Abstract:
A rebar installation system that uses rebar drive stations to secure rebar against the inner surface of a coil for securing thereto. The system may increase the ease and speed with which the rebar can be attached while reducing the amount of manpower necessary to complete the project.

Description:
BACKGROUND 
       [0001]    The present invention is generally directed to coils for construction and, more specifically, to a rebar installation system for use with coils or reinforcement cages. 
         [0002]    Typically, reinforced coils tend to be used during construction to reinforce concrete posts. For example, a hole can be drilled, the reinforced coil placed therein and then concrete poured thereover to provide a reinforced concrete caisson, post, or pier. Conventionally, the iron spirals can be anywhere from 15 to 130 feet (or even longer) and multiple spirals can be inserted into drilled holes (once the straight rebar is attached to reinforce the coil) generally end to end to form much longer lengths. When coils are generally attached end to end there is typically a period of overlap of the spirals of a specified length and also an overlap of a portion of the rebar. That is, the rebar may also extend beyond the end of a spiral to facilitate the rebar being connected to the adjacent spiral. The iron spirals can have a diameter from anywhere from 2 to 14 feet or more. 
         [0003]    In the past, reinforced coils have been constructed by rolling a single piece of rebar through bending equipment to produce a spiral of a desired diameter, pitch, and length. Then six or so workers must each support each straight rebar piece while the supported rebar is tied to the spiral using steel tie wire. Those straight rebar pieces that must be held above the lower quarter points (points above four o&#39;clock and eight o&#39;clock) along the inside of the coil can be difficult to hold in place and the work is backbreaking and labor intensive. 
         [0004]    It may be advantageous to provide rebar installation system that avoids the need for so many workers, that simplifies the installation of rebar, and which facilitates more efficient securing of rebar in position in the coil for securing thereto. 
       SUMMARY 
       [0005]    Briefly speaking, one embodiment of the present invention is directed to a rebar installation system adapted for locating rebar along an inner surface of a coil. The rebar installation system including a rebar drive station. The rebar drive station including a main mount. A main plate is supported by the main mount and is adapted to support rebar thereon. The main plate generally defining a plane. First and second wing plates are each connected to the rebar drive station and are each configured to pivot about a separate point proximate to the main plate for rotational motion generally through the plane. The first and second wing plates are each adapted to support rebar thereon. First and second lateral rams each extend between the main mount and one of the first and second wing plates. The first and second lateral rams are configured to drive the first and second wing plates generally outwardly from the main mount. A vertical ram is generally located proximate an opposite side of the main mount from the main plate for operation generally within the plane. A wheel is located on an end of the vertical ram distal from the main support and is adapted to support the main mount on rebar. Wherein the rebar drive station is configured to move into the coil with assistance from the wheel. Once the rebar drive station is located within the coil the vertical ram is adapted to extend to cause the rebar supported by the main plate to press against the inner surface of the coil and the first and second lateral rams are adapted to extend to cause the first and second wing plates to rotate generally outwardly so that the rebar supported thereon is pressed against the inner surface of the coil. 
         [0006]    In a separate aspect, one embodiment of the present invention is directed to a rebar installation system adapted for locating rebar along an inner surface of a coil. The rebar installation system including a rebar drive station. The rebar drive station including a main mount. A main plate is supported by the main mount and is adapted to support rebar thereon. First and second wing plates are each connected to the rebar drive station and are configured to each pivot about a separate point proximate to the main plate for rotational motion. First and second lateral rams each extend between the main mount and one of the first and second wing plates. The first and second lateral rams are configured to drive the first and second wing plates generally outwardly from the main mount. A vertical ram is generally located proximate an opposite side of the main mount from the main plate for operation generally within the plane. A wheel is located on an end of the vertical ram distal from the main support and is adapted to support the main mount on rebar. Wherein the rebar drive station is configured to move into the coil along a central longitudinal axis thereof with assistance from the wheel. Once the rebar drive station is located within the coil the vertical ram is adapted to extend to cause the rebar supported by the main plate to press against the inner surface of the coil and the first and second lateral rams are adapted to extend to cause the first and second wing plates to rotate generally outwardly so that the rebar supported thereon is pressed against the inner surface of the coil. 
         [0007]    In another aspect, the present invention is directed to a rebar installation system adapted for locating rebar along an inner surface of a coil. The rebar installation system including a rebar drive station. The rebar drive station including a main mount. A main plate is supported by the main mount and is adapted to support rebar thereon. The main plate generally defining a plane. First and second wing plates are each connected to the rebar drive station and are each configured to pivot about a separate point proximate to the main plate for rotational motion generally through the plane. The first and second wing plates are each adapted to support rebar thereon. Wherein the rebar drive station is configured to move into the coil with assistance from the wheel. Once the rebar drive station is located within the coil the rebar drive station is adapted to cause the rebar supported by the main plate to press against the inner surface of the coil and the to cause the first and second wing plates to rotate generally outwardly so that the rebar supported thereon is pressed against the inner surface of the coil. 
         [0008]    In a separate aspect, the present invention is directed to a rebar drive station including a main mount. A main plate is supported by the main mount and is adapted to support rebar thereon. First and second wing plates are each connected to the rebar drive station and are each configured to pivot proximate to the main plate for rotational motion. The first and second wing plates are each adapted to support rebar thereon. Wherein the rebar drive station is configured to move into the coil with assistance from the wheel. Once the rebar drive station is located within the coil the rebar drive station is adapted to cause the rebar supported by the main plate to press against the inner surface of the coil and to cause the first and second wing plates to rotate generally outwardly so that the rebar supported thereon is pressed against the inner surface of the coil. 
