Apparatus for and method of forming concrete and transferring loads between concrete slabs

Abstract

An embodiment configured according to principles of the invention of an apparatus for transferring a load between a first concrete slab and a second concrete slab, defining a joint, includes a plate configured to transfer a load between concrete slabs, a form having a slot configured to closely receive a first portion of the plate prior to pouring concrete thereon, and a sheath configured to receive a second portion of the plate. An embodiment configured according to principles of the invention of a method of forming concrete includes providing a plate configured to transfer a load between concrete slabs; providing a form having a slot configured to closely receive a first portion of the plate; positioning the form to receive concrete; inserting the first portion in the slot wherein a second portion of the plate is exposed; pouring a first volume of concrete on the form and the second portion; curing the first volume of concrete and defining a first slab; removing the form from the first slab and exposing the first portion; and disposing a sheath on the first portion. An embodiment configured according to principles of the invention of a method of forming concrete includes providing a plate configured to transfer a load between concrete slabs; providing a form having a slot configured to closely receive a first portion of the plate; positioning the form to receive concrete; inserting the first portion in the slot wherein a second portion of the plate is exposed; disposing a sheath on the second portion; pouring a first volume of concrete on the form and the sheath; and curing the first volume of concrete and defining a first slab. An embodiment configured according to principles of the invention of a method of forming concrete includes providing a form configured to secure a sheath thereto, thereby orienting an exterior of the sheath for contacting concrete when poured thereon; positioning the form to receive concrete; securing the sheath to the form; pouring a first volume of concrete on the form and the exterior; and curing the first volume of concrete and defining a first slab.

Description

REFERENCE TO EARLIER APPLICATIONS [0001] This Application claims the benefit of U.S. Provisional Patent Application Ser. No. 60 / 650,954, filed Feb. 9, 2005, and incorporates by reference and is a continuation-in-part of: U.S. Utility patent application Ser. No. 11 / 077,557, filed Mar. 11, 2005, by Stephen F. McDonald for Method of Forming Concrete and an Apparatus for Same; U.S. Utility patent application Ser. No. 11 / 109,781, filed Apr. 20, 2005, by Michael E. Carroll for Method of Forming Concrete and an Apparatus for Transferring Loads Between Concrete Slabs; and U.S. Utility patent application Ser. No. 11 / 229,978, filed Sep. 19, 2005, by Richard D. Jordan et al. for Apparatus for and Method of Forming Concrete and Transferring Loads Between Concrete Slabs.BACKGROUND OF THE INVENTION [0002] Conventional concrete pavement installation involves preparing then positioning forms around an area intended for pavement. The forms have vertical inner surfaces to receive and contain poured c...

AI Technical Summary

Benefits of technology

"The invention provides a method and apparatus for forming concrete that overcomes disadvantages of previous methods. The apparatus includes a plate for transferring loads between concrete slabs, a form with a slot for receiving the plate, and a sheath for protecting the plate during curing. The method involves positioning the form to receive concrete, inserting the plate into the slot, pouring concrete on the form and the plate, curing the concrete, and disposing a sheath on the plate or form. The invention offers improved elements and arrangements that are cost-effective and reliable."

Problems solved by technology

Very large pavements require substantial form preparation and positioning.

Regardless of whether the forms are long or short, field chamferring requires considerable time for large pavement areas.

Unfortunately, forms in the field typically have a height that is less than a true height for an appropriate slab thickness.

These forms of inadequate height typically may be positioned so that the top surfaces are at an appropriate height relative to the desired pavement surface height, but present bottom surfaces that do not contact, thus admit gaps through which poured concrete leaks.

This wastes concrete and requires additional work to remove the excess portions.

Concrete leakage from the forms, especially at the butt joints, leaves depressions in a finished slab surface causing poor aesthetics.

The depressions also impair surface coverings, such as tile, because the uneven surface promotes uneven or incomplete covering layout and adhesion.

Cured leaked concrete also impinges on adjacent slabs causing voids and / or increasing the chances of obtaining a locked construction, which leads to cracks and joint failures.

Finally, removing the cured excess typically damages the slab from which the excess is chiseled.

Unfortunately, none of the foregoing provides a method of forming concrete and an apparatus for same that includes stiff, infinitely long, pre-chamferred forms with predetermined true height.

As the concrete of the slab cures, forces derived from the exothermal curing reactions cause generally vertical cracks to develop through the slab thickness at the reduced cross-sections below each groove.

Aggregate interlock causes wear among slab intersections with increasing use of the pavement.

Additionally, cyclical and extreme temperature changes decrease slab volumes.

Thus, over time, as traffic continuously passes over a joint, the intersections wear and become smooth, then fail altogether, resulting in relative vertical displacement of adjacent slab sections, hence a rough pavement surface.

Joint failure also becomes increasingly susceptible to water intrusion, which may freeze and cause damage among adjacent slabs.

Among other problems, the foregoing techniques involve significant time and labor to produce and place the dowels.

Drawbacks of the foregoing include the cost and labor associated with producing separate mounting and load plates, then assembling same following curing of a first concrete slab.

Such restraint of movement in directions other than parallel to the longitudinal axes of dowels 1200 could result in slab failure in the form of cracking.

Unfortunately, none of the foregoing provide a method of forming concrete and an apparatus for same that includes partially coated load plates carried in slotted forms.

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