Abstract:
This is a reinforcing apparatus that can be prefabricated for easy installation at the construction site. The reinforcing members must be properly spaced and supported for reinforcing the structure into which it shall be incorporated. Various spacing members are described for the apparatus. One embodiment folds into a collapsed structure prior to shipping and unfolds on the construction site. Another has a structure where the reinforcing members are snapped onto spacing members at the construction site, making for a quick assembly. Yet another has a structure in which the reinforcing members are clipped into place on the spacing member prior to use. The apparatus, once assembled or unfolded, can be self-supporting.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    Construction projects often require reinforcing elements for structural supports. By way of example, most pillars, pylons or columns are made by first excavating a site to a sufficient depth, then pouring concrete into moulds which form the shape of the structure, usually a base and column to form a pillar, pylon, or column. Generally, reinforcing elements are placed into their moulds prior to or during the pouring of the structural material, for example concrete, so as to give that material increased tensile and shear strength.  
           [0002]    A well-known example of reinforcing elements used in the construction industry is a steel reinforcing bar known as a rebar. Rebars are generally steel rods, and are ribbed to provide an increased and irregular surface area of the reinforcing element for contacting the structural material, usually concrete. The structural material envelops the rebar, flowing between the ribbed surfaces. Contractors usually place discrete rebar segments approximately parallel to the ground of the excavated site upon which the structure will stand within the mould for the base of the structure and axially within the mould to reinforce the body of the structure itself.  
           [0003]    Any lack of continuity between the discrete segments of the reinforcing elements reduces the structural loading capacity of the completed structure since there remains a volume of structural material that is not being reinforced. It is often within this volume of non-reinforced structural material that fault lines, heaving and cracking of the structural material will develop. If the structural material is subjected to frost, moisture, and resettling of excavated earth, then the volume of non-reinforced structural material will be particularly susceptible to the development of fault lines, heaving, and cracking.  
           [0004]    Even if the reinforcing elements are joined so as to eliminate this volume of unreinforced structural material, the reinforcing elements may become misaligned, no longer forming a continuous reinforcing structure, unless properly secured before the structural material is poured. Further, uneven spacing between discrete sites of reinforcement, either radially or axially, can also reduce the structural integrity of the finished structure. Even spacing of the reinforcements ensures that the ability of the structure to absorb tensile and shear loading conditions is optimized throughout the length, the cross-section, and the footing of the structure.  
           [0005]    Further, properly immobilizing discrete reinforcing elements is a laborious process requiring particular skills and time, making it an expensive process step in the construction process.  
         SUMMARY OF THE INVENTION  
         [0006]    The invention comprises reinforcing elements and spacing members to mount the reinforcing elements so as to create an apparatus that can be folded or disassembled, shipped, and installed on the excavated site with minimum labour costs and delays. The apparatus, once installed, is then placed into the moulds that will receive the poured structural material, for example concrete. The pouring of the structural material is achieved in one step, again reducing labour and material costs. Once the structural material is poured and cured, the reinforcing elements reinforce the structural materials against tensile and shear stresses.  
           [0007]    In accordance with the invention, reinforcing elements are joined at pre-selected points along their length by spacing members to form a reinforcement apparatus. Each spacing member holds the reinforcing elements at a fixed interval from one another at several points. The reinforcement apparatus includes at least two spacing members, near each end of the length of the reinforcement apparatus. Longer lengths may include more spacing members to increase the structural integrity of the reinforcing structure.  
         DETAILED DESCRIPTION OF THE INVENTION  
         [0008]    The reinforcing elements are preferably shaped into three segments. The first segment extends along the length of the reinforcement apparatus, and serves to reinforce the length of the structure into which it will be incorporated. The second segment is oriented away from the length of the reinforcement apparatus and reinforces the base of the structure. The third segment is oriented away from the other segments, creating a foot, so as to keep the second segment from laying directly on the excavated site. The raising of the reinforcing elements of the reinforcement apparatus by means of the orientation of the third segments of the reinforcing elements allows the structural material to flow around and under the reinforcing elements. In this way, the foot of the reinforcement apparatus ensures that the reinforcement apparatus will be almost completely enveloped by the structural material during pouring, ensuring that the structure, once completed, will have greater resistance to tensile and shear loading conditions.  
