Field transition ties

Abstract

A field transition tie having a tie assembly portion having a first tie end portion and an opposed second tie end portion having a stop surface formed thereon, a clamp component having a main body having a longitudinal opening formed therethrough to form a chamber that is sized and configured for seating a tie rod such that the clamp component has a plurality of threaded fastener receiving openings formed therein that extend partly through the main body and that communicate with the chamber. The transition tie also includes a plurality of break-away fasteners having a main body that includes a head portion and a stem portion connected to the head portion by a break-away feature, and first and second strut elements that are connected to the clamp component and to the tie assembly portion to form an integrated assembly.

Description

RELATED APPLICATION

[0001] The present application claims priority to U.S. provisional patent application Ser. No. 63 / 747,792, filed on Jan. 21, 2025, and entitled Field Transition Ties, the contents of which are herein incorporated by reference.BACKGROUND OF THE INVENTION

[0002] The present invention is directed to ties for concrete, and more specifically to field transition ties for concrete structures.

[0003] Conventional concrete walls may be created by pouring concrete into a suitable concrete form. As is known in the art, concrete foundation walls are generally poured between two sets of concrete forms disposed in essentially parallel relationship and defining therebetween a channel having a dimension for the desired thickness of the concrete wall. Such opposed, spaced apart walls are generally held in a fixed relationship relative to each other against the immense weight of any poured concrete by tie-wires and turnbuckle assemblies having abutment surfaces against which a locking or latching arm on adjacent form sections abut. Once assembled into the shape of the wall, wet concrete is poured into the channel formed between the concrete forms and allowed to dry. The concrete forms typically comprise multiple form panels, which may for example be formed of wood, metal or any other suitable well known material. The height of the form panel may vary by application.

[0004] Multiple form panels may be placed side-by-side in order to construct a wall of a desired length. Because the wet poured concrete takes the shape of the forms in which it is placed, the finished concrete wall corresponds in configuration to the assembled form. Therefore, it is important to align precisely the panels composing the concrete form in order to ensure that the finished wall has the desired appearance and strength.

[0005] The concrete forming systems can also employ tie-rods that are disposed between aligned panels in order to keep the panels properly spaced apart and to ensure that the panels are coupled to each other in a secure manner. The tie rods extend through openings formed in the spaced apart form panels and hold the sections against relative movement toward each other. The tie-rods may extend outwardly of the sections by a selected amount as is known in the art. The portion of the tie-rods that extend beyond the panel forms typically include a looped or flattened or coined section that is adapted to engage with the latch that is coupled to the panel bar. Once the concrete is poured between the panel forms and allowed to cure, the portion of the tie rods that extend beyond the concrete walls can be snapped off. Conventional tie rods are typically formed of metal, such as steel.

[0006] Field transition ties are widely used in the construction industry, particularly in the formation of concrete structures. The ties serve as important components that facilitate the transition between different field sections of a concrete formwork system. By securing adjacent formwork panels, field transition ties ensure alignment and structural integrity during the concrete pouring and curing processes.

[0007] Conventionally, field transition ties are designed to provide temporary support and positioning for the formwork. They are typically constructed from steel or other durable materials capable of withstanding the pressures exerted by wet concrete. The ties can be reusable or single-use, depending on their material composition and specific design. Common designs include wire loop ties, wedge ties, and threaded rod systems, each catering to various project requirements and load-bearing capacities.

[0008] There are many concrete structures, called generally “slabs”, created to function as spread footings, machine bases, pile caps, grade beams, and the like. The concrete structures typically have a selected thickness (e.g., 6 feet or less) and a selected horizontal dimension (e.g., 10 to 80 feet or more). Conventional concrete structures are commonly created by setting up edge form panels and then connecting opposing form panels with tensile ties that remain embedded in the emplaced concrete.

[0009] Ties of a required or specific length are frequently manufactured, but their cost, particularly including the freight costs to ship long-length ties from a manufacturing site to the installation site, and frequently in small numbers, is quite high, and can require a long time to deliver the product. A stock tensile rod, called a pencil rod, is currently used in the industry as one way to produce the necessary long ties in the field, without the need for specially ordered specific-length ties. The pencil rod is typically about 0.25 inches in diameter and is commonly supplied in predetermined lengths of twelve feet or twenty feet. For longer ties, it is supplied in rolls, which have to be laboriously and imperfectly straightened in the field to serve as tensile tie members. The connection of the pencil rod to the edge forms is typically done with reusable rod clamps which connect to the pencil rod with a set screw or ratchet lever on the outside of the forms.

