the cavity, the second bore permitting the second rebar to extend therethrough into the cavity and towards the first end. The second opening is shown as opening 132 in FIG. 4.

At 206, the method 200 includes forming the first concrete slab, the first concrete slab including the first rebar. In some embodiments, forming the first concrete slab includes pouring a wet concrete material into a frame or mold to form the first concrete slab and positioning the first rebar in the wet concrete material so as to embed the splice device in the first concrete slab.

In some embodiments, the splice device may be arranged adjacent a side of the first concrete slab such that second opening is facing a side of the second concrete slab so as to allow the second rebar to extend therethrough and into the cavity. In some embodiments, the splice device may be embedded in the first concrete slab so that a second end of the splice device that includes the second opening is exposed at the side of the first concrete slab adjacent the second concrete slab. The first concrete slab is shown as concrete slab 108, the first rebar is shown as rebar 116, the second concrete slab is shown as concrete slab 110, and the second rebar is shown as rebar 118 in FIG. 2.

At 208, the method 200 includes forming the second concrete slab, the second concrete slab comprising the second rebar. In some embodiments, forming the second concrete slab includes pouring a wet concrete material into a frame or mold to form the second concrete slab and positioning the second rebar in the wet concrete material of the second concrete slab so that a portion of the second rebar extends from the second concrete slab and into the cavity of the splice device through the second opening.

In some embodiments, forming the second concrete slab includes pouring the second concrete slab so the second end of the splice device is adjacent the second concrete slab. In some embodiments, the second concrete slab is formed adjacent the first concrete slab to minimize a gap between the first concrete slab and the second concrete slab. In some embodiments, the splice device may be installed in a pour strip between the first concrete slab and the second concrete slab. In other embodiments, the splice device may be installed so as to extend between the first concrete slab and the second concrete slab.

In some embodiments, step 206 is performed before step 204. In some embodiments, steps 204, 206, and 208 are interchangeable.

At 210, the method 200 includes, after forming the first concrete slab and the second concrete slab, filling a fill material into the cavity through one of the inlet and the outlet. The fill material may be used to fill the cavity while the fill material is in a liquid state. That is, the fill material may be directed into the cavity through the inlet when in the liquid state. In addition, in the liquid state, the fill material may fill the unoccupied space in the cavity. The splice device may be filled with the fill material until excess fill material is observed escaping from the outlet in response to the cavity being full of the fill material.

In some embodiments, when the second rebar is located in the cavity, the fill material fills the space of the cavity and surrounds the second rebar. In some embodiments, the second rebar may further include one or more features formed on its outer surface such as, for example, threads, and the fill material may form around the threads of the second rebar. The fill material is shown as fill material 140 in FIG. 2.

In some embodiments, the method 200 includes, in response to the fill material curing in the cavity, the splice device securely fixes the second rebar in the cavity and couples the first rebar to the second rebar. In some embodiments, the fill material may cure in the cavity after a certain amount of time. In addition, since the fill material fills the space of the cavity and surrounds the second rebar, the second rebar is retained in the cavity by the fill material once the fill material has sufficiently cured to the hardened state. That is, once hardened, the fill material restricts movement of the second rebar relative the splice device in the axial or radial direction. As the splice device is fixedly attached to the first rebar at the first opening, the curing of the fill material in the cavity fixedly attaches the second rebar to the splice device in the cavity, and the splice device thereby fixedly couples the first rebar of the first concrete slab to the second rebar of the second concrete slab.

FIGS. 12A-12D show sectional views of a floor construction system 1100, for providing mechanical reinforcement between adjacent concrete slabs. The system 1100 operates to replace a traditional construction method of placing an expansion joint between these adjacent concrete slabs. For convenience of illustration, the concrete slabs are not shown drawn to scale. The embodiments discloses herein for reinforcing adjacent concrete slabs may be used with concrete slabs of any of a variety of standard dimensions. Note that while reference is made throughout to concrete slabs, for efficiency, it should be understood that the concepts disclosed herein will work for all forms of concrete known and used in constructing floor systems, including reinforced concrete, composite concrete, and engineered cementitious composites by way of example.

Note that various resources exist for determining the necessity for a an expansion joint and/or the appropriate size of the gap between adjacent slabs, based on building lengths and temperature conditions. One such example is the “Federal Construction Council, 1974, Technical Report No. 65, 1974, Expansion Joints in Buildings, National Research Council, Washington, D.C. It shows a graph of a general understanding of allowable building lengths (without requiring an expansion joint) in relation to a design temperature change. The system and techniques discloses herein may be used with slab and/or building lengths up to about 1000 feet or, in some cases, even larger length

As shown in FIG. 12A, a first concrete slab 1108 and a second concrete slab 1110 are separated by a gap 1112a having a separation distance (i.e., a width) 1112a. As explained in more detail throughout, this gap 1112 a between the adjacent concrete slabs allows for the slabs to move with respect to each other after pouring of the slabs and during curing and/or thermal expansion. As further shown, a first rebar 1116 is coupled to an end of a splice device (e.g., coupler) 1104, both of which are embedded in the first concrete slab 1108. A second rebar 1118 is embedded in the second concreted slab 1110 with an exposed (i.e., leading) end extending out of the slab and toward the adjacent concrete slab 1108 and not the splice device 1104. The splice device 1104 includes a body 1120 extending from a first end 1122 to a second end 1124 and defining an internal cavity 1128. During preparation, the splice device 1104 is positioned approximately (i.e., plus or minus two inches) flush with the face of the concrete slab 1108 facing the adjacent concrete slab 1110, with the first rebar 1116 extending from the first end 1122 in an oppositive direction (i.e., away from the adjacent concrete slab 1110).

