Concrete reinforcement support spacer

Abstract

A concrete reinforcement support spacer for supporting reinforcement bars at a desired elevation above a substrate during concrete pouring operations. The spacer comprises a serpentine body extending between a first end and a second end and forming alternating concave and convex portions. The serpentine body includes a top surface configured to support at least one reinforcement bar, a bottom portion, and a plurality of support feet extending downwardly from the bottom portion to rest on the substrate. An internal void space is formed within the serpentine body and is configured to receive poured concrete to facilitate full integration of the spacer with the cured concrete. In preferred embodiments, the bottom portion comprises at least one serpentine-shaped bottom portion that independently forms its own serpentine configuration. The spacer can be traversed by workers after reinforcement placement, can be vertically stacked to adjust reinforcement elevation, and can be cut to accommodate non-standard spacing requirements. The spacer is preferably manufactured as a unitary structure from recycled polymeric materials.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63 / 755,755, filed Feb. 7, 2025, entitled “CONCRETE REINFORCEMENT SUPPORT SPACER,” the entire disclosure of which is incorporated herein by reference.FIELD

[0002] The present invention relates generally to concrete construction equipment and, more particularly, to support structures for positioning and maintaining reinforcement materials at proper elevations within concrete slabs during installation and curing.BACKGROUND

[0003] In concrete construction, particularly in the formation of reinforced concrete slabs, it is essential to position reinforcing materials such as rebar, wire mesh, or other reinforcement at a specific height and location within the concrete pour. Traditional methods of achieving proper reinforcement placement typically require the assembly and installation of multiple separate components, including support bases, vertical spacers, and top supports or chairs.

[0004] Conventional concrete reinforcement support systems suffer from several disadvantages. First, they require significant labor time for assembly and installation, as workers must handle and position three or more separate parts for each support point. Second, the multiple components increase material costs, shipping expenses, and storage requirements. Third, many existing support devices cannot withstand foot traffic after placement, requiring workers to exercise extreme care when moving across the work site, which further increases installation time and labor costs.

[0005] Additionally, many prior art support devices are constructed from materials that do not fully integrate with the surrounding concrete, potentially creating weak points or voids in the finished structure. Some devices also lack sufficient void space to allow concrete to flow through and around the support structure, which can result in incomplete concrete coverage and compromised structural integrity.

[0006] Furthermore, existing support systems often lack versatility in installation configurations. When field conditions require modifications—such as accommodating different slab thicknesses, transverse footing beds, or alternative reinforcement placements—workers must either carry multiple types of support devices or perform time-consuming field modifications.

[0007] There exists a need in the art for a concrete reinforcement support system that addresses these deficiencies by providing a single-piece device that reduces installation time and labor costs, withstands foot traffic after placement, fully integrates with concrete through engineered void space design, and offers versatile installation options to accommodate varying field conditions.NOTES ON CONSTRUCTION

[0008] The use of the terms “a”, “an”, “the” and similar terms in the context of describing the invention are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising”, “having”, “including” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. The terms “substantially”, “generally” and other words of degree are relative modifiers intended to indicate permissible variation from the characteristic so modified. The use of such terms in describing a physical or functional characteristic of the invention is not intended to limit such characteristic to the absolute value which the term modifies, but rather to provide an approximation of the value of such physical or functional characteristic.

[0009] Terms concerning attachments, coupling and the like, such as “connected” and “interconnected”, refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both moveable and rigid attachments or relationships, unless specified herein or clearly indicated by context. The term “operatively connected” is such an attachment, coupling or connection that allows the pertinent structures to operate as intended by virtue of that relationship.