[0010] Despite the widespread use, conventional field transition ties present several notable disadvantages. One of the primary concerns is the labor-intensive nature of their installation and removal. The process often involves multiple manual steps, including precise alignment, securing with fasteners, and ensuring proper tension, which can significantly increase labor costs and project timelines. Furthermore, misalignment during installation can compromise the structural integrity of the final concrete product, leading to costly rework and potential safety hazards.

[0011] Another disadvantage of traditional field transition ties is their susceptibility to corrosion, especially when exposed to moisture and other environmental factors over time. Corroded ties can weaken the connection between formwork panels, resulting in formwork failure or deformation. Additionally, single-use ties contribute to material waste, as they must be discarded after each use, leading to increased project costs and environmental concerns. Finally, conventional ties often lack adaptability for complex or non-standard formwork configurations. Projects requiring curved, angled, or irregularly shaped transitions may necessitate custom solutions, further complicating the installation process and driving up costs.

[0012] Still other disadvantages of conventional field-made long ties with pencil rods include the expense of the reusable rod clamps, the labor to setup and remove the rod clamps, the expense and somewhat limited availability of straight pencil rod lengths, difficulty of using coiled pencil rod for longer lengths, the inability to provide a breakneck, or the feature that allows a tie to be broken back at a depth from the surface of the concrete (a common requirement for many jobs).SUMMARY OF THE INVENTION

[0013] The field transition tie of the present invention provides a device for creating long concrete formwork ties in the field using readily available tensile rods, such as for example #3 rebar or pencil rod. The present invention features a field transition tie having one end with a standard tie configuration for specific formwork systems (e.g., loop tie end for Steel Ply forms or button head snap tie end for job-built formwork) and an opposite end with a connector portion, such as a clamping mechanism. that accepts the tensile rods up to ½ inch diameter. The clamping mechanism can include tapped holes for accommodating breakaway bolts with conical ends that indent the tensile rod when tightened, providing over 4500 pounds of pull-out resistance. The field transition tie also includes an end stop element positioned at a convenient whole-inch distance (e.g., three inches) from a concrete form face, enabling users to cut tensile rods to precise lengths for consistent assembly. For Steel Ply applications, the field transition tie may incorporate a high-strength swivel feature that eliminates the need to orient loops on long ties. This field-assembled device eliminates expensive reusable hardware like rod clamps, reduces labor costs, utilizes readily available materials, and allows for customized tie end characteristics while using inexpensive #3 rebar for the majority of the tie length.

[0014] The present invention is directed to a field transition tie having a tie assembly portion having a first tie end portion and an opposed second tie end portion having a stop surface formed thereon, a clamp component having a main body having a longitudinal opening formed therethrough to form a chamber that is sized and configured for seating a tie rod, the clamp component having a plurality of threaded fastener receiving openings formed therein that extend partly through the main body and that communicate with the chamber, a plurality of break-away fasteners, wherein each of the plurality of break-away fasteners has a main body that includes a head portion and a stem portion connected to the head portion by a break-away feature, and first and second strut elements that are connected to the clamp component and to the tie assembly portion to form an integrated assembly.

[0015] The break-away feature of the break-away fasteners is a cut-out portion. The longitudinal opening of the clamp component can be aligned with the stop surface of the tie assembly portion. The stem portion of the break-away fasteners has a conical end portion disposed opposite the head portion. Further, the first tie end portion of the tie assembly portion has a looped end portion or a button head configuration. According to one embodiment, the clamp component has a hexagonal shape.

[0016] The stop surface of the tie assembly portion is positioned a predetermined distance from an end portion of the first tie end portion. The break-away fasteners are configured to have the head portion break off from the step portion when a predetermined torque is applied thereto, providing an indication that sufficient clamping force has been achieved. The predetermined torque can be between about 28 and about 40 ft-lbs of torque.