           [0009]    The reinforcing elements are joined together by two or more spacing members which provide proper support and orientation of the reinforcing elements of the reinforcing apparatus. Use of the spacing members does not require having skilled workmen perform an intricate alignment of the reinforcing elements. Moreover, the spacing members provide structural support to the reinforcing elements by keeping them immobilized prior to, during and after the pouring of the structural materials. The spacing members are usually mounted near the bottom and top of the structure to be reinforced so as to keep the ends of the reinforcing elements properly aligned; however, spacing mechanisms may also be placed at any points of stress along the length of the reinforcing elements. For example, a third spacing member can be placed at a point that is approximately equidistant from the spacing members at the ends of the reinforcing elements.  
           [0010]    There are various embodiments of the spacing members that can be used to achieve the proper spacing of the reinforcing elements. Further, the spacing members are typically configured to fold or collapse for ease of shipping prior to assembly for use. In one embodiment, a spacing member comprising a folding spacer can fold and unfold so that the reinforcing elements are arranged in a compact volume for ease of packing and shipping the reinforcement apparatus to the construction site. In another embodiment, the spacing member comprises of interlocking fittings mounted on the reinforcing elements and on a retaining member. The interlocking fittings mounted to the reinforcing elements can be snapped and unsnapped into place on the corresponding interlocking fittings mounted to the retaining members, so as to create a reinforcement apparatus that can be disassembled for shipment and reassembled for use. In yet another embodiment of the spacing member, the reinforcing elements can be held in place when clipped to a clipping spacer. Alternatively, the spacing members can rigidly interconnect the reinforcing elements on a customized spacer shape so that there is no folding or dismantling of the apparatus structure once assembled. A rigidly interconnected spacing member would be used for unique applications.  
           [0011]    For example, in the construction industry, rebars are used to reinforce concrete. As an embodiment of this invention, standard rebars are forged and bent to create a second segment extending substantially perpendicularly to the first segment of the rebars. The ends of the second segments are again bent away from the first segments of the rebars to create a third segment. When a plurality of rebars is arranged such that the first segments are arranged in a generally parallel relation, and the second segments all extend generally outwardly or radially outwardly, then the third segments form a small feet at the bottom end of each of the second segments.  
           [0012]    The rebars are oriented so that the second segments with the small feet extend radially outward away from one another when viewed from above. The rebars are then mounted to at least two spacing members, so as to ensure that they will be properly aligned when placed within a structural mould upon the excavated site. The rebars have an axial length throughout the structural moulds, bend substantially perpendicularly within the footing mould, and rest upon the small feet. The role of the small feet is to ensure that virtually the entire length of the rebar will be well enveloped by the concrete during pouring by allowing the concrete to flow underneath virtually the entire rebar apparatus. In this way, the structural support available from the rebar apparatus is maximized, from the excavated ground on which the foot portion rests, through the footing base and up through the length of the structure using a continuous reinforcement apparatus.  
           [0013]    One preferred embodiment of the spacing member is the folding spacer. The folding spacer comprises a first member building two smaller members with channel arms mounted to it using a linking member with a locking mechanism, such as a clevis pin or shoulder bolt spring assembly. In the closed or folded position, the locking mechanism on the linking member is not triggered. As the channel arms swing open to their fully opened positions, the smaller member to which it is attached and the channel of the channel arm align. This alignment triggers the spring mechanism on the linking member to actuate and lock the channel arm in the proper position. The first member and all of the channel arms are each mounted to one reinforcing element, for example one rebar. Folding bars may also be mounted to a reinforcing element and added to the channel arm, smaller member and linking member assembly. The folding bars should be shaped in such a manner that when the assembly of reinforcing elements is closed, the folding spacer is neatly aligned with the reinforcing elements staggered next to one another. When opened, the assembly of reinforcing elements should have evenly spaced reinforcing elements that can be adjusted or locked into proper position. Each folding bar has a rear arm stop block that aligns itself with the channel arm during the unfolding of the reinforcing elements.  
