Note: Descriptions are shown in the official language in which they were submitted.
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THERMAL BREAK FOR CONCRETE SLABS
FIELD OF THE INVENTION
100011 The present invention generally relates to concrete slab
construction. In particular, the
present invention is directed to a thermal break for concrete slabs.
BACKGROUND
[0002] Concrete slabs that overhang or extend beyond exterior walls of
buildings, such as slabs
used for balconies and similar, are extensions of a main building structure
but are exposed to the
outside and not thermally insulated from the main structure. Because of this,
heat can be conducted
into or out of a building through such concrete slabs. In this way,
overhanging slabs can allow heat
to escape from the interior of a building on cold days (or heat to enter a
building on hot days),
creating an inefficient area in the thermal envelope of the building.
[0003] Several attempts have been made to address this problem, including
U.S. Patent No.
8,973,317 to Larkin, U.S. Pat. No. 4,959,940 to Witschi, and U.S. Pat. No.
8,092,113 to Penzkofer.
Larkin discloses the use of a "relatively thin flat panel of thermal
insulating material" between the
overhanging concrete slab and the main structure with holes in the material
for reinforcing bars to
pass through. However, Larkin does not include any transverse force bars
passing through the
insulating barrier. Witschi and Penzkofer do include transverse force bars
passing through an
insulating barrier but include additional components such as articulation
elements or face plates that
tend to increase the complexity of the installation process.
SUMMARY OF THE DISCLOSURE
[0004] In an exemplary embodiment, a thermal break system for separating
concrete slabs, is
provided that includes a thermally insulating body sized and configured to
separate a first area for an
interior concrete slab from a second area for an exterior concrete slab, the
insulating body being
load-bearing structural foam and including a plurality of reinforcing tension
rod holes and a plurality
of reinforcing shear rod holes, wherein the plurality of shear rod holes pass
through the insulating
body at a non-horizontal angle. A plurality of reinforcing shear rods are
included, and each of the
plurality of reinforcing shear rods includes a first bend at a first point to
form an angled portion that
substantially matches the non-horizontal angle of the plurality of shear rod
holes, wherein each of
the plurality of reinforcing shear rods is inserted through the thermally
insulating body via respective
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ones of the plurality of shear rod holes such that the angled portion is
within the insulating body and
the first point is aligned with a first side of the insulating body, wherein
each of the plurality of
reinforcing shear rods each include a washer welded near the first point,
wherein each of the
plurality of shear rods include a second bend at a second point where each of
the plurality of
reinforcing shear rods exits respective ones of the plurality shear rod holes
on a second side of the
insulating body such that exterior portions of each of the plurality of shear
rods are substantially
horizontal, and wherein each washer is secured to the thermally insulating
body.
[0005] Additionally or alternatively, the insulating body has an R-value of
at least 2.
[0006] Additionally or alternatively, each of the plurality of reinforcing
shear rods is a size 43
rebar.
[0007] Additionally or alternatively, the system includes no plates on a
first side or a second
side of the insulating body, wherein no compression struts pass through the
insulating body, and
wherein no articulating elements protrude through the insulating body into the
first area or the
second area.
[0008] In another exemplary embodiment, a thermal break system is prepared
by a process that
includes forming, from a load-bearing, thermally insulating structural foam
material, an insulating
body such that the insulating body is sized and configured to separate a first
area for an interior
concrete slab from a second area for an exterior concrete slab; drilling a
plurality of reinforcing
tension rod holes through the insulating body; drilling a plurality of
reinforcing shear rod holes
through the insulation body at a non-horizontal angle; welding a washer to
each of a plurality of
reinforcing shear rods; bending each of the plurality of reinforcing shear
rods at a first point to form
a plurality of bent reinforcing shear rods; inserting the plurality of bent
reinforcing shear rods
through the plurality reinforcing shear rod holes in the insulating body such
that the first point is
aligned with a first side of the insulating body; bending, while inserted in
the insulating body, the
plurality of reinforcing shear rods at a second point, the second point being
aligned with a second
side of the insulating body, such that portions of the plurality of
reinforcing shear rods extending
from the first side of the insulating body and extending from the second side
of the insulating body
are substantially horizontal: and securing each washer to the insulating body.