[0017] The present invention is also directed to a method of creating a field-assembled transition tie system, comprising cutting a tie rod to a predetermined length, inserting a first end of the tie rod into a first clamp component of a first field transition tie until the first end of the tie rod contacts a stop surface formed on a tie assembly portion of the first field transition tie, inserting a second end of the tie rod into a second clamp component of a second field transition tie until the second end of the tie rod contacts a stop surface formed on a tie assembly portion of the second field transition tie, inserting a plurality of break-away fasteners into the clamp components of the first and second field transition ties, and tightening the break-away fasteners until a head portion breaks off of each break-away fastener, thereby securing the tie rod within the clamp components and to the first and second field transition ties to form a continuous transition tie assembly.BRIEF DESCRIPTION OF THE DRAWINGS

[0018] These and other features and advantages of the present invention will be more fully understood by reference to the following detailed description in conjunction with the attached drawings in which like reference numerals refer to like elements throughout the different views. The drawings illustrate principals of the invention and, although not to scale, show relative dimensions.

[0019] FIG. 1 is a top perspective view of a transition tie system having a tie rod and a pair of field transition ties according to the teachings of the present invention.

[0020] FIG. 2 is a top perspective view of a portion of the transition tie system of FIG. 1 showing the tie rod coupled to one of the field transition ties according to the teachings of the present invention.

[0021] FIG. 3 is a side perspective view of the transition tie system of FIG. 1 according to the teachings of the present invention.

[0022] FIG. 4 is an exploded unassembled view of the field transition tie according to the teachings of the present invention.

[0023] FIG. 5 is an assembled view of the field transition tie of FIG. 4 according to the teachings of the present invention.

[0024] FIG. 6 is a top perspective view of the field transition tie according to the teachings of the present invention.

[0025] FIG. 7 is a side perspective view of the field transition tie according to the teachings of the present invention.

[0026] FIG. 8 is a perspective view of the clamp component of the field transition tie according to the teachings of the present invention.

[0027] FIG. 9 is a top perspective view of the clamp component according to the teachings of the present invention.

[0028] FIG. 10 is a side perspective view of the clamp component according to the teachings of the present invention.

[0029] FIG. 11 is a perspective view of a break-away fastener used with the clamp component according to the teachings of the present invention.

[0030] FIG. 12 is a side perspective view of the break-away fastener according to the teachings of the present invention.

[0031] FIG. 13 is another embodiment of the field transition tie according to the teachings of the present invention.DETAILED DESCRIPTION OF THE INVENTION

[0032] The present invention is directed to forming transition ties in the field using a range of inexpensive, convenient, and / or readily available tie rods. The field transition tie of the present invention has a tie assembly portion having one end having and region configured for use with the formwork system being used, such as a loop tie end for the commonly used Steel Ply forms, a button head snap tie end for job-built formwork with slotted wedges, and the like. The other end of the tie assembly portion includes a stop surface that can serve as a surface for an end of the tie rod to contact. One method of providing the connection to a field-cut tie rod is with a clamp component of the field transition tie having an opening formed therein that is sized and configured to seat the tie rod. The clamp component and the tie assembly portion can be welded to strut elements to form the field transition tie. The clamp component has tapped fastener receiving openings formed therein for receiving and seating break-away fasteners with conical ends. The fasteners can break, or twist off, outside the fastener receiving openings when a selected torque has been applied thereto, thus providing a simple indication that sufficient clamping force has been applied to the tensile rod. The conical bolt ends indent the steel tensile rod to provide a greater resistance to withdrawal of the tensile rod from the hex tube. With this arrangement, a connection between the field transition tie and a tie rod can be easily and reliably made to exceed 4500 pounds of pull-out resistance. This meets the requirements of most applications where there is an advantage to field-making a tie.

[0033] The field transition tie of the present invention provides many benefits and advantages over conventional tie systems, including the lack of a need for expensive reusable hardware (e.g., rod clamps) since field-made ties using the field transition tie of the present invention are a drop in replacement for normal ties for the relevant form systems and can easily utilize #3 rebar (e.g., about ⅜ inch diameter) as a tie rod which is less expensive than pencil rods and can sustain a higher load, can be formed or made quickly and with little labor and separate from the installation, and the ends of the tie rod can be configured to have characteristics needed for the project (e.g., corrosion protection, stainless steel, different breakneck depths, plastic cones, fiberglass, and the like) while still using inexpensive #3 rebar for most of the needed length.