According to various embodiments, before pouring the concrete, the length and position of the second rebar 1118 and the coupler 1104 is chosen so as to define a gap 1112b of width D2 between the leading end of rebar 1118 and the first end 1122 of the body 1120 of the splice device 1104. In various embodiments, the width of the gap 1112b (D2) is selected to be about equal to the width of the gap 1112 (D1), which is created during the second pour. The width of the gap D1 is determined using known design criteria and characteristics of the particular project. According to various embodiments the difference between D1 and D2 is less than about 5%, and in other embodiments, the difference is less than about 10%. In other embodiments, the second rebar 1118 is positioned with the leading end at the approximate longitudinal center of the cavity 1128. In certain embodiments, the second rebar 1118 is positioned with the leading end located within about 25% of the longitudinal center of the cavity 1128.

FIG. 12B illustrates the floor construction system 1100 where the concrete slabs have 1108 and 1110 have expanded due to a temperature increase. As shown, the gaps 1112a and 1112b having widths of D1 and D2, respectively, have reduced. In other words the gap between the adjacent concrete slabs 1108 and 1110 is now smaller. As the gap width D1 was appropriately selected based on know criteria, no interference of slab 1108 and slab 1110 occurs. In other words, a smaller gap 1112b remains even following thermal expansion of the slabs. Further, there is no interference of the leading edge of the rebar 1118 with the first end 1122 of the body 1120. In other words, a smaller gap 1112b remains between the rebar 1118 and the second end 1122 of the body 1120.

FIG. 12C illustrates the floor construction system 1100 where the concrete slabs have 1108 and 1110 have retracted due, for example, to a temperature decrease. As shown in FIG. 12C, in the event of shrinkage or retraction due to a lower temperature, gaps 1112a and 1112b increases. In other words the gap width D1 and D2 increase at similar rates. In this embodiment no interference damage occurs due to contraction related to reduced temperatures, creating a wider gap D1 and D2. Further, as shown, the exposed length of rebar 1118 is selected such than upon retraction the end portion of the rebar 1118 remains inside the body 1120 of the splice device 1104. In various embodiments, in the fully retracted state, the rebar extends at least 20% along the length of the cavity 1128 inside the body 1120. In other embodiments, in the fully retracted state, the rebar extends at least 30% along the length of the cavity 1128 inside the body 1120. In other embodiments, in the fully retracted state, the rebar extends at least 50% along the length of the cavity 1128 inside the body 1120.

According to some embodiments, the thermal movement of the system continues until the building thermal envelope is completed and mechanical heating and cooling system are operational and are able to stabilize the temperature inside the building. During the time after casting and stabilizing the interior temperature, the system is able to expand and contract due to exterior thermal changes without causing building damage if all elements have been designed as would be for a traditional expansion joint. After thermal stabilization of the interior of the building the gap 1112a and gap 1112b return to near the as cast position, since that was near the temperature for casting and curing the concrete, but the gap has been further increased due to concrete shrinkage that has occurring during the this curing time.

FIG. 12D illustrates the floor construction system 1100 where the concrete slabs have 1108 and 1110 have reached a final position, for example, after construction has reached a stage where thermal changes are minimal. As shown in FIG. 12D, at this stage, the cavity 1128 of the device 1120 has been filled with the fill material to complete this construction of this embodiment. Furthermore, the gap 112a is also filled with fill material. This secures the position of the rebar 1118 inside the splice device 1104 to increase the mechanical coupling between the adjacent concrete slabs. And the filler material fills the gap between the slab removing the need for a traditional expansion joint cover.

All known similar devices and methods only address the known pour strip or delay strip, which is a device and a method that addresses the shortening due to concrete shrinkage. This concept includes forming and shoring and a larger gap between the first and second slab. The width of the gap is mostly related to rebar bond length and sometime a width necessary for stressing post-tension concrete.

In some embodiments, the first rebar 1116 has a threaded end, which is coupled to a threaded bore in the body 1120. In other embodiments, the first rebar 1116 extend through the bore into a cavity in the body 1120 and is coupled to the splice device using a filler material as further described herein. In some embodiments, the first rebar 1116 is threaded along its full length, while in other embodiments, the first rebar 1116 is threaded only at an end portion. In some embodiments, the first rebar 1116 is, for example, a Williams threaded rebar, while the second rebar 1118 is a traditional continuation rebar. In certain embodiments, the first rebar 1116 is larger than the second rebar 1118, for example, the first rebar 1116 may be a #14 rebar and the second rebar 1116 may be a #11 rebar.

FIG. 13 is a sectional side view of the splice device 1104, according to various embodiments. In some embodiments, the body 1120 of splice device 1104 may have a generally cylindrical shape. In some embodiments, the body 1120 may be a cylindrical body extending in a longitudinal direction along an axis, L1. In some embodiments, the body 1120 of splice device 1104 may have any elongate shape with a geometric base. For example, the body 1120 of splice device 1104 may by generally cylindrical with a flat surface on one of its exterior sides, the flat surface extending in the longitudinal direction between first end 1122 and second end 1124. In other embodiments, the body 1120 of splice device 1104 may include a geometric shape (e.g., a circle, an ovoid, a triangle, a square, a rectangle, a hexagon, an octagon, or the like).

The body 1120 of splice device 1104 defines an opening 1130 on the first end 1122, an opening 1132 on the second end 1124 an a cavity 1128. The body 1120 further defines an inlet 1134 and an outlet 1136. In some embodiments, the body 1120 may define each of the cavity 1128, opening 1130, opening 1132, inlet 1134, and outlet 1136. In other embodiments, the body 1120 may be formed so as to include each of the cavity 1128, opening 1130, opening 1132, inlet 1134, and outlet 1136 extending therethrough. That is, in some embodiments, one or more bores may extend through body 1120 and into cavity 1128, thereby placing cavity 1128 in fluid communication with an exterior region of the splice device 1104 through the respective bores. In this regard, in some embodiments, opening 1130, opening 1132, inlet 1134, and outlet 1136 may be openings formed on an exterior surface 1144 of body 1120 and associated with respective bores extending through the body 1120 and into the cavity 1128.