[0010] The use of any and all examples or exemplary language (e.g., “such as” and “preferably”) herein is intended merely to better illuminate the invention and the preferred embodiment thereof, and not to place a limitation on the scope of the invention. Nothing in the specification should be construed as indicating any element as essential to the practice of the invention unless so stated with specificity.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Further advantages of the invention are apparent by reference to the detailed description when considered in conjunction with the figures, which are not to scale so as to more clearly show the details, wherein like reference numerals represent like elements throughout the several views, and wherein:

[0012] FIG. 1 is a top plan view of a concrete reinforcement support spacer according to one embodiment of the present invention;

[0013] FIG. 2 is a bottom plan view of the spacer of FIG. 1;

[0014] FIG. 3 is a left side elevation view of the spacer of FIG. 1;

[0015] FIG. 4 is a right side elevation view of the spacer of FIG. 1;

[0016] FIG. 5 is an elevation view of a first end of the spacer shown in FIG. 1;

[0017] FIG. 6 is an elevation view of a second end of the spacer shown in FIG. 1;

[0018] FIG. 7 is a cross-sectional view of the spacer shown in FIG. 1 and taken along line “7-7”;

[0019] FIG. 8 is a detail view of a portion of the spacer shown in FIG. 1 and identified by “FIG. 8”;

[0020] FIG. 9 is a detail view of a portion of the spacer shown in FIG. 2 and identified by “FIG. 9”;

[0021] FIG. 10 depicts a building site having spacers placed beneath reinforcement bar before concrete has been poured;

[0022] FIG. 11 is a top down view of a portion of the building site of FIG. 10 showing a single spacer placed beneath reinforcement bar before concrete has been poured;

[0023] FIG. 12 is a detail view of the single spacer shown in FIG. 11;

[0024] FIG. 13 depicts a plurality of spacers shown in FIG. 1 in a stacked configuration suitable for transport; and

[0025] FIG. 14 depicts an end of the stacked configuration of spacers shown in FIG. 13 showing three spacers nested together.DETAILED DESCRIPTION

[0026] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

[0027] Referring now to FIGS. 1-6 there is shown a self-supporting concrete reinforcement support spacer 100 according to a preferred embodiment of the present invention. The spacer 100 comprises a serpentine body 102 that extends between a first end 104 and a second end 106. The serpentine body 102 forms a continuous wave-like structure along its longitudinal axis.

[0028] The serpentine body 102 forms alternating curved segments 108 that create a repeating pattern along the length of the spacer 100. These curved segments 108 define concave portions 110 having a first radius R1 and convex portions 112 having a second radius R2 that are each located along the length of the spacer 100. In the illustrated embodiment, the spacer 100 is generally linear (i.e., straight) in configuration, the first radius R1 and the second radius R2 are equivalent to one another and range from approximately 4 inches to 10 inches. However, in other embodiments, the first radius R1 and the second radius R2 may differ from one another and may have radii that are smaller than 4 inches or that are larger than 10 inches. By modifying the radii R1, R2 and / or by modifying the orientation of concave portions 110 with respect to adjacent convex portions 112, spacers 100 with non-linear configurations (e.g., round or curved) may be provided. In all cases, as illustrated, the concave portions 110 curve inwardly while the convex portions 112 curve outwardly (as viewed from the left-hand side of spacer 100 in FIG. 1), creating the characteristic serpentine or wave-like configuration.

[0029] As shown in FIG. 7, which is a cross-sectional view taken along line “7-7” in FIG. 1, the serpentine body 102 comprises a top surface 114 that extends along the length of the spacer 100 from the first end 104 to the second end 106. The top surface 114 is configured to support at least one reinforcement bar 130 (shown in FIG. 10, FIG. 11, and FIG. 12), which may be an individual “rebar” or a rebar mat / grid or the like. In the illustrated embodiment, the top surface 114 is formed by a single rib that is substantially plain or flat, providing a stable platform upon which the reinforcement bar 130 can rest. However, in other embodiments, the top surface 114 may be formed by two or more ribs and each may have a plain, flat, rounded, contoured, or provide other surface configurations. For example, in certain embodiments, channels, indentations, or other surface features (not shown) may be provided along the top surface 114 for securely positioning and, optionally, securing reinforcement bar 130 to the spacer 100.