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[0009] In another exemplary embodiment, a system for preparing a thermally
broken, cast-in-
place concrete slab is provided that includes a thermally insulating body
configured to separate a
first area for an interior concrete slab from a second area for an exterior
concrete slab, the insulating
body being load-bearing structural foam and including a plurality of
reinforcing tension rod holes
and a plurality of reinforcing shear rod holes, wherein the plurality of shear
rod holes include
washers secured to the insulating body to limit rod twisting and wherein the
plurality of shear rod
holes pass through the insulating body at a non-horizontal angle. A plurality
of reinforcing tension
rods are configured to pass through a respective one of the plurality of
tension rod holes and extend
into the first area and the second area. A plurality of reinforcing shear rods
are bent at a first point to
form an angle that substantially matches the non-horizontal angle of the
plurality of shear rod holes,
wherein when inserted into the plurality of shear rod holes, the plurality of
reinforcing shear rods are
bent at a point where each of the plurality of reinforcing shear rods exit
respective ones of the
plurality shear rod holes such that an exterior portion of each of the
plurality of shear rods is
substantially horizontal.
100101 Additionally or alternatively, a plurality of cross tension rods are
included, wherein each
of the plurality of cross tensions rods are substantially perpendicular to the
plurality of reinforcing
tension rods.
[0011] Additionally or alternatively, each of the plurality of cross
tension rods is secured to one
or more of the plurality of reinforcing tension rods.
[0012] Additionally or alternatively, each of the plurality of cross
tension rods is secured to one
or more of the plurality of shear rods.
[0013] Additionally or alternatively, each of the plurality of cross
tension rods is secured to one
or more of the plurality of reinforcing tension rods and one or more of the
plurality of shear rods.
[0014] Additionally or alternatively, a plurality of washers are secured
around a respective one
of the plurality of shear rod holes.
[0015] Additionally or alternatively, the insulating body has an R-value of
at least 2.
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[0016] Additionally or alternatively, each of the plurality of reinforcing
tension rods is a size 45
rebar.
[0017] Additionally or alternatively; each of the plurality of reinforcing
shear rods is a size 43
rebar.
[0018] In another exemplary embodiment, method for installing a thermally
broken, cast-in-
place concrete slab includes bending a plurality of reinforcing shear rods at
a first point to form a
first point angle; inserting the plurality of bent reinforcing shear rods
through a plurality of angled
reinforcing shear rod holes in a load-bearing, thermally insulating structural
foam body configured to
separate an interior concrete slab from an exterior concrete slab such that
the first point angle is
aligned with the first side of the insulating body; bending, while inserted in
the insulating body, the
plurality of reinforcing shear rods at a second point to form a second point
angle, the second point
angle being aligned with the second side of the insulating body, wherein a
first portion of each of the
plurality of reinforcing shear rods extends from the first side of the
insulating body and a second
portion of each of the plurality of reinforcing shear rods extends from the
second side of the
insulating body and wherein the plurality of reinforcing shears rods are
substantially parallel with the
plurality of reinforcing tension rods on the second side and the second side
of the insulating body;
inserting a plurality of reinforcing tension rods through a plurality of
reinforcing tension rod holes in
the insulating body such that a first portion of each of the plurality of
reinforcing tension rods
extends from a first side of the insulating body and a second portion of each
of the plurality of
reinforcing tension rods extends from a second side of the insulating body;
and pouring concrete
over the plurality of reinforcing tension rods and reinforcing shear rods on
both the first side and the
second side of the insulating body to form an exterior concrete slab and an
interior concrete slab.
[0019] Additionally or alternatively, placing on both the first side and
the second side of the
insulating body a plurality of cross tension rods substantially perpendicular
to the plurality of
reinforcing tension rods is included.