[0034] The present invention relates to systems and devices for connecting and installing tie rods or pencil rods in concrete applications. FIGS. 1-3 shown an example transition tie system 10 that employs an opposed pair of field transition ties 20, 20 that help capture and support an intermediate tie rod 22. As used herein, the term “tie rod” or “tie rod component” refers to an elongated structural tension member, sometimes also referred to as a pencil rod, that is configured to extend between two or more spaced-apart structural elements and to carry axial tensile loads for maintaining a predetermined spatial relationship between such elements. The tie rod generally comprises an elongated, substantially cylindrical body defining a longitudinal axis and having sufficient tensile strength to resist separation forces imposed on the structural elements to which it is coupled. The tie rod may be of unitary construction or formed from multiple interconnected segments, and may include threaded, partially threaded, upset, swaged, or otherwise formed end portions configured to engage complementary anchoring or reaction components, such as nuts, wing nuts, cones, bearing plates, washers, couplers, form ties, or other load-transfer or fastening elements.

[0035] The tie rods may be implemented in a variety of forms depending on the intended application, load requirements, and installation environment. By way of example, the tie rods can include continuously threaded rods, partially threaded rods having threaded end regions and an unthreaded shank, smooth rods configured for use with wedge-type or clamp-type anchors, high-strength form ties for concrete formwork systems, reusable or disposable snap ties, she-bolt ties, taper ties, coil-threaded ties, or segmented rod assemblies joined by couplers. Pencil rods commonly refer to tie rods having relatively small diameters, such as on the order of several millimeters to a few centimeters, and are frequently used in light-to-medium duty formwork or temporary bracing applications, although larger-diameter tie rods may be employed for higher load capacities or permanent structural installations.

[0036] In operation, the tie rod is positioned to span between opposing structural members, such as form panels, walls, frames, or other load-reacting components, and is secured at one or both ends such that the rod is placed in tension during service. The primary function of the tie rod is to resist separation of the structural members under applied loads, including hydrostatic pressure from uncured concrete, soil pressure, wind loads, dead loads, live loads, or other transient or sustained forces. By transmitting tensile forces along its longitudinal axis, the tie rod maintains a desired spacing between the structural elements and inhibits bowing, spreading, misalignment, or other deformation that could adversely affect dimensional accuracy, surface quality, or structural performance.

[0037] The tie rods may be fabricated from steel or other metallic or composite materials selected to provide suitable tensile capacity, fatigue resistance, ductility, and environmental durability. The material composition, diameter, length, thread profile, surface treatment, and mechanical properties of a given tie rod may be selected based on anticipated loading conditions, reuse cycles, exposure environment, and compliance with relevant construction standards or building codes. Accordingly, tie rods, including pencil rods, function as fundamental tensile load-bearing elements enabling controlled spacing, load transfer, and structural stability in a wide range of temporary and permanent construction systems.

[0038] In concrete forming applications, for example, the tie rod can be installed between opposed form faces prior to placement of concrete so as to define and preserve the thickness of a wall or other cast structural element. During placement and curing of the concrete, the tie rod counteracts outward forces exerted on the formwork, thereby maintaining the geometry of the form assembly. After curing, the tie rod may be removed, fractured at predetermined break points, cut flush with the concrete surface, or left embedded within the structure, depending on system design, corrosion considerations, and applicable regulatory or performance criteria. In various embodiments, the construction system may further include modular concrete forming panels, commonly referred to as steel ply forms. As used herein, a “steel ply form” refers to a reusable concrete form panel having a rigid steel frame and a concrete-contacting facing, typically formed from plywood, composite sheet material, or a polymeric panel, secured to the frame. The steel frame defines a peripheral boundary of the panel and provides structural rigidity, dimensional stability, and resistance to deformation under hydrostatic loads generated during placement of uncured concrete. A steel ply form panel generally comprises a substantially planar forming face supported by a surrounding steel perimeter frame and, in some embodiments, one or more internal steel ribs or cross-members extending between opposing sides of the frame. The frame and any internal ribs may be welded, bolted, or otherwise fixed together to form a unitary structure capable of withstanding repeated loading and reuse. The forming face is configured to present a smooth or otherwise controlled surface to the concrete, thereby imparting a desired surface finish to the cured structure.