According to various embodiments, the body 1120 is formed of stainless steel and has a length of from about one to about three feet. According to certain embodiments, the body 1120 has a length of about 18 inches. In various embodiments, the body 1120 is generally cylindrical in shape and has outer diameter of between about two and about five inches. In certain embodiments, the body 1120 has an outer diameter of between about three and about 3.5 inches, for example, about 3.2 inches. In certain embodiments, the body 1120 has an inner diameter (defining the cavity 1128) of between about 1.5 and about 4 inches. In various embodiments, the body 1120 has an inner diameter of between about two and about three inches, for example about 2.5 inches. In various embodiments, the body 1120 has a wall thickness of between about 0.3 and 0.8 inches. In certain embodiments, the body 1120 has a wall thickness of about 0.5 inches.

The splice device 1104 includes the cavity 1128 formed within the body 1120. The cavity 1128 may be of any geometric shape. In some embodiments, the cavity 1128 is a generally cylindrical cavity extending along a longitudinal length of the body 1120 and substantially parallel to axis, L1. The cavity 1128 may be in fluid communication with each of the opening 1130, opening 1132, inlet 1134, outlet 1136, or any combinations thereof.

The cavity 1128 may include ridges 1156 circumferentially formed on the side of the cavity 1128. The ridges 1156 may be configured to facilitate retaining the fill material 1140 in the cavity 1128. That is, the fill material 1140 may fill the unoccupied space in the cavity 1128 including the space formed by the ridges 1156. Accordingly, the fill material 1140 (e.g., a curable, hardened resin) is formed around the eccentric features (e.g., threads) of the rebar 1118 and is formed in the space of the ridges 1156, thereby limiting movement of the fill material 1140 in the cavity 1128 and also restricting movement of the rebar 1118 in the axial direction and the radial direction.

The rebar 1116 may be coupled to the first end 1122 of the body 1120 of splice device 1104 by installing the rebar 1116 into the opening 1130 so as to engage the threads 1148 of bore 1146 using the corresponding threads on rebar 1116. In addition, to connect rebar 1116 to rebar 1118 using the splice device 1104, the rebar 1118 is positioned so that a portion of the rebar 1118 is located in the cavity 1128, and then fill material 1140 is directed into cavity 1128 using inlet 1134 so as to fill the unoccupied space of the cavity 1128 with the fill material 1140. Upon the fill material 1140 that is filling the cavity 1128 curing to the hardened state, the fill material 1140 hardens around the rebar 1118 and retains the rebar 1118 in the cavity 1128 and in the splice device 1104.

In some embodiments, the splice device 1104 includes inlet 1134. In some embodiments, the splice device 1104 includes outlet 1136. As shown in FIG. 13, the splice device 1104 includes inlet 1134 and outlet 1136. In some embodiments, the inlet 1134 may be located adjacent the first end 1122 and the outlet 1136 may be located adjacent the second end 1124 on the body 1120 of splice device 1104.

The inlet 1134 includes a bore 1152 extending through the body 1120 and into the cavity 1128 at a side of the body 1120. The inlet 1134 may extend in a radial direction along axis, L2. In some embodiments, the axis, L2, may be perpendicular to axis, L1. In other embodiments, the axis, L2, may be substantially perpendicular to axis, L1. The inlet 1134 may include a diameter sufficient to allow fill material 1140 to be directed into the cavity 1128 through the inlet 1134.

The splice device 1104 includes an outlet 1136. The outlet 1136 includes a bore 1154 extending through the body 1120 and into the cavity 1128 at a side of the body 120. The outlet 1136 may extend in a radial direction along axis, L3. In some embodiments, the axis, L3, may be perpendicular to axis, L1. In other embodiments, the axis, L3, may be substantially perpendicular to axis, L1. In some embodiments, the axis, L2, may be parallel to axis, L3. In other embodiments, the axis, L2, may be substantially parallel to the axis, L3, and the axis, L2, and the axis, L3, may be substantially perpendicular to the axis, L1. The outlet 1136 may include a diameter sufficient to allow fill material 1140 to exit the cavity 1128 through outlet 1136 in response to the cavity 1128 being filled with the fill material 1140.

In some embodiments, the inlet 1134 and outlet 1136 may be located at a same side of the body 1120. In some embodiments, the inlet 1134 may be in alignment with the outlet 1136 on the side of body 1120. In other embodiments, the inlet 1134 and outlet 1136 may be located at substantially the same side. In yet other embodiments, the inlet 1134 and outlet 1136 may be located at different sides of the body 1120. For example, the axis, L2, of the inlet 1134 and the axis, L3, of the outlet 1136 may both be substantially perpendicular to the axis, L1, but the axis, L2, and the axis, L3, not be parallel to each other.