[0020] Additionally or alternatively, securing each of the plurality of
cross tension rods to one
or more of the plurality of reinforcing tension rods is included.
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[0021] Additionally or alternatively, securing each of the plurality of
cross tension rods to one
or more of the plurality of shear rods.
[0022] Additionally or alternatively, securing each of the plurality of
cross tension rods to one
or more of the plurality of reinforcing tension rods and to one or more of the
plurality of shear rods
is included.
[0023] Additionally or alternatively, securing a plurality of washers
around a respective ones of
the plurality of shear rod holes is included.
[0024] Additionally or alternatively, the insulating body has an R-value of
at least 2.
[0025] Additionally or alternatively, each of the plurality of reinforcing
tension rods is a size 46
rebar.
[0026] Additionally or alternatively, each of the plurality of reinforcing
shear rods is a size #4
rebar.
[0027] A system for preparing a thermally broken, cast-in-place concrete
slab comprising:
[0028] In another exemplary embodiment, a thermally insulating body is
provided that has a
first side and s second side, the insulating body being configured to separate
a first area for an
interior concrete slab from a second area for an exterior concrete slab, the
insulating body being
load-bearing structural foam and including a plurality of reinforcing tension
rod holes and a plurality
of reinforcing shear rod holes, wherein the plurality of shear rod holes
include washers secured to
the insulating body to limit rod twisting and wherein the plurality of shear
rod holes pass through the
insulating body at a non-horizontal angle. A plurality of reinforcing tension
rods are each
configured to through a respective one of the plurality of tension rod holes
and extend into the first
area and the second area. A plurality of reinforcing shear rods are each of
the plurality of
reinforcing shear rods being bent at a first point to form an angle that
substantially matches the non-
horizontal angle of the plurality of shear rod holes, wherein when inserted
into the plurality of shear
rod holes, the plurality of reinforcing shear rods are bent at a point where
each of the plurality of
reinforcing shear rods exit respective ones of the plurality shear rod holes
such that an exterior
portion of each of the plurality of shear rods is substantially horizontal,
wherein the system includes
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no plates on the first side or the second side of the insulating body, wherein
no compression struts
pass through the insulating body, and wherein no articulating elements
protrude through the
insulating body into the first area or the second area.
[0029] Additionally or alternatively, a plurality of cross tension rods are
substantially
perpendicular to the plurality of reinforcing tension rods.
[0030] Additionally or alternatively, each of the plurality of cross
tension rods is secured to one
or more of the plurality of reinforcing tension rods.
[0031] Additionally or alternatively, each of the plurality of cross
tension rods is secured to one
or more of the plurality of shear rods.
[0032] Additionally or alternatively, each of the plurality of cross
tension rods is secured to one
or more of the plurality of reinforcing tension rods and one or more of the
plurality of shear rods.
[0033] Additionally or alternatively, a plurality of washers are secured
around a respective one
of the plurality of shear rod holes.
[0034] Additionally or alternatively, the insulating body has an R-value of
at least 2.
10035] Additionally or alternatively, each of the plurality of reinforcing
tension rods is a size 45
rebar.
[0036] Additionally or alternatively, each of the plurality of reinforcing
shear rods is a size 43
rebar.
[0037] In another embodiment, a thermal break kit contains a thermally
insulating body
including a plurality of apertures, wherein at least some of the apertures
extend non-horizontally
from a first side to a second side; a plurality of twice bent reinforcing
shear rods coupled to the
thermally insulating body; and a plurality of reinforcing tension rods with
instructions on insertion
and securing of the plurality of reinforcing tension rods with the thermally
insulating body.
[0038] Additionally or alternatively, a plurality of cross tension rods are
installed substantially
perpendicular to the plurality of reinforcing tension rods.
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[0039] Additionally or alternatively, each of the plurality of cross
tension rods is secured to one
or more of the plurality of reinforcing tension rods.
[0040] Additionally or alternatively, each of the plurality of cross
tension rods is secured to one
or more of the plurality of shear rods.
