Note: Descriptions are shown in the official language in which they were submitted.
CONCRETE REPAIR DEVICE
[0001]
[0002] The installation of fiber-reinforced polymer (FRP) in slots cut into
concrete is a
technique developed over the years by the concrete repair industry and has
become the generally
accepted way to repair pre-cast concrete double tee systems. The present
disclosure is directed to
a method and apparatus for strengthening concrete, more particularly directed
to a method and
apparatus for strengthening and/or repairing concrete connections, and still
more particularly
directed to a method and apparatus for connecting, strengthening and/or
repairing the flange-to-
flange connections for pre-cast and pre-stressed double tee systems.
BACKGROUND OF THE DISCLOSURE
[0003] Concrete structures are commonly used for buildings, parking
garages, and the like.
Over time, cracks can develop within concrete structures. If such cracks are
left unrepaired, the
cracks can result in failure of the structure. This is a particular problem
for parking garages
wherein large loads from vehicles travel daily over the concrete surface. To
prevent the failure of
the concrete structure without having to replace the entire structure, the
damaged concrete structure
is often repaired by cutting the damaged section away from a pre-existing
concrete section, and
then pouring new concrete into the cutout portion. However, new concrete does
not always bond
perfectly with the pre-existing concrete, thus resulting in the propagation of
cracks in the joint
between the old and new concrete.
[0004] Other methods have been used to repair damaged concrete structures
and maintain the
mechanical connection between the new concrete section and a pre-existing
concrete section. One
prior art repair method involves first removing the damaged concrete and then
drilling holes in the
pre-existing concrete using a rotary impact hammer drill. Thereafter, an
adhesive is placed into
the holes, and reinforcing bars are inserted such that the bars extend beyond
the outer wall of the
pre-existing concrete and are generally perpendicular to the joint between the
pre-existing concrete
section and the gap defining the area where the new concrete is to be poured.
The new concrete is
then poured adjacently to the pre-existing concrete such that the ends of the
reinforcing bars extend
into the new concrete and bond with the new concrete when the new concrete
cures. As a result,
when the new concrete cures, it will be joined to the pre-existing concrete
via the reinforcing bars.
When attaching external fixtures to pre-existing concrete sections, holes are
commonly drilled
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using a standard rotary drill, and the anchors are either bonded or friction-
fitted within the drilled
holes. The external fixtures are then mounted onto the anchors.
[0005] Several disadvantages are associated with these past methods of
repair and attachment
of newly poured concrete. For instance, the drilling of multiple holes into
the existing concrete is
a slow and labor-intensive process. Additionally, the vibrations associated
with the drilling of the
holes can cause an entire section of concrete to fail. Moreover, once a hole
is drilled, it must be
subsequently cleaned of dust and concrete particles in order to permit the
adhesive to properly
bond to the concrete. Furthermore, cracks can form over time in the joint
between the new concrete
section and the pre-existing concrete. As such, when moisture seeps down these
cracks, the
metallic reinforcing bars will rust, corrode, and subsequently fail, thereby
necessitating further
repair of the concrete section. Also, a phenomenon known in the industry as
"burping" may occur,
whereby air pockets become trapped within the hole once the reinforcing bar is
installed, thereby
preventing at least a portion of the adhesive from bonding with the
reinforcing bar. Such defective
bonding can lead to premature failure of the reinforced joint.
[0006] The repair of concrete structures such as a parking garage
structure, a concrete
driveway, or the like that is disposed above T-shaped concrete beams can be
problematic. The
concrete structures are typically joined together by metal clips. As cracks
form in the concrete
structures, moisture seeps into the concrete supports and corrodes the metal
clips. Such metal clip
corrosion ultimately causes the metal clip to fail, which can result in the
collapsing of a concrete
slab within the parking garage. One prior art method to repair this type of
damage involves welding
or bolting a supplemental joining apparatus to both supports, thereby
retaining them together. This
method is expensive and labor intensive. Additionally, the repair is
aesthetically unappealing.
Another prior art method to repair this type of damage involves cutting
through the concrete to
access and replace the failed metal clip. Again, this process is labor
intensive and expensive.
[0007] Another prior art method to repair concrete structures disposed
above T-shaped
concrete beams is disclosed in US Patent No. 6,312,541. The '541 patent
discloses the use of a
half-moon-shaped molded composite insert that is inserted into a cut slot in
the concrete slab. The
slot is cut generally perpendicular to the T-shaped concrete beams and across
the gap between two
concrete structures. An epoxy material is used to secure the composite insert
in the cut slot. The
composite insert includes a plurality of cavities that facilitate in the
bonding of the composite insert
within the cut slot in the concrete slab. Although the molded composite insert
is an improvement
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over prior art methods to repair damaged concrete, there remains a continued
need to improve the
strength and durability of the repaired concrete.
[0008] Another prior art method to repair concrete structures disposed
above T-shaped
concrete beams is disclosed in US Patent No. 8,567,146. The '146 patent
discloses a composite
material for use in repairing concrete. A slot is cut into two adjacently
positioned concrete slabs
and the composite material is inserted into the cut and adhesively connected
to the concrete slabs.
Although the composite insert is an improvement over prior art methods to
repair damaged
concrete and/or to connect together adjacently positioned concrete slabs,
there remains a continued
need to improve the strength and durability of the repaired concrete and/or
connected concrete and
to reduce cracking in the repaired and/connected concrete.
SUMMARY OF THE DISCLOSURE
[0009] The present disclosure is directed to a method and apparatus for
connecting,
strengthening, and/or repairing concrete connections, and more particularly
directed to a method
and apparatus for connecting, strengthening, and/or repairing the flange-to-
flange connections for
pre-cast and pre-stressed double tee systems; however, it can be appreciated
that the method can
be used to connect other concrete systems and other non-concrete systems. The
method of the
present disclosure includes the use of an improved composite material bonded
to a region of
concrete. The method of the present disclosure is simple to implement,
generally less expensive
than welding or bolting a supplemental joining apparatus to the concrete, and
only requires a small
region about the concrete to be closed down for repair and/or connection, thus
minimizing the need
to close off the complete concrete structure during the repair and/or
connection process.
[0010] In one non-limiting aspect of the present disclosure, the improved
composite material
includes a first fiber system that is partially or fully coated, partially or
fully saturated, and/or
partially or fully incorporated in a resin material. The improved composite
material can be formed
of a first fiber system, or can be formed of two or more fiber systems. The
improved composite
material is designed to resist tensile loading and simple shear to facilitate
in the repair and/or
connection of concrete.