[0030] The top surface 114 may be sized to accommodate standard reinforcement bar diameters commonly used in the construction industry. In some embodiments, the top surface 114 may be wide enough to support multiple parallel reinforcement bars 130 simultaneously, allowing a single spacer 100 to support multiple bars.

[0031] As shown in FIGS. 3, 4, and 7, the serpentine body 102 further comprises a bottom portion 118. As discussed further below, the bottom portion 118 provides the structural foundation of the spacer 100 and serves as the attachment point for support feet that contact a substrate upon which the spacer rests. Overall, when viewed in cross section (as in FIG. 7), preferred spacers 100 are generally shaped like an arrowhead or chevron, with a wide bottom portion, preferably including two or more contact points (i.e., support feet) where the serpentine body contacts the substrate, and angled sides terminating at a narrower single top surface 114.

[0032] In a significant aspect of the invention, the bottom portion 118 comprises at least one serpentine-shaped bottom portion 120 (shown as first serpentine-shaped bottom portion 120A on the left of top surface 114 and second serpentine-shaped bottom portion 120B on the right of top surface 114 in FIG. 1) that, independently of the overall serpentine body 102, forms its own serpentine configuration. As best shown in FIGS. 1 and 2 and as detailed in FIGS. 8 and 9, the serpentine-shaped bottom portion 120 includes alternating curved segments 121 that create a repeating pattern along the length of the spacer 100. These curved segments 121 define concave portions 122 having a third radius R3 and convex portions 124 having a fourth radius R4. As noted above, in the illustrated embodiment, the spacer 100 and the bottom portion 118 are generally linear (i.e., straight) in configuration, the third radius R3 and the fourth radius R4 are equivalent to one another and range from approximately 0.5 inches to 2 inches. However, in other embodiments, the third radius R3 and the fourth radius R4 may differ from one another and may have radii that are smaller than 0.5 inches or that are larger than 2 inches. By modifying the radii R3, R4 and / or by modifying the orientation of concave portions 122 with respect to adjacent convex portions 124, serpentine-shaped bottom portions 120 with non-linear configurations (e.g., round or curved) may be provided. In all cases, as illustrated, the concave portions 122 curve inwardly while the convex portions 124 curve outwardly (as viewed from the left-hand side of spacer 100 in FIG. 8), creating the characteristic serpentine or wave-like configuration.

[0033] This dual serpentine configuration, where both the overall body 102 and the bottom portion 118 have independent serpentine patterns, provides several advantages. First, it creates enhanced self-supporting structural rigidity by providing wave-like support structures in multiple orientations. Second, it maximizes an internal void space (discussed further below) that is available for concrete integration. Third, it distributes loads more effectively across the substrate.

[0034] In a preferred embodiment shown in FIG. 1, FIG. 2, FIG. 8 and FIG. 9, the serpentine-shaped bottom portion 120 comprises a pair of serpentine-shaped bottom portions 120 located on either side of the top surface 114. In the illustrated embodiment, the left serpentine-shaped bottom portion 120A is oriented opposite to the right serpentine-shaped bottom portion 120B such that a convex portion 124 of the left serpentine-shaped bottom portion is aligned with a concave portion 122 of the right serpentine-shaped bottom portions 120. This alignment creates repeating wide base sections that are separated by narrow base sections where a concave portion 122 of the left serpentine-shaped bottom portion 120A is aligned with a convex portion 124 of the right serpentine-shaped bottom portions 120B. Thus, each of the serpentine-shaped bottom portions 120 has its own wave-like pattern that is independent of the wave pattern of the overall serpentine body 102. The serpentine-shaped bottom portions 120 form the alternating concave portions 122 and convex portions 124 with radii that may be smaller than the radii of the concave portions 110 and convex portions 112 of the overall serpentine body 102. This tighter wave pattern in the serpentine-shaped bottom portions 120 provides a broader, more stable foundation while maintaining the open internal structure.