         [0009]    In a separate aspect, the present invention is directed to a rebar drive station including a main mount. A main plate is supported by the main mount and is adapted to support rebar thereon. First and second wing plates are each connected to the rebar drive station and are each configured to pivot proximate to the main plate for rotational motion. The first and second wing plates are each adapted to support rebar thereon. Wherein the rebar drive station is configured to move into the coil with assistance from the wheel. Once the rebar drive station is located within the coil the rebar drive station is adapted to cause the rebar supported by the main plate to press against the inner surface of the coil and to cause the first and second wing plates to rotate generally outwardly so that the rebar supported thereon is pressed against the inner surface of the coil. Wherein the outer surface of the main and first and second wing plates is arcuate and are configured such that when the main and first and second wing plates are pressing rebar against the inner surface of the coil there is rebar spaced along the coil generally along the upper half of the coil. 
         [0010]    In a separate aspect, the present invention is directed to a method of attaching rebar to an inner surface of a coil. The method includes the steps of: positioning rebar on at least two drive stations; moving at least two rebar drive stations into a coil by moving the at least two drive stations generally along a longitudinal axis thereof; moving a main plate of each rebar drive station toward the inner surface of the coil to secure rebar against an inner surface of the coil; and moving first and second wing plates of each rebar drive station about separate pivot points to secure rebar against an inner surface of the coil, the main and first and second wing plates of each drive station moving through a common plane, wherein the outer surface of the main and first and second wing plates of each rebar drive station are arcuate and are configured such that when the main and first and second wing plates are pressing rebar against the inner surface of the coil there is rebar spaced along the coil generally along a segment of the inner circumference of the coil. 
         [0011]    In a separate aspect, the present invention is directed to a rebar installation system adapted for locating rebar along an inner surface of a coil. The rebar installation system including a rebar drive station. The rebar drive station including a main mount. A main plate is supported by the main mount and is adapted to support rebar thereon. The main plate generally defining a plane. First and second wing plates are each connected to the rebar drive station and are each configured to pivot about a separate point proximate to the main plate for rotational motion generally through the plane. The first and second wing plates are each adapted to support rebar thereon. First and second lateral rams each extend between the main mount and one of the first and second wing plates. The first and second lateral rams are configured to drive the first and second wing plates generally outwardly from the main mount. A vertical ram is generally located on the main mount generally within the plane. Wherein once the rebar drive station is located within the coil the vertical ram is adapted to extend to cause the rebar supported by the main plate to press against the inner surface of the coil and the first and second lateral rams are adapted to extend to cause the first and second wing plates to rotate generally outwardly so that the rebar supported thereon is pressed against the inner surface of the coil. 
         [0012]    In a separate aspect, the present invention is directed to a rebar installation system adapted for locating rebar along an inner surface of a coil. The rebar installation system including a rebar drive station. The rebar drive station including a main mount. A main plate is supported by the main mount and is adapted to support rebar thereon. First and second wing plates are each connected to the rebar drive station and are each configured to pivot about a separate point proximate to the main plate. The first and second wing plates are each adapted to support rebar thereon. Wherein once the rebar drive station is located within the coil the vertical ram is adapted to press against the inner surface of the coil and the first and second wing plates are configured to press the rebar supported thereon against the inner surface of the coil. 
         [0013]    In a separate aspect, the present invention is directed to a rebar installation system adapted for locating rebar along an inner surface of a coil. The rebar installation system including a rebar drive station. The rebar drive station including a main mount. A main plate is supported by the main mount and is adapted to support rebar thereon. First and second wing plates are each connected to the rebar drive station and are each configured to pivot about a separate point proximate to the main plate. The first and second wing plates are each adapted to support rebar thereon. Wherein once the rebar drive station is located within the a single ram is adapted to drive the rebar supported on the main plate against the inside of the coil and to drive the first and second wing plates to press the rebar supported thereon against the inner surface of the coil. 
         [0014]    In a separate aspect, the present invention is directed to a rebar installation system adapted for locating rebar along an inner surface of a coil. The rebar installation system including a rebar drive station. The rebar drive station including a main mount. A main plate is supported by the main mount and is adapted to support rebar thereon. First and second wing plates are each connected to the rebar drive station and are each configured to pivot about a separate point proximate to the main plate. The first and second wing plates are each adapted to support rebar thereon. Wherein once the rebar drive station is located within the a single ram is adapted to drive the rebar supported on the main plate against the inside of the coil and to drive the first and second wing plates to press the rebar supported thereon against the inner surface of the coil. The single ram being connected to the first and second lateral wing plates via a drive yolk. 
         [0015]    In a separate aspect, the present invention is directed to a rebar installation system adapted for locating rebar along an inner surface of a coil. The rebar installation system including a rebar drive station. The rebar drive station including a main mount. A main plate is supported by the main mount and is adapted to support rebar thereon. First and second wing plates are each connected to the rebar drive station and are each configured to pivot about a separate point proximate to the main plate. The first and second wing plates are each adapted to support rebar thereon. Wherein once the rebar drive station is located within the a single ram is adapted to drive the rebar supported on the main plate against the inside of the coil and to drive the first and second wing plates to press the rebar supported thereon against the inner surface of the coil. The single ram being connected to the first and second lateral wing plates via a bell crank. 
