CONNECTION SYSTEM

Description

FIELD OF THE INVENTION

[0001] The invention relates to construction and to a connection system, for example for connecting reinforcement of a floor to a wall prior to pouring concrete of the floor. The invention may also relate to a rebate former for construction. More particularly, but not exclusively, the invention relates to a rebate former for forming a rebate in a concrete component for floor and / or wall connections.BACKGROUND OF THE INVENTION

[0002] It has been previously proposed to provide a connection system including a rebate box for providing a structural connection between concrete components. However, the applicant has identified that existing connection systems may be difficult to use, require a dense population of reinforcement anchorages and yet provide relatively low tensile capacity.

[0003] The applicant has identified that it would be advantageous to provide an improved connection system for providing a structural connection between concrete components, which addresses one or more of the disadvantages of existing connection systems.

[0004] Examples of the invention seek to provide an improved connection system which obviates or at least alleviates one or more disadvantages of existing connection systems, or at least to provide a useful alternative.

[0005] Earlier patent document WO 2014 / 026024 A1 discloses a formwork system for forming a rebate in the face of a core produced by slip form casting. The system comprises a rebate former having a rear part and a forward part to close a hollow interior thereof, and reinforcing bar couplers being engaged with the rear part by a clamping nut. EP 0 121 510 A2 disclosures an anchoring box for concrete reinforcing rods. In order to assemble, use is made of a coupling sleeve that is engaged and fixed in a profile having a trapezoidal crosssection.SUMMARY OF THE INVENTION

[0006] In accordance with one aspect of the present invention there is provided a connection system for providing a construction joint between a first concrete component and a second concrete component, as recited in the appended claims. The connection system includes a rebate former for forming a rebate in a first concrete component, wherein the rebate former is formed of sheet metal, the rebate former including an elongated backing, the elongated backing having folded edges to a predefined depth.

[0007] The connection system includes a plurality of anchors coupled to the elongated backing, each of the anchors having an internal thread for receiving an external thread of a reinforcing bar for reinforcing a second concrete component.

[0008] Preferably, each of the anchors has a foot for providing anchorage in the first concrete component. More preferably, the foot is a tapered foot. Even more preferably, the foot is in the form of a circular tapered foot.

[0009] In a preferred form, each of the anchors has one or more external ribs along a length of the anchor for providing anchorage in the first concrete component. More preferably, each of the external ribs is tapered outwardly toward a free end of the anchor. Even more preferably, each of the anchors is in the form of a threaded insert.

[0010] In a preferred form, the rebate former has folded ends to provide structural rigidity.

[0011] Preferably, the connection system includes a lid for covering an internal cavity of the rebate former defined by the elongated backing and the folded edges. More preferably, the connection system includes at least one strap extending around the rebate former and the lid to secure the lid to the rebate former.

[0012] In one form, the rebate former includes a row of anchors mounted longitudinally of the rebate former. More preferably, the rebate former includes a plurality of parallel rows of anchors mounted longitudinally of the rebate former.

[0013] Preferably, the connection system includes a plurality of parallel rebate formers joined by an intermediate section. More preferably, each rebate former has a plurality of rows of anchors mounted thereto.

[0014] In a preferred form, the rebate former includes a cross strut extending across a width of the internal cavity of the rebate former. More preferably, the cross strut is in the form of a brace which is movable along a length of the rebate former.

[0015] According to the invention, each anchor is provided with a securing plug, the securing plug having an external thread for threading into the internal thread of the anchor. Preferably, the securing plug has an external thread having the same pitch as the external thread of a reinforcing bar for threading into the female thread of the anchor. More preferably, the securing plug is arranged with an enlarged base to facilitate threading manually by hand. In one form, the securing plug is formed of plastic material.

[0016] The connection system includes a resilient washer located between the securing plug and the respective anchor to facilitate a seal of the internal thread of the anchor against ingress of concrete.

[0017] In one form, the rebate former is dimpled on the backing and on the folded edges to facilitate retention of the rebate former within surrounding concrete.

[0018] Preferably, the connection system includes a threaded reinforcing bar threaded into each anchor, with an external thread of the threaded reinforcing bar mating with an internal thread of the anchor.