[0041] Additionally or alternatively., each of the plurality of cross
tension rods is secured to one
or more of the plurality of reinforcing tension rods and one or more of the
plurality of shear rods.
[0042] Additionally or alternatively, a plurality of washers are secured
around a respective one
of the plurality of shear rod holes.
[0043] Additionally or alternatively, the insulating body has an R-value of
at least 1
[0044] Additionally or alternatively, each of the plurality of reinforcing
tension rods is a size 45
rebar.
[0045] Additionally or alternatively, each of the plurality of reinforcing
shear rods is a size #3
rebar.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] For the purpose of illustrating the invention, the drawings show
aspects of one or more
embodiments of the invention. However, it should be understood that the
present invention is not
limited to the precise arrangements and instrumentalities shown in the
drawings, wherein:
[0047] FIG. 1 is perspective view of a thermally broken cast-in-place
concrete connection in
accordance with an embodiment of the present invention;
[0048] FIG. 2 is a perspective view of the thermally broken cast-in-place
concrete of FIG. 1
with the concrete in outline;
[0049] FIG. 3A is a perspective view of a thermal barrier with rebar
installed in accordance
with an embodiment of the present invention:
[0050] FIG. 3B is a top view of the thermal barrier structure of FIG. 3A;
[0051] FIG. 3C is a side view of the thermal barrier structure of FIG. 3A;
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[0052] FIG. 3D is a front view of the thermal barrier structure of FIG. 3A;
[0053] FIG. 3E is a rear view of the thermal barrier structure of FIG. 3A;
[0054] FIG. 4 is perspective view of a thermally broken cast-in-place
concrete connection in
accordance with another embodiment of the present invention;
[0055] FIG. 5 is a perspective view of the thermally broken cast-in-place
concrete of FIG. 4
with the concrete in outline;
[0056] FIG. 6A is a perspective view of a thermal barrier with rebar
installed in accordance
with an embodiment of the present invention:
[00571 FIG. 6B is a top view of the thermal barrier structure of FIG. 6A;
[00581 FIG. 6C is a side view of the thermal barrier structure of FIG. 6A;
[0059] FIG. 6D is a front view of the thermal barrier structure of FIG. 6A;
[0060] FIG. 6E is a rear view of the thermal barrier structure of FIG. 6A;
[0061] FIG. 7A is a perspective view of the theinial barrier structure
without rebar installed;
[0062] FIG. 7B is a cutaway view of the thermal barrier structure of FIG.
7A:
[0063] FIG. 7C is another cutaway view of the thermal barrier structure of
FIG. 7A;
[0064] FIG. 8A is a cutaway side view of the thermal barrier structure
showing a partially
installed reinforcement shear bar:
[00651 FIGS. 8B-8C depict the installation of a reinforcement shear bar in
the thermal barrier
structure; and
100661 FIG. 9 is a perspective view of a pre-fabricated thermal break
system in accordance with
an embodiment of the present invention.
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DESCRIPTION OF THE DISCLOSURE
[00671 A thermal break system for thermally isolating concrete slabs is
provided that is easy to
install and results in a structurally secure concrete slab construction. The
system may be compiled
in a kit or package that can be delivered to a construction site and that
includes the components
necessary to install the thermal break system.
10068] At a high level, the thermally isolating system includes a thermally
insulating barrier,
such as a section of load-bearing structural foam, that is sized to be
positioned between an exterior
concrete slab and an interior concrete slab of a main structure. The thermally
insulating barrier
includes sets of holes therethrough. A first type of sets of holes are sized
and configured to
accommodate reinforcing tension bars that will pass through the foam barrier
and be embedded in
both the interior and exterior concrete slabs when poured. A second type of
sets of holes are sized
and configured to accommodate reinforcing shear bars that will also pass
through the foam barrier
and be embedded in both the interior and exterior concrete slabs. The
reinforcing shear bars,
however, are inserted through the barrier prior to being sent to the
construction site and are angled
within the foam barrier such that the reinforcing shear bars enter the foam on
the interior concrete
slab side at, for example, a higher point than the reinforcing shear bars exit
the foam barrier on the
exterior concrete slab side. In addition, washers may be welded to the
reinforcing shear bars and
then, after the shear bars are inserted into the barrier, secured to the foam
to prevent twisting of the
bars. During fabrication of the system, the reinforcing shear bars are passed
through the angled
holes and then bent at the exit point so that the reinforcing shear bars are
substantially horizontal on
both sides of the barrier. Upon arrival at a construction site, reinforcing
tension bars are inserted
through the pre-drilled tension bars holes and then concrete is poured on both
sides of the barrier to
form the interior and exterior concrete slabs.