[0011] In another and/or alternative non-limiting aspect of the present
disclosure, the fibers
used in the first fiber system can include one or more types of fibers (e.g.,
carbon fibers, glass
fibers, aramid fibers [Kevlar0, Twaron0, etc.], boron fibers, hemp, basalt
fibers, etc.). The first
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fiber system can include one or more layers of fibers. As such, the first
fiber system can be formed
of: 1) a single layer of fibers that are positioned fully parallel or
substantially parallel to one
another (0-100 [and all values and ranges therebetween] deviation to one
another), and which layer
of fibers are optionally connected together by an arrangement other than an
adhesive or other
binding material (e.g., stitching, staples, melted bond, clips, pins, etc.);
2) a plurality of layers of
fibers that are positioned fully parallel or substantially parallel to one
another, and wherein the two
or more layers of fibers are connected together by an arrangement other than
an adhesive or other
binding material (e.g., stitching, staples, melted bond, clips, pins, etc.);
3) a single layer of fiber
rovings that are positioned fully parallel or substantially parallel to one
another (0-100 [and all
values and ranges therebetween] deviation to one another), and which single
layer of fiber rovings
are optionally connected together by an arrangement other than an adhesive or
other binding
material (e.g., stitching, staples, melted bond, clips, pins, etc.); 4) two or
more layers of fiber
rovings, and wherein the two or more layers of fiber rovings are positioned
fully parallel or
substantially parallel to one another, and wherein the two or more layers of
fiber rovings are
optionally connected together by an arrangement other than an adhesive or
other binding material
(e.g., stitching, staples, melted bond, clips, pins, etc.); 5) two or more
layers of fiber rovings that
are positioned non-parallel to one another (e.g., 15 -165 [and all values and
ranges therebetween]
deviation to one another, +45 to -45 , +300 to -300, +60 to -600, +15 to 75
), and optionally one
or more layers of fiber rovings are positioned parallel to one or more other
layers of fiber rovings,
and wherein two or more layers of fiber rovings are optionally connected
together by an
arrangement other than an adhesive or other binding material (e.g., stitching,
staples, melted bond,
clips, pins, etc.); 6) a fabric material formed of two or more layers of woven
fibers that are
positioned non-parallel to one another (e.g., 15 -165 [and all values and
ranges therebetween]
deviation to one another, +45 to -45 , +30 to -30 , +60 to -60 , +15 to 75
), and wherein the
two or more layers of fabric are optionally connected together by an
arrangement other than an
adhesive or other binding material (e.g., stitching, staples, melted bond,
clips, pins, etc.); 7) two
or more layers of fabric material formed of two or more layers of woven fibers
that are positioned
non-parallel to one another, and wherein the two or more layers of fabric
material are connected
together by an arrangement other than an adhesive or other binding material
(e.g., stitching, staples,
heat/melted bond, clips, pins, etc.); or 8) one or more layers fabric material
formed of two or more
layers of woven fibers that are positioned non-parallel to one another, and
wherein one or more
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layers of rovings or fibers are positioned on one or both sides of the one or
more layers of fabric
material, and wherein the two or more fabric layers (when used) are connected
together by an
arrangement other than an adhesive or other binding material (e.g., stitching,
staples, melted bond,
clips, pins, etc.), an wherein the one or more layers of fiber rovings or
fibers are optionally
connected to one or more other layers by an arrangement other than an adhesive
or other binding
material (e.g., stitching, staples, melted bond, clips, pins, etc.). After the
first fiber system is
formed, it can be optionally partially or fully saturated and/or infused with
one or more binders
(e.g., resin, adhesive, polymer, etc.).
[0012]
In another and/or alternative non-limiting aspect of the present disclosure,
the volume
of fibers used for each fiber layer in the first fiber system can be the same
or different. In one non-
limiting design, the first fiber system includes three fiber layers, wherein
the first and third fiber
layers having over 60% (e.g., 60.0001-100% and all values and ranges
therebetween) of the fibers
running parallel to the longitudinal axis of the improved composite material,
and the second fiber
layer positioned between the first and third fiber layers has over 60% (e.g.,
60.0001-100% and all
values and ranges therebetween) of the fibers running non-parallel to the
longitudinal axis of the
improved composite material. In another non-limiting design, the first fiber
system includes three
layers, wherein the first and third fiber layers having over 60% (e.g.,
60.0001%-100% and all
values and ranges therebetween) of the fibers running parallel to the
longitudinal axis of the
improved composite material, and the second fiber layer positioned between the
first and third
fiber layers has over 60% (e.g., 60.0001-100% and all values and ranges
therebetween) of the
fibers running non-parallel to the longitudinal axis of the improved composite
material, 20-50%
(and all values and ranges therebetween) of the fibers of the second fiber
layer are oriented at an
angle of +15 to +75 (and all values and ranges therebetween) relative to the
longitudinal axis of
the improved composite material, 20-50% (and all values and ranges
therebetween) of the fibers
of the second layer oriented at an angle of ¨15 to ¨75 (and all values and
ranges therebetween)
relative to the longitudinal axis of the improved composite material. In
another non-limiting
design, the first fiber system includes three layers, the first and third
layers formed of a carbon
fiber material and having over 80% (e.g., 80.0001-100% and all values and
ranges therebetween)
of the fibers running parallel to the longitudinal axis of the improved
composite material, and the
second layer positioned between the first and third fiber layers having over
80% (e.g., 80.0001-
100% and all values and ranges therebetween) carbon fibers, and the second
fiber layer having
Date recue / Date received 2021-11-04
over 80% (e.g., 80.0001-100% and all values and ranges therebetween) of the
fibers running non-
parallel to the longitudinal axis of the improved composite material.
[0013] In another and/or alternative non-limiting aspect of the present
disclosure, the improved
composite material can include a first fiber system having a tensile strength
of at least about 50
KSI. The tensile strength is the maximum stress that the fiber system can
withstand before failure
of the fiber system. In one non-limiting aspect of this embodiment, the
improved composite
material includes a first fiber system having a tensile strength of about 50-
800 KSI (and all values
and ranges therebetween). In another non-limiting aspect of this embodiment,
the improved
composite material includes a first fiber system having a tensile strength of
at least about 300 KSI.
In another non-limiting aspect of this embodiment, the improved composite
material includes a
first fiber system having a tensile strength of at least about 350 KSI. In
another non-limiting aspect
of this embodiment, the improved composite material includes a first fiber
system having a tensile
strength of about 350-700 KSI. In another non-limiting aspect of this
embodiment, the improved
composite material includes a first fiber system having a tensile strength of
about 400-675 KSI.
In another and/or alternative non-limiting embodiment of the disclosure, the
improved composite
material can include a first fiber system having a tensile modulus of at least
about 3 MSI. Tensile
modulus is an indicator of the stiffness of the fiber. Tensile modulus is the
applied stress on the
fiber, based on force and cross-sectional area of the fiber, divided by the
observed strain at such
stress level. In one non-limiting aspect of this embodiment, the improved
composite material
includes a first fiber system having a tensile modulus of about 3-60 MSI (and
all values and ranges
therebetween). In another non-limiting aspect of this embodiment, the improved
composite
material includes a first fiber system having a tensile modulus of at least
about 10 MSI. In another
non-limiting aspect of this embodiment, the improved composite material
includes a first fiber
system having a tensile modulus of at least about 15 MSI. In another non-
limiting aspect of this
embodiment, the improved composite material includes a first fiber system
having a tensile
modulus of about 15-50 MSI. In another non-limiting aspect of this embodiment,
the improved
composite material includes a first fiber system having a tensile modulus of
about 18-35 MSI. In
one non-limiting example, the first fiber system has a tensile strength of
about 400-640 KSI and a
tensile modulus of about 25-40 MSI.
[0014] In another and/or alternative non-limiting aspect of the present
disclosure, the first fiber
system of the improved composite material has a thickness of at least 0.0005
in., and typically
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0.0005-1 in. (and all values and ranges therebetween), and typically 0.03-0.5
in., and more
typically 0.06-0.3 in.