[0039] Steel ply forms are commonly provided in standardized modular sizes and shapes, including rectangular panels of varying heights and widths, corner panels, filler panels, and specialty panels, enabling assembly of formwork structures having different wall lengths, heights, and geometries. Adjacent panels may be connected to one another using mechanical connectors such as wedges, clamps, pins, bolts, or proprietary locking devices to form a substantially continuous forming surface. The panels are typically arranged in opposed form lines, spaced apart to define a cavity corresponding to the thickness and shape of the concrete element to be cast.

[0040] In use, opposing steel ply form panels are held in a predetermined spaced relationship by one or more tie rods extending between the panels and engaging apertures, slots, or embedded hardware in the steel frames or associated walers or strongbacks. The tie rods cooperate with external fastening elements, such as nuts, bearing plates, cones, or washers, to place the rods in tension and resist outward forces generated by the fluid concrete. In this manner, the steel ply forms and the tie rods operate together as an integrated forming system that maintains dimensional accuracy and structural stability during concrete placement and curing. The steel ply forms provide several functional advantages, including high load-carrying capacity, resistance to impact and job-site abuse, compatibility with a wide range of tie rod systems and accessories, and the ability to be repeatedly reused over numerous forming cycles. The steel frame also facilitates reliable attachment of walers, braces, scaffolding brackets, and other auxiliary components commonly employed in forming operations. Accordingly, steel ply forms serve as durable, modular forming elements that cooperate with tie rods and related fastening components to define and maintain the geometry of cast-in-place concrete structures, such as walls, columns, foundations, and other structural members.

[0041] FIG. 4 shows an exploded view of the field transition tie 20 of the invention and FIGS. 5-7 show an assembled and connected view of the field transition tie 20. The illustrated field transition tie 20 includes a tie assembly portion 30 for contacting or coupling to the panels in a concrete forming system, strut elements 50, and a mechanical connection assembly 60. The illustrated tie assembly portion includes a main body 32 having a first tie end portion 34 and an opposed second tie end portion 36. The first tie end portion 34 can be configured to be compatible with a selected type of concrete forming system with which the tie is intended to be used. The first tie end portion 34 functions as an interface region between the body of the field transition tie 20 and one or more components of a formwork system, and is shaped, dimensioned, or otherwise formed to mechanically engage complementary hardware or structural features of a particular form panel, frame, or connecting device. By providing a configurable end portion, a single field transition tie design may be adapted for compatibility with multiple form systems while maintaining consistent tensile load-carrying capability through the main body of the tie. In the current example, the first tie end portion 34 is configured as a loop-type end, in which the material of the tie is bent, forged, or otherwise formed to define a closed or partially closed loop sized to receive a pin, wedge, hook, or similar retaining element associated with a first type of form system, such as for example Steel Ply form systems. In other embodiments, the end portion may be configured as a button-type end, sometimes referred to as a headed or enlarged end, having a locally increased cross-section or formed head that is dimensioned to seat within a slot, keyhole opening, or receptacle of a second type of form panel or frame. In such configurations, the button-type end resists pull-through under tensile loading while permitting rapid installation and removal without threaded fasteners. Other end portion configurations are also contemplated, including but not limited to threaded ends for engagement with nuts or couplers, tapered ends, swaged ends, hooked ends, flattened or eyelet-style ends, and ends incorporating detachable adapters or fittings. In some embodiments, the end portion may be permanently formed as part of the tie, while in other embodiments the end portion may be modular or replaceable, allowing the same tie body to be fitted with different end geometries depending on job-site requirements or form system selection.

[0042] The purpose of the first tie end portion 34 is to provide reliable load transfer between the field transition tie 20 and the formwork system, to prevent unintended disengagement during concrete placement, and to facilitate efficient installation, alignment, and removal of the tie. When the field transition tie 20 is placed in tension between opposing form panels, the first tie end portion 32 bears against or interlocks with corresponding features of the form system so that tensile forces are transmitted from the tie into the form structure without excessive local deformation or slippage. Accordingly, the configurable end portion enables the field transition tie to function as a universal or multi-system interface component, reducing the need for system-specific ties while preserving structural performance and operational convenience.