[00691 Turning to the figures, and in particular FIGS. 1-3E, a thermally
broken cast-in-place
concrete slab 100 includes an exterior slab 104, an interior slab 108, and an
insulating barrier 112,
which provides a thermal break between interior slab 108 and exterior slab
104. Running through
insulating barrier 112 are reinforcing tension bars 116 (e.g., 116a-116b) and
reinforcing shear
bars 120 (e.g., 120a-120c), which continue on either side of barrier 112 and
are embedded in both
interior slab 108 and exterior slab 104, thereby providing structural
integrity for exterior slab 104. In
addition, reinforcing cross tension bars 124 (e.g., 124a, 124c, 124d, 124e,
124i) may be embedded in
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either interior slab 108 or exterior slab 104 in an orientation running
perpendicular to tension
bars 116 and shear bars 120. The reinforcement bars may be of any size
suitable for the intended
construction project, and preferably for typical construction projects
reinforcing tension bars 116
will be 45 or 46 rebars and reinforcing shear bars 120 will be 43 or 44
rebars.
100701 Barrier 112 is preferably made of load-bearing structural foam
having an R-value of
about 2 per inch and will have a length to approximately match the widths of
the concrete slabs to be
thermally separated. The height of barrier 112 will similarly preferably
approximately match the
height of the concrete slabs to be separated, and the thickness may be any
suitable thickness that
provides sufficient insulating properties while also allowing for adequate
structural integrity of
concrete slab 104. The load-bearing structural foam of barrier 112, as a
thermal break between
concrete slabs as described herein, additionally adequately handles all the
compression forces
typically exerted by concrete slabs that are part of structures, which
eliminates the need for having
steel compression struts that pass through the thermal break. Material from
which barrier 112 is
made may be 500-280 Structural Thermal Break Material from ArmathermTM of
Acushnet,
Massachusetts.
100711 Barrier 112 includes a plurality of tension bar holes for
accommodating reinforcing
tension bars 116. Tension bar holes pass generally straight through the
barrier at a single height so
that reinforcing tension bars 116 remain generally parallel with the
lengthwise direction of the slabs.
Tension bar holes are pre-drilled prior to shipment to a construction site
based on the needs of the
slabs to be constructed. In addition, a plurality of reinforcing shear bar
holes for accommodating
reinforcing shear bars 120 are drilled through barrier 112. Reinforcing shear
bar holes pass through
barrier 112 at an angle, preferably about a 45 degree angle, sloping downward
from an interior side
132 to an exterior side 128 of barrier 112 for cantilever conditions.
(Alternatively, reinforcing shear
bar holes may slope upward from an interior side 132 to an exterior side 128
of barrier 112 for
simple span conditions.) In addition, barrier 112 includes washers 136 (e.g.,
136a-136c) on one side
of the reinforcing shear bar. Washers 136 are welded onto shear bars 120 prior
to insertion and then
secured to barrier 112 when shear bars 120 are inserted, and serve to prevent
twisting of installed
reinforcement shear bars 120.
100721 In operation, distal ends of reinforcing tension bars 116 and
reinforcing shear bars 120
are designated as the ends that will be embedded in interior concrete slab
108. Then proximate ends
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of reinforcing tension bars 116 are fed through the reinforcing tension bar
holes of barrier 112 such
that the distal ends protrude through interior side 132 a distance that
reinforcing tension bars 116
will be embedded in interior concrete slab 108. In a preferred embodiment,
tension bars 116 are
inserted through barrier 112 at the construction site.