[0035] With reference to FIGS. 3-7, support feet 126 are formed at the bottom of each the serpentine-shaped bottom portion 120. Preferably, the support feet 126 are located along the entire length of the spacer 100 and provide a point of contact with a substrate 128 (e.g., aggregate, vapor barrier, etc.) upon which the spacer 100 rests (shown in FIG. 11 and FIG. 12) so as to distribute loads carried by spacer along its entire length.

[0036] Each support foot 126 comprises a base portion 132 configured to directly contact the substrate 128. The base portion 132 may have a flattened or enlarged surface area to distribute the load and prevent the spacer 100 from sinking into soft substrates or puncturing vapor barriers or other protective layers that may be present on the substrate 128. Preferably, each support foot 126 further comprises an intermediate portion 134 that forms the “serpentine” shape of the bottom portion 118 and that also connects the base portion 132 to the bottom portion 118 of the serpentine body 102. The intermediate portion 134 may taper or neck down between the base portion 132 and the bottom portion 118, providing structural strength while minimizing material usage.

[0037] The support feet 126 are spaced apart along the length of the serpentine body 102 at intervals that provide adequate stability to the spacer 100 when resting on the substrate 128. In the illustrated embodiment, the support feet 126 are positioned at regular intervals, though irregular spacing may be employed in alternative embodiments to accommodate specific load distribution requirements or substrate conditions.

[0038] A key feature of the present invention is an internal void space 136 (FIGS. 3, 4, 7, and FIG. 8) formed within the serpentine body 102. Preferably, the internal void space 136 extends substantially along the entire length of the serpentine body 102 from the first end 104 to the second end 106. The void space 136 may be formed as a single, continuous void or as multiple, separate voids. The internal void space 136 is bounded by the top surface 114, the bottom portion 118, and the interior walls of the serpentine body 102. The internal void space 136 serves multiple important functions. First, it reduces the overall weight of the spacer 100, making it easier to handle and transport. Second, it reduces material usage, lowering manufacturing costs and environmental impact. Third, and most importantly, the internal void space 136 is configured to receive poured concrete and facilitate full integration of the spacer 100 with the cured concrete structure.

[0039] When concrete is poured over the spacer 100 and the reinforcement bar 130, the liquid concrete flows into and fills the internal void space 136. Upon curing, the concrete within the internal void space 136 becomes an integral part of the surrounding concrete structure, effectively “locking” the spacer 100 into the cured concrete. This integration eliminates weak points or voids that might otherwise be created by solid spacers that do not allow concrete penetration. The volume of the internal void space 136 may be substantial. In one embodiment, the internal void space 136 has a volume of approximately 20-30 cubic inches. However, this volume will vary depending on the specific dimensions and configuration of the spacer 100. In other embodiments, the internal void space 136 has a volume less than 20 cubic inches or more than 30 cubic inches. This engineered void space 136 is specifically designed to ensure complete integration of the spacer 100 with the poured concrete while maintaining structural integrity of the spacer 100 itself.

[0040] The spacer 100, including the serpentine body 102, top surface 114, bottom portion 118, support feet 126, and all associated structures, is preferably formed as a unitary structure. That is, the spacer 100 is manufactured as a single integral piece without requiring assembly of separate components. This unitary construction provides several advantages over multi-component spacer systems. First, unitary construction eliminates the need for on-site assembly, reducing installation time and labor costs. Second, it eliminates potential weak points or failure modes associated with joints, fasteners, or other connection mechanisms. Third, it simplifies inventory management and reduces the risk of missing or mismatched components. The spacer 100 may be manufactured using various molding or forming techniques suitable for producing hollow or internally-voided structures. Suitable manufacturing methods include but are not limited to injection molding, compression molding, rotational molding (roto-molding), extrusion profile molding, vacuum forming, 3D printing (including rapid prototyping and multi-armed printing), and soft tool injection molding.

