Rock engineering structure support system employing mechanically fastened adjacent mesh assemblies

Abstract

A rock engineering structure support system employing mechanical fastening of adjacent mesh assemblies. A steel based support assembly that can be manufactured without field welding includes a plurality of crimped joints of different sizes and shapes for replacing welding to achieve connections between steel assemblies. Each crimped joint mechanically couples two or three steel members together, such as coupling a perimeter steel member of one steel assembly with a perimeter steel member of an adjacent steel assembly. Each crimped joint includes a body having two or more arcuate recessed surfaces each for receiving one steel member. In a first configuration of the crimped joint, a pair of spaced apart arms extend from the body and define an opening through which a steel member is passed and seated in the recessed surfaces. A deforming force is applied to the two arms to deform the body into a second configuration in which the arms abut or nearly abut at outer tips or ends.

Description

Technical Field

[0001] This specification generally relates to the manufacture of physical structures formed by a substructure or integral structural support system or steel mesh, on which foam, concrete, stucco, shotcrete, or other materials may be applied or installed. These structures or physical structures may include outdoor and indoor set designs (or “rockwork”) suitable for use in amusement park and theme park rides and attractions, or in shopping malls, urban parks, and other environments. More specifically, this specification relates to a structural support system or network for such physical structures, designed to join adjacent mesh assemblies (i.e., segments or mesh panels formed by bent and joined steel reinforcement segments or members (or rods or bars typically formed of metals such as steel) using mechanical fastening instead of welded joints). Background Technology

[0002] Reinforcing bars (or ribs), typically made of steel, are widely used as tensioning devices in building or physical structures to reinforce primary structural materials, such as providing reinforcement in masonry, concrete, and other material structures. Reinforcing bars are used to strengthen the material they are embedded in, which is then in a tensile state. For example, concrete and many other structural materials are very strong under compression but relatively weak under tension; reinforcing bars significantly increase the tensile strength of the structure constructed from them. The most common type of reinforcing bar is made of carbon steel, but other readily available types include stainless steel, which can be used when corrosion resistance is required.

[0003] While reinforced steel systems are extremely useful for providing shaping and strengthening of the substructure, their fabrication and installation can be labor-intensive. For example, theme park and amusement park operators currently construct large-scale architectural structures throughout their parks to replicate physical structures or rockwork, thereby replicating sets and outdoor or indoor environments suitable for rides or attractions. Rockwork is typically fabricated using substructures or support structures formed by networks or systems of reinforced steel components or meshes, each consisting of a steel mesh or multiple intersecting steel members or segments. To provide the unique shape of rocks and structures found in nature, the steel bars can be bent, allowing the mesh to be non-planar. Each reinforced steel component may include a boundary formed by steel members (“boundary reinforcement”) and infill reinforcement members extending between the boundary reinforcement.

[0004] In the fabrication of physical structures, all the reinforcing mesh or rebar assemblies are properly arranged on site and then joined together to form the supporting structure or system of the physical structure, which is then completed by applying one or more layers of material (such as mortar, cementitious mix, concrete, foam, etc.) to the reinforcing mesh assemblies. Currently, the joining of all these reinforcing mesh assemblies is weld-intensive, which can be a labor-intensive process that may involve following multiple environmental and safety regulations, and therefore can significantly increase the overall construction time of the structure or rock engineering. Each mesh or rebar assembly can be large (e.g., one side of a roughly square mesh is 6 to 8 feet), and many weld joints can be used along each side or length of the boundary to join adjacent mesh or rebar assemblies. For example, conventional construction practice might use inter-mesh connections throughout the perimeter of each mesh in a structural support system with weld joints of 2 inches every 6 inches. Since hundreds of mesh or rebar assemblies are used in each manufactured rock engineering or physical structure, this can result in the use of thousands of weld joints to join the mating parts of the rebar together. Summary of the Invention

[0005] The inventors recognized a need for a rebar-based support assembly that can be manufactured with minimal or no on-site welding. To this end, the inventors designed numerous crimp joints (or joining hardware) of different sizes and shapes that can be used in place of welded joints to achieve connections between rebar assemblies (or between mesh panels). Each crimp joint can be used to mechanically join or attach two or three rebar members together, for example, to join the boundary rebar of one mesh panel in a structural support system or network to the boundary rebar of an adjacent mesh panel.