100731 To fabricate the thermal break system, washers 136 are welded to
reinforcing shear bars
120 so that washers 136 can later be secured to barrier 112. Then reinforcing
shear bars 120 are bent
at points that correspond to the points where reinforcing shear bars 120 will
enter exterior side 128
of barrier 112, at an angle appropriate for the angle through which
reinforcing shear bars will pass
through barrier 112. Then bent reinforcing shear bars 120 are fed through
barrier 112. Reinforcing
shear bars 120 are then bent a second time at another point, pivoting until
the proximal ends are
again parallel with their distal ends and with reinforcing tension bars 116.
This post-insertion
bending during the fabrication process is preferable due to properties of
barrier 112, which is made
of load-bearing structural foam that is not conducive to having a bent bar fed
through an angled hole.
Washers 136 that are welded to shear bars 120 are then secured to barrier 112
with, for example,
screws passing through pre-drilled holes in washers 136, which serve to
prevent twisting of shear
bars 120. In addition, washers 136 may provide a supporting element for
assisting with the bending
of reinforcing shear bar 120 while the angled portion resides within barrier.
[0074] The assembled thermal break system is then delivered to the
construction site and
installed where the concrete slabs are to be constructed. Once barrier 112 is
in place, tension bars
116 are inserted through the pre-drilled holes, and cross tension bars 124 may
be added. Cross
tension bars 124 may be tied to reinforcing tension bars 116 and/or
reinforcing shear bars 120 in
interior slab 108 and exterior slab 104. Then concrete is poured to form
thermally broken cast-in-
place concrete slab 100 without the need for plates to sandwich the insulating
material, steel
compression struts passing through the thermal break, or articulating elements
protruding through
the insulating material and into the concrete slabs.
100751 In another exemplary embodiment, shown in FIGS. 4-7C, a thermally
broken cast-in-
place concrete slab 200 includes an exterior slab 204, an interior slab 208,
and an insulating
barrier 212, which provides a thermal break between interior slab 208 and
exterior slab 204.
Running through insulating barrier 212 are reinforcing tension bars 216 (e.g.,
216a-216d) and
reinforcing shear bars 220 (e.g., 220a-220e), which continue on either side of
barrier 212 and are
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embedded in both interior slab 208 and exterior slab 204, thereby providing
structural integrity for
exterior slab 204. In addition, reinforcing cross tension bars (not shown) may
be embedded in either
interior slab 208 or exterior slab 204 in an orientation running perpendicular
to tension bars 216 and
shear bars 220. The reinforcement bars may be of any size suitable for the
intended construction
project, and preferably for typical construction projects reinforcing tension
bars 216 will be 45 or 46
rebars and reinforcing shear bars 220 will be #3 or 44 rebars.
[0076] Barrier 212 is preferably made of load-bearing structural foam
having an R-value of
about 2 per inch and will have a length to approximately match the widths of
the concrete slabs to be
thermally separated. The height of barrier 212 will similarly preferably
approximately match the
height of the concrete slabs to be separated, and the thickness may be any
suitable thickness that
provides sufficient insulating properties while also allowing for adequate
structural integrity of
concrete slab 204. The load-bearing structural foam of barrier 212, as a
thermal break between
concrete slabs as described herein, additionally adequately handles all the
compression forces
typically exerted by concrete slabs that are part of structures, which
eliminates the need for having
steel compression struts that pass through the thermal break.
[00771 In addition, washers 236 (e.g., 236a-236e) may be included on one
side of reinforcing
shear bar holes, as can be seen in FIGS. 6B, 6C, and 6E, by welding, for
example. Washers 236 that
are attached to shear bars 220 can be secured to barrier 212 when shear bars
220 are inserted, thus
preventing twisting of installed reinforcement shear bars 220.