           [0014]    For example, if mounting four rebars, one folding bar would be added to the folding spacer as described at one clevis pin assembly, and would unfold just like the channel arm that shares its clevis pin assembly. If an application required a fifth rebar for the rebar apparatus, an additional folding bar would be added either to the other channel arm, smaller member and clevis pin assembly or the same one where the first one was added. However, the geometry of the folding spacer preferably ensures that the rebars are evenly distributed over the cross sectional area into which the concrete is to be poured.  
           [0015]    Another preferred embodiment of the spacing member is the snapping spacer. The snapping spacer preferably comprises a retaining member onto which female fittings are attached. The reinforcing elements have fixed to them a male guide. The male guide is a fitting that is to be slidingly inserted into the larger female fitting attached to the retaining member. The number of female fittings on the retaining member is based upon the number of reinforcing elements to be used for the application. The male guide is fixed along a length of the reinforcing element well above the footing base, facing oppositely to the radial reinforcement component of the reinforcing element. There are at least two male guides fixed on each reinforcing element so as to accommodate at least two spacers at opposite ends of the reinforcing element. The male guide slides into a female fitting and is held in place by a linking piece. Once all of the reinforcing elements are attached to the spacer, the reinforcing apparatus may be used.  
           [0016]    A further preferred embodiment of the spacing member is the clipping spacer. The clipping spacer comprises a retaining member onto which clipping means are mounted. The retaining member may be in any shape, so long as it minimally impedes the flow of the structural material upon pouring. Reinforcing elements are mounted onto the clips that have sufficient elasticity to open and close in a spring like fashion around them, thus holding the reinforcing elements in an appropriate configuration for reinforcing the poured structural material.  
           [0017]    Another embodiment of the spacing member is the spacer with permanently mounted reinforcing elements. The spacer with permanently mounted reinforcing elements would comprise reinforcing elements fixed to at least one, but preferably two or more retaining members. The retaining members can have virtually any shape, so long as they minimally impede the flow of the structural material when pouring begins. For example, circular retaining members of varying diameter are preferable to a central cross bar mechanism if the area occupied by the central cross bar mechanism will impede concrete flow more than the area occupied by the circular retaining member.  
           [0018]    A guiding means, for example spring clips, may be mounted to the reinforcing elements so as to orient them within the mould for the pouring of the structural material. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]    [0019]FIG. 1 is a perspective view showing an embodiment of a reinforcement apparatus within a sectioned pillar mould.  
         [0020]    [0020]FIG. 2 is an elevation view of an embodiment of a reinforcing apparatus of the present invention showing relative locations of the spacing members along the length of an embodiment of the reinforcing apparatus.  
         [0021]    [0021]FIG. 3 is a plan view of a reinforcing element with a configuration of bends made along its length.  
         [0022]    [0022]FIGS. 4A and 4B are perspective views showing two folding spacing members assembled to three reinforcing elements in their folded and unfolded positions respectively.  
         [0023]    [0023]FIGS. 5A and 5B are perspective views showing a folding spacing member of FIGS. 4A and 4B in an opened and closed position respectively.  
         [0024]    [0024]FIG. 5C is a magnified view of the linking means of the spacing members shown in FIGS. 5A and 5B.  
         [0025]    [0025]FIGS. 6A and 6B are perspective views showing two folding spacing members assembled to four reinforcing elements shown in their folded and unfolded positions respectively.  
         [0026]    [0026]FIGS. 7A and 7B are perspective views of the folding spacing member of FIGS. 6A and 6B in the closed and opened positions, respectively.  
