Modular steel concrete reinforcement system
a concrete reinforcement and modular technology, applied in the field of concrete reinforcement steel construction, can solve the problems of increasing the steps and thus costs in the overall construction process, increasing costs, and all these processes are costly, and achieve the effect of maintaining the ductility of rebar panels and facilitating intersections
Inactive Publication Date: 2005-12-22
VITTONE DOMENIC
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Benefits of technology
"The present invention is a system and method for creating weld-stabilized rebar panels using a special gas metal arc welding process. The system includes a rebar shear, bender, welding jig, rebar welder, power source, and rolling tables to move the rebar from one location to another. The rebar is first cut to length and then bent to required curvature using the rebar bender. It is then aligned in the welding jig and welded using the rebar welder. The system uses specific settings on the welder and power source to create a flare bevel groove weld that meets the grade A706 requirements. The use of shielding gas helps create the fusion between the rebar and consumable electrode of the welder without causing any carbon breakdown in the rebar, which maintains its ductility. The technical effects of this invention include improved stability and strength of reinforced concrete structures, reduced labor costs, and improved efficiency in construction."
Problems solved by technology
All of these processes are costly because they are labor intensive and time consuming.
Further, inherent weaknesses within each method limits the size and shape of panel that can be produced, thereby increasing the steps and thus costs in the overall construction process.
As a result, conventional reinforcement steel bars (rebar) assembly methods require more steps with increased costs, resulting in the construction of structurally compromised rebar panels.
Tie wire constructed rebar panels often structurally fail for several reasons.
Firstly, the connection resulting from the tying process is subject to human inconsistencies.
Thus, structural inconsistencies often exist in panels where more than one person is constructing a panel, or a single person becomes fatigued while doing so.
Even if tied correctly, tied rebar connections severely limit panel size due to wire strength and overall rebar intersection rigidity.
Wire tied panels are often incapable of supporting the panel's weight during their placement, often yielding a displacement of the tied rebar members known as “raking.” As the spacing of the rebar must be made within the tolerances specified by the engineer, the displaced rebar must be retied in its specified location increasing labor costs.
The couplers are more time consuming to use than the wire tie method discussed above.
However, panels constructed with mechanical couplers are very costly with regards to the multiple steps required to assemble them and the price of the couplers themselves.
All prior welding techniques have not achieved metallurgical properties meeting the requirements for reinforced concrete.
Consequently, a rebar panel constructed with welds not having appropriate metallurgical properties is not desirable and may increase the likelihood of a structural failure.
Method used
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[0020] The present invention provides a system and method for construction of weld-stabilized rebar panels. By way of overview and with reference to FIG. 1, the preferred embodiment of the present invention includes a welded rebar manufacturing center 10 including a rebar shear 12 used to cut the rebar to predetermined lengths; a rebar bender 14 used to impart required curvature to the rebar; a welding jig 16 used to align the rebar in the desired rebar panel configuration; a rebar welder 18, preferably a gas metal arc welder (GMAW); a power source 20, such as an 100-185 KW electrical generator (for example, a Lincoln Power Source 400); and one or more rolling tables 22 facilitating the movement of the rebar from the rebar shear to the rebar bender and ultimately to the welding jig. In operation, the rebar starts at rebar shear 12, where the rebar is cut, as necessary, to predetermined lengths. The rebar then travels along rolling table 22a to rebar bender 14, where any required cur...
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Abstract
A method of welding reinforcement steel bars (rebar) and assembly of fusion-welded rebar into panel assemblies that are self-stabilizing to withstand the rigors of transport to and positioning within construction sites. The rebar welding method generates fusion welds in such a manner that the weld imparts stability and strength to the welded rebar assemblies. The rebar welds permit the assembling of larger and more varied rebar panel configurations without the need for tie wire or other coupling devices. Further, the welded panels allow positioning of large rebar configurations, insuring that the spacing of the individual bars exceeds all required tolerances. The self-stabilizing fusion rebar welding process allows a more efficient, flexible and rapid method of rebar panel construction by using assembly systems on mobilized trailers or at stationary locations.
Description
PRIORITY CLAIM [0001] This application is a Continuation of U.S. Application Ser. No. 10 / 624,977 filed Jul. 21, 2003, which application is a Continuation of U.S. Application Ser. No. 08 / 823,037, filed on Mar. 29, 2001, which claims priority to U.S. provisional application Ser. No. 60 / 193,408, entitled Modular Steel Concrete Reinforcement System, filed Mar. 29, 2000. Each and all of the foregoing applications are incorporated by reference as if fully set forth herein.FIELD OF THE INVENTION [0002] This invention relates generally to concrete reinforcing steel construction and, more specifically, to the efficient prefabrication and non-structural welding of rebar panels for use in concrete structures. This invention further relates to the fabrication of welded rebar panels on site as well as off site, thereby reducing the cost associated with time, material and labor. BACKGROUND OF THE INVENTION [0003] Currently, rebar panels are constructed by wire tying, mechanical couplers, and occa...
Claims
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IPC IPC(8): A47J36/02B21F27/10B21F27/12B21F27/20B23K9/00E04C5/01E04C5/04E04C5/06
CPCB21F11/00B21F27/10B21F27/121B21F27/20B23K9/0026E04C5/064B23K2201/22B23K2203/04E04C5/01E04C5/04B23K9/007B23K2101/22B23K2103/04
InventorVITTONE, DOMENIC
OwnerVITTONE DOMENIC