[0006] As an alternative to welding, each crimp joint comprises a body having two or more arcuate recessed surfaces, each for receiving a reinforcing bar. In a first configuration of the crimp joint (or before deformation), a pair of spaced-apart arms (or extensions) extend from the body and define an opening through which a reinforcing bar can be passed and positioned in the recessed surfaces. When two or three reinforcing bars are in the recessed surfaces, a deformation force is applied inward to the outer surfaces of the two arms to deform the body into a second configuration in which the arms abut (or nearly abut) at their outer tips or ends. This movement of the arms can be achieved using a hydraulic crimping machine or similar tool that applies the deformation force; for example, a hydraulic crimping machine or similar tool with a C-head can provide a force of 6 to 12 tons. In the second configuration, the two or three reinforcing bars abut against the recessed surfaces of the body and are generally held in place within the body such that the reinforcing bars are mechanically joined together, thereby restricting movement of the reinforcing bars along or across their longitudinal axes by the deformed crimp joint (or the crimp joint in the second configuration).

[0007] More specifically, a structural support system or network for manufacturing physical structures (e.g., rock engineering for theme parks or other facilities) is provided. The system includes multiple reinforcing steel assemblies. Each reinforcing steel assembly includes a first set of reinforcing steel members extending around an outer boundary and a second set of reinforcing steel members arranged in a crisscross pattern to fill the space within the outer boundary. The system also includes multiple double-reinforcing steel crimp joints interconnecting adjacent pairs of reinforcing steel assemblies. Each double-reinforcing steel crimp joint receives one reinforcing steel member from the first set of reinforcing steel members of each adjacent pair and maintains the two received reinforcing steel members in abutting contact.

[0008] In some embodiments, each double rebar crimp joint includes a body having a pair of recessed surfaces configured to receive two received rebar members and a pair of spaced-apart arms surrounding the two received rebar members. The body is capable of plastic deformation under a deformation force from a first configuration to a second configuration, in which the tips of the spaced-apart arms define openings larger than the outer diameter of each of the two received rebar members to provide access to the pair of recessed surfaces; in the second configuration, the openings are smaller than the outer diameter of each of the two received rebar members. The deformation force can be in the range of 6 to 12 tons (e.g., 10 to 12 tons), and the body is formed of steel. The steel can be carbon steel having a hardness in the range of 60 to 75 HRB, or it can be stainless steel having a hardness of less than about 90 HRB.

[0009] In some embodiments, the system may further include a plurality of reinforcing ribs and a plurality of three-reinforcement crimp joints that mechanically connect the reinforcing ribs to the boundary reinforcements of a set of adjacent pairs of reinforcing assemblies in the plurality of reinforcing assemblies. In this case, each three-reinforcement crimp joint may include a body having three recessed surfaces configured to receive one of the reinforcing ribs and two of the first set of reinforcing ribs, and having a pair of spaced-apart arms surrounding one of the reinforcing ribs and the two reinforcing ribs. The body of the three-reinforcement crimp joint may be plastically deformed under deformation forces from a first form to a second form, in which the tips of the spaced-apart arms define openings larger than the outer diameter of each of the one of the reinforcing ribs and the two reinforcing ribs to provide access to the recessed surfaces; in the second form, the size of the openings is reduced, and the one of the reinforcing ribs and the two reinforcing ribs remain in abutting contact. In some embodiments, the deformation forces are in the range of 6 to 12 tons, and the body is formed of carbon steel with a hardness in the range of 60 to 75 HRB or stainless steel with a hardness less than approximately 90 HRB. Attached Figure Description

[0010] Figure 1A and1B These are front views and partial cross-sectional views showing more details of a rock engineering or physical structure manufactured according to the methods taught in this specification;

[0011] Figure 2 A portion of a structural support system or network is shown, illustrating the use of mechanical joints and reinforcements to interconnect or connect adjacent steel reinforcement assemblies or mesh pairs;

[0012] Figures 3A-3D It is a perspective view, side view and end view of the double rebar crimped joint before deformation or "crimping" (or in the first or undeformed state), and a side view of the double rebar crimped joint during deformation or crimping for connecting or fastening two rebar rods or rebar members together (putting the crimped joint in the second or deformed state).

[0013] Figures 4A-4C These are perspective, side, and end views of the three-reinforcement crimped joint before deformation or "crimping"; and

[0014] Figure 5 A flowchart is shown illustrating the manufacturing process of the physical structure for connecting mesh components using the crimp connector of the present invention. Detailed Implementation

[0015] In short, the following description illustrates a physical structure that can be constructed using an underlying structural support system or network, such as rock engineering for theme parks. The support system or network is made of multiple interconnected or joined steel reinforcement assemblies or plates (also referred to herein as "mesh"), each assembly or plate formed from multiple or multiple segments of steel reinforcement shaped or bent and joined together, thus defining the skeleton of the physical structure when all the steel reinforcement assemblies or plates are interconnected. The physical structure can then be completed by applying one or more layers of material (e.g., plaster, cement, concrete, foam, etc.) to the support system or network.