[0041] The spacer 100 may be manufactured from various polymeric materials. In a preferred embodiment, the spacer 100 is manufactured from recycled polymer materials, providing environmental benefits by diverting waste materials from landfills and reducing the consumption of virgin polymer resins. Suitable polymeric materials include but are not limited to polyethylene, polypropylene, polyvinyl chloride (PVC), acrylonitrile butadiene styrene (ABS), and various polymer blends and composites. The material selected for manufacturing the spacer 100 should possess adequate compressive strength to support the weight of reinforcement bars 130 and foot traffic, adequate stiffness to maintain the desired spacing during concrete pouring, and adequate durability to withstand handling during shipping and installation. The material should also be chemically compatible with concrete and should not adversely affect the curing process or long-term durability of the concrete structure.

[0042] The dimensions of the spacer 100 may be varied to accommodate different applications and reinforcement requirements. In representative embodiments, the height of the spacer 100 (measured from the substrate 128 to the top surface 114) may be approximately 1.56 inches, though spacers may be manufactured in various heights ranging from approximately 1 inch to 6 inches or more to accommodate different concrete slab thicknesses and required concrete cover over the reinforcement. The length of the spacer 100 (measured from the first end 104 to the second end 106) may vary based on application requirements. In one embodiment, the spacer 100 has a length of approximately 36 inches, providing support along a substantial length of reinforcement bar 130. However, lengths may range from approximately 12 to 48 inches depending on handling preferences and job site requirements. Longer spacers 100 reduce the total number of spacers required for a given project, while shorter spacers may be easier to handle and may fit more efficiently in shipping containers. The overall width of the spacer 100 (measured perpendicular to the longitudinal axis) affects the lateral stability of the supported reinforcement bar 130. In typical embodiments, the width may range from approximately 3 to 10 inches at the widest points corresponding to the maximum extent of the concave portions 110 and convex portions 112 of the overall serpentine body 102 (see width W1 in FIG. 1). Likewise, the width of the bottom portion 118 may range from approximately 1 to 3 inches at the widest points corresponding to the maximum extent of the concave portions 122 and convex portions 124 of the serpentine-shaped bottom portion 120 (see width W2 in FIG. 8). In each case, a wider spacer 100, including width W1 and width W2, provides greater resistance to tipping or rolling, particularly when subject to lateral forces during concrete pouring. The dimensions provided above are illustrative only and are not intended to limit the scope of this disclosure in any way. Persons of skill in the art will appreciate that dimensions larger or smaller than those given above may be used in alternative embodiments for various applications.

[0043] Referring now to FIG. 5 and FIG. 6, the end elevation views show the first end 104 and second end 106 of the spacer 100, respectively. These views illustrate the cross-sectional profile of the serpentine body 102 at the terminal ends, showing the relationship between the top surface 114, the bottom portion 118 with the serpentine-shaped bottom portions 120, and the support feet 126 extending downwardly therefrom.

[0044] Referring now to FIG. 10, there is shown a building site depicting the spacers 100 in use. Multiple spacers 100 are placed on the substrate 128 at desired locations. The support feet 126 rest directly on the substrate 128, supporting the serpentine body 102 at the desired elevation. Reinforcement bars 130 are positioned on the top surfaces 114 of the spacers 100. Next, as shown in FIG. 11, which provides a top-down view of a portion of the building site shown in FIG. 10, a single spacer 100 is shown placed beneath reinforcement bar 130 before concrete has been poured. This view illustrates the positioning of the spacer 100 relative to the reinforcement bar 130 and shows how multiple reinforcement bars may be oriented in different directions while being supported by the spacers 100. Lastly, as shown in FIG. 12, which is a detail view of the single spacer shown in FIG. 11, the top surface 114 provides a stable support platform for the reinforcement bar 130. The reinforcement bars 130 may be oriented parallel to the longitudinal axis of the spacers 100, perpendicular to the longitudinal axis, or at any other desired orientation. Multiple reinforcement bars 130 may be supported by a single spacer 100.