         [0027]    [0027]FIG. 7C is a magnified view of the linking means of the channel arm, the folding arm, and the smaller member to which they are held.  
         [0028]    [0028]FIGS. 8A and 8B are views showing two snapping spacing members assembled to three reinforcing elements held in a snapped configuration viewed from above and in elevation respectively.  
         [0029]    [0029]FIGS. 9A and 9B are views showing snapping spacing members of FIGS. 8A and 8B assembled to three reinforcing elements held in an unsnapped configuration viewed in elevation and from above respectively.  
         [0030]    [0030]FIGS. 10A and 10B are views showing an exploded view in elevation and from above, of an alternate embodiment of a snapping spacing member assembly when spacing three reinforcing elements.  
         [0031]    [0031]FIGS. 11A and 11B are views of the snapping spacing member of FIGS. 8A and 8B,  9 A and  9 B, or  10 A and  10 B showing the retaining member with the interlocking fittings mounted, depicted from the top and from the side, respectively.  
         [0032]    [0032]FIGS. 12A and 12B are views showing an elevation view and a top view respectively of an interlocking fitting, depicted in this embodiment as a male guide, attached to a reinforcing element.  
         [0033]    [0033]FIGS. 13A and 13B are views showing an elevation view and a top view respectively of the clipping spacing member with four reinforcing elements inserted.  
         [0034]    [0034]FIGS. 14A and 14B are views showing a clipping spacing member viewed in elevation and from above.  
         [0035]    [0035]FIGS. 15A and 15B are views showing a reinforcing apparatus with five reinforcing elements and a clipping spacer viewed in elevation and from above respectively, in assembled form.  
         [0036]    [0036]FIGS. 16A and 16B are views showing a clipping spacing member viewed in elevation and from above respectively, in a retaining member structure. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0037]    [0037]FIG. 1 shows the cross-section of the view of the reinforcing apparatus. A footing mould and a column mould for the pouring of a concrete pillar are shown with the reinforcing apparatus inside. Element  2  is the column mould into which the structural material is to be poured. Element  4  is the footing mould upon which element  2  sits, and into which concrete is also poured. Element  5  indicates a reinforcing element which is held by a folding spacing member indicated by element  3 .  
         [0038]    [0038]FIG. 2 shows a reinforcing apparatus, with two spacing members ( 3 ), in this case, one of which is located approximately  15  inches from the base of the reinforcing apparatus and the other one which is located approximately  15  inches from the top of the reinforcing apparatus. Depending on the length of the reinforcing apparatus, additional reinforcement may be added by placing another spacing member at points between the two spacing members.  
         [0039]    [0039]FIG. 3 shows the shaping of a reinforcing element used to reinforce the structure. The reinforcing element is bent at angle Q between the first segment H and the second segment W of the reinforcing components. At the end of the second segment W, there is a third segment P created by bending the tip of the second segment W at angle T away from first segment H. In a preferred embodiment, angle Q is 90 degrees or more, and angle T is approximately in the range of 30 to 60 degrees. This shape of the reinforcing element would be particularly useful in reinforcing a column structure. However, the various segments may be bent along a different shape structure. First segment H can be shaped to fit the structure to be reinforced, while second segment W and third segment P can be shaped to conform with the base of the structure to be built.  
         [0040]    Three Reinforcing Elements and the Folding Structure  
         [0041]    In one embodiment illustrated by FIGS. 4A and 4B, this invention comprises three reinforcing elements bent as shown in FIG. 3, in accordance with the dimensions of the footing mould and the structure to be built. The three reinforcing elements  5  are mounted to two separate folding spacing members  45 . More spacing members can be added along the axial portion of the reinforcing elements for further structural support if required. One reinforcing element  5  is mounted to first member  10  of the folding spacer, while the other two reinforcing elements are mounted to channel arms  15 . The channel arms  15  are attached to first member  10  by linking means  20 , which has a spring means  25  and a loading means  30 . The loading means  30  keeps tension in the spring means  25  to force a smaller member  12 , that is part of the first member that overlaps the channel arm, into the channel of the channel arm when the reinforcing apparatus is opened as it is shown in FIG. 4B.  