[0015] In another and/or alternative non-limiting aspect of the present
disclosure, the improved
composite material includes a first fiber system formed of a plurality of
fiber layers wherein the
thickness of two or more of the fiber layers is optionally non-uniform. In one
non-limiting
embodiment, the one or more of the outer fiber layers of the improved
composite material have a
thickness that is less than the thickness of one or more of the fiber layers
located between the outer
fiber layers. In one non-limiting example, the one or more outer fiber layers
of the improved
composite material have a thickness of at least 0.005 in., and generally 0.005-
0.2 in. (and all values
and ranges therebetween), and typically 0.01-0.02 in. (e.g., 0.0125 in.,
etc.). The thickness of the
outer layers can be substantially the same (e.g., 0-15% of the thickness of
one another and all
values and ranges therebetween). In another non-limiting example, the one or
more fiber layers
located between the two outer layers have a thickness of at least 0.005 in.,
and generally 0.005-0.5
in. (and all values and ranges therebetween), and typically 0.01-0.34 in.
(e.g., 0.035 in., 0.07 in.,
etc.). When the first fiber system includes three or more fiber layers, the
thickness of the one or
more of the fiber layers positioned between the outer fiber layers can
optionally be greater than
the thickness of the one or more outer fiber layer; however, this is not
required. In one non limiting
example, the outer layers of the first fiber system are at least 0.005 in.,
and generally 0.005-0.2 in.
(and all values and ranges therebetween), and typically 0.01-0.125 in. (e.g.,
0.035 in., etc.), and
the thickness of one or more of the fiber layers located between the outer
fiber layers is least 0.005
in., and generally 0.005-0.4 in. (and all values and ranges therebetween), and
typically 0.1-0.22 in.
(e.g., 0.07 in., etc.).
[0016] In another and/or alternative non-limiting aspect of the present
disclosure, the improved
composite material includes a first fiber system and optionally one or more
additional fiber
systems. The one or more optional additional fiber systems can be the same or
similar to the first
fiber system as discussed above. The first fiber system can be secured to at
least one other fiber
system by use of an adhesive (e.g., resin, etc.) such that the sides of the
fiber systems facing one
another are bonded together by the adhesive. The first fiber system can have
the same or different
composition, same or different number of layers, and/or same or different
fiber orientation.
[0017] In another and/or alternative non-limiting aspect of the present
disclosure, the improved
composite material can include a resin material selected from vinyl ester
resins, epoxy resins,
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polyester resins, acrylic resins, polyurethane resins, phenolic resins, alkyd
resins, polycarbonate
resins, polyamide resins, and/or silicone resins. In one non-limiting
embodiment of the disclosure,
the resin material includes a vinyl ester resin. In another non-limiting
embodiment of the
disclosure, the resin material includes an epoxy resin. Generally, the first
fiber system is partially
or fully impregnated and/or saturated with the resin material; however, this
is not required.
[0018]
In another and/or alternative non-limiting aspect of the present disclosure,
the improved
composite material optionally includes a first fiber system sandwiched between
two outer layers
of dielectric insulating material. As used herein, a dielectric insulating
material is a material
having low conductivity and which creates obstruction in the flow of current.
As defined herein,
a dielectric insulating material has an electrical conductivity of less than
5.5 x 10-3 S/m, and
typically, a dielectric insulating material has an electrical conductivity of
less than 5.5 x 10-6 S/m.
Non-limiting examples of dielectric insulating material includes fiberglass
fiber layers, Kevlar0
fiber layers, resin material layers, etc. The first fiber system and the one
or more layers of dielectric
insulating material can include the same or different material. In one non-
limiting embodiment of
the disclosure, the improved composite material includes a first fiber system
partially or fully
impregnated with and/or saturated with one or more types of resin material,
and each side of the
improved composite material includes one or more layers of dielectric
insulating material formed
of a different material from the first fiber system. In one non-limiting
example, the first fiber
system is partially or fully impregnated with an adhesive (e.g., resin
material, etc.), and the outer
layer on both sides of the improved composite material includes a layer of
dielectric insulating
material having a different composition from at least one of the fiber layers
of the first fiber system.
In another non-limiting example, the improved composite material only incudes
a first fiber system
that is partially or fully impregnated with an adhesive (e.g., resin material,
etc.), and the outer layer
on both sides of the first fiber system includes a layer of dielectric
insulating material having a
different composition from at least one of the fiber layers of the first fiber
system, and the adhesive
that is used to partially or fully impregnate the first fiber system may or
may not be of the same
composition as the dielectric insulating material. In another non-limiting
example, the first fiber
system includes one or more fiber layers having an electrical conductivity of
greater than 0.5 S/m.
In another non-limiting example, the first fiber system includes one or more
carbon fiber layers
having an electrical conductivity of greater than 1 S/m. In another non-
limiting example, the first
fiber system includes one or more carbon fiber layers having an electrical
conductivity of greater
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than 1 S/m, and the outer layer on both sides of the improved composite
material includes a resin
layer having an electrical conductivity of less than 0.1 S/m. The thickness of
the dielectric
insulating material when it forms the outer layer of the improved composite
material is generally
less than the thickness of the first fiber system; however, this is not
required. In one non-limiting
example, the thickness of the dielectric insulating material is at least
0.0001 in., generally 0.005-
0.5 in. (and all values and ranges therebetween), and typically 0.01-0.34 in.
(e.g., 0.035 in., 0.07
in., etc.). In one specific examples, the outer layers of the improved
composite material are formed
of a resin material that is a dielectric insulating material and wherein each
layer of the resin
material has a thickness of 0.01-0.1 in. (and all values and ranges
therebetween), and wherein one
or both layers of the resin material have a thickness less than the thickness
of the first fiber system.
[0019] In another and/or alternative non-limiting aspect of the present
disclosure, one or both
of the outer layers of the improved composite material is optionally non-
smooth to facilitate in
securing the improved composite material to the adhesive (e.g., resin, etc.)
used to secure the
improved composite material in the slot in the concrete. The non-smooth
surface on one or both
of the outer layers can be formed by ridges, slots, pits, ribs, or other non-
smooth texture. In one
non-limiting embodiment, the non-smooth surface on one or both of the outer
layers is formed by
a plate or mold used to mold, stamp, or compress one or both of the outer
layers partially or fully
formed of an adhesive material (e.g., resin, etc.) to create the non-smooth
surfaces on one or both
of the outer layers of the improved composite material. Generally, the
improved composite
material does not include any openings or holes that detract from the strength
of the improved
composite material.
[0020] In another and/or alternative non-limiting aspect of the present
disclosure, the improved
composite material is optionally at least partially formed by partially or
fully saturating and/or
impregnating the first fiber system with an adhesive (e.g., resin material,
etc.) and then pressing
the one or more layer of the first fiber system together until the adhesive
dries and/or cures. A
vacuum can optionally be applied during the pressing and drying/curing steps.
The process for
forming the improved composite material can be by a batch process or a
continuous process. The
adhesive material can be pre-applied and/or applied as the one or more layers
of the first fiber
system are brought together.