         [0016]    In another aspect the present invention is directed to a method of attaching rebar to an inner surface of a coil. The method including the steps of: positioning rebar on at least two drive stations; moving at least two rebar drive stations into a coil by moving the at least two drive stations generally along a longitudinal axis thereof; moving a main plate of each rebar drive station toward the inner surface of the coil to secure rebar against an inner surface of the coil; and moving first and second wing plates of each rebar drive station about separate pivot points to secure rebar against an inner surface of the coil, wherein the moving of the main plate and the moving of the first and second wing plates is driven by a single ram. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0017]    The foregoing summary, as well as the following detailed description of the preferred embodiments of the present invention will be better understood when read in conjunction with the appended drawings. For purposes of illustrating the invention, there are shown in the drawings, embodiments which are presently preferred. It is understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings: 
           [0018]      FIG. 1  is a perspective view of coil being positioned within a hole prior to the insertion of concrete; The coil is being hoisted by a crane and includes a generally circular shape with straight rebar pieces reinforcing the coil; The rebar is generally spaced along an inner surface of the coil; The coil can be any one of a coil, a spiral, a spiral coil, a reinforcement cage, a reinforcement structure or the like without departing from the scope of the present invention; 
           [0019]      FIG. 2  is a perspective view of a preferred rebar installation system according to the present invention; A carrier vehicle may be used to transport multiple rebar drive stations into a coil along a generally central longitudinal axis of the coil; The vehicle may include a hydraulic fluid reservoir, a hydraulic pump, an engine to drive the hydraulic fluid, and wheels powered by hydraulic or electric motors, controls and an operator&#39;s station or the like; Hydraulic hoses and or other control lines may extend from the vehicle through a rod (also referred to as a main mount or support member (which can be a rectangle, square, round or irregular shape when viewed in cross-section)) to the drive station(s); The rebar drive stations can include a main plate and first and second wing plates that can each support rebar; 
           [0020]      FIG. 3  is a perspective view illustrating the rebar drive stations just prior to insertion into a coil along a longitudinal axis of the coil; The coil may be supported on a spiral jig or the like; The first and second wing and main plates are generally retracted prior to insertion so that the outer diameter of the drive stations (including the supported rebar) is less than the inner diameter of the coil; 
           [0021]      FIG. 4  is a perspective view illustrating the rebar drive stations just after insertion into a coil; Although a preferred carrier vehicle is shown for movement of the rebar drive stations into the coil those of ordinary skill in the art will appreciate from this disclosure that any suitable mechanism or method for movement of the rebar drive stations may be used without departing from the scope of the present invention; 
           [0022]      FIG. 5  is side elevational view of the rebar drive system of  FIG. 2  illustrating that tube sections (also referred to as main mounts) can be assembled end-to-end to create a rebar installation system in which multiple rebar drive stations cooperate to lift lengths of rebar that can be hundreds of feet in length or more; the dashed assembly line shows the alignment that will be needed between the rebar installation system and the coil to allow insertion; As shown in more detail in  FIGS. 11 and 17  it is preferable that the various tube sections are connected by bolting together connection plates and securing any fluid or control lines via quick connects; The preferred sectional nature of the rebar installation system allows the system to be used with coils of any length; 
           [0023]      FIG. 6  is a side elevational view of the rebar installation system of  FIG. 2  showing the drive stations mostly inserted into the coil; Coil supporting jigs or any other stabilizing structure may be spaced at any desired interval to allow the coil to be held securely in position during the rebar installation process; 
           [0024]      FIG. 7  is a perspective view of a preferred embodiment of a jig used to support the coil; The jig may include tubes, tube segments and holders that face generally inwardly to support a piece of rebar therein; The rebar supported by the holders preferably forms a bearing surface against which the coil can be positioned; 
           [0025]      FIG. 8  is a perspective view of the jig of  FIG. 7  supporting a coil therein; The exterior of the coil is preferably positioned against straight rebar pieces that are supported by the holders; 
           [0026]      FIG. 9  is a front view of the jig showing illustrating how the jig can be adjusted to support coils of various diameters; A coil of smaller diameter is shown in solid lines and larger diameter coils, as well as the position of parts of the jigs to accommodate such coils, is shown in phantom lines; This can allow the jigs used to support coils to be used with coils of various diameters; Alternatively, the jig may not be adjustable or may only be partially adjustable (such as only allowing the top bar to be detached) without departing from the scope of the present invention; 
           [0027]      FIG. 10  is an exploded view of the rebar installation system of  FIG. 2  showing the vehicle with a main mount and connection plate thereto; The connection plate on the vehicle can be used to attach to a tube section with rebar drive stations located thereon; Additional tube sections can be added as desired to increase the length over which the rebar installation system extends; A main mount (or tube section) can have zero, one, two, or more rebar drive stations located thereon without departing from the scope of the present invention; 
           [0028]      FIG. 11  is a partial perspective view illustrating a preferred rebar drive station; The rebar drive station can include a main mount (or tube section); A main plate may be supported by the main mount and can be adapted to support rebar thereon; The main plate can generally define a plane; First and second wing plates may each be connected to the rebar drive station and each configured to pivot about a separate point proximate to the main plate for rotational motion generally through the plane; The first and second wing plates are preferably each adapted to support rebar thereon; First and second lateral rams can each extend between the main mount and one of the first and second wing plates; The first and second lateral rams may be configured to drive the first and second wing plates generally outwardly from the main mount; A vertical ram can be generally located proximate an opposite side of the main mount from the main plate for operation generally within the plane. A wheel may be located on an end of the vertical ram distal from the main support and to support the main mount on rebar; Hydraulic hose lines may include quick connects to facilitate connection therewith; Holes are shown proximate to cutouts which may be used to allow steel ties to be inserted therethrough and then twisted about a corresponding portion of rebar; 
           [0029]      FIG. 12  is a partial perspective view illustrating a rebar drive station with the first and second wing plates and the main plate extended and supporting rebar thereon; Rebar is also supported on temporary rebar supports located under the main mount; Although the first and second wing plates and the main plate are shown fully extended, in use the first and second wing plates and the main plate may only be partially extended due to the size of the inner diameter of the coil; The use of the first and second wing plates and the main plate in the fully extended position correspond to the use of the rebar drive station with a coil that has the maximum interior diameter with which the rebar installation system is configured to operate; 