FIGS. 14A-14C are plan views of the first end 1122 of the splice device 1104, according to various embodiments. A shown, the splice device 1104 includes an opening 1130 extending into the first end 1122 and into the cavity 1128 of the body 1120. The opening 1130 is defined by a bore 1146 extending through the body 1120 and into the cavity 1128. The opening 1130 includes a diameter that is equal to or larger than a diameter of the rebar extending therethrough. In addition, in some embodiments, bore 1146 may include threads 1148 formed on an inner surface of the bore 1146, the threads 1148 being configured to engage corresponding threads located on an outer surface of the rebar 1116 for fixedly attaching the body 1120 of splice device 1104 to the rebar 1116. In this regard, in some embodiments, splice device 1104 may be installed into concrete slab 1110 by installing the rebar 1116 into the opening 1130 of body 1120 of splice device 1104 so as to fixedly attach the rebar 1116 to the splice device 1104, and then the wet concrete material may be poured to form the concrete slab 1110, the splice device 1104 and rebar 1116 being positioned in the concrete material so that the first end 1122 of the splice device 1104 is arranged on the side of the concrete slab 1108 that is facing the adjacent concrete slab 1110. As shown in FIGS. 14A-14C, the first end 1122 surrounding the bore 1130 has a distinct shape. In FIG. 14A, the portion surrounding the bore 1130 is generally cylindrical. In FIG. 14B, the portion surrounding the bore 1130 is generally cylindrical with a flat on each of opposing sides. In FIG. 14C, the portion surrounding the bore 1130 is hexagonal. The various embodiments disclosed herein my be used with a splice device having a first end 1122.

FIG. 15 is a rear plan view of the second end 1124 of the splice device 1104, according to some embodiments. The splice device 1104 includes opening 1132. The opening 1132 may include a bore 1150 extending through the body 1120 and into cavity 1128. The opening 1132 and bore 1150 have a diameter that is larger than a diameter of the rebar extending therethrough to permit the rebar 1118 to extend through the opening 1132 and into the cavity 1128 towards the first end 1122. In addition, the opening 1132 may include a size and dimensions that allows the rebar 1118 to move in an axial direction and a radial direction relative the splice device 1104.

In some embodiments, as illustrated in FIG. 15, the opening 1132 may be shaped as a slot 1142, which has a width that is greater than a height to permit both an axial movement and a lateral movement of the rebar 1118 extending through the slot 1142 and into the cavity 1128 prior to filling the cavity 1128 with the fill material 1140. In this regard, the splice device 1104 may be fixedly attached to the rebar 1116 at the bore 1146 and the size of the slot 1142 at the second end 1124 may allow the rebar 1118 extending therethrough to move in the axial and lateral direction to accommodate for movement of the rebar 1118 relative the splice device 1104 prior to filling the cavity 1128 with the fill material 1140. In various embodiments, the slot 1142 has a height that is between about the diameter of the rebar 1118 extending therethrough and double the diameter of the rebar 1118 extending therethrough. In various embodiments, the slot has a height this is between the diameter of the rebar extending therethrough and about three times the diameter of the rebar. In certain embodiments, the coupler 1104 is designed for use with #11 rebar. In exemplary embodiments, the slot 1142 has a height of between about 1.41 inches (the outside diameter of #11 rebar) and 1.6 inches, for example, the slot has a height of about 1.550 inches. In such embodiments, the slot has a width of between about 1.5 inches and about 2.5 inches, for example, the slot has a width of about 2.3 inches.

In some embodiments, the slot 1142 may be rectangular in geometry with arcuate ends. That is, in some embodiments, the sides of the slot 1142 may have an arcuate shape matching or similar to a shape of the rebar 1118 extending therethrough. In some embodiments, the slot 1142 includes an upper surface configured to be able to contact a rebar's outer surface and provide sufficient strength to be a part of a self-supporting concrete slab (which uses rebars and splice devices) and/or be a part of a floor to a wall connection. In some embodiments, the slot 1142 includes a lower surface configured to be able to contact a rebar's outer surface and provide sufficient strength to be a part of a self-supporting concrete slab (which uses rebars and splice devices) and/or be a part of a floor to a wall connection.

In some embodiments, the body 1120 of splice device 1104 may further include portions 1160a, 1160b. The portions 1160 may protrude from the body 1120 at the second end 1124 in a radial direction relative the axis, L1. In some embodiments, each of the portions 1160a, 1160b may further include an aperture 1162a, 1162b extending therethrough. The splice device 1104 may receive one or more fasteners, each of the aperture 1162a, 1162b receiving a respective fastener therethrough for mounting the splice device 1104 to a structural member such as a form work (e.g., made of wood) connected to the concrete slab 1108 or concrete slab 1110 during the floor construction process. In some embodiments, the splice device 1104 may include one or more of the portions 1160a, 1160b. In some embodiments, the splice device 1104 may include a first portion 1160a and a second portion 1160b arranged at opposite sides of the body 1120 from each other, the first portion 1160a including a first aperture 1162a and the second portion 1160b including a second aperture 1162b for receiving a respective fastener therethrough.

FIG. 16 is an exposed perspective view of the floor construction 1100, according to various embodiments. As shown in FIG. 16, in floor construction 1100, the floor 1102 may include a first concrete slab 1108 and a second concrete slab 1110. In some embodiments, the concrete slab 1108 may include one or more rebars 1116 and concrete slab 1110 may include one or more rebars 1118. In addition, the concrete slab 1108 and the concrete slab 1110 may be connected to each other by coupling one or more of the plurality of rebar 1116 to one or more of the plurality of rebar 1118 using a respective splice device (e.g., coupler) 1104. In this regard, the splice device 1104 may be utilized to connect one or more of the rebars of a concrete slab such as the rebar 1116 of concrete slab 1108 to one or more of the rebars of another concrete slab such as the rebar 1118.

The concrete slab 1108 includes rebar 1116 and rebar 1116′, and the concrete slab 1110 includes rebar 1118 and rebar 1118′. Splice device 1104 may be utilized to fixedly couple the rebar 1116 to the rebar 1118 and the splice device 1104′ may be utilized to fixedly couple the rebar 1116′ to the rebar 1118′.