100781 Turning to FIGS. 7A-7C, barrier 212 includes a plurality of tension
bar holes 214 (e.g.,
214a-214d) for accommodating reinforcing tension bars 216. Tension bar holes
214 pass generally
straight through barrier 212 at a single height so that reinforcing tension
bars 216 remain generally
parallel with the lengthwise direction of the slabs. A plurality of
reinforcing shear bar holes 218
(e.g., 218a-218e) for accommodating reinforcing shear bars 220 are also
included in barrier 212.
Reinforcing shear bar holes 218 pass through barrier 212 at an angle, sloping
downward from an
interior side 232 to an exterior side 228 of barrier 212 for cantilever
conditions. (Alternatively,
reinforcing shear bar holes 218 may slope upward from an interior side 232 to
an exterior side 228 of
barrier 212 for simple span conditions (not shown).)
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[0079] FIGS. 8A-8C are cut-away views of barrier 212 that has been cut to
size for forming a
thermal break for a concrete slab. Tension bar holes 214 (e.g., 214a-214d) are
pre-drilled for
accommodating tension bars to be inserted at the construction site.
Additionally, shear bar holes 218
(e.g., 218a-218e) are drilled where reinforcing shear bars will be inserted.
As can be seen in FIG.
7C, shear bar holes 218 pass through barrier 212 at an angle (in a preferred
embodiment, at a 45
degree angle).
[0080] In operation, distal ends of reinforcing tension bars 216 and
reinforcing shear bars 220
are designated as the ends that will be embedded in interior concrete slab
208. Then proximate ends
of reinforcing tension bars 216 are fed through the reinforcing tension bar
holes of barrier 212 such
that the distal ends protrude through interior side 232 a distance that
reinforcing tension bars 216
will be embedded in interior concrete slab 208. In a preferred embodiment,
tension bars 216 are
inserted through barrier 212 at the construction site.
[0081] To fabricate a prefabricated thermal break system 250 (shown in FIG.
9), washers 236
(e.g.. 236e as shown in FIG. 8A) are welded to reinforcing shear bars 220 and
then reinforcing shear
bars 220 are bent at points 240 (e.g., point 240e in FIG. 8A), which
correspond to the point where
reinforcing shear bars 220 will enter exterior side 228 of barrier 212, at an
angle appropriate for the
angle through which reinforcing shear bars will pass through barrier 212. Then
bent reinforcing
shear bars 220 are fed through barrier 212. Reinforcing shear bars 220 are
then bent a second time at
points 244 (e.g., 244e in FIG. 8B), pivoting until the proximal ends are again
parallel with their
distal ends, i.e., generally horizontal. This bending during the installation
process is necessitated by
properties of barrier 212, which is made of load-bearing structural foam that
is not conducive to
having a bent bar fed through an angled hole. Washers 236 are then secured to
barrier 212 with, for
example, screws passing through pre-drilled holes in washers 236, which serve
to prevent twisting of
shear bars 220. In addition, washers 236 may provide a supporting element for
assisting with the
bending of reinforcing shear bar 220 while angled portion 221 resides within
barrier 212.
[0082] The assembled thermal break system 250 is then delivered to the
construction site and
installed where the concrete slabs are to be constructed. Once barrier 212 is
in place, reinforcing
tension bars 216 are inserted through pre-drilled holes 214 and cross tension
bars may be added.
Cross tension bars may be tied to reinforcing tension bars and/or reinforcing
shear bars in interior
slab and exterior slab. Then concrete is poured to form thermally broken, cast-
in-place concrete slab
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200 without the need for plates to sandwich the insulating material, steel
compression struts passing
through the thermal break, or articulating elements protruding through the
insulating material and
into the concrete slabs.
[0083] Exemplary embodiments have been disclosed above and illustrated in
the accompanying
drawings. It will be understood by those skilled in the art that various
changes, omissions, and
additions may be made to that which is specifically disclosed herein without
departing from the
spirit and scope of the present invention.
14