[0016] Importantly, adjacent reinforcing bar assemblies or plates are connected or physically joined together using mechanical metal fittings instead of welding. In particular, newly designed crimp joints (e.g., double-reinforcing bar crimp joints) are used to join or connect the boundary reinforcing bars of adjacent reinforcing bar assemblies (i.e., the reinforcing bars along the outer perimeter or boundary) instead of numerous welded joints. Furthermore, crimp joints (e.g., triple-reinforcing bar crimp joints) secure the reinforcing bars for reinforcement by connecting two filler reinforcing bars (i.e., reinforcing bars extending between the boundary reinforcing bars of the reinforcing bar assembly or mesh) to another reinforcing bar, replacing welding.

[0017] Figure 1AAn exemplary rockwork (or physical structure) 100 is shown that can be manufactured using the mechanical joining techniques described in this specification. As shown, the rockwork 100 is designed to replicate rocky slopes or cliffs that can be found in nature and may be ideal for the background of theme park rides or attractions. The rockwork 100 is partially formed by an underlying support system or network comprising a plurality of steel reinforcement components or meshes joined together. For example, the system or network may include two adjacent or side-by-side meshes 102 and 104 shown, and the system or network may be covered by a material layer with an outer coating 110 shown to provide the appearance and texture of natural rock (or, in some cases, imaginary rock).

[0018] As discussed in more detail below, two adjacent mesh panels 102 and 104 are mechanically interconnected or joined along a joint 108, at which the boundary reinforcement of each mesh panel 102, 104 abuts against each other. It should be understood that the rockwork 100 may include dozens to hundreds (or more) mesh panels 102, 104 to provide a substructure or network for the material layer; therefore, using mechanically joined metal parts or mesh panels instead of welding offers numerous advantages, including increased safety, reduced labor, and a significant reduction in the time required to manufacture the rockwork 100.

[0019] Figure 1B This is a cross-sectional view of a rock engineering structure, showing details of mesh 104. As shown, mesh 104 comprises multiple pieces or segments of reinforcing bars 105 arranged in a crisscross pattern to form a reinforcing mesh. For example, mesh 104 can be large, such as having side lengths of 5 to 8 feet, with 7-foot side lengths used in some embodiments of rock engineering 100, and filler bars are provided at a 6-inch offset in each direction (vertical and horizontal) extending between the outer boundary bars. The reinforcing bars 105 can be physically interconnected, for example by welding at intersections, and can be individually bent to give mesh 104 the desired shape (e.g., mesh 104 is not typically as...). Figure 1B (See planar shape shown). Metal strips 107 can be attached to the back or inside of the reinforcing bars 105 to complete the mesh 104. To fabricate the rockwork 100, an outer layer material or sculpted outer coating 110 can be applied to the mesh 104, for example, to an initial layer or base coat 111 that serves as a base or connecting layer for the reinforcing bars 105. These two layers can be formed from the same or different materials, such as different mixtures of plaster, cement, concrete, foam, shotcrete, etc., and the sculpted outer coating 110 can be sculpted or otherwise treated (e.g., sprayed with one or more layers of paint) to provide the desired external shape, texture, and appearance of the rockwork 100.

[0020] In short, the creation of new joining metal parts or "press joints" is to facilitate or support the joining of non-planar structures (e.g., Figure 1A Mesh panels 102 and 104 are joined together without welding. In particular, using crimp joints instead of welded joints simplifies the process of connecting mesh panels in support systems or networks used in rock engineering, and this can be easily extended to other structures utilizing reinforcing steel. For this purpose, custom-designed crimp joints, which can be made of carbon steel, stainless steel, or galvanized steel, are used to fasten two boundary reinforcing bars together, eliminating the need for welding. As the two boundary reinforcing bars are received in the crimp joint, a deformation or deformation force is applied to the arms of the crimp joint to deform it through plastic deformation, thereby keeping the two reinforcing bars in abutting contact. The deformation force can be applied using hand tools, such as a crimping gun, or a standard hydraulic crimping machine capable of providing deformation forces in the range of 6 to 12 tons (e.g., the BURNDY® Patriot C-head battery crimping machine, which can be both freestanding and hydraulic). After the crimp joint transforms from a first form for receiving reinforcing bars to a second form in which the reinforcing bars are closed and mated together, the crimp joint restricts or even prevents lateral and longitudinal (or sliding) movement of the reinforcing bars (e.g., a single crimp joint can provide the joint strength of one to three or more welded joints, which are typically arranged along the seam / joint between two adjacent meshes at 2-inch welded joints every 6 inches of length).

