Method of Making an Apparatus for Forming Concrete

Abstract

An apparatus for forming concrete includes a form having a slot configured to closely receive a plate. The slot is defined by one or more annular surfaces having central axes perpendicular to a direction in which the slot receives the plate. A method for forming same includes providing a sheet of form material; disposing a release layer on the sheet; cutting the sheet into a plurality of forms having a predetermined form height; and cutting a slot in each of each of the plurality of forms. Another apparatus for forming concrete includes a plate having a first portion and a second portion. A coating is disposed on the first portion. When disposed in a joint defined by a first volume of concrete and a second volume of concrete, the first volume of concrete adheres only to the coating and the second volume of concrete adheres only to the second portion. A method for forming concrete includes providing a plate having a coated first portion and a second portion; providing a form having a slot configured to closely receive the second portion; inserting the second portion in the slot; positioning the form to receive concrete; pouring a volume of concrete on the form and the first portion; curing the volume of concrete and defining cured concrete; and removing the form from the cured concrete. The plate remains in the cured concrete.

Description

REFERENCE TO EARLIER APPLICATION [0001] This Application is a divisional application of U.S. patent application Ser. No. 11 / 077,557, filed Mar. 11, 2005, for Method of Forming Concrete and an Apparatus for Transferring Loads Between Concrete Slabs, which claims the benefit of and is a continuation-in-part of U.S. Provisional Patent Application Ser. No. 60 / 650,954, filed Feb. 9, 2005, for Method of Forming Concrete and an Apparatus for Same by Stephen F. McDonald.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 concrete. The forms have horizontal top surfaces, which typically are level with the surface of the poured concrete, or, once cured, pavement surface. The forms have back surfaces that rest against appropriately-spaced stakes for holding the forms in place. To provide clearance for finish troweling, c...

AI Technical Summary

Benefits of technology

"The invention provides a method and apparatus for forming concrete using partially coated load plates carried in slotted, stiff, infinitely long, pre-chamferred forms with predetermined true height. The invention also includes a form having a slot defined by one or more annular surfaces having central axes perpendicular to a direction in which the slot receives the plate. Additionally, the invention includes a plate having a coated first portion and a second portion, and a form having a slot configured to closely receive the second portion. The invention improves the process of forming concrete by providing a more efficient and cost-effective method."

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.

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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