           [0030]      FIG. 13  is a partial perspective view illustrating a rebar drive station with the first and second wing plates and the main plate retracted and supporting rebar thereon; Dashed lines also illustrate how the first and second wing plates, the main plate, and the wheel are all preferably configured for movement within a common plane; those of ordinary skill in the art will appreciate from this disclosure that the first and second wing plates, the main plate, and the wheel can all be offset so that they don&#39;t operate in the same plane without departing from the scope of the present invention; 
           [0031]      FIG. 14  is a front view of the rebar drive station of  FIG. 13  illustrating the first and second wing plates and the main plate extended; It is preferred, but not necessary that the position of the main plate is adjusted by operation of the vertical ram located under the main mount; As such, the main plate is considered to be extended when the vertical ram lifts the main mount on which the main plate is supported; 
           [0032]      FIG. 15  is a front view of the rebar drive station of  FIG. 14  with the first and second wing plates and the main plate retracted; It is preferred that the retraction of the main plate is accomplished by withdrawal of the vertical ram that is located below the main mount; However, those of ordinary skill in the art will appreciate from this disclosure that the main plate may be moveably connected to the main mount via a ram located above the main mount; 
           [0033]      FIG. 16  is a front view of the rebar drive station of  FIG. 14  with the first and second wing plates and the main plate extended to press the supported rebar against the inner surface of the coil; While in this example the plates are not fully extended they are extended to the proper distance for pressing rebar against the inside of coil of the size shown; Arrows also show the movement of rebar from the temporary rebar supports to the lower half of the coil; The temporary rebar supports allow the rebar to be manually positioned in a ready fashion; The temporary rebar supports can in some embodiments support enough rebar for the entire reinforcement operation and the amount of rebar supported thereon can be greatly larger than that shown without departing from the scope of the present invention; 
           [0034]      FIG. 17  is a broken away view showing two tube sections secured together using the connection plates; The figure also illustrates that the main and lateral wing plates and wheel may all generally operate within a common plane (also shown in  FIG. 13 ); The main mount may be formed by a tube section that includes a housing located thereunder that encloses at least part of the vertical ram; The main mount can also be formed out of a modified I-beam or any other suitable structure without departing from the scope of the present invention; 
           [0035]      FIG. 18  is an enlarged broken away perspective view showing the wheel of a rebar drive station positioned on a straight section of rebar; To move the rebar drive stations into the coil it is preferred that a piece of generally straight guide rebar is positioned at the lowest central point on the inner surface of the coil; Wheels for each of the rebar drive stations may be positioned on the guide rebar such that the wheels provide vertical support for the rebar drive stations and associated tube sections during insertion into the coil; 
           [0036]      FIG. 19  illustrates how the rebar drive station of  FIG. 11  can be used with coils having different diameters; Phantom lines illustrate the positioning of the first and second wing plates, the main plate, and the wheel when used with a larger diameter coil; 
           [0037]      FIG. 20  illustrates a second preferred embodiment of a rebar drive station that uses a two bar linkage with each of the first and second wing plates to increase the distance along which the plates can be extended; the rebar drive station is shown with the first wing plate extended; 
           [0038]      FIG. 21  illustrates the rebar drive station of  FIG. 20  with the first wing plate retracted; 
           [0039]      FIG. 22  is a partial broken away view of a third preferred embodiment of a rebar drive station that uses a single vertical ram to operate the main and first and second wing plates; the vertical ram may be a double sided piston that projects above and below the central tube; a bell crank may be connected to a support plate about a bell crank center of rotation with one end of the bell crank connected to a top end of the vertical ram piston and another end of the bell crank being connected to a wing plate; Another bell crank may also be secured to the top of the vertical ram piston to allow both first and second wing plates to be simultaneously operated be a single ram; This may allow the rebar drive station to operate using a single ram;  FIG. 22  illustrates the rebar drive station with the single vertical ram positioned so as to fully extend the main and first and second wing plates; 
           [0040]      FIG. 23  is a partial broken away view similar to  FIG. 22  showing the single vertical ram positioned to retract the main and first and second wing plates; 
           [0041]      FIG. 24  is a partial broken away view of a fourth preferred embodiment of the rebar drive station of the present invention; The lateral support plate  78  may include a lever that extends outwardly from the pin in generally another direction from the lateral support plate to engage a lateral ram; The rebar drive station is shown with the main and first and second wing plates extended; 
           [0042]      FIG. 25  is a partial broken away view of the rebar drive station of  FIG. 24  showing the lateral ram  132  extended to retract the associated lateral wing plate; 
           [0043]      FIG. 26  is a partial broken away view of a fifth preferred embodiment of the rebar drive station of the present invention; The wheel may be slidably positioned within a sleeve; A spring can be connected between the wheel and the lower end of the double sided piston; The top end of the piston can be secured to a drive yolk; The drive yolk can be connected to a lever of the lateral wing plate via a cam slot;  FIG. 26  shows the rebar drive station with the ram piston fully withdrawn to cause the lateral wing plates to be fully extended and the wheel to be fully extended; 
           [0044]      FIG. 27  is a partial broken away view of the rebar drive station of  FIG. 26  located within a coil; The vertical ram can piston may be fully extended to cause the lateral wing plates and wheel to retract to allow the rebar drive station to be inserted into the coil; and 
           [0045]      FIG. 28  is a partial broken away view of the rebar drive station of  FIG. 26  which illustrates the vertical ram piston partially retracted to slightly extend the first and second lateral wing plates and to cause the bottom wheel to extend and drive the main plate against the inside of the coil. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0046]    Certain terminology is used in the following description for convenience only and is not limiting. The words “right,” “left,” “upper,” and “lower” designate directions in the drawings to which reference is made. The words “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the rebar installation system and designated parts thereof. The term “coil”, as used in the claims and the corresponding portions of the specification, means “any one of a coil, a spiral, a spiral coil, a reinforcement cage, a rectilinear reinforcement cage, a reinforcement structure or the like.” The term “generally within the same plane” or the like, as used in the claims and in corresponding portions of the specification, is understood to include components that move within planes that are planar parallel and spaced apart by up to six inches. The terminology includes the words above specifically mentioned, derivatives thereof, and words of similar import. Additionally, the words “a” and “one” are defined as including one or more of the referenced item unless specifically stated otherwise. 