In some embodiments, the floor 1102 may include a gap 1112 between concrete slabs 1108 and 1110, which functions as an expansion joint. In some embodiments, the gap 1112 has a dimension of between one inch and four feet. In other embodiments, the gap 1112 has a dimension of between two inches and two feet. In other embodiments, the gap 1112 is greater than four feet.

The splice device 1104, as shown in FIG. 16, is embedded in the concrete slab 1108 with the rebar 1116 fixedly attached (e.g., by threads) to the body 1120 of the splice device 1104 at the bore 1130. As shown, the rebar 1116 is also embedded in the concrete slab 1108. The rebar 1118 is embedded in the concrete slab 1110 and extends longitudinally beyond the face of the slab 1110 and into the splice device 1104.

FIG. 17 shows a prior art configuration a traditional expansion joint 1170 between concrete slabs 1171. The configuration includes traditional double steel frame solution, including double steel beams 1172 and double steel columns 1174 supporting a metal deck 1176. The gap between the two supporting beams is of appropriate width such that the gap between the two concrete slabs is of appropriate width based on known design criteria. This second frame will remain as an element in the building for the life of the building, even though its function was only to prevent damage to building during the early phases of construction before internal temperatures could be stabilized once the building thermal envelope was complete and mechanical equipment functional. Further, it will require an expansion joint cover and require maintenance for the life of the building. In addition, this design on both sides of the expansion joint will require an added lateral restraint system, either a concrete shearwall, steel bracing or a steel movement frame or similar element, doubling the lateral system elements required with no expansion joint. The purpose of these lateral resistance elements is to stabilize the building laterally for wind and seismic loads. Increasing the strength of two existing lateral resistance elements at the ends of a larger building is much more cost effective that adding two additional elements on both sides of the expansion joint. Eliminating the expansion joint is a significant construction cost and reduces maintenance cost over the life of the building.

FIGS. 18A and 18B show embodiments according to the disclosed technology. FIG. 18A shows an initial state also shown in FIGS. 12A and 18B shows the final state also shown in FIG. 12D with the gap width, based on ambient temperatures. As shown, a slab 1108 is the first pour containing device of 1104. The threaded rebar 1116 is connected to device 1108. In FIG. 18A and FIG. 18B, slab 1110 is the second pour containing the rebar 1118. The pours 1108 and 1110 typically are cast on metal deck 1180 and 1182. This is common practice for this type of construction. In some embodiments wood forming material could be used to form the slabs/pours 1108 and 1110. The pour 1110 contains the rebar 1118 which is inserted into cavity in the body of the cavity of device 1104 and held back from the cavity end near the location where the rebar 1116 connects to the device 1104. The gap 1112b between the leading edge of the regard 1118 and the back of the cavity 1128 of the device 1104 is formed to generally match the gap 1112a between the slabs. In some embodiments the slab/pours are reversed or on opposite sides.

FIG. 18B shows embodiments of the completed application of the disclosed technology. Both the device 1104 and the gap 1112a are filled with the fill material (e.g., a grout) 1179. As detailed above, in this final configuration, the pours 1108 and 1110 and mechanically coupled by the rebar 1118 being fixed inside the coupler 1104 by the fill material. A shown, in some embodiments an upper column 1190 may be present, for example, for a multi-story building. As shown, the pours 1108 and 1110 are supported on a steel plate 1184, which is supported by a single steel beam 1186 and column 1188. This is a change from the prior art of FIG. 17 of the double beam and column (i.e., frame) configuration. This reduction from double supports to a single support is enabled by the structural support provided by the coupler 1104 fixed to the rebar 1118 in the final configuration.

FIGS. 19A-19D show prior art for some embodiments of a traditional prior art expansion joint. FIG. 19A shows an expansion joint made of structural concrete framing, using an additional structural concrete frame. As shown, an expansion joint 1200 is disposed between concrete slabs 1202, which are supported by two concrete beams 1204, which in turn are supported by two concrete columns 1206.

FIG. 19B, FIG. 19C, and FIG. 19D is prior art for some embodiments of a traditional expansion joint made of single structural concrete framing. In this embodiment the traditional expansion joint 1300 between concrete slab 1302 and 1304 uses a slide or slip surface (e.g., a bearing pad) 1306 on the bearing of one of the slabs. The concrete slabs are supported by a concrete beam 1308 and concrete column 1310. These embodiments are the traditional structural concrete solutions used with an expansion joint. This embodiment is the traditional double concrete frame solution or the bearing slip surface. The gaps between the supporting beams are of appropriate width such that the gap between the two concrete slabs is of appropriate width based on known design criteria. These constructions will remain as an element in the building for the life of the building, even though its function was only to prevent damage to building during the early phases of construction before internal temperatures could be stabilized once the building thermal envelope was complete and mechanical equipment functional.

Further, it will require an expansion joint cover (not shown) and require maintenance for the life of the building. In addition, this design on either side of the expansion joint will require an added lateral restraint system, either a concrete shearwall, steel bracing or a concrete moment frame, doubling the lateral system elements required with no expansion joint. In addition, this design on both sides of the expansion joint will require an added lateral restraint system, either a concrete shearwall, steel bracing or a concrete moment frame or similar element, doubling the lateral system elements required with no expansion joint. The purpose of these lateral resistance elements is to stabilize the building laterally for wind and seismic loads. Increasing the strength of two existing lateral resistance elements at the ends of a larger building is much more cost effective that adding two additional elements on both sides of the expansion joint. Eliminating the expansion joint is a significant construction cost and reduces maintenance cost over the life of the building.

