Abstract:
A cap includes a resilient body including a passageway formed in the body for receiving an end of a cable therein. The passageway has a retention feature for maintaining the cable end of a horizontally extending cable inside the passageway from inadvertent separation with the passageway.

Description:
RELATED APPLICATION 
       [0001]    This application claims priority to U.S. Provisional Patent Application Ser. No. 61/347,894, filed May 25, 2010, entitled “Method And Apparatus For Covering An End Of A Cable Extending From A Form During The Manufacture Of Molded Structural Members.” 
     
    
     FIELD 
       [0002]    The disclosure relates to a method and apparatus for covering an end of a cable extending from a form during the manufacture of molded structural members. More particularly, the present disclosure is directed to an apparatus and method for manufacture of a cover for covering the ends of cables associated with concrete structures. 
       BACKGROUND 
       [0003]    Concrete structural members include structural tees, panels, and connections between girders and columns to help assemble or reinforce the structural members together. These structural members may include cables embedded within the structural members that are subjected to tensile loading in order to increase the load carrying capacity of the structural members. 
         [0004]    To maximize efficiencies associated with the manufacture of the structural members, pouring forms from which the structural members are manufactured are aligned between adjacent aisles of a manufacturing facility, with contiguous lengths of cables extending through the forms and spanning the aisles. During a subsequent manufacturing step, cables are cut between adjacent forms using a cable saw, the resulting ends of the cables having a “sharpened edge” with the potential for injury as a result of even incidental contact with the cable ends. 
         [0005]    At the time of this writing, in an effort to minimize the possibility of injury, caps may be installed over the ends of the cables as provided by the Occupational Safety &amp; Health Administration (OSHA), Title 29 of The Code Of Federal Regulations (CFR), Part 1926—Safety and Health Regulations for Construction, Subpart Q—Concrete And Masonry Construction. However, this portion of the OSHA regulations is directed to vertically extending rebar and the like, in an effort to prevent impalement, such as by falling on the vertically extending rebar. While caps as provided under the above-referenced regulations appear to function well for vertically extending rebar, the caps do not appear to function well for horizontally extending cables. In other words, the caps configured in accordance with the above-referenced regulations are primarily maintained in position by virtue of gravity for vertically extending rebar, and do not reliably remain in position at the end of a horizontally oriented cable, or worse, a cantilevered horizontally oriented cable, in which the end of the cable contains a downwardly directed slope below horizontal. Stated another way, the caps configured in accordance with the above-referenced regulations may be over-sized with respect to the horizontally oriented cable, and lack a sufficient frictional component in order to prevent inadvertent or unintended removal of the cap from the end of the horizontally extending cable. 
         [0006]    What is needed is a cap that is configured for installation over an end of a horizontally extending cable that will reliably remain in an installed position over the cable end in order to prevent injury associated with contacting the cable end, is inexpensive to manufacture and reusable. 
       SUMMARY 
       [0007]    The present invention includes a cap having a resilient body including a passageway formed in the body for receiving an end of a cable therein. The passageway has a retention feature for maintaining the cable end of a horizontally extending cable inside the passageway from inadvertent separation with the passageway. 
         [0008]    The present invention further includes an apparatus for forming a cap including a base and an elongated member extending outwardly from the base. A tube has an end for placement of the tube over the member, the tube forming a substantially fluid tight seal with the base. The tube is configured to receive a liquid material between the tube, the member and the base to form a cap upon curing, the cap includes a resilient body including a passageway formed in the body for receiving an end of a cable therein. The passageway has a retention feature for maintaining the cable end of a horizontally extending cable inside the passageway from inadvertent separation with the passageway. 
         [0009]    The present invention still further includes a method for forming a protective cap configured for covering an end of a horizontally extending cable from inadvertent separation therebetween. The method further includes providing a base having an elongated member extending outwardly from the base and positioning a tube having an end over the member, the end forming a substantially fluid tight seal with the base. The method further includes pouring sufficient liquid material between the tube, the member and the base to cover the member. The method further includes curing the liquid material to form the cap and separating the cap from the member and the base. 
         [0010]    An advantage is a cap that is configured for installation over an end of a horizontally extending cable that will reliably remain in an installed position over the cable end in order to prevent injury associated with contacting the cable end. 
         [0011]    A further advantage is a cap configured for installation over an end of a horizontally extending cable that is inexpensive to manufacture. 
         [0012]    A still further advantage is a cap configured for installation over an end of a horizontally extending cable that is reusable. 
         [0013]    Other features and advantages of the present disclosure will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the disclosure. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIG. 1  is a top perspective view of a structural member manufactured using the present disclosure. 
           [0015]      FIG. 2  is an arrangement of forms to manufacture the structural member of  FIG. 1 . 
           [0016]      FIG. 3  is an arrangement of forms to manufacture the structural member of  FIG. 1 , using the present disclosure. 