[0019] In accordance with another aspect of the present invention, there is provided a method of providing a construction joint between a first concrete component and a second concrete component, as recited in the appended claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The invention is further described by way of non-limiting example only, with reference to the accompanying drawings in which: Figure 1 is a perspective view of a connection system in accordance with an example of the present invention, shown prior to embedment in concrete components; Figure 2 is a cross-sectional view of a connection system in accordance with an example of the present invention, forming a structural connection between two concrete components; Figure 3 is a cross-sectional view of a connection system having a rebate former with parallel rows of anchors; Figure 4 is a cross-sectional view of a connection system having a pair of parallel rebate formers; Figure 5 is a cross-sectional view of a connection system having a pair of parallel rebate formers, each with parallel rows of anchors; Figure 6 is a perspective view of a connection system, showing an internal cavity beneath a lid; Figure 7 is an end view of a connection system, depicted prior to connecting reinforcing bars to the anchors; Figure 8 is a perspective view of a connection system having parallel rows of anchors; Figure 9 is a perspective view of the connection system of Figure 8, shown fitted with threaded plugs; and Figure 10 shows a detailed side view of an anchor of the connection system shown in Figure 9; Figure 11 shows a range of different configurations of connection systems; Figure 12 shows a pair of rebate formers, each with a single row of anchors; Figure 13 shows a plurality of rebate formers, each with a pair of anchor rows; Figure 14 shows a connection system having reinforcing bars connected to anchors thereof; Figure 15 shows an end view of a rebate former embedded in a first concrete component; Figure 16 shows the rebate former of Figure 15 shown with threaded plugs fitted; Figure 17 shows the rebate former of Figure 16 with the plugs removed; Figure 18 shows the rebate former of Figure 17 with reinforcing bars inserted; Figure 19 shows a rebate former cavity shown with a cross strut / brace; Figure 20 shows a table with anchorage capacity results of different anchors; Figure 21 shows a table of Design Capacity; Figure 22 shows a rebate former used with a single row of anchors; Figure 23 shows a rebate former used with a double row of anchors; Figure 24 shows a pair of rebate formers used, each with a single row of anchors; Figure 25 shows a pair of rebate formers used, each with a double row of anchors; Figure 26 shows a side view of a rebate former, depicting anchorage; Figure 27 shows a pair of rebate formers used, each with a single row of double ended anchors; Figure 28 shows a range of example connections; Figure 29 shows both sides of a threaded plug; Figure 30 shows a side view of a connection system with a plug fitted to each anchor; Figure 30a shows a cross sectional view of a plug fitted to each anchor; Figure 31 shows a perspective view of a resilient washer / seal; Figure 32 shows a perspective view of resilient washers is being used to seal beneath threaded plugs; Figure 33 shows a side view of an anchor fitted to a dimpled rebate former; and Figure 34 shows a connection system embedded in a first concrete component prior to removal of threaded plugs. DETAILED DESCRIPTION

[0021] With reference to Figures 1 to 34, there is shown various examples of a connection system 10. Advantageously, the connection system 10 has been developed by the applicant to facilitate improved rigidity, ease-of-use, efficiency and improved load-bearing capacity.

[0022] More specifically, as shown in the drawings, an example of the present invention provides a connection system 10 for providing a construction joint 12 between a first concrete component 14 and a second concrete component 16. The connection system 10 includes a rebate former 18 for forming a rebate 20 (see Figure 17) in the first concrete component 14. The rebate former 18 is formed of sheet metal, the rebate former 18 including an elongated backing 22, the elongated backing 22 having folded edges 24 to a predefined depth.

[0023] As shown clearly in Figures 8 and 9, the connection system 10 includes a plurality of anchors 26 coupled to the elongated backing 22. Each of the anchors 26 as an internal thread 28 (see Figure 30a) for receiving an external thread 30 of a reinforcing bar 32 for reinforcing the second concrete component 16.

[0024] Each of the anchors 26 has a foot 34 for providing anchorage in the first concrete component 14. The foot may be in the form of a tapered foot 34. Even more specifically, the foot may be in the form of a circular tapered foot 34.