FIGS. 20A and 20B show embodiments according to the disclosed technology. FIG. 20A shows an initial state also shown in FIGS. 12A and 20B shows the final state also shown in FIG. 12D. As shown, slab 1108 is the first pour containing device 1104. The threaded rebar 1116 is connected to device 1104. In FIG. 20A and FIG. 20B, slab 1110 is the second pour containing the rebar 1252. The pours 1110 and 1108 typically are cast on wood forms or other forming material such as metal. This is common practice for this type of construction. The pour 1110 contains the rebar 1118 which extends out of the pour 1110 and extends into the cavity 1128 in the body of the cavity of device 1104. The end of the rebar 1118 is positioned within the cavity 1128 with a gap 1112b between the end of the rebar and the end of the cavity where the rebar 1116 connects to the device 1104. The gap 1244 is formed typically from the rear of device 1246 and of width as previously described. More descriptions on the technology of the system of device and method were presented previously. In some embodiments the pours are reversed or on opposite sides.

FIG. 20B shows embodiments of the completed application of the described technology. Both the device 1104 and the gap 1112a are filled with the fill material described earlier in this technology. As shown, in some embodiments the upper column 1190 may exist for a multi-story building. As shown, the slabs 1108 and 1110 are supported by a single beam line 1308 without the permanent slip surface and a column line 1310. This is a change from the prior art of FIG. 19A and FIG. 19B of the double beam and column (i.e., frame) or permanent slip surface on the single beams. Embodiments are for FIG. 19C and FIG. 19D and other embodiments cast-in-place horizontal slab and beam construction.

FIG. 21 is prior art for some embodiments of a traditional prior art expansion joint 1400 made of structural concrete framing. FIG. 21 is a two-way concrete flat slab system (i.e., slabs with no beams only columns). As shown, adjacent concrete slabs 1402 are separated by an expansion join 1400. The slabs 1402 are supported by concrete columns 1404. This system of concrete construction requires no beams but may require expansion joints based on known design criteria. These embodiments are the traditional structural concrete solutions, rather than two beam line, there are two column lines used with an expansion joint. This embodiment is the traditional double concrete frame solution. The gap between the two supporting columns is of appropriate width such that the gap between the two concrete slabs is of appropriate width based known design criteria. This second frame (i.e., slab and two column lines) will remain as an element in the building for the life of the building, even though its function was only to prevent damage to building during the early phases of construction before internal temperatures could be stabilized once the building thermal envelope was complete and mechanical equipment functional.

Further, it will require an expansion joint cover (not shown) and require maintenance for the life of the building. In addition, this design on either side of the expansion joint will require an added lateral restraint system, either a concrete shearwall, bracing or a concrete moment frame, doubling the lateral system elements required with no expansion joint. Eliminating the expansion joint is a significant construction cost and reduces maintenance cost over the life of the building.

FIGS. 22A and 22B show embodiments according to the disclosed technology. FIG. 22A shows an initial state and 22B shows the final state. As shown, the 1108 is the first pour containing device 1104. The threaded rebar 1116 is connected to device 1104. The slab 1110 is the second pour containing the rebar 1118. The pours 1108 and 1110 typically are cast on wood forms or other forming material such as metal. This is common practice for this type of construction. The pour 1110 contains the rebar 1118, which extends out of the pour 1110 and into the cavity 1128 of the device 1104. The end of the rebar 1118 is positioned back from the end of the cavity 1128 where the rebar 1116 connects to the device 1104. The gap 1112a is formed typically from the rear of device 1104. More descriptions on the technology of the system of device and method were presented previously. In some embodiments the slab/pours are reversed or on opposite sides.

FIG. 22B shows embodiments of the completed application of the technology. Both the device 1104 and the gap 1112b are filled with the fill material (e.g., grout) described earlier in this technology. In some embodiments, an upper column 1190 may exist for a multi-story building. As shown, the slabs 1108 and 1110 are supported by a single concrete column 1308. This is a change from the prior art of FIG. 21 of the double column line and slab. The single concrete column 1308 is sufficient due to the structural support provided by the coupler 1104 fixed to the rebar 1118 as shown in FIG. 22B.

FIG. 23 is a method 2300 for making a floor construction, according to some embodiments. The method 2300 may include, in some embodiments, a first concrete slab and a second concrete slab that may be connected together using one or more splice devices such as, for example, the system 1100 shown in FIG. 12.

At 2302, the method 2300 includes installing (e.g., attaching or coupling) the splice device onto an end of a first rebar of the first concrete slab, for example, by threading an end of the rebar into the first end of the splice device. In some embodiments, the splice device includes a cylindrical body including a first opening at a first end, a second opening at a second end, an inlet, an outlet, and a cavity within the cylindrical body. In some embodiments, installing the splice device onto the end of the first rebar includes installing the first rebar into a first opening of the splice device.

In some embodiments, the first bore comprises one or more threads formed on an inner surface of the first bore, the one or more threads being configured to engage corresponding threads on the first rebar in response to installing the first rebar into the first bore. In this regard, in some embodiments, installing the splice device onto the end of the first rebar includes threading the first rebar into a first opening of the splice device, the first rebar including threads corresponding to one or more threads formed on an inner surface of a first bore of the first opening. The splice device is shown as splice device 1104 in FIG. 13. The cylindrical body is shown as body 1120, the first opening is shown as opening 1130, the second opening is shown as opening 1132, the inlet is shown as inlet 1134, the outlet is shown as outlet 1136, and the cavity is shown as cavity 1128 in FIG. 13. In addition, the first bore is shown as bore 1146, the threads of the first bore is shown as threads 1148 in FIG. 13.

At 2304, the method 2300 includes positioning a portion of a second rebar of the second concrete slab into the cavity, the second rebar extending through the second opening. In some embodiments, the splice device is configured to receive the portion of the second rebar in the cavity, the second bore permitting the second rebar to extend therethrough into the cavity and towards the first end. held back an appropriate gap to accommodate thermal expansion. The second opening is shown as opening 1132 in FIG. 13.