[0045] A significant advantage of the present invention is that workers can traverse over the spacers 100 after the reinforcement bars 130 have been positioned. The serpentine body 102 and support feet 126 are configured to withstand foot traffic without collapsing, bending, or allowing the reinforcement bars 130 to be displaced from their desired positions. This traversability greatly improves installation efficiency and safety, as workers do not need to carefully step around or over individual spacers as they position additional reinforcement or perform other installation tasks.

[0046] The spacers 100 may be arranged in various configurations to suit different reinforcement layouts. Spacers 100 may be positioned in a grid pattern with uniform spacing between adjacent spacers or with random or non-uniform spacing. However, advantageously, the grid pattern shown in FIG. 10 provides uniform support across the entire reinforcement field. The serpentine configuration of the spacers 100 naturally creates channels 138 between adjacent spacers 100 that allow for efficient concrete flow during pouring operations. The serpentine body 102 provides lateral stability to the reinforcement bars 130. The wave-like structure of the serpentine body 102 naturally resists lateral displacement, keeping the reinforcement bars 130 in position even when subject to forces that might otherwise cause displacement, such as foot traffic, vibration during concrete pouring, or the flow of concrete itself.

[0047] When concrete is poured over the reinforcement bars 130 and spacers 100, the liquid concrete flows around and through the spacers 100. Critically, the concrete fills the internal void spaces 136 of the spacers 100 and flows through the channels 138 between adjacent spacers 100. As the concrete cures, it hardens within the internal void spaces 136, creating a mechanical interlock between the spacers 100 and the surrounding concrete structure. This full integration of the spacers 100 with the cured concrete provides several benefits. First, it eliminates voids or weak points that might otherwise compromise structural integrity. Second, it ensures that the spacers 100 become permanent, load-bearing components of the finished structure rather than simply being embedded foreign objects. Third, it prevents potential corrosion or degradation pathways that might exist if voids remained around the spacers.

[0048] Referring now to FIGS. 13 and 14, there is shown a plurality of spacers 100 in a stacked and nested configuration suitable for transport. For shipping and storage, the spacers 100 may be bundled together in nested groups. The serpentine configuration allows multiple spacers 100 to be nested or stacked efficiently, reducing the overall volume required for shipping and storage. Bundled spacers 100 can be easily transported to job sites and distributed as needed.

[0049] In addition to stacking spacers 100 for efficient transport, spacers 100 may also be stacked vertically at the job site to adjust the elevation of supported reinforcement bars 130. For applications requiring greater concrete cover or thicker slabs, multiple spacers 100 may be stacked one atop another, with the serpentine body 102 of the upper spacer resting on the top surface 114 of the lower spacer, creating a stable stacked configuration. The spacers 100 may also be cut or trimmed to accommodate non-standard spacing requirements or to fit around obstacles. The material and construction of the spacers 100 allows them to be easily cut with common hand tools or power tools available at construction sites, providing versatility in the field.

[0050] The spacer 100 is designed to meet or exceed typical construction specifications for concrete reinforcement supports. In one embodiment, the spacer 100 has been tested and certified under the designation “DBV-40-L2,” indicating compliance with European standards (Euro code 2) for load-bearing capacity and durability. Testing has demonstrated that the spacer 100 can support loads well in excess of those encountered in typical construction applications.

[0051] The spacer 100 provides numerous advantages over prior art support systems. First, it reduces installation labor by replacing traditional multi-component systems (often requiring three or more separate parts) with a single unitary spacer. Second, it reduces installation time through faster placement and the ability to traverse the spacers during installation. Third, it reduces transportation and storage costs through efficient bundling and reduced weight. Fourth, it provides superior integration with poured concrete through the internal void space design. Fifth, it offers versatility through the ability to stack, cut, and arrange spacers in various configurations.

[0052] The spacer 100 also provides environmental benefits. The use of recycled polymer materials diverts waste from landfills and reduces reliance on virgin materials. In preferred embodiments, the spacer 100 is manufactured from 100% recycled polymeric materials, significantly reducing the carbon footprint associated with concrete construction projects. The reduced weight of the spacers 100 compared to solid alternatives reduces fuel consumption during transportation, lowering the overall environmental impact.