[0025] As can be seen in Figure 7, each of the anchors 26 has one or more external ribs 36 along a length of the anchor 26 for providing anchorage in the first concrete component 14. Each of the external ribs 36 may be tapered outwardly toward a free end of the anchor 26. Each of the anchors 26 may be in the form of a threaded insert.

[0026] The rebate former 18 may have one or more folded ends 38 to provide structural rigidity.

[0027] The connection system 10 may include a lid 40 for covering an internal cavity 42 of the rebate former 18 defined by the elongated backing 22 and the folded edges 24. The connection system 10 may include at least one strap 44 extending around the rebate former 18 and the lid 40 to secure the lid 40 to the rebate former 18. Alternatively, with reference to Figure 6 and Figure 9, straps 44 may instead be used around the rebate former 18 without the lid 40 fitted.

[0028] The rebate former 18 may include a row of anchors 26 mounted longitudinally of the rebate former 18 (see, for example, Figure 12). In another form, the rebate former 18 may include a plurality of parallel rows of anchors 26 mounted longitudinally of the rebate former 18 (see, for example, Figure 13).

[0029] The connection system 10 may include a plurality of parallel rebate formers 18 joined by an intermediate section 46, as shown in Figure 4. Each rebate former 18 may have a plurality of rows of anchors 26 mounted thereto, as shown in Figure 5.

[0030] With reference to Figure 6, the rebate former 18 may include a cross strut 48 extending across a width of the internal cavity 42 of the rebate former 18. The cross strut 48 may be in the form of a brace which is movable along a length of the rebate former 18.

[0031] Also as shown in Figure 6, each anchor 26 is provided with a securing plug 50, the securing plug 50 having an external thread 52 for threading into the internal thread 28 of the anchor 26. As shown in Figure 29, the securing plug 50 may have an external thread 52 having the same pitch as the external thread 30 of a reinforcing bar 32 for threading into the internal thread 28 of the anchor 26. This may be advantageous as the external thread 52 is therefore a coarse thread and is much quicker to thread in and thread out the securing plug 50 when compared with a metric thread. The securing plug 50 may be arranged with an enlarged base 54 (see Figure 29) to facilitate threading manually by hand. In one form, the securing plug 50 is formed of plastic material.

[0032] The connection system 10 includes a resilient washer 56 (see Figure 31 and Figure 32) located between the securing plug 50 and the respective anchor 26 to facilitate a seal of the internal thread 28 of the anchor 26 against ingress of concrete.

[0033] With reference to Figure 32, the rebate former 18 may be dimpled on the backing 22 and on the folded edges 24 to facilitate retention of the rebate former 18 within surrounding concrete.

[0034] After casting of the first concrete component 14 and removal of the securing plugs 50, the connection system 10 includes a threaded reinforcing bar 32 threaded into each anchor 26, with an external thread 30 of the threaded reinforcing bar 32 mating with an internal thread 28 of the anchor 26 (see Figure 18).

[0035] Advantageously, as the anchors 26 provided with a coarse thread for threaded insertion of externally threaded reinforcing bar 32, this facilitates direct insertion of the reinforcing bar 32 into the internal thread 28 of each anchor 26 rather than requiring a metric thread to be tapped on to an end of the reinforcing bar 32. This may be advantageous as it may facilitate cutting on-site of a reinforcing bar 32 to size, then threading of the cup and of the reinforcing bar 32 directly into the anchor 26 without needing to form a metric thread on an end portion of the reinforcing bar 32.

[0036] Accordingly, invention also provides a method of providing a construction joint 12 between a first concrete component 14 and a second concrete component 16. The method includes the steps of: providing a connection system 10 according to the invention including a rebate former 18 for forming a rebate 20 in the first concrete component 14, wherein the rebate former 18 is formed of sheet metal, the rebate former 18 including an elongated backing 22, the elongated backing 22 having folded edges 24 to a predefined depth; providing a plurality of anchors 26 coupled to the elongated backing 22, each of the anchors 26 having an internal thread 28; providing a plurality of reinforcing bars 32, each of the reinforcing bars 32 having an external thread 30 along its length; and threading one of the reinforcing bars 32 into each of the anchors 26 such that, for each anchor 26, an external thread 30 of a reinforcing bar 32 is threaded into the internal thread 28 of the anchor 26 to tighten the reinforcing bar 32 relative to the anchor 26 for providing reinforcement for the second concrete component 16.