         [0047]    Referring to  FIGS. 1-21 , wherein like numerals indicate like elements throughout, preferred embodiments of a rebar installation system are shown and designated as  30 . Briefly stated, rebar installation system is adapted to secure rebar in position inside a coil to facilitate securing the rebar in position to form a concrete reinforcement cage (shown supported by a crane  42  in  FIG. 1 ). 
         [0048]    The rebar installation system  30 , the rebar drive station  36 , and their component parts are preferably formed from a half inch plate which may be formed by steel, alloy, or any other suitable material. However, those of ordinary skill in the art will appreciate from this disclosure that the rebar installation system and its various components can be formed from any materials having any suitable thicknesses without departing from the scope of the present invention. 
         [0049]    Referring to  FIGS. 2 ,  10 , and  15 , the rebar installation system  30  is adapted for locating rebar  40  along an inner surface of a coil  38 . The coil  38  is preferably used to stabilize and reinforce a poured or cast concrete structure. The coil is preferably formed of steel but may be formed of any suitable material. The coil  38  may be formed by a spiral bar or bars or may be formed by discrete circular steel members. Alternatively, the coil  38  may have a non-circular cross sectional shape without departing from the scope of the present invention. If the coil  38  is a spiral it preferably has a pitch of two inches or more and may vary along the caisson. 
         [0050]    Referring to  FIGS. 7-9 , it is preferred, but not necessary, that the coil  38  is supported by a jig  54  while the rebar installation system  30  is inserted along a longitudinal axis  116  (shown in  FIG. 5 ) of the coil  38 . The jig preferably includes adjustable tubes  56  and tube segments  58  to accommodate coils  38  of different diameters. The ends of the tube segments  58  that are proximate the coil preferably include holders  100  that support rebar  40  against which the exterior of the coil is positioned. Although one preferred method of supporting the coil is disclosed, those of ordinary skill in the art will appreciate from this disclosure that any suitable method for securing the coil  38  can be used with the rebar installation system without departing from the scope of the present invention. 
         [0051]    The rebar installation system  30  is adapted to allow installation of rebar  40  along an inner surface of the coil in a spaced apart, or adjoining, side by side fashion to reinforce the coil  38  as shown in  FIG. 1 . When the coil is properly reinforced it may be positioned using a crane  42 . Referring still to  FIG. 1 , the crane may use cabling  44 , pulleys  52 , and a support  46  to maneuver the reinforced coil  38 . Those of ordinary skill in the art will appreciate from this disclosure that any suitable mechanism can be used to move the reinforced coil without departing from the scope of the present invention. 
         [0052]    The rebar installation system  30  preferably includes a rebar drive station  36 . One or more rebar drive stations  36  may be used to position rebar  40  against the coil  38  to allow the rebar  40  to be secured thereto. One method of securing the rebar is to use steel ties. However, welding or any other suitable attachment method can be used without departing from the scope of the present invention. 
         [0053]    Referring to  FIG. 11 , the rebar drive station  36  preferably includes a main mount  32 . The main mount  36  can, but is not necessarily, formed by a tube section which may have at least one end with a connection plate  92  thereon. While the tube section  32  is illustrated as having a generally square cross-sectional shape and being hollow, those of ordinary skill in the art will appreciate from this disclosure that the tube section may have any shape and may not define a hollow passage without departing from the scope of the present invention. The hollow which is preferably defined by the tube section  32  may allow for hydraulic fluid lines  95 ,  97 ,  99  and/or control lines to be located therein (further described below). 
         [0054]    The main mount  36  is preferably adapted to engage another tube section  104 ,  106 . The other tube section preferably has at least one rebar drive station  36 . As shown in  FIGS. 5  and  10 , the can allow the rebar installation system  30  to be adjusted in length depending on the coil  38  in which rebar  40  is being installed. 
         [0055]    Referring to  FIGS. 13 ,  14 , and  16 , it is preferred, but not necessary that the main mount comprises a tube section  32  and a housing  76  located thereon which is adapted to secure a vertical ram  96  to the rebar drive station  36 . The vertical ram  96  is preferably located below the tube section  32  and is partially enclosed by the housing  76  such that the ram piston  94  extends therefrom. The vertical ram  96  (as well as the first and second lateral rams  64 A,  64 B which are further described below) are preferably formed by hydraulic rams having pistons  94 . Alternatively, the vertical ram  96  can be housed in the tube section or otherwise positioned in any suitable fashion without departing from the scope of the present invention. If the vertical ram  96  is located within the tube section  32 , then any control lines could pass along a side of the vertical ram  96  or the outside of the tube  32 . However, those of ordinary skill in the art will appreciate from this disclosure that any suitable drive mechanism, solenoid, gear arrangement, electrical motor, or gearing can be used to drive the rams  64 A,  64 B,  96  without departing from the scope of the present invention. 
         [0056]    Referring to  FIG. 16 , flanges  74  may extend laterally outwardly from the rebar drive station. The flanges  74  may form rebar supports for temporarily holding rebar  40  during insertion of the rebar installation system  30  into a coil  38 . The flanges  74  are preferably adapted to support rebar  40  thereon to facilitate transport and manual removal thereof. Once the rebar installation system  30  is inserted into the coil  38 , rebar  40  located on the flanges  74  can be manually removed and positioned along the inner surface of the coil  38  generally, but not necessarily, at locations below the midway height or the bottom one third of the height of the coil  38  and manually held for securing to the coil. Manual placement of rebar  40  at lower points on the coil  38  is easier since the rebar  40  does not have to be lifted by a substantial amount and in most cases is moved downwardly from the flanges  74 . Dashed circles on the left rebar support  74  show the position in which rebar  40  held during insertion of the rebar installation system  30  into the coil. Arrows extending from the dashed circles show the path through which the rebar  40  was moved for placement along an inner surface of the coil  38 . While it is preferred that two rebar supports  74  extend from either side of the housing  76  of the tube section  32 , those of ordinary skill in the art will appreciate from this disclosure that any number of rebar supports  74  can be used or omitted altogether without departing from the scope of the present invention. 