[0053] While the foregoing description has focused on a specific embodiment with a particular serpentine configuration, those skilled in the art will recognize that various modifications may be made without departing from the spirit and scope of the invention. For example, the amplitude and frequency of the serpentine waves may be varied. The number, size, and placement of support feet 126 may be modified. The cross-sectional shape of the serpentine body 102 may be varied. Other alternative embodiments may include spacers 100 with different overall heights to accommodate varying slab thicknesses and reinforcement placement requirements. Taller versions of the spacer 100 may be scaled up proportionally or may incorporate additional structural features such as internal ribs or buttresses to maintain rigidity at greater heights.

[0054] The top surface 114 may be modified in alternative embodiments to include features that provide additional retention or positioning assistance for reinforcement bars 130. However, the plain or flat top surface 114 of the preferred embodiment provides the advantage of accommodating reinforcement bars of any diameter and any orientation without requiring precise alignment.

[0055] The serpentine body 102 may incorporate additional features in alternative embodiments. For example, identification markings, brand names, size indicators, or orientation guides may be molded into or printed on surfaces of the spacer 100. Textured surfaces may be incorporated to improve grip or traction.

[0056] The spacer 100 may be manufactured in different colors to indicate different height ratings, load capacities, or other specifications. Color coding facilitates rapid identification and sorting of spacers on job sites where multiple spacer types may be in use simultaneously.

[0057] While the illustrated embodiment shows support feet 126 extending downwardly from the serpentine-shaped bottom portions 120, alternative configurations of support feet are possible. For example, support feet may extend from different portions of the bottom portion 118, or the number and distribution of support feet may be varied to suit specific load distribution requirements or substrate conditions.

[0058] The first radius and second radius of the concave portions 110 and convex portions 112 of the overall serpentine body 102 may be equal or different. Similarly, the third radius and fourth radius of the concave portions 122 and convex portions 124 of the serpentine-shaped bottom portion 120 may be equal or different. These radii may be selected to optimize structural performance, material usage, ease of manufacturing, and other design considerations. In some embodiments, the radii of the serpentine-shaped bottom portion 120 (third and fourth radii of concave portions 122 and convex portions 124) are smaller than the radii of the overall serpentine body 102 (first and second radii of concave portions 110 and convex portions 112). This relationship creates a configuration wherein the serpentine-shaped bottom portions 120 have tighter, more frequent waves than the overall body wave pattern, providing enhanced support structure while maintaining a large internal void space 136.

[0059] The spacers 100 may be used in various concrete construction applications including but not limited to floor slabs, foundation slabs, sidewalks, driveways, parking lots, warehouse floors, and other horizontal concrete structures. The spacers 100 may also be used in specialized applications such as overlays on existing concrete, elevated decks, and seismic-resistant structures.

[0060] The spacer 100 is particularly well-suited for large-scale projects where efficiency and cost-effectiveness are paramount. Construction projects involving thousands of square feet of concrete can realize significant labor and time savings through the use of the spacer 100 compared to traditional multi-component support systems.

[0061] The ability to traverse the spacers 100 provides particular advantages in projects requiring complex reinforcement layouts with multiple intersecting or overlapping layers of reinforcement bars 130. Workers can position and adjust reinforcement without the constant concern of damaging spacers or displacing previously-positioned reinforcement.

[0062] The material formulation of the spacer 100 can be optimized for specific environmental conditions. For example, UV-resistant formulations can be used for applications where spacers may be exposed to sunlight for extended periods before concrete pouring. Chemical-resistant formulations can be used in applications involving aggressive soil conditions or special concrete admixtures.

[0063] Having described the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. Those skilled in the art will recognize that various changes can be made to the specific embodiments described herein without departing from the spirit and scope of the invention. The dimensions, materials, and specifications provided herein are exemplary and should not be construed as limiting the scope of the invention.