[0021] In another and/or alternative non-limiting aspect of the present
disclosure, the improved
composite material has a certain size, shape, and thickness to achieve the
desired repair and/or
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connection strength for the concrete. In one non-limiting embodiment of the
disclosure, the
longitudinal length of the improved composite material is 8-25 in. (and all
values and ranges
therebetween), and typically 12-18 in. When the length of the improved
composite material is less
than about eight in., the desired resistance to tensile loading and simple
shear is generally not
achieved. When the length of the improved composite material is greater than
about 25 in., little
(if any) improvement in resistance to tensile loading and simple shear is
noticed. The height of
the improved composite material is selected to be less than the thickness of
the concrete being
repaired and/or connected together; however, this is not required. In one non-
limiting
embodiment, the maximum height of the improved composite material is at least
about 1.5 in. In
one non-limiting aspect of this embodiment, the maximum height of the improved
composite
material is about 1.5-6 in. (and all values and ranges therebetween), and
generally about 2-3.5 in.
The width or thickness of the improved composite material is at least about
0.05 in. In one non-
limiting aspect of this embodiment, the thickness of the improved composite
material is about
0.05-0.5 in. (and all values and ranges therebetween), and generally about 0.1-
0.3 in. The thickness
of the improved composite material can be uniform or vary along the
longitudinal length of the
improved composite material.
[0022]
In another and/or alternative non-limiting aspect of the present disclosure,
the shape of
the improved composite material is generally selected to fit within a cut slot
in the concrete. In
one non-limiting aspect of the disclosure, the two side profiles of the
improved composite material
along the longitudinal length of the improved composite material are in a
generally parallel
relationship to one another; however, this is not required. In one non-
limiting embodiment, the
thickness of the improved composite material along 50-100% (and all values and
ranges
therebetween) of the longitudinal length of the improved composite material is
constant. In one
non-limiting embodiment, the bottom surface of the improved composite material
includes a
curved portion or the full bottom surface is a curved surface. When only a
portion of the bottom
of the improved composite material includes a curved surface, generally about
20-99% (and all
values and ranges therebetween) of the bottom surface includes a curved
surface. The radius of
curvature of the one or more curved surfaces on the bottom of the improved
composite material is
generally about 4-9 in. (and all values and ranges therebetween). In one non-
limiting
configuration, the middle portion of the bottom surface of the improved
composite material is flat
and the two side portions of the bottom surface are curved.
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[0023] In another and/or alternative non-limiting aspect of the present
disclosure, the improved
composite material has curved ends. The radius of curvature of the curved ends
is generally about
0.1-1 in. (and all values and ranges therebetween). The curved ends of the
improved composite
material reduce stress points at such region of the improved composite
material which results in
reduced cracking of the concrete at or near the ends of the improved composite
material and/or
reduces the incidence of the adhesive disengaging from the improved composite
material and/or
concrete at or near the ends of the improved composite material.
[0024] In another and/or alternative non-limiting aspect of the present
disclosure, the improved
composite material has a recessed portion in the upper region of the improved
composite material.
The recessed portion is generally located in the top middle region of the
improved composite
material. The recessed position is generally about 5-60% (and all values and
ranges therebetween)
the longitudinal length of the improved composite material, and generally
about 20-40% the
longitudinal length of the improved composite material. In one non-limiting
example, when the
longitudinal length of the improved composite material is about 12-18 in., the
longitudinal length
of the recessed portion is 2.4-7.2 in. The maximum depth of the recessed
portion is about 5-50%
(and all values and ranges therebetween) of the maximum height of the improved
composite
material, and generally about 10-30% of the maximum height of the improved
composite material.
In one non-limiting example, when the maximum height of the improved composite
material is 2-
4 in., the maximum depth of the recess portion is 0.2-1.2 in. The ends of the
recessed portion can
optionally include curved transitions. The curved transition (when used) can
be a sinusoidal or
wave-shaped transition; however, this is not required. The radius of curvature
of the one or more
curved transitions is generally about 0.2-2 in. (and all values and ranges
therebetween), and
generally 0.5-1.5 in. The recessed portion is formed in the improved composite
material to
improve the flexibility of the improved composite material along the
longitudinal length of the
improved composite material. Such increased flexibility has been found to
reduce the incidence
of stress cracks at or near the location of the secured improved composite
material in the concrete
without sacrificing the strength of connection formed by the improved
composite material.
[0025] In another and/or alternative non-limiting aspect of the present
disclosure, the improved
composite material has a tensile strength along the x-y axis or longitudinal
axis of at least about
50 KSI (e.g., 50-150 KSI and all values and ranges therebetween), a
compressive strength along
the x-y axis or longitudinal axis of at least about 40 KSI (e.g., 40-135 KSI
and all values and ranges
11
Date recue / Date received 2021-11-04
therebetween), a compressive strength through the z axis or thickness of at
least about 5 KSI (e.g.,
5-12 KSI and all values and ranges therebetween), a shear strength through the
z axis or thickness
of at least about 10 KSI (e.g., 10-30 KSI and all values and ranges
therebetween), and/or an inter-
laminar shear along the x-y axis or longitudinal axis of at least about 1 KSI
(e.g., 1-3 KSI and all
values and ranges therebetween).
[0026] In another and/or alternative non-limiting aspect of the present
disclosure, the method
for using the improved composite material includes the step of adhesively
connecting the improved
composite material to the concrete. Many different types of adhesives can be
used. Generally, the
adhesive is an epoxy adhesive; however, other or additional adhesives can be
used. When an
epoxy adhesive is used, the epoxy is generally a two-part, 100% solids epoxy
that is thixotropic in
nature. This type of adhesive bonds well to both the improved composite
material and the concrete.
However, other adhesives that include vinyl ester resins, polyester resins,
acrylic resins,
polyurethane resins, phenolic resins, alkyd resins, polycarbonate resins,
polyamide resins, and/or
silicone resins can also or alternatively be used. The curing time for the
adhesive is generally
about 1-5 hours, depending on the temperature. The bonding strength of the
improved composite
material to the concrete is at least about 1 KSI. In one embodiment of the
disclosure, bonding
strength of the adhesive to the concrete is 1-6 KSI (and all values and ranges
therebetween). In
another one non-limiting aspect of this embodiment, the bonding strength of
the adhesive to the
concrete is at least about 1.5 KSI. In another non-limiting aspect of this
embodiment, the bonding
strength of the adhesive to the concrete is at least about 1.8 KSI. In another
non-limiting aspect
of this embodiment, the bonding strength of the adhesive to the concrete is at
least about 2 KSI.
In another non-limiting aspect of this embodiment, the bonding strength of the
adhesive to the
concrete is about 2-5 KSI. In another non-limiting aspect of this embodiment,
the bonding strength
of the adhesive to the concrete is about 2.2-4 KSI. In another non-limiting
aspect of this
embodiment, the bonding strength of the adhesive to the concrete is about 2.4-
3.2 KSI. The
adhesive used to bond the improved composite material to the concrete can be
the same or different
from the adhesive or resin used to bond one or more fibers layers together in
the improved
composite material and/or to form the one or more outer layers of the improved
composite material.