           [0017]      FIG. 4  is an exemplary embodiment usable to fabricate a cap of the present disclosure. 
           [0018]      FIG. 5  is a cross section taken along line  5 - 5  of  FIG. 4 . 
           [0019]      FIG. 6  is a further embodiment usable to fabricate a cap of the present disclosure. 
           [0020]      FIG. 7  is a cross section taken along line  7 - 7  of  FIG. 6 . 
       
    
    
       [0021]    Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. 
       DETAILED DESCRIPTION 
       [0022]    Referring to  FIGS. 1-3 , the present disclosure is directed to an apparatus and/or method for fabricating a product  10  including a product positioned in a form  14  into which material is poured, and upon curing of the material, produces the product. In an exemplary embodiment, the material to be poured in the form is cement (forming concrete upon curing), and the product formed is a concrete structural member, such as a Tee beam, also referred to as a T-beam or double Tee block (shown in  FIG. 1 ), panels or connections between girders and columns. As shown, multiple forms  14  may be located in close proximity to each other to maximize efficiencies associated with fabrication of the T-beams. Cables  12  are embedded within the structural members and subjected to tensile loading in order to increase the load carrying capacity of the structural members. As shown in  FIG. 2 , caps  16 , which are configured for use with vertically extending rebar for purposes of preventing impalement, but which caps are not configured for use with horizontally extending cables, and more specifically, not configured for use with cantilevered horizontally extending cables, are shown resting on the floor, having slid off the cable ends, exposing the cable ends for possible injury. In contrast, as shown in  FIG. 3 , caps  24 , each of which caps having a body including a passageway that may be configured for use with horizontally extending cables  12  or cantilevered horizontally extending cables, will remain reliably secured to the end of the cables. 
         [0023]      FIG. 1  further shows a cast concrete T-beam  10  having an essentially flat supporting top panel  18  and a pair of dependent legs  20  extending downwardly from the panel. Reinforcing tension cables  12  may be embedded in the beam as shown. 
         [0024]    T-beams  10  are cast using a mold or form defining the shape of the legs and the lower surface and sidewalls of the top panel.  FIG. 2  illustrates the portion of the form  14  used to form one leg  20  ( FIG. 1 ) or the knee junction with the top panel. Cables  12  are rigged and guides  22  ( FIG. 1 ) are positioned in the knee portions of the form at intervals along the length of the legs where openings will be required in the completed beam for utility wires, conduits, water lines, and the like. 
         [0025]      FIGS. 4-5  show an exemplary apparatus configured to manufacture caps of the present disclosure. Elongated members  26 , such as cable segments corresponding in size to tension cables  12  ( FIG. 1 ) are mounted in a base  28  configured to accommodate multiple cable segments. In one embodiment, elongated members or cable segments  26  are of the same diameter, such as ⅜ of an inch, although the cable segments may be of different diameters or define non-circular profiles, as desired or needed. A tube  30  is configured to slide over a corresponding elongated member or cable segment  26 . In one embodiment, each cable segment  26  is associated with a positioning feature  32 , such as a recess-sized to receive one end of tube  30 . In a further embodiment, positioning feature or recess  32  is a counterbore configured such that tube  30  concentrically surrounds the cable segment. After tube  30  is positioned over a corresponding cable segment  26  and secured to base  28  using the positioning feature  32 , a body  17  including a liquid material  34  poured into the tube until the level of material is above the top surface of the cable segment. In other words, material  34  completely surrounds the exposed portion of cable segment  26 , that is the portion of the cable segment that extends outwardly from base  28 . In one embodiment, material  34  is an elastic and resilient material. 
         [0026]    Upon curing, material  34  is collectively separated from tube  30 , cable segment  26  and base  28 , forming a cylindrical cap  24  (also see  FIG. 3 ). In another embodiment, cap  24  may include other shapes, depending upon the profile of tube  30 . The resilient cap  24 , despite retaining the helical profile of cable segment  26  along the inner surfaces of cap  24  during its fabrication and forming a frictional contact with an outer surface of an end of a cable, such as horizontally extending cable  12  ( FIG. 2 ), should relatively easily slide over an end of the cable. However, by virtue of being molded over an elongated member or cable segment of substantially the same or smaller size, resilient cap  24  should provide a conformal fit over an end of a cable that should typically require a removal force greater than the weight of the cap to separate the cap from the cable. To further achieve reliable retention of cap  24  over the cable end, material  34  should be composed of a material having an enhanced coefficient of static friction with respect to cable material such as a polymer. In one embodiment, the polymer is a rubber material. In addition, by virtue of cap  24  having a closed end and forming a conformal fit over a cable end, such insertion of the cap over the cable end may require overcoming a vacuum force to effect separation between the cap and the cable end. In another embodiment, cap  24  may be formed using a cable segment  26  that is of a cross sectional area, typically a diameter, that is less than the cross sectional areas of corresponding cable ends over which the cap is manually installed over, resulting in the cap applying a compressive force against the cable end, in addition to the enhanced coefficient of static friction between the cap and the cable end, resulting in the cap forming a further reliable fit with respect to the cable end. 