[0037] The following features and / or advantages may be present in examples of the invention, according to the following aspects:Modular Unit Placement

[0038] Pre-assembled unit ready pick and place onsite installation directly to formwork. Removes the requirement to drill through shuttering onsite. Flexibility of placement onsite vertical and horizontally. Standard single row configuration units to suit smaller slab sizes (140mm to 180mm) with centrally placed lap bars. Standard double row configuration units to suit medium to large sized slabs (190mm to 500mm) with top and bottom lap bars. Multiple row placement ability with single row configuration units to suit extra-large slab sizes (500mm plus). Rows placed at top and bottom of slab. Added ability to place different anchor sizes for top and bottom reinforcing. Multiple row placement ability with double row configuration units to suit extra-large slab sizes (500mm plus). Rows placed at top and bottom of slab. Added ability to place different anchor sizes for top and bottom reinforcing. Standard 1000mm unit length to facilitate simple take-off and ordering. The units can be cut onsite into infills to match specific length requirements. Internal supports can be moved to block cut ends. Standardised predefined rebate depth of 30mm to suit unit placement before first lay of reinforcing in the wall. Modular Anchor Placement

[0039] Units use a perforated sheet metal base, punched as a template which accurately spaces and configures structural anchors or couplers at required centers laterally across the joint and spaces them at cover requirements for top and bottom reinforcing (on double row configurations). Available in different anchor sizes (RB12, RBA16, RB20, RBA20, RB25 and RB32). Optimised anchor / coupler centers to meet connection design parameters. Unit base assembly restrains attached coupler / anchors perpendicular the rebated joint face. The refined 30mm rebate positions the anchors at the optimal embedment depth in the wall to provide maximum shear cone efficiency. Rebated channel provides added positive shear resistance. Threaded Lap Bars

[0040] Screw in structural 500 MPa lap bars for easy connection onsite. Optional full-length lap bar connection to floor to wall continuality system through use of a full length threaded structural reinforcing bars or a screw on coupler connection system. This reduces lapping at lap bars giving reduced bars cost of overlapping bars and congestion in reinforcing. Lap lengths are not limited by what can fit into the box lengths (i.e. bar laying in typical pull-out bar systems). This allows the standard 1000mm box length to be cut to any shorter infill length with easy and allows for fully developed lap lengths on these shorter lengths. Reduction in weight of continuity systems during setup and transport. Reduces exposure of tripping hazards created by pull-out bars systems. Improves installer exposure to repetitive stress injuries caused by bending out multiple pull-out bars. Optimised Bar Anchorage

[0041] Headed anchorage rather than looped or cogged reo lap bars being tied into vertical reinforcing. The 30mm predefined rebates places the anchors at the correct embedment to maximise shear cone size and efficiency in the placed-in slab. Cogged anchor of design development length for correct embedment when used with coupler fittings. The structural anchors used are genuine Reidbar fittings optimised for use with structural Reidbar. They are manufactured to the highest quality and tolerance to match the connecting bar. When tested in concrete against theoretically calculated alternative systems they achieve up to a 30% increase in efficiency over the other systems allowing for a reduction in anchor quantities required for connections. This reduces cost of fittings and labour as well as reducing reinforcing congestion. Anchors optimised in centers and layers in prefabricated units to give maximum anchorage performance with minimal in place anchors. Standard anchor application suitable for all types rebated structural connections on multi-level projects: floor to wall wall to wall precast panel to floor precast panel to wall wall to capping slab crane penetrations stair flights and landings corbels beam to wall / column Securing Nailing Plate and Washer

[0042] Secures couplers or anchors to the unit assembly with a bolt and nut functionality during setup with formwork and pouring of concrete. Easy attachment during manufacturing and removal onsite of nailing plates from couplers / anchors using a ½" driver and cordless drill. Nailing plate thread matches the thread of coupler / anchor and blocks void and thread profile during the concrete pour to prevent concrete slurry ingress into the fitting. Sizes available in to suit RBA16, RB20, RBA20, RB25 and RB32 Reidbar couplers and anchors. Rubber washer fits between coupler / anchor and nailing plate to create a secure seal to prevent slurry ingress into the rebate box unit during the concrete pour. Washer acts as an anti-vibration device for the nailing plates to ensure coupler / anchor remains tight until pouring. Dimpled Unit Base