[0027] In another and/or alternative non-limiting aspect of the present
disclosure, the method
for using the improved composite material includes the step of cutting a slot
into the concrete slab
wherein the improved composite material can be fully or partially inserted
into the cut slot. The
12
Date recue / Date received 2021-11-04
size, length, and depth of the slot are selected to ensure that the improved
composite material is
properly inserted into the cut slot of the concrete. Generally, only one piece
of improved composite
material is placed in the cut slot; however, it can be appreciated that more
than one piece of
improved composite material can be placed into the cut slot. In one non-
limiting embodiment of
the disclosure, the slot width is at least about 100% the width or thickness
of the improved
composite material. The minimum slot width is selected to ensure that a
sufficient amount of
bonding material can be positioned between the improved composite material and
the concrete. In
addition, the slot width is not greater than about 500% the width or thickness
of the improved
composite material. A slot width that is too large will result in the improper
bonding of the
improved composite material to the concrete. A too large slot results in a
thick adhesive layer
which can result in the failure in the adhesive from shear prior to the
composite fully engaging the
forces being applied to the concrete. In one non-limiting aspect of this
embodiment, the slot width
in the concrete is about 100-500% (and all values and ranges therebetween) the
width or thickness
of the improved composite material, and generally 105-300% the width or
thickness of the
improved composite material. In another non-limiting aspect of this
embodiment, the slot width
in the concrete is about 110-250% the width or thickness of the improved
composite material. The
slot width may or may not be constant along the longitudinal length of the
slot. It has been found
that the wobble and variation of slot width can enhance the bond between the
concrete and
improved composite material by adding texture to the inside of the cut slot.
In another non-limiting
embodiment of the disclosure, the cut slot depth is at least about 100% of the
depth or height of
the improved composite material. The depth of the slot is limited by the
thickness of the concrete.
Generally, the cut slot should not be cut fully through the concrete. In one
non-limiting aspect of
this embodiment, the slot depth is about 100-300% (and all values and ranges
therebetween) of the
depth or height of the improved composite material, and typically the cut slot
depth is 110-200%
of the depth or height of the improved composite material. In another non-
limiting aspect of this
embodiment, the slot depth is about 120-180% (e.g., 140%, etc.) of the depth
or height of the
improved composite material. In another non-limiting aspect of this
embodiment, the slot depth
is at least about 0.1 in. (e.g., 0.1-0.5 in. and all values and ranges
therebetween) less than the
thickness of the concrete. Generally, the top of the improved composite
material is placed below
the top surface of the concrete when the improved composite material is
inserted into the cut slot
and the adhesive is generally placed around and over the top of the top of the
improved composite
13
Date recue / Date received 2021-11-04
material when the improved composite material is properly positioned in the
cut slot. In still
another non-limiting embodiment of the disclosure, the cut slot length
generally is at least about
100% the longitudinal length of the improved composite material. In another
non-limiting aspect
of the present disclosure, the slot length is generally about 100-150% (and
all values and ranges
therebetween) the longitudinal length of the improved composite material, and
typically the slot
length is 101-115% the longitudinal length of the improved composite material.
[0028]
In another and/or alternative non-limiting aspect of the present disclosure,
the method
for using the improved composite material includes the optional step of
cutting a slot into one or
more concrete structures or slabs at a nonparallel angle to form a nonparallel
cut slot between the
two concrete structures or slabs. Generally, in a structure such as, but not
limited to, a parking
garage, T-shaped beams (e.g., T-shaped concrete beams, etc.) are used to
support a plurality of
concrete structures or slabs. In such an arrangement, a gap exists between the
two concrete
structures or slabs. The cut slot of the present disclosure can optionally be
cut at a nonparallel
angle to such gap and also cut into the concrete structures or slabs
positioned on both sides of the
gap. The size, length, and depth of the cut slot are selected to ensure that
the improved composite
material is properly inserted into the cut slot of the concrete structure or
slab. In one non-limiting
embodiment of the disclosure, the angle of the cut slot relative to the gap
between the two concrete
structures or slabs is about 10-170 (and all values and ranges therebetween).
In one non-limiting
aspect of this embodiment, the angle of the cut slot relative to the gap
between the two concrete
structures or slabs is about 20-160 . In another non-limiting aspect of this
embodiment, the angle
of the cut slot relative to the gap between the two concrete structures or
slabs is about 30-150 . In
another non-limiting aspect of this embodiment, the angle of the cut slot
relative to the gap between
the two concrete structures or slabs is about 45-135 . It has been found that
when the angle of the
cut slot relative to the gap between the two concrete structures or slabs is
about 45-135 , the full
load transfer of the improved composite material to the concrete is obtained
and a very high lateral
shear in the joint is also obtained. The 45-135 angle allows the improved
composite material to
handle the forces in tension rather than through thickness shear. Generally,
the cut slot is cut so
that the cut slot is centered between the two concrete structures or slabs;
however, this is not
required. When more than one cut slot is cut into the two concrete structures
or slabs, the cut slots
can be cut in a parallel or nonparallel relationship to one another. In one
non-limiting arrangement,
14
Date recue / Date received 2021-11-04
two adjacent positioned cut slots are cut at +/-30-600. Such alternating cut
slots allow for the
maximum tension transfer to the improved composite material in the cut slots.
[0029] In another and/or alternative non-limiting aspect of the present
disclosure, non-fully
dried and/or non-fully cured adhesive secures the improved composite material
in the cut slot or
opening in the concrete structure and generally fills the remaining void in
the cut slot or opening
after the improved composite material is inserted into the cut slot or
opening. Prior to the non-
fully dried and/or non-fully cured adhesive and/or the improved composite
material being inserted
into the slot or opening, the cut slot or opening is generally cleaned. The
cut slot or opening can
be cleaned by various means (e.g., pressurized air, water, cleaning solvent,
etc.). In one
arrangement, the cut slot or opening is cleaned with 30-150 psi or greater oil-
free compressed air.
In another non-limiting arrangement, non-fully dried and/or non-fully cured
adhesive is optionally
placed in the cut slot or opening prior to the improved composite material
being inserted into the
cut slot or opening. One or both sides of the improved composite material can
be optionally coated
with non-fully dried and/or non-fully cured adhesive prior to the improved
composite material
being inserted into the cut slot or opening. In one non-limiting arrangement,
non-fully dried and/or
non-fully cured adhesive is placed in the cut slot or opening prior to the
improved composite
material being inserted into the cut slot or opening and one or both sides of
the improved composite
material are coated with adhesive prior to the improved composite material
being inserted into the
cut slot or opening. When the improved composite material includes an adhesive
(e.g., resin
material, etc.) to at least partially form the improved composite material,
the adhesive is generally
fully dried and/or fully cured prior to 1) the improved composite material
being coated on one or
both sides with a non-fully dried and/or non-fully cured adhesive prior to the
improved composite
material being inserted into the cut slot or opening, and/or 2) the improved
composite material
being inserted into the cut slot or opening. As such, the improved composite
material is a generally
fully formed and includes a fully dried or cured adhesive prior to use.
[0030] In still yet another and/or alternative non-limiting aspect of the
present disclosure, when
more than one portion of a concrete structure is to be connected,
strengthened, and/or repaired by
the improved composite material, the slot angles of the multiple cut slots can
be selected to
improve the strength of the connected and/or repaired region; however, this is
not required. In one
non-limiting embodiment of the disclosure, a plurality of cut slots are cut in
the concrete structure
at an angle generally parallel to one another. In another non-limiting
embodiment of the
Date recue / Date received 2021-11-04
disclosure, a plurality of cut slots are cut in the concrete structure at an
angle that is negative to the
angle of another cut slot (e.g., +300 to ¨30 , +45 to ¨45 , +60 to ¨60 ,
etc.).
[0031] In another and/or alternative non-limiting aspect of the present
disclosure, there is
provided a novel method for repairing and/or connecting one or more concrete
structures or slabs.