Claims

1. A concrete reinforcement support spacer comprising:a serpentine body extending between a first end and a second end and forming alternating concave portions having a first radius and convex portions having a second radius, the serpentine body comprising:a top surface configured to support a reinforcement bar;a bottom portion;a plurality of support feet extending downwardly from the bottom portion, the support feet configured to rest on a substrate; andan internal void space formed within the serpentine body, wherein the internal void space is configured to receive concrete and facilitate integration of the spacer with the concrete.

2. The concrete reinforcement support spacer of claim 1, wherein the bottom portion comprises at least one serpentine-shaped bottom portion that, independently of the serpentine body, forms alternating concave portions having a third radius and convex portions having a fourth radius.

3. The concrete reinforcement support spacer of claim 2, wherein the at least one serpentine-shaped bottom portion comprises a pair of serpentine-shaped bottom portions located on opposing sides of the top surface.

4. The concrete reinforcement support spacer of claim 2, wherein the third and fourth radii are each smaller than the first and second radii.

5. The concrete reinforcement support spacer of claim 1, wherein the spacer is formed as a unitary structure comprising the top surface, the bottom portion, and the plurality of support feet.

6. The concrete reinforcement support spacer of claim 1, wherein the internal void space extends substantially along an entire length of the serpentine body from the first end to the second end.

7. The concrete reinforcement support spacer of claim 1, wherein the plurality of support feet are spaced apart along a length of the serpentine body to provide stability to the spacer when resting on the substrate.

8. The concrete reinforcement support spacer of claim 1, wherein the spacer is configured to support multiple parallel reinforcement bars simultaneously.

9. The concrete reinforcement support spacer of claim 1, wherein the serpentine body is configured to provide lateral stability to the reinforcement bar when positioned on the top surface.

10. The concrete reinforcement support spacer of claim 1, wherein each of the plurality of support feet comprises a base portion configured to contact the substrate and an intermediate portion connecting the base portion to the bottom portion.

11. A method of supporting concrete reinforcement comprising:placing a plurality of concrete reinforcement support spacers on a substrate, each spacer comprising a serpentine body with a plurality of support feet extending downwardly and an internal void space;positioning at least one reinforcement bar on a top surface of each of the plurality of spacers;traversing over the plurality of spacers after positioning the at least one reinforcement bar; andpouring concrete over the at least one reinforcement bar and the plurality of spacers, wherein the concrete fills the internal void space of each spacer to integrate the spacers with the poured concrete.

12. The method of claim 11, wherein traversing over the plurality of spacers comprises walking on the spacers without displacing the reinforcement bar.

13. The method of claim 11, further comprising arranging the plurality of spacers in a grid pattern to support multiple parallel reinforcement bars.

14. The method of claim 11, further comprising stacking multiple spacers vertically to adjust an elevation of the reinforcement bar relative to the substrate.

15. The method of claim 11, further comprising cutting at least one spacer to accommodate a non-standard spacing requirement.

16. The method of claim 11, wherein the plurality of spacers are shipped in bundles prior to placing on the substrate.

17. The method of claim 11, wherein the serpentine body of each spacer provides lateral stability to prevent displacement of the reinforcement bar during the pouring of concrete.

18. A support system for concrete reinforcement bars comprising:a plurality of spacers, each spacer comprising:a continuous serpentine structure extending along a longitudinal axis;a reinforcement support surface positioned on an upper portion of the serpentine structure;a plurality of ground-engaging feet distributed along a lower portion of the serpentine structure; anda hollow interior region configured to receive poured concrete;wherein the plurality of spacers are configured to be arranged in an array to support one or more reinforcement bars in a spaced relationship relative to a substrate.

19. The support system of claim 18, wherein each spacer is configured to be traversed by foot traffic without displacing the one or more reinforcement bars.

20. The support system of claim 18, wherein the hollow interior region of each spacer is configured to achieve full integration with poured concrete upon curing.

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