         [0042]    As shown in FIGS. 5A, 5B, and  5 C, the first member  10  of the folding spacer has two smaller members  12  that are shown in this embodiment as being approximately 120 degrees apart. The two channel arms  15  are mounted to the smaller members using a linking means  20 , either a shoulder bolt or a clevis pin. The linking means has a compressed spring  25  inserted on its length prior to it attaching the channel arm to the smaller member. The spring is held in place by the loading means  30 , shown here as a nut for a shoulder bolt. If a clevis pin were used as the linking means, then a roll pin could be used as the loading means.  
         [0043]    When folded, the three reinforcing elements appear adjacent to one another as shown in FIG. 4A. As the apparatus opens, the channel arms  15  align with the smaller member to which they are mounted. Once aligned, the spring means  25  extends, forcing the smaller members into the channels of the channel arms  15 , locking the reinforcing elements in position. The reinforcing elements are roughly equidistant to one another, in a triangular configuration when fully opened as shown in FIGS. 4B and 5A.  
         [0044]    Four Reinforcing Elements and the Folding Structure  
         [0045]    In another embodiment as shown at FIGS. 6A and 6B, this invention comprises four reinforcing elements  5  bent as previously described and shown in FIG. 3, attached to two folding spacers. The folding spacers work as set out above except for having a folding member  35  and a rear arm stop block  40 . One reinforcing element  5  is mounted to first member  10 , two are mounted to channel arms  15 , and the last is mounted to folding member  35 . The two channel arms are mounted to the smaller members  12  of first member  10 , which for this application is shaped like a “T”. Folding member  35  is mounted to one of the channel arms  15 , through the same linking means assembly described in FIGS. 4A, 4B,  5 A,  5 B and  5 C. Rear arm stop block  40  aligns with the smaller member to which folding member  35  is mounted when folding member  35  is in the closed position as shown in FIG. 6A. Rear arm stop block  40  and folding arm  35  rotate together through 180 degrees to the open position and align with the small member  12  when opened, as shown in FIG. 6B. Folding member  35  has a bend in it so that it aligns neatly with channel arm  15  of the small member  12  to which it is attached when closed.  
         [0046]    As shown in FIGS. 7A and 7B, the apparatus opens like the three reinforcing element model, except that one of the channel arms  15  is attached to a folding member  35  as well as to the smaller member  12  of the first member. Folding member  35  is mounted to another reinforcing element. The folding member  35  is attached to the channel arm  15  through linking means  20 , with spring means  25  and loading means  30 . The folding member  35  has a bend in it so that its reinforcing element will lie next to the one on the channel arm  15  that is mounted to the same smaller member of the first member  10  when the apparatus is folded. Once the channel arms  15  have been fully opened, the folding arm  35  is opened by rotating it until the fourth reinforcing element is positioned approximately midway between the two adjacent ones. There is a rear arm stop block  40  on the folding arm which aligns with the smaller member of the first member so that the reinforcing element mounted to the folding member is properly aligned with the other reinforcing members in the open position. The reinforcing elements roughly resemble the corners of a square when viewed from above.  
         [0047]    The Three Discrete Element Snapping Structure  
         [0048]    As with the folding structures, the reinforcing elements are bent as described in FIG. 3. FIG. 8A illustrates a top view of a reinforcing apparatus whereby a spacing member is comprised of a retaining member  55 , with fittings  60 , which are preferably female fittings, onto which corresponding fittings  65 , which are preferably male fittings, are interlocked. Retaining member  55  may have any closed geometric shape, so long as the shape chosen minimally impedes the flow of concrete. Fittings  65  are mounted to reinforcing elements  5  prior to assembly and interlock onto retaining member  55  through fittings  60 . FIG. 8B presents the side view corresponding to the top view shown in FIG. 8A.  