Such concrete structures or slabs can optionally be supported relative to one
another such as by,
but not limited to, T-shaped beams, etc. The basic steps for the novel method
are as follows: 1)
cutting a slot into the adjacently positioned concrete structures or slabs
such that the cut slot crosses
a portion of the region of the two adjacently positioned concrete structures,
2) inserting the
improved composite material into the cut slot such that the improved composite
material spans
across the gap between the adjacently positioned concrete structures or slabs,
and 3) securing the
improved composite material in the cut slot. Generally, the improved composite
material is fully
formed and includes a fully dried or cured adhesive prior to being inserted
into the cut slot. When
the improved composite material is partially formed of an adhesive, the
adhesive used to partially
form the improved composite material can be the same or different from the
adhesive used to
secure the improved composite material in the cut slot.
[0032] In another and/or alternative non-limiting aspect of the present
disclosure, the novel
method for connecting, strengthening, and/or repairing one or more concrete
structures or slabs
can optionally include additional steps. Such additional steps include, but
are not limited to, a)
cutting the cut slot into the adjacently positioned concrete structures or
slabs such that each
concrete structure or slab has generally the same slot length, slot width,
slot depth, and/or slot
profile, b) cutting the cut slot into the adjacently positioned concrete
structures or slabs at a
particular angle relative to the gap between the adjacently positioned
concrete structures or slabs,
c) cleaning the cut slot prior to inserting the improved composite material
into the cut slot, d)
cleaning the cut slot prior to inserting non-fully dried and/or non-fully
cured adhesive into the cut
slot, e) using a particular length, thickness, vertical width, shape, and/or
composition for the
improved composite material for use in the cut slot, f) placing masking about
the cut slot to inhibit
or prevent adhesive from contacting the top surface of the concrete that is
located adjacent to the
cut slot, g) inserting a non-fully dried and/or non-fully cured adhesive into
one or more portions
of the cut slot prior to inserting the improved composite material into the
cut slot, h) applying a
non-fully dried and/or non-fully cured adhesive and/or primer to one or more
outer surfaces of the
improved composite material prior to inserting the improved composite material
into the cut slot,
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i) inserting the improved composite material into the cut slot until the top
edge of the improved
composite material is positioned below the top surface of the concrete that is
located adjacent to
the cut slot, j) applying a non-fully dried and/or non-fully cured adhesive
into the cut slot after the
improved composite material has been inserted into the cut slot to fill the
cut slot with such
adhesive, k) applying a non-fully dried and/or non-fully cured adhesive on the
top surface of the
concrete located adjacent to the cut slot and over the top edge of the
improved composite material
located in the cut slot, 1) removing any damaged concrete about or adjacent to
the cut slot and
replacing the damaged concrete with new concrete and/or durable polymer
material (e.g., epoxy,
etc.), m) cutting the cut slot through a damaged region of concrete so the
improved composite
material facilitates in securing the new concrete and/or durable polymer
material in the region from
which the damaged concrete form was removed and replaced with new concrete
and/or durable
polymer material new concrete and/or durable polymer material, and/or n)
alternating the cut slot
angle of multiple cut slots in the concrete structure. As can be appreciated,
one or more of the
above listed additional steps can be used in the method of the present
disclosure. Also, it will be
appreciated that any combination of the above listed additional steps can be
used in the method of
the present disclosure. Lastly, it can be appreciated that all of the above
listed additional steps can
be used in the method of the present disclosure.
[0033] The improved composite material has several advantages, namely:
[0034] = The shape of the improved composite material has two parallel
sides extending for
a sufficient distance so enough of the cut sections of the two concrete
sections can be bonded to
the improved composite material.
[0035] = The orientation of the fibers in the improved composite material
provide for greater
strength to the improved composite material and the connection formed by the
improved composite
material.
[0036] = The improved composite material does not need to be placed through
a metal clip
to connect together two T-shaped planks.
[0037] = The improved composite material has no holes or slots through the
body of the
improved composite material that would compromise the strength of the improved
composite
material.
[0038] = Less adhesive is potentially required to secure the improved
composite material in
a cut slot in the concrete.
17
Date recue / Date received 2021-11-04
[0039] = The improved composite material has improved tensile capacity,
compressive
capacity, shear capacity, and/or flexibility.
[0040] = The improved composite material is versatile and can be used in
many different
concrete repairs and/or connection applications.
[0041] = The improved composite material is designed to adequately engage
the tee beam
system with enough area to form a desired bond with the desired strength.
[0042] = The improved composite material is configured to better fit into a
cut slot in the
concrete.
[0043] = The improved composite material reduces stress cracks that form
near the ends or
nose of the improved composite material when connected in the cut slot.
[0044] = The improved composite material has improved linear flexibility
along the
longitudinal length of the improved composite material.
[0045] = The improved composite material reduces cracking of the concrete
as a result of
negative moment of the tees.
[0046] = The improved composite material allows for increased vertical
bending.
[0047] = The improved composite material reduces stress in the concrete at
the ends or nose
of the improved composite material during reverse bending and vertical
shearing of the connected
concrete.
[0048] = The improved composite material allows for depression of a backer
rod and
adhesive into the cut slot after the improved composite material has been
fully inserted into the cut
slot.
[0049] = The improved composite material in the new thinner decks can be
installed without
cutting through the bottom of the deck.
[0050] = The improved composite material is shaped to better fit the 14"
blade curve in the
cut slot.
[0051] = The improved composite material is absent sharp corners to avoid
stress
concentration in the concrete near the repair/connection region.
[0052] = The recess portion in the in the top center of the improved
composited material
allows installation/removal of the joint sealer between the tees.
[0053] = The improved composite material reduces the incidence of pop-out
of the adhesive
on the top of the improved composite material by allowing a thicker coating of
adhesive to be
18
Date recue / Date received 2021-11-04
placed on the top edge of the improved composite material when the improved
composite material
is inserted and secured in the cut slot.
[0054] = The improved composite material meets or exceeds all currently
published ACT,
PCI, and Biscuit design requirements and specifications.
[0055] = The improved composite material increases vertical bending
capacity by at least
330% over current biscuit configurations.
[0056] = The improved composite material significantly reduces stress in
concrete at the
nose of a flange during reverse bending and vertical shearing.
[0057] = The improved composite material allows for installation in all
currently produced
Double Tee thicknesses.
[0058] = The improved composite material allows for depression of j oint
sealant and backer
rod.
[0059] It is one non-limiting object of the present disclosure to provide a
method and apparatus
for connecting, strengthening and/or repairing concrete that is less labor
intensive than previous
repair systems.
[0060] It is another and/or alternative non-limiting object of the present
disclosure to provide
a method and apparatus for connecting, strengthening, and/or repairing
concrete that will not
corrode over time.
[0061] It is another and/or alternative non-limiting object of the present
disclosure to provide
a method and apparatus for connecting, strengthening, and/or repairing
concrete that reduces the
incidence of cracking at or near the concrete connection location.
[0062] It is another and/or alternative non-limiting object of the present
disclosure to provide
a method and apparatus for connecting, strengthening, and/or repairing
concrete that includes the
use of an improved composite material.
[0063] It is another and/or alternative non-limiting object of the present
disclosure to provide
a method and apparatus for connecting, strengthening, and/or repairing
concrete that minimizes
the risk of damaging pre-existing concrete during the repair process.