[0021] Figure 2 A portion of a structural support system or network (“Support System” 200) is shown, illustrating the use of mechanical joining and reinforcement to interconnect or join adjacent reinforcing bar assemblies or mesh pairs. Specifically, the Support System 200 shown includes at least three mesh panels 210, 220, and 230 physically joined or joined together using the novel crimp joint design described herein. Each mesh panel 210, 220, and 230 includes reinforcing bars around its periphery or edge to define its outer side or boundary, and these reinforcing bars are shown as boundary bars 212, 222, and 232, respectively. The boundary bars 212, 222, and 232 can be stronger reinforcing bars, such as #2 to #4 bars; in some embodiments of the Support System 200, #3 bars (i.e., reinforcing bar bars with an outer diameter of 0.375 inches (OD)) are used. Although smooth reinforcing bars are shown in the figure, it should be understood that conventional deformed outer surface reinforcing bars can be used. The reinforcing bars can be formed from steel, as known in the art, selected not only based on strength but also on corrosion resistance, such as treated carbon steel, stainless steel, etc.

[0022] Extending between the boundary reinforcement bars 212, 222, and 232 are additional reinforcement bars, which may be the same as the boundary reinforcement bars 212, 222, and 232, or may be smaller diameter bars, such as #2 or #3 bars (or even smaller diameter bars), and these bars are shown as intersecting and offset filler bars 214, 224, and 234 (which may be offset by various distances, such as in the range of 4 to 10 inches, with a 6-inch offset used in some embodiments of the support system 200). The boundary reinforcement bars 212, 222, and 232 may be joined by welding at the corners of each mesh 210, 220, and 230 to join the filler bars 214, 224, and 234 to each other and to the boundary reinforcement bars 212, 222, and 232. A metal mesh or plate 216 may be applied to the reinforcement bars on the back or inside of the mesh 210, 220, and 230.

[0023] Instead of welding, use multiple crimp joints to join mesh panels 210, 220, and 230 together, for example, by placing a crimp joint every 12 to 24 inches along the seam between adjacent mesh pairs (in contrast to methods such as placing more welded joints every 6 inches). Figure 2 The mechanical connection of the mesh panels is illustrated, wherein the mating boundary reinforcements 212 and 222 of mesh panels 210 and 220 are joined or held together by crimp joints 236 in an abutting contact manner. Similarly, adjacent mesh panels 210 and 230 are partially joined together by crimp joints 236 that mate with boundary reinforcements 212 and 232. As discussed in more detail below, the crimp joints 236 may take the form of double-reinforcement crimp joints, which are configured to join two reinforcement members that generally have the same outer diameter together. After the two reinforcements 212, 222 or 212, 232 are received in the body of the crimp joint within the recessed surface, each crimp joint 236 is deformed by plastic deformation such that an arm extending from the body of the crimp joint extends at least partially around each reinforcement 212, 222 or 212, 232, so that the reinforcements 212, 222 or 212, 232 remain in abutting contact. In some cases, the plastic deformation is provided using hand tools such as hydraulic crimping machines or crimping guns (or other tools available for field work).

[0024] In addition, steel reinforcements (or "stiffeners" or "crossbars") can be provided in the support system 200 at one or more joints or seams between two adjacent mesh panels. This is in Figure 2As shown, reinforcing bars 240 are connected to the abutting boundary bars 212 and 232 of meshes 210 and 230 via crimp joints 246. Therefore, crimp joint 246 differs from crimp joint 236 in that it is configured to join three bars together, or a three-bar crimp joint, which will be described in detail below. Reinforcing bars 240 may have the same outer diameter as boundary bars 212 and 232 (e.g., both could be #3 bars), or their outer diameters may differ (e.g., larger or smaller than the boundary bars), and crimp joint 246 is selected to accommodate the outer diameters of these three reinforcing bars (i.e., boundary bars 212, 232, and reinforcing bar 240) (e.g., having a recessed surface suitable in size and shape for receiving three bars with their respective outer diameters).

[0025] Support system 200 can be used to illustrate typical joints performed in the field (e.g., in a site as part of a rock engineering structure) using one or more crimp designs. While not limiting, it should be noted that the inventors have designed crimp joints to handle the following joint scenarios: (a) joints between boundary reinforcements (e.g., #3 reinforcement to #3 reinforcement) using double-reinforcement crimp joints with recessed surfaces configured for matching outer diameters; (b) joints between transverse reinforcements and two boundary reinforcements (e.g., #3 reinforcement to #3 reinforcement and #3 reinforcement) using triple-reinforcement crimp joints with matching or different outer diameters; (c) joints between filler reinforcements and transverse reinforcements (e.g., #2 filler reinforcement to #3 reinforcement) using double-reinforcement crimp joints with recessed surfaces configured for different outer diameters; and (d) joints of three reinforcements (e.g., #2 filler reinforcement, #3 additional reinforcement, and #3 transverse reinforcement) using triple-reinforcement crimp joints with at least two different outer diameters.