         [0057]    Referring to  FIG. 12 , a main plate  60  is preferably supported by the main mount  32  and is adapted to support rebar thereon  40 . The main plate  60  may have a generally arcuate upper surface and can include notches or cutouts  66  therein for supporting rebar  40 . While the main plate  60  is shown as supporting five generally evenly spaced pieces of rebar  40 , those of ordinary skill in the art will appreciate from this disclosure that the main plate can be configured to hold any number of rebar and may use irregular spacing without departing from the scope of the present invention. 
         [0058]    Referring to  FIG. 13 , it is preferably, but not necessary, that the main plate  60  generally defining a plane  63  (which is shown in phantom lines). The main mount  32  may include a support plate  70  thereon on which the main plate  60  is positioned. It is preferred that the main plate  60  is connected to the support plate  70  via bolts  80 . However, those of ordinary skill in the art will appreciate from this disclosure that the main plate  60  and the support plate  70  can be connected using any suitable method or may be formed as a single piece without departing from the scope of the present invention. 
         [0059]    Referring to  FIGS. 14 and 17 , it is preferred that first and second wing plates  62 A,  62 B are each connected to the rebar drive station  36  and each configured to pivot about a separate point  68  proximate to the main plate  60  for rotational motion generally through the plane  63 . It is more preferred, but not necessary, that the first and second wing plates  62 A,  62 B are pivotally connected to the main plate  60  by pin  82  at pivot point  68 . 
         [0060]    The first and second wing plates  62 A,  62 B are each adapted to support rebar thereon. While first and second wing plates  62 A,  62 B are each shown as supporting three generally evenly spaced pieces of rebar  40 , those of ordinary skill in the art will appreciate from this disclosure that the first and second wing plates  62 A,  62 B can be configured to hold any number of rebar  40  and may use irregular spacing without departing from the scope of the present invention. While the preferred rebar drive stations  36  are shown with three rebar supporting plates  60 ,  62 A,  62 B, those of ordinary skill in the art will appreciate from this disclosure that additional sets of two wing plates may be added to increase the size of coil with which the rebar installation system can operate. That is secondary wing plates can each be added to the ends of the first and second wing plates  62 A,  62 B to allow the rebar installation system  30  to be modified on site to operate with even larger diameter coils  38  or to increase the segment of the coil along which rebar is positioned without departing from the scope of the present invention. 
         [0061]    It is preferred that the outer surface of the main plate  60  and first and second wing plates  62 A,  62 B is arcuate and is configured such that when the main plate  60  and first and second wing plates  62 A,  62 B are pressing rebar  40  against the inner surface of the coil  38  (as shown in  FIG. 16 ) there is rebar spaced along the coil generally along the upper half of the coil  38 . It is more preferred that the main plate  60  and first and second wing plates  62 A,  62 B are configured such that when the main plate  60  and first and second wing plates  62 A,  62 B are pressing rebar  40  against the inner surface of the coil  38  there is rebar  40  spaced along the coil  38  generally along approximately fifty percent of the inner circumference of the coil  38 . It is further preferred that the main plate  60  and first and second wing plates  62 A,  62 B are configured such that when the main plate  60  and first and second wing plates  62 A,  62 B are pressing rebar  40  against the inner surface of the coil  38  there is rebar  40  spaced along the coil  38  generally along approximately fifty five percent of the inner circumference of the coil  38 . It is more preferred still that the main plate  60  and first and second wing plates  62 A,  62 B are configured such that when the main plate  60  and first and second wing plates  62 A,  62 B are pressing rebar  40  against the inner surface of the coil  38  there is rebar  40  spaced along the coil  38  generally along approximately sixty percent of the inner circumference of the coil  38 . 
         [0062]    It is preferred, but not necessary, that flanges  74  extend generally laterally outwardly from the rebar drive station  36  and are adapted to support rebar  40  thereon to facilitate transport and manual removal thereof. Each of the first and second wing plates  62 A,  62 B may include a lateral support plate  78 . 
         [0063]    Referring to  FIG. 14 , first and second lateral rams  64 A,  64 B can each extend between the main mount  32  and one of the first and second wing plates  62 A,  62 B. The first and second lateral rams  64 A,  64 B can each configured to drive the first and second wing plates  62 A,  62 B generally outwardly from the main mount  32 . It is preferred that the first and second lateral rams  64 A,  64 B and the vertical ram  96  are formed by hydraulic pistons. Control lines  95 ,  97 ,  99  for the hydraulic pistons may extend at least partially through the tube section  32 . The rams can be formed by any suitable solenoid, gearing arrangement or gearing without departing from the scope of the present invention. 
         [0064]    It is preferred, but not necessary that the position of the main plate  60  is adjusted by operation of the vertical ram  96  located under the main mount  32 . As such, the main plate  60  may be considered to be extended when the vertical ram  96  lifts the main mount  32  on which the main plate  60  is supported. A vertical ram may be generally located proximate an opposite side of the main mount  32  from the main plate for operation generally within the plane  63 . 
         [0065]    Referring to  FIGS. 17 and 18 , a wheel  72  may be located on an end of the vertical ram  96  distal from the main support  32  and may be adapted to support the main mount  32  on rebar  40 . It is preferred, but not necessary, that the rebar drive station  36  is configured to move into the coil  38  with assistance from the wheel  72 . Once the rebar drive station  36  is located within the coil  38  the vertical ram  96  may be adapted to extend to cause the rebar  70  supported by the main plate  60  to press against the inner surface of the coil  38  and the first and second lateral rams  64 A,  64 B can be adapted to extend to cause the first and second wing plates  62 A,  62 B to rotate generally outwardly so that the rebar  40  supported thereon is pressed against the inner surface of the coil  38 . Those of ordinary skill in the art will appreciate from this disclosure that the wheel  72  can be omitted without departing from the scope of the present invention. 