[0064] It is another and/or alternative non-limiting object of the present
disclosure to provide
a method and apparatus for connecting, strengthening, and/or repairing two
adjacent pre-existing
sections of concrete.
19
Date recue / Date received 2021-11-04
[0065] It is another and/or alternative non-limiting object of the present
disclosure to provide
an improved composite material for use in connecting, strengthening, and/or
repairing two
adjacent pre-existing sections of concrete comprising a first fiber system and
an adhesive, and
wherein the improved composite material has a top edge, a bottom edge, a first
end, a second end,
a front face, a back face, a length, a width and a depth, and wherein at least
one of the first and
second ends optionally includes a curved surface between said top and bottom
edges, and wherein
said top edge includes a recess portion positioned between said first and
second ends, and wherein
the first fiber system includes one or more layers of fiber, and wherein said
adhesive is optionally
at least partially coated on and/or at least partially impregnated in said
first fiber layer.
[0066] It is another and/or alternative non-limiting object of the present
disclosure to provide
an improved composite material for use in connecting, strengthening, and/or
repairing two
adjacent pre-existing sections of concrete wherein the first fiber system
includes one or more fiber
layers.
[0067] It is another and/or alternative non-limiting object of the present
disclosure to provide
an improved composite material for use in connecting, strengthening, and/or
repairing two
adjacent pre-existing sections of concrete, and wherein said first fiber
system includes one or more
fiber layers, low electrically-conducing outer layers are formed on the outer
surfaces of the
improved composite material.
[0068] It is another and/or alternative non-limiting object of the present
disclosure to provide
an improved composite material for use in connecting, strengthening, and/or
repairing two
adjacent pre-existing sections of concrete, and wherein said first fiber
system includes one or more
fiber layers, and wherein the fiber layers have the same composition, the same
thickness, the same
shape, the same configuration, and/or the same fiber orientation.
[0069] It is another and/or alternative non-limiting object of the present
disclosure to provide
an improved composite material for use in connecting, strengthening, and/or
repairing two
adjacent pre-existing sections of concrete wherein the recessed portion has a
longitudinal length
less than 50% a longitudinal length of the improved composite material.
[0070] It is another and/or alternative non-limiting object of the present
disclosure to provide
an improved composite material for use in connecting, strengthening, and/or
repairing two
adjacent pre-existing sections of concrete wherein the recess portion has a
depth that is less than
50% the maximum height of the improved composite material.
Date recue / Date received 2021-11-04
[0071] It is another and/or alternative non-limiting object of the present
disclosure to provide
an improved composite material for use in connecting, strengthening, and/or
repairing two
adjacent pre-existing sections of concrete wherein the first and/or second
ends are rounded.
[0072] It is another and/or alternative non-limiting object of the present
disclosure to provide
an improved composite material for use in connecting, strengthening, and/or
repairing two
adjacent pre-existing sections of concrete wherein the bottom edge has an
improved profile that
better fits into a cut slot in the concrete.
[0073] It is another and/or alternative non-limiting object of the present
disclosure to provide
an improved composite material for use in connecting, strengthening, and/or
repairing two
adjacent pre-existing sections of concrete wherein the adhesive secures the
first fiber system to the
concrete.
[0074] It is another and/or alternative non-limiting object of the present
disclosure to provide
an improved composite material for use in connecting, strengthening, and/or
repairing two
adjacent pre-existing sections of concrete wherein low electrically-conducing
outer layers are
formed on the outer surfaces of the improved composite material.
[0075] It is another and/or alternative non-limiting object of the present
disclosure to provide
an improved composite material for use in connecting, strengthening, and/or
repairing two
adjacent pre-existing sections of concrete wherein low electrically-conducing
outer layers are
formed on the outer surfaces of the improved composite material.
[0076] It is another and/or alternative non-limiting object of the present
disclosure to provide
an improved composite material for use in connecting, strengthening, and/or
repairing two
adjacent pre-existing sections of concrete wherein low electrically-conducing
outer layers are
formed on the outer surfaces of the improved composite material, and wherein
the outer layers are
formed of a different material from the fiber layers of the first fiber
system.
[0077] It is another and/or alternative non-limiting object of the present
disclosure to provide
an improved composite material for use in connecting, strengthening, and/or
repairing two
adjacent pre-existing sections of concrete wherein the first and second ends
of the first fiber system
includes a curved surface between the top and bottom edges.
[0078] It is another and/or alternative non-limiting object of the present
disclosure to provide
an improved composite material for use in connecting, strengthening, and/or
repairing two
21
Date recue / Date received 2021-11-04
adjacent pre-existing sections of concrete wherein the curved surfaces of the
first and second ends
of the first fiber system have the same radius of curvature.
[0079] It is another and/or alternative non-limiting object of the present
disclosure to provide
an improved composite material for use in connecting, strengthening, and/or
repairing two
adjacent pre-existing sections of concrete wherein the first fiber system
includes fibers selected
from the group consisting of carbon fibers, glass fibers, aramid fibers, boron
fibers, and basalt
fibers.
[0080] It is another and/or alternative non-limiting object of the present
disclosure to provide
an improved composite material for use in connecting, strengthening, and/or
repairing two
adjacent pre-existing sections of concrete wherein the improved composite
material has no
openings through the front and back face.
[0081] It is another and/or alternative non-limiting object of the present
disclosure to provide
a method for connecting, strengthening and/or repairing a longitudinal axis of
a concrete structure
comprising: a) providing an improved composite material comprising a first
fiber system and an
adhesive, and wherein the improved composite material has a top edge, a bottom
edge, a first end,
a second end, a front face, a back face, a length, a width and a depth, and
wherein at least one of
the first and second ends includes a curved surface between said top and
bottom edges, and wherein
said top edge includes a recess portion positioned between said first and
second ends, and wherein
the first fiber system includes a first fiber layer, said first fiber layer
including a plurality of fibers,
and wherein said adhesive at least partially coated on and/or at least
partially impregnated in said
first fiber layer; b) cutting a slot in the concrete, wherein the cut slot
intersects and crosses the
longitudinal axis of the gap; c) inserting the improved composite material in
the cut slot; and, d)
inserting an adhesive in the cut slot to secure the improved composite
material in the cut slot.
[0082] It is another and/or alternative non-limiting object of the present
disclosure to provide
a method for connecting, strengthening, and/or repairing a longitudinal axis
of a concrete structure
wherein the cut slot is cut at an angle of about 15-165 relative to a
longitudinal axis of the gap,
and wherein the cut slot has a longitudinal axis that is non-parallel to the
longitudinal axis of the
gap.
[0083] It is another and/or alternative non-limiting object of the present
disclosure to provide
a method for connecting, strengthening, and/or repairing a longitudinal axis
of a concrete structure
wherein about 30-70% of a longitudinal length of the improved composite
material is positioned
22
Date recue / Date received 2021-11-04
on one side of the gap between the two adjacently positioned concrete slabs
and a remainder of
the longitudinal length of the improved composite material is positioned on
the other side of the
gap.
[0084] It is another and/or alternative non-limiting object of the present
disclosure to provide
a method for connecting, strengthening, and/or repairing a longitudinal axis
of a concrete structure
wherein at least one of the first and second ends includes a curved surface
between the top and
bottom edges, and wherein a majority of the top edge is generally parallel to
the bottom edge, and
wherein the top edge has a longitudinal length that is greater than a
longitudinal length of the
bottom edge, a majority of the bottom edge is generally parallel to the top
edge.