[0026] Figures 3A-3D These are perspective, side, and end views of a double-reinforcing bar crimped joint before deformation or "crimping" to join or fasten the two reinforcing bar rods or members together, and a side view of the double-reinforcing bar crimped joint during deformation or crimping. More specifically, Figures 3A-3D A double-reinforcing bar crimp joint is shown for joining two reinforcing bar rods or members arranged to extend in parallel and abut against each other. The crimp joint 300 includes a body 312 from which two spaced-apart arms or extension members (“arms” 320, 322) extend. A pair of side-by-side recessed surfaces 314, 316 are disposed within the body 312 and partially surrounded by the arms 320, 322, which extend away from the body 312 to outer edges or tips 321, 323.

[0027] The body 312 and arms 320, 322 can be made of a metal selected based on strength and the ability to plastically deform without breaking, and their dimensions can be determined accordingly. For example, the metal can be carbon steel, which can be treated to provide corrosion resistance (e.g., electroplating or galvanizing) and / or a specific hardness. It has been determined through testing that it is desirable to use steel with a hardness within the range that allows the crimped joint 300 to deform under deformation forces in the range of 6 to 12 tons (e.g., deformation forces applied by a hydraulic crimping machine of 10 to 12 tons in some preferred embodiments). In some cases, carbon steel (e.g., 1018 steel) is used, which has been annealed or otherwise treated to reduce its hardness to below 75 HRB, for example, in the range of 60 to about 75 HRB, where the range of about 68 to about 71 HRB has proven useful in prototypes. In other cases, stainless steel (SS) can be used to provide the desired strength and hardness (deformability) properties, such as 304 SS, etc.

[0028] The body 312 may have a width W selected to provide sufficient strength and contact (constraint) area between the crimped body 312 and the receiving reinforcing bar. C For example, the range is 0.25 to 0.5 inches, and in some cases 0.375 inches. Similarly, the height H of the body 312... C Arms 320, 322, chosen to be long enough to wrap around and at least partially surround the received rebar when crimped onto it, are, for example, in the range of 0.5 to 1.5 inches, with approximately 0.75 inches used in some crimp joints 300. Recessed surfaces 314, 316 may have matching or different inner diameters prior to crimping to fully receive and mate (butt contact) the rebar. Therefore, for each surface 314, 316, the inner diameter R... I You can choose an inner diameter R that is slightly larger than the outer diameter OD of the rebar. For example, for a rebar bar with an outer diameter of 0.25 inches (or a #2 rebar), the inner diameter R... I It can be approximately 0.26 to 0.29 inches, for a 0.375-inch outer diameter rebar (or #3 rebar), with an inner diameter R. I It can be approximately 0.377 to 0.382 inches, etc. Choose the outer diameter R of arm 320 or 322. O To provide a deformable steel arm thickness, which, after plastic deformation, will have sufficient strength to maintain the received reinforcing bar thickness, for example, in the range of 0.3 to approximately 0.5 inches, in one embodiment utilizing 1018 steel annealed to 68 to 71 HRB (e.g., 69 HRB ± 1 HRB), the outer diameter R O For approximately 0.37 inches, select a hardness to ensure that the crimping machine (e.g., a 12-ton crimping machine) can press the material of the crimp joint 300 tightly onto the receiving rebar rod / rebar piece.

[0029] Figure 3D A crimp joint 300 for joining reinforcing bars (“boundary bars” 340, 342) is shown. As shown, the boundary bars 340, 342 have the same outer diameter, but the other crimp joints are configured for two different outer diameters. Each boundary bar 340 and 342 is received within the internal space of the body 312 to abut against the recessed surface 314 or 316, and the bars 340, 342 are parallel to each other. A deformation force F is applied to the outer surface of the arms 320, 322. D (For example, using a hydraulic crimping machine that provides a force of up to approximately 12 tons), the arms are moved together or crimped together. This causes the tips 321 and 323 of the arms 320 and 322 to contact each other or be spaced apart by a distance smaller than the outer diameter of the reinforcing bars 340 and 342. Furthermore, by applying a deformation force F... D The provided deformation forces the two reinforcing bars 340 and 342 into abutting contact within the main body 312, and then maintains this abutting contact. This abutting contact is achieved and the crimped joint 300 transitions from its first form (e.g., ...). Figures 3A-3C As shown) it transforms into the second form (as shown) Figure 3D When (as shown), the deformation force F can be removed. D The crimp joint 300 will mechanically hold the two reinforcing bars 340 and 342 together.