         [0066]    Referring to  FIGS. 2-6 , a carrier vehicle  34  may support another connection plate  92  that is adapted to secure at least one main mount  32  thereto. The at least one main mount  32  preferably including the rebar drive station  36 . The carrier vehicle  34  may include a reservoir  93 , pump  101 , and pump engine  103  for supplying fluid to the vertical and first and second lateral rams  64 A,  64 B,  96  and can also includes controls  105  for operating any rebar drive stations  36  connected thereto. The reservoir  93  is preferably be in fluid communication with rebar drive stations  36  connected to the carrier vehicle  30  via fluid conduits  95 ,  97 ,  99  which extend through a tube  32  that forms the main mount  32 . The vehicle may include wheels  50  driven by motors  107  along tracks  48 . While one preferred configuration for the vehicle  34  and one preferred method of moving the rebar drive stations  36  is disclosed, those of ordinary skill in the art will appreciate from this disclosure that any suitable mechanism or method for positioning at least one rebar drive station within the coil  38  can be used without departing from the scope of the present invention. 
         [0067]    As shown in  FIG. 19 , the rebar drive station  36  can preferably be separately used with coils  38  having different inner diameters. This allows a single rebar installation system  30  to preferably be useable with projects involving coils having different diameters instead of needing a separately constructed rebar installation system every time a coil of a new diameter is to be worked on. By adjusting the displacement of the vertical and first and second hydraulic rams  96 ,  64 A,  64 B, the rams can preferably cooperate with the curved outer surface of the main and first and second wing plates  60 ,  62 A,  62 B to position the supported rebar  40  at locations corresponding to different coil inner diameters, thus increasing the range of coils  38  with which the rebar drive station  36  can be used. 
         [0068]    It is preferred, but not necessary, that a controller  103  allows the first and second lateral rams  64 A,  64 B to be simultaneously operated. Referring to  FIG. 5 , it is preferred that at least one stability rod  110  is disposed on the main mount  32  or another portion of the tube section such that the rod  110  is configured to abut the inner surface of the coil to assist in the stabilization of the rebar drive station  36  and supporting tube, rod, or main mount  32  during insertion into the coil. It is preferably that at least two stability rods  110  are located proximate an end of the rebar installation system distal from the vehicle to help control torque that is experienced by the central tube during insertion into the coil  38 . It is further preferably, but not necessary that two stability rods are provided for each direction of torque and that the rods may be adjustable and/or removable. Additional stability rods may also be located at intermediate locations along the length of the whole tube that is inserted in to the coil during the reinforcement process. 
         [0069]    Referring to  FIGS. 20 and 21 , an alternative embodiment of the rebar installation system  30  may include a two bar linkage positioned between each of the first and second wing plates  62 A,  62 B and the main support  32 . The two bar linkage is formed by first and second links  122 A,  122 B joined at a linkage pivot  124 . Each of the first and second lateral rams  64 A,  64 B preferably extend between the linkage pivot  124  associated with one of the first and second wing plates  62 A,  62 B and the main mount  60 . The main mount  32  of either embodiment may include lateral plates  84 . 
         [0070]    A preferred embodiment of attaching rebar to an inner surface of a coil according to the present invention is described below. Those of ordinary skill in the art will appreciate from this disclosure that generally similar steps and generally similar structural components of the rebar installation system  30  described below may: generally have similar structure, generally include similar alternate constructions, and generally operate in a similar manner as that described above, unless stated otherwise. The steps of the method of the present invention can be performed in any order, interchanged with other steps, or omitted, without departing from the scope of the present invention. 
         [0071]    One preferred method of the present invention for attaching rebar  40  to an inner surface of a coil  38  includes the step of positioning rebar  40  on at least two drive stations  36 . At least two rebar drive stations  36  are moved into a coil by moving the at least two drive stations  36  generally along a longitudinal axis  116  thereof (i.e., along a longitudinal axis  116  of the coil  38 ). A main plate  60  of each rebar drive station  36  is moved toward the inner surface of the coil  38  to secure rebar  40  against an inner surface of the coil  38 . 
         [0072]    It is preferred that the step of moving the rebar drive stations  36  into the coil  38  includes placing a guide rebar  112  along a lowest central point  114  of the coil  38 . The rebar drive stations  36  may each include a wheel  72  that is positioned on the guide rebar  112  to facilitate moving the rebar drive stations  36  into the coil  38 . 
         [0073]    First and second wing plates  32 A,  32 B of each rebar drive station  36  are preferably moved about separate pivot points  68  to secure rebar  40  against an inner surface of the coil  38 . The main and first and second wing plates  60 ,  62 A,  62 B of each rebar drive station  36  may move through a common plane  63 . The outer surface of the main and first and second wing plates  60 ,  62 A,  62 B of each rebar drive station  32  may be arcuate and may be configured such that when the main and first and second wing plates  60 ,  62 A,  62 B are pressing rebar against the inner surface of the coil  38  there is rebar  40  spaced along the coil generally along a segment of the inner circumference of the coil  38 . Rebar  40  that is detachably supported on the rebar drive stations  36  may be manually moved and positioned along lower portions of the inner surface of the coil  38 . 
         [0074]    Referring to  FIGS. 22 and 23  a third preferred embodiment of a rebar drive station may include a single vertical ram  96  to operate the main and first and second wing plates  60 ,  62 A,  62 B. The vertical ram  96  may be a double sided piston that includes a piston  94  which projects above and below the central tube  32 . A bell crank  126  may be connected to a support plate  70  about a bell crank center of rotation  130  with one end of the bell crank connected to a top end of the vertical ram piston  94  and another end of the bell crank  126  being connected to a wing plate  62 A via a drive rod/connector  128 . Another bell crank (not shown) may also be secured to the top of the vertical ram piston  94  to allow both first and second wing plates  62 A,  62 B to be simultaneously operated be a single ram  96 . This may allow the rebar drive station  36  to operate using a single ram  96 . Referring specifically to  FIG. 22  the rebar drive station  36  is shown with the single vertical ram piston  94  positioned so as to fully extend the main and first and second wing plates  60 ,  62 A,  62 B. Referring specifically to  FIG. 23  the single vertical ram piston  94  is positioned to retract the main and first and second wing plates  60 ,  62 A,  62 B. 