[0043] The illustrated tie assembly portion 30 also includes the second tie end portion 36 that includes a stop element 38. The stop element 38 can be formed in a selected configuration and shape and can be formed as a coiled section of the tie assembly portion 30. The end portion of the coiled section has an axial end face or surface 40 that forms a stop surface that enables the tie rod to contact, if desired. The end stop surface is disposed a predefined distance from the outermost edge of the first tie end portion 34 so as to define a predictable distance for the end user. For example, the distance between the tip or end of the first tie end portion 34 and the stop surface can be about three inches, although other distances are also contemplated by the present invention. The coiled portion can define a support portion and enlarged stop interface for abutment against an end of the tie rod.

[0044] The field transition tie 20 can also include a connection assembly 60 for connecting and securing a portion of the tie rod 22 to the field transition tie 20. The connection assembly 60 can include a clamp component 70 and one or more fasteners 90. The clamp component 70 can be any suitable device for connecting the tie rod 22 to the field transition tie 20 and for clamping or securing the tie rod thereto. According to one embodiment, as also shown in FIGS. 8-10, the clamp component 70 can have a main body 72 that has an axially extending opening 74 formed completely through the length of the main body 72 between opposed ends. The ends can have chamfers 78 formed therein to help guide and seat the tie rod 22. The opening 74 forms a chamber 76 that is sized and configured for seating the tie rod 22. The opening 74 can be aligned with the stop surface 40. The main body can also have one or more fastener receiving openings 80 formed therein. The fastener receiving openings 80, 80 can be sized and configured to accommodate fasteners 90 of a selected type. The fastener receiving openings 80 can be threaded so as to connect with and accommodate threaded fasteners so as to secure the fasteners 80 to the clamp component 70. The fastener receiving openings 80 communicate with the chamber 76 formed by the opening 74. The main body 72 of the clamp component 70 can have any selected shape, such as a hexagonal shape.

[0045] As shown for example in FIGS. 11 and 12, the illustrated fasteners 90 can include a main body 92 having a head portion 94 and an attached stem portion 96. The fasteners 90 can be constructed as break away fasteners (e.g., bolts) that can have a head portion that breaks away from or snaps off when subjected to a rotational force of a selected level. The head portion 94 is sized and configured to be engaged with a tightening tool. The stem portion 96 can have a top end portion 100 that is formed as a break-away feature or portion and an opposed conical end 104. Specifically, the top-end portion 100 can have a cut-out 102 formed therein that forms a reduced cross-section and a weakened or frangible section that enables the head portion 94 to snap off from the stem portion 96. The cut-out 102 thus defines a predetermined failure location. In operation, the fastener 90 is mounted in the fastener receiving openings 80 formed in the clamp component 70 and tightened to draw the clamp component 70 and fasteners 90 into load-transferring engagement with the tie rod 22 and associated formwork components. As tightening torque is applied to the head portion 94, tensile and torsional stresses increase within the frangible cut-out section 102. When a predetermined torque or axial load threshold is reached, corresponding to a desired clamping force or preload, the cut-out portion 102 fractures, thereby separating the head portion 94 from the stem portion 96. The remaining portion of the stem portion 96 remains captured within the fastener receiving openings and hence the clamp component 70, maintaining the established clamping force and securing the tie rod therein. The use of break-away bolts provides several functional advantages, including consistent and repeatable installation torque, reduced risk of over-tightening or under-tightening, and improved reliability of the mechanical connection between the tie rod and the fasteners 90 and clamp component 70. In addition, removal of the head portion 94 after fracture inhibits unauthorized loosening or tampering and reduces the likelihood of protruding hardware interfering with adjacent formwork components or concrete placement operations. In some embodiments, the cut-out portion or section 102 can be formed as an annular groove, a localized reduction in diameter, a notched region, or a material discontinuity selected to produce predictable fracture behavior under applied torque. The break-away fasteners 90 may be formed from steel or other suitable metallic materials, and may include corrosion-resistant coatings or surface treatments as required for job-site conditions. Accordingly, the break-away fasteners 90 function as a controlled-failure fastener that enables reliable clamping of the tie rod 22 while simplifying installation and enhancing the robustness of the overall formwork assembly.