[0030] Figures 4A-4C Another embodiment of the crimp joint 400 in its first or non-deformed form is shown. The crimp joint 400 is a three-reinforcement crimp joint configured to join three reinforcing bars or members together. In the example shown, the crimp joint 400 is configured to receive and engage three reinforcing bars or members having the same outer diameter (e.g., three #2 or #3 reinforcing bars), but other embodiments are configured to have a recessed surface suitable for receiving two or three reinforcing bars / bars with different outer diameters. More specifically, Figures 4A-4C A three-bar crimp joint is shown for joining three reinforcing bars or reinforcing members arranged to extend in parallel and abut against each other. The crimp joint 400 includes a body 412 from which two spaced-apart arms or extension members (“arms” 420, 422) extend. Three side-by-side recessed surfaces 414, 416, and 418 are disposed within the body 412 and partially surrounded by the arms 420, 422, which extend away from the body 412 to outer edges or tips 421, 423.

[0031] The body 412 and arms 420, 422 can be made of a metal selected based on its strength and ability to plastically deform without breaking, and their dimensions can be determined accordingly. For example, the metal can be stainless steel (SS) with a specific hardness, such as 90 HRB or less. It has been determined through testing that it is desirable to use stainless steel with a hardness within the range that allows the crimp joint 400 to deform under deformation forces in the range of 6 to 12 tons (e.g., applied by a 10 to 12-ton hydraulic crimper, with a 12-ton crimper used in some preferred embodiments), such as 304 stainless steel or other types of stainless steel. In other cases, carbon steel can be used as discussed with respect to crimp joint 300.

[0032] The body 412 may have a width W selected to provide sufficient strength and contact (constraint) area between the crimped body 412 and the receiving reinforcing bar. C For example, the range is 0.25 to 0.5 inches, and in some cases 0.375 inches. Similarly, the height H of the body 412... C Arms 420, 422, chosen to be long enough to wrap around and at least partially surround the received rebar when crimped onto it, are, for example, in the range of 0.5 to 1.5 inches, with approximately 1.0 inch used in some crimp joints 400. Recessed surfaces 414, 416, and 418 may have matching or different inner diameters prior to crimping to fully receive and mate (butt contact) the rebar. Therefore, for each surface 414, 416, and 418, the inner diameter R... I and R 中心 (R I For surfaces 416 and 418, the inner diameter can be slightly larger than the outer diameter of the rebar. For example, for a rebar bar with an outer diameter of 0.25 inches (or a #2 rebar), the inner diameter R... I and R 中心 It can be approximately 0.26 to 0.29 inches, for a 0.375-inch outer diameter rebar (or #3 rebar), with an inner diameter R. I and R 中心 It can be approximately 0.377 to 0.382 inches, etc. Choose the outer diameter R of arm 420 or 422. O This is to provide a deformable and sufficiently strong reinforcement bar after plastic deformation to maintain its arm thickness, for example, in the range of 0.3 to approximately 0.5 inches. In one embodiment utilizing 304 SS (e.g., 1 inch × 0.5 inch bars), the outer diameter R... O It is approximately 0.37 inches. Like Figure 3DSimilar to the crimp joint 300 shown, the crimp joint 400 receives three reinforcing bars in the body 412 within surfaces 414, 416, and 418 and then deforms by applying a deformation force to the outer surfaces of arms 420 and 422 until all three reinforcing bars abut in contact and the tips 421 and 423 of the arms form contact or near contact (e.g., the spacing between them is less than the minimum outer diameter of the three received reinforcing bar rods / reinforcing bars).

[0033] Figure 5 A flowchart of a physical structure fabrication process 500 using the crimp joints of the present invention for connecting mesh panels (or rebar assemblies) is shown. Method 500 begins at step 505, in which the construction of a physical structure, such as a rock engineering project, begins for a specific construction site (e.g., a theme park attraction). Step 505 may include designing the external shape, texture, and appearance and feel of the physical structure. Method 500 proceeds to step 510, in which a support system for the physical structure is designed, including dividing the support system into multiple rebar plates / assemblies or mesh panels. Step 510 also includes fabricating each mesh panel for the support system, each mesh panel typically comprising a perimeter or outer edge formed by boundary rebar (e.g., #3 rebar arranged generally in a rectangular or square pattern) and an inner mesh formed by multiple intersecting filler rebars (e.g., #2 rebar extending vertically and horizontally at 6 inches or other offsets). The filler rebars and / or boundary rebars may be bent before assembly into mesh panels to provide a desired non-planar shape suitable for a specific section of the rock engineering or physical structure (e.g., each mesh panel may be planar or non-planar).