         [0075]    Referring to  FIGS. 24 and 25 , a fourth preferred embodiment of the rebar drive station  36  of the present invention. The lateral support plate  78  may include a lever  134  that extends outwardly from the pin  82  in generally another direction from that of the lateral support plate  78  to engage a lateral ram  132 . Referring specifically to  FIG. 24 , the rebar drive station  36  is shown with the main and first and second wing plates  60 ,  62 A,  62 B extended. Referring specifically to  FIG. 25 , the lateral ram  132  extended to retract the associated lateral wing plate  62 A. 
         [0076]      FIGS. 26-28  illustrate a fifth preferred embodiment of the rebar drive station  36  of the present invention. The wheel  72  may be slidably positioned within a sleeve  96 . A spring  142  can be connected between the wheel  72  and the lower end of the double sided ram piston  140 . The top end of the piston  140  can be secured to a drive yolk  138 . The drive yolk  138  can be connected to a lever  134  of the lateral wing plate  62 A via a cam slot  136 . Referring specifically to  FIG. 26  the rebar drive station  36  is shown with the ram piston  140  fully withdrawn to cause the lateral wing plates  62 A to be fully extended and the wheel  72  to be fully extended. Referring specifically to  FIG. 27 , the rebar drive station  36  is shown placed within a coil  38  with the vertical ram piston  140  fully extended to cause the lateral wing plates  62 A,  62 B and wheel  72  to retract to allow the rebar drive station  36  to be inserted into the coil  38 . Referring specifically to  FIG. 28 , the rebar drive station  36  has the vertical ram piston  140  partially retracted to slightly extend the first and second lateral wing plates  62 A,  62 B and to cause the bottom wheel  74  to extend and drive the main plate  60  against the inside of the coil  38 . 
         [0077]    Referring to  FIGS. 1-19 , one preferred embodiment of the invention operates as follows. A coil  38  is positioned on a jig  54 . The appropriate number of tube sections  104 ,  106  are secured in an end-to-end fashion to a mount section  102  attached to a carrier vehicle  34 . The tube sections  102 ,  104 , and  106  are secured together via mounting plates  92  and fluid and control lines  95 ,  97 ,  99  extending through each tube section  102 ,  104 ,  106  are connected via quick connects  91 . Alternatively, the first drive station  36  may be connected on a tube attached to the vehicle without mount section  102  and the associated mounting plate  92  located therebetween without departing from the scope of the present invention. 
         [0078]    Rebar  40  is positioned on main and first and second wing plates  60 ,  62 A,  62 B of the drive stations  36  which are generally in an at least partially retracted position  90 . Steel ties can be inserted through holes  77  (shown in  FIG. 11 ) and then wrapped about a portion of rebar to secure the rebar  40  in a proximate cutout  66 . Although steel ties and holes  77  can be used to secure rebar on the main and first and second wing plates  60 ,  62 A,  62 B, those of ordinary skill in the art will appreciate from this disclosure that any other suitable method can be used without departing from the scope of the present invention. Rebar  40  is also positioned on the flanges  74  of the drive stations for later manual removal. While the flanges  74  are shown having a certain number, width, and length, those of ordinary skill in the art will appreciate from this disclosure that their dimensions and number can be varied as desired without departing from the scope of the present invention. The flanges  74  may also be L-shaped so that the short leg extends below the flange to add additional support. The height of the flanges  74  relative to the tube section  32  can be varied without departing from the scope of the present invention. 
         [0079]    A piece of generally straight guide rebar  112  is then positioned at the lowest central point  114  on the inner surface of the coil. Wheels  72  for each of the rebar drive stations  36  are positioned on the guide rebar  112  such that the wheels  72  provide vertical support for the rebar drive stations  36  and associated tube sections  102 ,  104 ,  106  during insertion into the coil. Stability rods  110  preferably contact an inner surface of the coil  38  to reduce twisting torque on the tube sections  102 ,  104 ,  106  during insertion. Alternatively, the single vertical ram could be replaced with a framed two wheel insertion modules without departing from the scope of the present invention. 
         [0080]    Then, the vehicle  34  moves the rebar drive stations  36  into the coil  38 . After the rebar drive stations  36  are properly positioned, the vertical ram  96  is activated to extend the main plate  60  toward the upper inner surface of the coil  38  and secure rebar  40  thereagainst. Then, the first and second lateral rams  62 A,  62 B are activated to extend the first and second lateral rams  62 A,  62 B toward the coil  38  to secure rebar  40  thereagainst. The tying of the rebar in position can be done using steel ties to secure the rebar in position before the rebar system  30  is removed from the coil. It is preferred that the rebar  40  is tied to the coil  38  every ten to twelve feet or any preferred interval and is called a template. Then, the steel ties that may secure the rebar to the rebar drive station  36  via the holes  77  are removed and the rebar dive station  36  removed from the coil  38 . Once the rebar drive station  36  is removed from the coil  38 , the rebar  40  is tied to additional intersections between the rebar and the coil. The rebar  40  may be tied to the coil at every other intersection or more of the coil. In some cases, the rebar  40  may be tied to fewer intersections depending on the project. Afterwards, the rebar  40  supported on the flanges is manually positioned along the inner surface of the coil. The rebar  40  is then preferably tied to the coil to form the completed reinforcement cage. A crane may then be used to insert the structure in a hole or to load it onto a transport vehicle. If the completed reinforcement cage is to be stockpiled or transported a standard rack system may be used without departing from the scope of the present invention. 
         [0081]    It is recognized by those skilled in the art, that changes may be made to the above described embodiment of the invention without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiment disclosed, but is intended to cover to all modifications which are within the spirit and scope of the invention as defined by the appended claims and the drawings.