[0046] With reference to FIGS. 4-6, the strut elements 50 can be secured, such as by welding, to the tie assembly portion 30 and to the clamp component 70 to form a single integrated and unitary assembly.

[0047] The field transition tie 20 of the present invention provides a comprehensive solution for creating long concrete formwork ties, in field conditions, using readily available tie rods, such as #3 rebar or pencil rods. The transition tie system 10 can include multiple field transition ties 20 to form a dual-ended assembly that mounts a toe rod therebetween. The tie assembly portion 30 of the field transition ties 20 can be formed to include standard tie rod configurations specific to the formwork systems being employed, including loop tie ends for commonly used Steel Ply forms and button head snap tie ends for job-built formwork systems with slotted wedges. An example of a field transition tie 20 having a button head portion is shown in FIG. 13. Like reference numeral indicate like parts throughout the various views. The illustrated field transition tie 20 has a tie assembly portion 110 having a first tie end portion 112 shaped as a button head and an opposed second tie end portion 114 having a stop surface 40.

[0048] The field transition tie 20 can include a mechanical connection assembly 60 formed at an end opposite the tie assembly portion 30. The mechanical connection assembly 60 can include a clamp component 70 configured, for example, as a hexagonal steel tube with an internal opening 74 designed to accept tensile rods 22 up to a selected size, for example up to about 0.5 inches in diameter. The clamp component 70 is configured to have, for example, an internal dimension of about 0.488±0.004 inches in diameter and features tapped fastener receiving openings 80 for accepting and seating breakaway fasteners 90 with, for example, conical ends. The clamp component 70 can be secured such as by welding to the struts 50 to form the structural connection within the tie assembly portion 30.

[0049] The fasteners 90 can be configured to include a breakaway feature, such as the the cut-out 102. The fasteners 90 can be constructed from medium carbon steel with specific heat treatment to achieve 120,000 PSI minimum tensile strength, 92,000 PSI minimum yield strength, and 14% minimum elongation. The breakaway mechanism is engineered to shear at between about 28 to about 40 ft-lbs torque, providing a reliable indication that sufficient clamping force has been applied to the tensile rod 22. The fasteners 90 feature 5 / 16-18 Class 2A rolled threads and incorporate Nylok patches requiring 25-40 in-lbs initial torque.

[0050] The conical end of the stem portion 96 of the fasteners 90 are designed to indent the steel tensile rod 22 upon tightening, creating enhanced resistance to withdrawal of the tensile rod 22 from the clamp component 70. This clamping arrangement enables connections between the field transition tie 20 and tie rods 22 to reliably exceed 4500 pounds of pull-out resistance, meeting the requirements for most applications where field-assembly of ties provides operational advantages.

[0051] The second tie end portion 36 of the tie assembly portion 30 can include a stop surface 40 that is positioned at a precise, whole-inch distance from the end or tip of the first tie end portion 34 or of the concrete forms. In the embodiment disclosed herein, this distance is established at about three inches from the concrete surface as poured. This configuration enables users requiring tie rods 22 for specific slab widths to calculate precise tensile rod lengths by subtracting 6 inches (3 inches on each end) from the total wall thickness, thereby creating a simplified assembly process where tensile rod ends are inserted in the field transition tie 20 to the stop surface 40 and the fasteners 90 are tightened to produce long ties of consistent length. The tie assembly portion 30 of the field transition tie 20 can be configured to have a swivel capability formed therein, such as that disclosed in U.S. Pat. No. 9,133,635, to the assignee hereof, the contents of which are herein incorporated by reference. This swivel mechanism eliminates the operational complexity of orienting loops on opposing ends of ties that may extend 20 feet or more in length. The swivel feature enables users to clamp the tie onto the tensile inner rod without concern for loop orientation, with the user subsequently rotating the loop by hand to fit into the form slots when connecting the tie to edge forms.