At 2306, the method 2300 includes forming the first concrete slab, the first concrete slab including the first rebar. In some embodiments, forming the first concrete slab includes pouring a wet concrete material into a frame or mold to form the first concrete slab and positioning the first rebar in the wet concrete material so as to embed the splice device in the first concrete slab.

In some embodiments, the splice device may be arranged adjacent a side of the first concrete slab such that second opening is facing a side of the second concrete slab so as to allow the second rebar to extend therethrough and into the cavity. In some embodiments, the splice device may be embedded in the first concrete slab so that a second end of the splice device that includes the second opening is exposed at the side of the first concrete slab adjacent the second concrete slab. The first concrete slab is shown as concrete slab 1108, the first rebar is shown as rebar 1116, the second concrete slab is shown as concrete slab 110, and the second rebar is shown as rebar 1118 in FIG. 12.

At 2308, the method 2300 includes forming the second concrete slab, the second concrete slab comprising the second rebar. In some embodiments, forming the second concrete slab includes pouring, includes appropriate gap to accommodate thermal expansion, a wet concrete material into a frame or mold to form the second concrete slab and positioning the second rebar in the wet concrete material of the second concrete slab so that a portion of the second rebar extends from the second concrete slab and into the cavity, and held back a gap from the cavity end to accommodate thermal expansion, of the splice device through the second opening.

In some embodiments, forming the second concrete slab includes pouring the second concrete slab so the second end of the splice device is adjacent the second concrete slab. In some embodiments, the second concrete slab is formed adjacent the first concrete slab with an appropriate gap to allow for thermal expansion between the first concrete slab and the second concrete slab. In other embodiments, the splice device may be installed so as to extend between the first concrete slab and the second concrete slab. In some embodiments, step 2306 is performed before step 2304. In some embodiments, steps 2304, 2306, and 2308 are interchangeable.

At 2310, the concrete slabs are allowed to undergo thermal expansion and/or contraction in response to ambient temperature changes. As detailed above, the spice device accommodates both expansion and contraction. During thermal expansion, the gap between the adjacent slabs reduces and the rebar extends further into the cavity in the splice device. During contraction, the gap between the adjacent slabs expands and the rebar retracts further away from the cavity in the splice device. The length of the body of the splice device and the placement of the rebar during the pouring process, ensures that a portion of the rebar extends at all times into the cavity of the splice device, such that at all times the splice device is providing support to the end of the rebar.

At 2312, the method 2300 includes, after forming the first concrete slab and the second concrete slab, filling a fill material into the cavity through one of the inlet and the outlet. The fill material may be used to fill the cavity, and the gap between slabs, while the fill material is in a liquid state. That is, the fill material may be directed into the cavity through the inlet when in the liquid state. In addition, in the liquid state, the fill material may fill the unoccupied space in the cavity. The splice device may be filled with the fill material until excess fill material is observed escaping from the outlet in response to the cavity being full of the fill material.

In some embodiments, when the second rebar is located in the cavity, the fill material fills the space of the cavity and surrounds the second rebar. In some embodiments, the second rebar may further include one or more features formed on its outer surface such as, for example, threads, and the fill material may form around the threads of the second rebar. The fill material is shown as fill material 1140 in FIG. 12D.

In some embodiments, the method 2300 includes, in response to the fill material curing in the cavity, the splice device securely fixes the second rebar in the cavity and couples the first rebar to the second rebar. In some embodiments, the fill material may cure in the cavity after a certain amount of time. In addition, since the fill material fills the space of the cavity and surrounds the second rebar, the second rebar is retained in the cavity by the fill material once the fill material has sufficiently cured to the hardened state. That is, once hardened, the fill material restricts movement of the second rebar relative the splice device in the axial or radial direction. As the splice device is fixedly attached to the first rebar at the first opening, the curing of the fill material in the cavity fixedly attaches the second rebar to the splice device in the cavity, and the splice device thereby fixedly couples the first rebar of the first concrete slab to the second rebar of the second concrete slab. The gap between the slabs is also filled with the fill material and cured.

Applications of the embodiments disclosed herein include all aspects of construction, including, but not limited to, buildings, towers, floating terminals, ocean structures and ships, storage tanks, nuclear containing vessels, bridge piers, bridge ducts, foundation soil anchorages, and virtually all other types of installations where normally reinforced concrete may be acceptable.

Preferred embodiments have been described. Those skilled in the art will appreciate that various modifications and substitutions are possible, without departing from the scope of the invention as claimed and disclosed, including the full scope of equivalents thereof.

The terminology used herein is intended to describe embodiments and is not intended to be limiting. The terms “a,” “an,” and “the” include the plural forms as well, unless clearly indicated otherwise. The terms “comprises” and/or “comprising,” when used in this Specification, specify the presence of the stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, and/or components.

Aspects

In some aspects, the techniques described herein relate to a device including: a body extending along a first longitudinal axis between a first end and a second end, the body including: a first opening, wherein the first opening includes a first bore at the first end, the first bore being configured to receive a first rebar of a first concrete slab; a second opening, wherein the second opening includes a second bore at the second end, the second bore being configured to receive a second rebar, with gap, of a second concrete slab; an inlet, wherein the inlet is at a second longitudinal axis, the second longitudinal axis extending in a first direction substantially perpendicular to the first longitudinal axis; an outlet, wherein the outlet is at a third longitudinal axis, the third longitudinal axis extending in a second direction substantially perpendicular to the first longitudinal axis; and a cavity, wherein the cavity extends along the first longitudinal axis and the cavity is in fluid communication with the first opening, the second opening, the inlet, and the outlet.