         [0049]    [0049]FIGS. 9A and 9B show a reinforcing structure in its disassembled form, prior to interlocking of the fittings  60  and corresponding fittings  65  on the retaining member and the reinforcing elements respectively. This diagram clearly shows the corresponding fittings  65  as being mounted to discrete reinforcing element  5  prior to interlocking onto retaining member  55 .  
         [0050]    [0050]FIGS. 10A and 10B show an exploded view of the reinforcing apparatus. Reinforcing element  5  is mounted to fitting  65 , the fitting that interlocks with fitting  60 . Fitting  60  is mounted to retaining member  55  within guide  70 , so as to prevent free rotation of fitting  60  on retaining member  55 . Preferably, when fitting  65  is being interlocked with fitting  60 , fitting  60  will remain immobilized against guide  70  so that fitting  60  will remain in the proper orientation for interlocking. In this example a nut and bolt, a roll pin or a spring-actuated detent can be used as a linking means to lock the fittings together. The retaining member should be large enough to accommodate the number of fittings required for the number of reinforcing elements to be used for the particular application, taking account of the cross sectional area of the structure to be reinforced.  
         [0051]    [0051]FIG. 11A shows a top view of the spacing mechanism, while FIG. 11B shows a side view of the spacing mechanism. Retaining member  55  has mounted to it fitting  60  and guide  70 . The three are joined by fixture  75 , which in a preferred embodiment might comprise a rivet or a nut and screw. Guide  70  immobilizes fitting  60  from freely rotating on retaining member  55  about fixture  75 . More fittings  60  and guides  70  can be mounted to retaining member  55  as more reinforcing elements are required for an application.  
         [0052]    [0052]FIG. 12A shows a side view of fittings  65  mounted to reinforcing element  5 , while FIG. 12B shows fitting  65  mounted to reinforcing element  5  from the top view. Element  80  represents the means by which fitting  60  and fitting  65  interlock, and in a preferred embodiment would comprise a spring loaded detent, a roll pin, or a nut and bolt assembly.  
         [0053]    Four Reinforcing Elements and the Clipping Structure  
         [0054]    [0054]FIG. 13A shows an assembled reinforcing structure comprising four reinforcing elements linked by clipping spacer  100 , when viewed from the side. FIG. 13B shows a top view of the same structure. As seen in FIG. 14A from the side, and FIG. 14B from above, clipping spacer  100  is comprised of lengths of material  125  joined at a central point, and onto which clips  120  have been joined at the ends. The clips  120  have sufficient elasticity to bend when inserting a reinforcing element and to return to their original shape once the insertion of the reinforcing element is completed. Further, the clips  120  also have sufficient rigidity and solidity to withstand the strain of the pouring of the structural materials.  
         [0055]    Five Reinforcing Elements and the Clipping Structure  
         [0056]    Shown in FIG. 15A is a side view of a reinforcing apparatus held together by a clipping spacer  105  where the clips are mounted to a retaining member  130  rather than being mounted on a rigid length of material as in the case of clipping spacer  100 . FIG. 15B shows the top view of the reinforcing apparatus shown in FIG. 15A. The retaining member  130  may have any closed geometry desired for the particular application, so long as it minimally impedes the flow of the structural material upon pouring. The reinforcing elements  5  are clipped onto the clips that have been previously mounted on the retaining member. FIG. 16A shows a side view of clipping spacer  105 , showing the clips  120  mounted on the retaining member  130 . FIG. 16B shows a top view of clipping spacer  105 , with clips  120  mounted to retaining member  130 .  
         [0057]    The Permanently Mounted Spacer System  
         [0058]    The spacers for this application are shaped like a closed and regular geometric figure, preferably a circle. The spacers would preferably be made from steel and welded to the reinforcing elements, though other materials and means of attachment are possible. The retaining members can be welded either inside or outside of the structure, depending on the desired spacing of the reinforcing elements, the level of shear stress reinforcement sought, the number of spacers to be used, and the size of the structure to be made.