         [0027]      FIGS. 6-7  show an alternate embodiment of an apparatus configured to manufacture caps of the present disclosure. Elongated members  126 , such as mechanical fasteners including a bolt or screw, corresponding in size to tension cables  12  ( FIG. 1 ) are mounted in a base  128  configured to accommodate multiple elongated members. As further shown in  FIG. 7 , a head  127  of elongated member  126  is received by a recess  130  formed in base  128 , with the elongated member extending through the base. In one embodiment, elongated members or mechanical fasteners  126  are of the same diameter, such as ⅜ of an inch, although the mechanical fasteners may be of different diameters or define non-circular profiles, as desired or needed. A tube  30  is configured to slide over a corresponding elongated member or mechanical fastener  126 . In one embodiment, each elongated member or mechanical fastener  126  is associated with a positioning feature  132 , such as a recess sized to receive one end of tube  30 . In a further embodiment, recess  132  is a counterbore configured such that tube  30  substantially concentrically surrounds the cable segment. In yet a further embodiment, recess  132  can be an annular ring that receives one end of tube  30 . After tube  30  is positioned over a corresponding elongated member or mechanical fastener  126  and secured to base  128  using the positioning feature, liquid material  34  is poured into the tube until the level of the material is above the top surface of the elongated member. In other words, material  34  completely surrounds the exposed portion of elongated members or mechanical fasteners  126  that extend outwardly from base  128 . 
         [0028]    Upon curing from a liquid phase to a solid phase, material  34  is collectively separated from tube  30 , elongated member  126  and base  128 , forming a cylindrical cap  124  (also see  FIG. 3 ). In another embodiment, cap  124  may include other shapes, depending upon the profile of tube  30  and elongated member  126 . For example, elongated member  126  may be a dowel rod. In another embodiment, such as with a mechanical fastener or other arrangement, elongated member  126  may have a cross sectional area that is non-uniform when taken from a view similar to that taken along line  7 - 7  of  FIG. 6 , or substantially parallel to the longitudinal direction of the elongated member. In one embodiment, the non-uniform profile can resemble a ribbed profile. In a further embodiment, cured material  34  is an elastic and resilient material. The resilient cap  124 , despite retaining the profile of elongated member  126 , i.e., passageway  138  formed along the inner surfaces of cap  124  during its fabrication, should easily slide over an end of a cable, such as horizontally extending cable  12  ( FIG. 2 ). As further shown in  FIG. 7 , an optional alignment feature  136 , such as a tapered surface positioned along the junction of elongated member  126  and base  128  permits passageway  138  to be more easily guided over an end of a cable  12  ( FIG. 2 ). However, by virtue of being molded over an elongated member or cable segment of substantially the same or smaller size, resilient cap  124  should provide a conformal fit over an end of a cable that should typically require a removal force greater than the weight of the cap. To further achieve reliable retention of cap  124  over the cable end, material  34  should be composed of a material having an enhanced coefficient of static friction with respect to cable material such as a polymer. In one embodiment, the polymer is a rubber material. In addition, by virtue of cap  124  having a closed end and forming a conformal and/or a compression fit between contacting surfaces of the cap and the cable over which the cap is slid over, such insertion of the cap over the cable end may require overcoming a vacuum force to effect separation between the cap and the cable end. In another embodiment, cap  124  may be formed using elongated member  126  having a cross sectional area, typically resembling a diameter, that is less than the cross sectional area of a corresponding contacting surface of a cable in close proximity of the cable end over which the cap is manually installed. The difference in cross sectional area results in the cap applying a compressive force against the cable end, in addition to the enhanced coefficient of static friction between the cap and the cable end. When such features are provided in combination, an enhanced retention of the cap with respect to the cable end results. 
         [0029]    In an alternate embodiment, cap  24 ,  124  may be formed of a material having ferromagnetic properties, providing a magnetic attraction to the cable end. In a further alternate embodiment, a ferromagnetic material can be positioned in the cap. For example, in one embodiment a ferromagnetic material  134  ( FIG. 7 ) can be placed in the liquid cap material prior to pouring the liquid cap material, such as placing the ferromagnetic material directly on the end of the elongated member or in close proximity thereof. Depending upon the strength of ferromagnetic material, a spacer (not shown) may be positioned between the end of the elongated member and the ferromagnetic material. In such constructions, the cross sectional area of the opening of the cap can be greater than the cross sectional area of the cable receiving the cap. 
         [0030]    While the disclosure has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this disclosure, but that the disclosure will include all embodiments falling within the scope of the appended claims.