[0043] Dimpled finish on unit base helps anchors base component into the slab when stripping lid. The dimpled finish maximises the contact surface area between connecting slabs by up to 5%. Eliminates need for scabbling rebate. Made of galvanised sheet metal to prevent corrosion in the rebate.

[0044] While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not by way of limitation. It will be apparent to a person skilled in the relevant art that various changes in form and detail can be made therein without departing from the scope of the invention as defined by the appended claims.

[0045] Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

[0046] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge.List of numbered features

[0047] Connection system10Construction joint12First concrete component14Second concrete component16Rebate former18Rebate20Elongated backing22Folded edges24Anchors26Internal thread28External thread30Reinforcing bar32Foot34External ribs36Folded end38Lid40Internal cavity42Strap44Intermediate section46Cross strut48Securing plug50External thread52Enlarged base54Resilient washer56

Claims

1. A connection system (10) for providing a construction joint (12) between a first concrete component (14) and a second concrete component (16), the connection system including: a rebate former (18) for forming a rebate (20) in the first concrete component, wherein the rebate former is formed of sheet metal, the rebate former including an elongated backing (22), the elongated backing having folded edges (24) to a predefined depth; and a plurality of anchors (26) coupled to the elongated backing, each of the anchors having an internal thread (28) for receiving an external thread (30) of a reinforcing bar (32) for reinforcing the second concrete component, wherein each anchor is provided with a securing plug (50), the securing plug having an external thread (52) for threading into the internal thread of the anchor, characterized in that the connection system (10) includes a resilient washer (56) located between the securing plug (50) and the respective anchor (26) to facilitate a seal of the internal thread (28) of the anchor against ingress of concrete.

2. A connection system (10) as claimed in claim 1, wherein each of the anchors (26) has a foot (34) for providing anchorage in the first concrete component (14).

3. A connection system (10) as claimed in claim 2, wherein the foot is a tapered foot (34).

4. A connection system (10) as claimed in claim 1, wherein each of the anchors (26) has one or more external ribs (36) along a length of the anchor for providing anchorage in the first concrete component (14).

5. A connection system (10) as claimed in claim 1, wherein each of the anchors (26) is in the form of a threaded insert.

6. A connection system (10) as claimed in claim 1, wherein the rebate former (18) has folded ends (28) to provide structural rigidity.

7. A connection system (10) as claimed in claim 1, wherein the connection system includes a lid (40) for covering an internal cavity (42) of the rebate former (18) defined by the elongated backing (22) and the folded edges (24).

8. A connection system (10) as claimed in claim 1, wherein the rebate former (18) includes a row of anchors (26) mounted longitudinally of the rebate former.

9. A connection system (10) as claimed in claim 1, including a plurality of parallel rebate formers (18) joined by an intermediate section (46).

10. A connection system (10) as claimed in claim 1, wherein the rebate former (18) includes a cross strut (48) extending across a width of an internal cavity (42) of the rebate former.

11. A connection system (10) as claimed in claim 1, wherein the rebate former (18) is dimpled on the backing (22) and on the folded edges (24) to facilitate retention of the rebate former within surrounding concrete.

12. A connection system (10) as claimed in claim 1, including the threaded reinforcing bar (32) threaded into each anchor (26), with the external thread (52) of the threaded reinforcing bar mating with the internal thread (28) of the anchor (26).

13. A method of providing a construction joint between a first concrete component (14) and a second concrete component (16), the method including the steps of: providing a connection system (10) as claimed in claim 1; providing a plurality of the reinforcing bars (32); and threading one of the reinforcing bars into each of the anchors (26) such that, for each anchor, the external thread (30) of a reinforcing bar is threaded into the internal thread (28) of the anchor to tighten the reinforcing bar relative to the anchor for providing reinforcement for the second concrete component.