[0034] Method 500 proceeds to step 520, in which the mesh is placed in an appropriate location on the construction site (e.g., a predetermined location in the support system being constructed). Then, in step 530, the arranged mesh is connected to any adjacent mesh using crimp joints as described herein. This may involve using multiple double-reinforcement crimp joints to connect the boundary reinforcement of adjacent meshes along joints or joints (e.g., one crimp joint every 12 to 24 inches along the length of the joint / joint). Step 530 may involve placing the crimp joint simultaneously on two boundary reinforcements such that both reinforcements are received within the recessed surface of the double-reinforcement crimp joint, and then applying a deformation force (e.g., using a hydraulic crimping machine) to deform the double-reinforcement crimp joint and connect the two parallel boundary reinforcements together in an abutting contact manner within the body of the double-reinforcement crimp joint. Step 530 may also involve applying transverse reinforcement or stiffeners along the mesh joints / slits. This may involve arranging the transverse reinforcements parallel to the two boundary reinforcements and placing the three-reinforcement crimp joints on the three reinforcement members such that they are received within the recessed surface of the three-reinforcement crimp joints. A deformation force (also typically using a crimping tool) is then applied to deform the arms of the three-reinforcement crimp joints, thereby forcing the three reinforcements into contact within the body of the crimp joint.

[0035] Method 500 proceeds to step 540, in which it is determined whether there are additional mesh panels to be installed or connected within the support system. If so, method 500 continues, repeating steps 520 and 530. In some embodiments, step 520 is repeated before repeating steps 530 and 540, until all mesh panels or a subset of all mesh panels are in place, and until the connection between all mesh panels is completed. When all mesh panels are in place, connected together and reinforced using the crimp joints of the present invention, method 500 proceeds to step 550. In step 550, the rock engineering or physical structure is completed by applying and finishing one or more layers of outer material to the mesh support system. This may involve applying plaster or a similar material to the reinforcing mesh, and then carving and finishing the outer surface of the applied layer (e.g., painting). When the outer layer is completed, method 500 may end at step 590.

[0036] While there are certain specificities in the description and illustrations of this invention, it should be understood that the disclosure of this invention is given by way of example, and those skilled in the art can make various changes to the combination and arrangement of the various parts without departing from the spirit and scope of the invention as defined by the appended claims.

[0037] For example, exemplary figures illustrate crimp joints for attachment between reinforcing bars; however, those skilled in the art will understand, based on the teachings provided herein, that such crimp joints can be adapted for other uses. In particular, in some cases, the crimp joints can be used to attach optical fibers to reinforcing bars, and other uses of the crimp joints can be mounting speakers to reinforcing bars. A crimp connection from a lightning rod to a reinforcing bar can also be used to attach a lightning rod to the mesh shown herein. An element can be attached to one or more of the meshes by placing a portion of another element (e.g., virtually any non-structural component) within a crimp joint with one or two reinforcing bars.

Claims

1. A support system for manufacturing physical structures, comprising: Multiple steel reinforcement assemblies, wherein each steel reinforcement assembly includes a first set of steel reinforcement members extending around an outer boundary and a second set of steel reinforcement members arranged in a crisscross pattern to fill the space within the outer boundary; as well as Multiple double-reinforcement crimp joints interconnect adjacent pairs of the plurality of reinforcement assemblies, wherein each double-reinforcement crimp joint receives one reinforcement member from the first set of reinforcement members of each adjacent pair of reinforcement assemblies and maintains the two received reinforcement members in abutting contact. Each double-reinforcing bar crimp joint includes a body having a pair of recessed surfaces configured to receive the two received reinforcing bars, and a pair of spaced-apart arms surrounding the two received reinforcing bars. The main body is capable of plastic deformation from a first form to a second form under the action of a deformation force. In the first form, the tips of the spaced-out arms define an opening larger than the outer diameter of each of the two received reinforcing bars to provide an entrance to the pair of recessed surfaces. In the second form, the opening is smaller than the outer diameter of each of the two received reinforcing bars.

2. The support system of claim 1, wherein the deformation force is in the range of 58.8 KN to 118 KN, and the main body is formed of steel.