In some aspects, the techniques described herein relate to a device, wherein the first bore includes one or more threads on an inner surface, the one or more threads being configured to engage corresponding threads on the first rebar in response to installing the first rebar into the first bore so as to connect the device to the first rebar.

In some aspects, the techniques described herein relate to a device, wherein the device is configured to receive a portion of the second rebar in the cavity, the second bore permitting the second rebar to extend therethrough into the cavity and towards the first end with gap.

In some aspects, the techniques described herein relate to a device, wherein the device is configured to receive a fill material in the cavity through one of the inlet and the outlet, wherein, in response to the fill material curing in the cavity, the fill material and the portion of the second rebar are retained in the cavity and connects the device to the second rebar.

In some aspects, the techniques described herein relate to a device, wherein the second bore includes a slot, the slot having a width that is greater than a height to permit a lateral movement of the second rebar.

In some aspects, the techniques described herein relate to a device, wherein the second bore is rectangular in geometry with arcuate ends.

In some aspects, the techniques described herein relate to a device, wherein the body includes: a first cylindrical portion, wherein the first cylindrical portion includes the inlet and the outlet arranged thereon, a second cylindrical portion, wherein the second cylindrical portion includes the first opening axially extending therethrough with gap, and an end wall, wherein the end wall is at the second end, the end wall including the second opening axially extending therethrough.

In some aspects, the techniques described herein relate to a device, wherein the first bore is a conical bore extending from the first opening having a first diameter to an opening to the cavity having a second diameter, the first diameter being wider than the second diameter.

In some aspects, the techniques described herein relate to a device, wherein the body is made of stainless steel.

In some aspects, the techniques described herein relate to an apparatus for splicing together rebar of concrete slabs, the apparatus including: a splice device including: a cylindrical body including: a first end, a second end, and at least one sidewall; a first bore extending through the cylindrical body at the first end, the first bore including: one or more threads on an inner surface, the one or more threads configured to engage corresponding threads on a first rebar of a first post-tensioned concrete slab in response to installing the first rebar into the first bore; a second bore extending through the cylindrical body at the second end, the second bore including: a slot, the slot configured to permit a portion of a second rebar of a second post-tensioned concrete slab to extend therethrough short of the cavity end; a third bore extending through the at least one sidewall; a fourth bore extending through the at least one sidewall; and a cavity, wherein the cavity is in fluid communication with the first bore, the second bore, the third bore, and the fourth bore.

In some aspects, the techniques described herein relate to an apparatus, wherein the splice device is configured to receive a grout material in the cavity through one of the third bore and the fourth bore; and wherein, in response to the grout material curing in the cavity, the grout material and the portion of the second rebar are retained in the cavity short of the cavity end and connects the splice device to the second rebar.

In some aspects, the techniques described herein relate to an apparatus, wherein the second bore is rectangular in geometry with arcuate ends, the slot having a width that is greater than a height to permit a lateral movement of the second rebar.

In some aspects, the techniques described herein relate to an apparatus, wherein the cylindrical body includes: a first cylindrical portion including: a first sidewall, the first sidewall including the third bore and the fourth bore extending therethrough, a second cylindrical portion including: a second sidewall, wherein the second cylindrical portion includes the first bore axially extending therethrough, and an end wall, wherein the end wall includes the second bore axially extending therethrough.

In some aspects, the techniques described herein relate to an apparatus, wherein the first bore is a conical bore extending from a first opening having a first diameter to an opening to the cavity having a second diameter, the first diameter being wider than the second diameter.

In some aspects, the techniques described herein relate to an apparatus, wherein the splice device is made of stainless steel; wherein the splice device further includes a coating material coating an exterior surface of the splice device to resist corrosion.

In some aspects, the techniques described herein relate to a method for making a concrete construction including a first concrete slab, a second concrete slab, the method including: installing a splice device onto an end of a first rebar for the first concrete slab, wherein the splice device includes a cylindrical body including a first bore at a first end, a second bore at a second end, an inlet, an outlet, and a cavity; positioning a portion of a second rebar of the second concrete slab into the cavity, the second rebar extending through the second bore; forming the first concrete slab, the first concrete slab including the first rebar; forming the second concrete slab, the second concrete slab including the second rebar; after forming the first concrete slab and the second concrete slab, filling a fill material into the cavity through one of the inlet and the outlet; and in response to the fill material curing in the cavity, the splice device securely fixes the second rebar in the cavity and couples the first rebar to the second rebar.

In some aspects, the techniques described herein relate to a method, wherein the first bore includes one or more threads formed on an inner surface of the first bore, the one or more threads being configured to engage corresponding threads on the first rebar in response to installing the first rebar into the first bore.

In some aspects, the techniques described herein relate to a method, wherein the splice device is configured to receive the portion of the second rebar in the cavity including the appropriate gap, the second bore permitting the second rebar to extend therethrough into the cavity and towards the first end.

In some aspects, the techniques described herein relate to a method, wherein forming the first concrete slab further includes: pouring the first concrete slab so the first end of the splice device is embedded in the first concrete slab.

In some aspects, the techniques described herein relate to a method, wherein forming the second concrete slab further includes: pouring the second concrete slab so the second end of the splice device is adjacent the second concrete slab, wherein the second concrete slab is formed adjacent the first concrete slab to minimize a gap between the first concrete slab and the second concrete slab's gap, wherein the second concrete slab is formed adjacent the first concrete slab to appropriately design a gap between the first concrete slab and the second concrete slab.

It is to be understood that the terms “first” and “second” can be interchangeable.

It is to be understood that changes may be made in detail, especially in matters of the construction materials employed and the shape, size, and arrangement of parts without departing from the scope of the present disclosure. This Specification and the embodiments described are examples, with the true scope and spirit of the disclosure being indicated by the claims that follow.