[0052] In operation, the end users in the field can determine the proper length of the tie rods 22 and can cut the tie rods 22 to a required length, if needed. The lengths can be calculated as the wall thickness minus six inches to accommodate the three-inch end stop surfaces 40 positions formed on each tie assembly portion 30 of the field transition ties 20. The transition tie system 10 employs multiple field transition ties 20. The opposed ends of the tie rod 22 can be inserted through the clamp components 70 of each field transition tie 20 until, if desired, the ends of the tie rods abut against, and hence contact, the stop surfaces 40. The fasteners 90 are then inserted into the fastener receiving openings 80 and tightened until the head portions 94 break off from the stem portion 96 at the cut-out regions 102 at a predetermined breakaway torque, indicating proper clamping force has been achieved.

[0053] The clamp component 70 can feature precise dimensional specifications including a 1.400±0.010 inch overall length, 0.940±0.005 inch width across flats, and 0.751 inch typical dimension for a hexagonal configuration. The internal threading of the fastener receiving openings 90 can consists of 5 / 16-18 UNC- 3B threads created using thread-forming taps with maximum minor diameter of 0.258 inches to achieve the required minimum 35 ft-lbs strip-out torque resistance. The end portions or regions of the clamp component 70 can include 60-degree chamfers and 0.03×45-degree chamfers at both ends with 0.720-inch inside diameter of outer chamfer. The field transition tie 20 is thus capable of functioning as a drop-in replacement for conventional tie rods 22 while providing enhanced versatility, reduced labor requirements, elimination of expensive reusable hardware, and the ability to customize tie end characteristics for specific project requirements including corrosion protection, stainless steel construction, varied breakneck depths, plastic cones, and fiberglass materials while utilizing inexpensive #3 rebar for the majority of the tie length.

[0054] It is intended that the invention not be limited to the particular embodiments disclosed above, but that the invention will include any and all particular embodiments and equivalents falling within the scope of the following appended claims.

Claims

1. A field transition tie, comprisinga tie assembly portion having a first tie end portion and an opposed second tie end portion having a stop surface formed thereon,a clamp component having a main body having a longitudinal opening formed therethrough to form a chamber that is sized and configured for seating a tie rod, the clamp component having a plurality of threaded fastener receiving openings formed therein that extend partly through the main body and that communicate with the chamber,a plurality of break-away fasteners, wherein each of the plurality of break-away fasteners has a main body that includes a head portion and a stem portion connected to the head portion by a break-away feature, andfirst and second strut elements that are connected to the clamp component and to the tie assembly portion to form an integrated assembly.

2. The field transition tie of claim 1, wherein the break-away feature is a cut-out portion.

3. The field transition tie of claim 2, wherein the longitudinal opening of the clamp component is aligned with the stop surface of the tie assembly portion.

4. The field transition tie of claim 3, wherein the stem portion of the break-away fasteners has a conical end portion disposed opposite the head portion.

5. The field transition tie of claim 4, wherein the first tie end portion of the tie assembly portion has a looped end portion.

6. The field transition tie of claim 4, wherein the first tie end portion of the tie assembly portion has a button head configuration.

7. The field transition tie of claim 4, wherein the clamp component has a hexagonal shape.

8. The field transition tie of claim 4, wherein the stop surface is positioned a predetermined distance from an end portion of the first tie end portion.

9. The field transition tie of claim 8, wherein the break-away fasteners are configured to have the head portion break off from the step portion when a predetermined torque is applied thereto, providing an indication that sufficient clamping force has been achieved.

10. The field transition tie of claim 9, wherein the predetermined torque is between about 28 and about 40 ft-lbs of torque.

11. A method of creating a field-assembled transition tie system, comprisingcutting a tie rod to a predetermined length,inserting a first end of the tie rod into a first clamp component of a first field transition tie until the first end of the tie rod contacts a stop surface formed on a tie assembly portion of the first field transition tie,inserting a second end of the tie rod into a second clamp component of a second field transition tie until the second end of the tie rod contacts a stop surface formed on a tie assembly portion of the second field transition tie,inserting a plurality of break-away fasteners into the clamp components of the first and second field transition ties, andtightening the break-away fasteners until a head portion breaks off of each break-away fastener, thereby securing the tie rod within the clamp components and to the first and second field transition ties to form a continuous transition tie assembly.

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