3. The support system of claim 2, wherein the steel is carbon steel having a hardness in the range of 60 to 75 HRB.

4. The support system of claim 2, wherein the steel is stainless steel having a hardness of less than 90 HRB.

5. The support system of claim 1 further includes a plurality of reinforcing ribs and a plurality of three-reinforcing bar crimp joints, the three-reinforcing bar crimp joints mechanically connecting the reinforcing ribs to a first set of reinforcing bar members of an adjacent pair of the plurality of reinforcing bar assemblies.

6. The support system of claim 5, wherein each three-reinforcement crimp joint includes a body having three recessed surfaces configured to receive two of two reinforcement members from an adjacent pair of one of the reinforcing bars and a plurality of reinforcement assemblies, and having a pair of spaced-apart arms surrounding one of the reinforcing bars and the two reinforcement members.

7. The support system of claim 6, wherein the body of the three-reinforcement crimp joint is capable of plastic deformation from a first form to a second form under the action of a second deformation force, wherein in the first form, the tips of the spaced-apart arms define an opening larger than the outer diameter of one of the reinforcing ribs and each of the two reinforcing bars to provide an entrance to the recessed surface, and in the second form, the size of the opening is reduced, and one of the reinforcing ribs and the two reinforcing bars remain in abutting contact.

8. The support system of claim 7, wherein the second deformation force is in the range of 58.8 KN to 118 KN, and the body is formed of carbon steel with a hardness in the range of 60 to 75 HRB or stainless steel with a hardness of less than 90 HRB.

9. A method for manufacturing a support structure for a physical structure, comprising: Place the first reinforcing steel plate at the first predetermined position on the supporting structure; The second reinforcing plate is placed at a second predetermined position in the supporting structure, wherein each of the first and second reinforcing plates includes a first set of reinforcing bars extending around an outer boundary and a second set of reinforcing bars arranged in a crisscross pattern to fill the space within the outer boundary; and wherein a pair of first set reinforcing bars from the first and second reinforcing plate assemblies are adjacent and parallel; and The pair of first-set steel bars are physically joined together by placing a crimp joint on the crimp joint and applying a deformation force to the crimp joint to plastically deform the crimp joint from a first form to a second form. Each crimp connector includes a body having a pair of recessed surfaces configured to receive the pair of first set of reinforcing bars and a pair of spaced-apart arms surrounding the received pair of first set of reinforcing bars, wherein, in a first configuration, the tips of the spaced-apart arms define openings larger than the outer diameter of each of the pair of first set of reinforcing bars to provide access to the pair of recessed surfaces, while in a second configuration, the openings are smaller than the outer diameter of each of the pair of first set of reinforcing bars.

10. The method of claim 9, wherein the deformation force is in the range of 58.8 kN to 118 kN.

11. The method of claim 10, wherein the body is formed of carbon steel with a hardness in the range of 60 to 75 HRB or stainless steel with a hardness less than 90 HRB.

12. The method of claim 9, wherein the support structure further includes reinforcing ribs, the method further includes connecting the reinforcing ribs, and the method further includes connecting the reinforcing ribs to the pair of first-group steel members by arranging three-reinforcement crimp joints on the pair of first-group steel members and the reinforcing ribs and applying a deformation force to the three-reinforcement crimp joints to plastically deform the three-reinforcement crimp joints from a first form to a second form.

13. The method of claim 12, wherein the three-reinforcement crimp joint comprises a body having three recessed surfaces configured to receive one of the reinforcing bars and a pair of reinforcing bars from the first set of reinforcing bars, and having a pair of spaced-apart arms surrounding the reinforcing bar and the pair of reinforcing bars from the first set of reinforcing bars.

14. A crimp joint for mechanically joining reinforcing bars in a support system of a physical structure, comprising: A body having at least two recessed surfaces, each recessed surface configured to receive a reinforcing bar; as well as A pair of spaced-apart arms surrounding the interior space of the body, which includes the at least two recessed surfaces. The main body is capable of being reconfigured from a first form to a second form through plastic deformation under the action of deformation force. In the first form, the tips of the spaced-out arms define an opening to the internal space that is larger than the outer diameter of each reinforcing bar to provide an entrance to the at least two recessed surfaces. In the second form, the opening is smaller than the outer diameter of each reinforcing bar.

15. The crimp joint of claim 14, wherein the deformation force is in the range of 58.8 KN to 118 KN, and the body is formed of steel.

16. The crimp joint of claim 15, wherein the steel is carbon steel having a hardness in the range of 60 to 75 HRB, or wherein the steel is stainless steel having a hardness of less than 90 HRB.

17. The crimp connector of claim 15, wherein the body has a width of at least 0.25 inches and each arm has a thickness of at least 0.1 inches.

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