[0085] It is another and/or alternative non-limiting object of the present
disclosure to provide
a method for connecting, strengthening, and/or repairing a longitudinal axis
of a concrete structure
wherein the first fiber system includes fibers selected from the group
consisting of carbon fibers,
glass fibers, aramid fibers, boron fibers, and basalt fibers.
[0086] It is another and/or alternative non-limiting object of the present
disclosure to provide
a method for connecting, strengthening, and/or repairing a longitudinal axis
of a concrete structure
wherein the improved composite material has no openings through the front and
back face.
[0087] It is another and/or alternative non-limiting object of the present
disclosure to provide
a method for connecting, strengthening and/or repairing a longitudinal axis of
a concrete structure
wherein the cut slot is cut at an angle of about 15-165 relative to the
longitudinal axis of the gap.
[0088] These and other objects and advantages will become apparent to those
skilled in the art
upon reading and following the description taken together with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0089] Reference may now be made to the drawings which illustrate various
non-limiting
embodiments that the disclosure may take in physical form and in certain parts
and arrangement
of parts wherein:
[0090] FIG. 1 is a fragmentary perspective view in cross-section of two pre-
existing sections
of concrete to be joined by a prior art concrete insert;
[0091] FIG. 2 is a sectional side elevation view of the pre-existing
sections of concrete of FIG.
1 joined by the prior art concrete insert;
23
Date recue / Date received 2021-11-04
[0092] FIG. 3 is a fragmentary perspective view in cross-section of two pre-
existing sections
of concrete to be joined by the improved composite material in accordance with
the present
disclosure;
[0093] FIG. 4 is a sectional side elevation view of the pre-existing
sections of concrete of FIG.
3 joined by the first version of the improved composite material of the
present disclosure;
[0094] FIG. 4A is a sectional side elevation view of the pre-existing
sections of concrete of
FIG. 3 joined by the second version of the improved composite material of the
present disclosure;
[0095] FIG. 5 is a cross-sectional view of FIG. 4;
[0096] FIG. 5A is a cross-sectional view of FIG. 4A;
[0097] FIG. 6 is a top elevation view of the first version of the improved
composite material
of the present disclosure;
[0098] FIG. 7 is a cross-sectional view of FIG. 6;
[0099] FIG. 8 is a side view of the first version of the improved composite
material that
illustrates dimensions of the improved composite material;
[00100] FIG. 9 is a side view of the second version of the improved composite
material that
illustrates dimensions of the improved composite material;
[00101] FIG. 10 is a top elevation view of the first version of the improved
composite material
of the present disclosure;
[00102] FIG. 11 is a cross-sectional view of FIG. 10;
[00103] FIG. 12 is a sectional side elevation view of the pre-existing
sections of concrete joined
by the first version of the improved composite material of the present
disclosure;
[00104] FIG. 13 is a sectional side elevation view of the pre-existing
sections of concrete of
FIG. 3 joined by a prior art Biscuit ;
[00105] FIG. 14 is a chart illustrating the amount of deflection of various
connection
arrangements verses the load applied to the connection created by the
connection arrangements;
and,
[00106] FIGS. 15-18 are tables illustrating the test results of the first
version of the improved
composite material as compared to an existing Biscuit and a steel slab
connection.
DETAILED DESCRIPTION OF THE NON-LIMITING EMBODIMENTS
24
Date recue / Date received 2021-11-04
[00107] A more complete understanding of the articles/devices, processes, and
components
disclosed herein can be obtained by reference to the accompanying drawings.
These figures are
merely schematic representations based on convenience and the ease of
demonstrating the present
disclosure, and are, therefore, not intended to indicate relative size and
dimensions of the devices
or components thereof and/or to define or limit the scope of the exemplary
embodiments.
[00108] Although specific terms are used in the following description for the
sake of clarity,
these terms are intended to refer only to the particular structure of the
embodiments selected for
illustration in the drawings and are not intended to define or limit the scope
of the disclosure. In
the drawings and the following description below, it is to be understood that
like numeric
designations refer to components of like function.
[00109]
The singular forms "a," "an," and "the" include plural referents unless the
context
clearly dictates otherwise.
[00110] As used in the specification and in the claims, the term "comprising"
may include the
embodiments "consisting of' and "consisting essentially of." The terms
"comprise(s),"
"include(s)," "having," "has," "can," "contain(s)," and variants thereof, as
used herein, are
intended to be open-ended transitional phrases, terms, or words that require
the presence of the
named ingredients/steps and permit the presence of other ingredients/steps.
However, such
description should be construed as also describing compositions or processes
as "consisting of'
and "consisting essentially of' the enumerated ingredients/steps, which allows
the presence of only
the named ingredients/steps, along with any unavoidable impurities that might
result therefrom,
and excludes other ingredients/steps.
[00111] Numerical values in the specification and claims of this application
should be
understood to include numerical values which are the same when reduced to the
same number of
significant figures and numerical values which differ from the stated value by
less than the
experimental error of conventional measurement technique of the type described
in the present
application to determine the value.
[00112] All ranges disclosed herein are inclusive of the recited endpoint and
independently
combinable (for example, the range of "from 2 grams to 10 grams" is inclusive
of the endpoints,
2 grams and 10 grams, and all the intermediate values).
[00113] The terms "about" and "approximately" can be used to include any
numerical value
that can vary without changing the basic function of that value. When used
with a range, "about"
Date recue / Date received 2021-11-04
and "approximately" also disclose the range defined by the absolute values of
the two endpoints,
e.g., "about 2 to about 4" also discloses the range "from 2 to 4." Generally,
the terms "about" and
"approximately" may refer to plus or minus 10% of the indicated number.
[00114] Referring now to the drawings wherein the showings are for the purpose
of illustrating
non-limiting embodiments of the disclosure only and not for the purpose of
limiting same, FIGS.
1 and 2 illustrate a typical concrete deck 20 that is disposed above concrete
T-shaped planks 30.
A prior art concrete insert 40 as disclosed in US Patent No. 6,312,541 is
illustrated as forming a
repair to the damaged concrete deck. The concrete deck is also illustrated as
supported by metal
clips 50 that join together the concrete T-shaped planks 30. The concrete
insert 40 is designed to
repair the metal clips 50 that have failed as a result of corrosion from
moisture that has seeped into
cracks 22 that have formed in concrete deck 20. The concrete insert 40 is
illustrated as a relatively
thin, elongated oblong-shaped structure having first and second major surfaces
42 and 43, a flat
top 45, and an arcuate side or edge 44. Edge 44 is curved. The peripheral
shape of edge 44 at
least approximates the shape of slot 60. The major surfaces 42 and 43 of the
concrete insert can
be textured to improve bonding of the concrete insert with epoxy 70. The
texturing may take the
form of ridges, dimples, or any other rough or uneven surface topography. The
concrete insert 40
can have interior walls 46 that define cavities 47 formed in the major
surfaces 42 and 43 extending
into, and typically through, the concrete insert to allow the epoxy 70 to flow
into the cavities 47
and bond to the concrete insert, as illustrated in FIG. 2. The cavities 47 may
be one of any size
and shape as long as they function to increase bonding of the epoxy 70 to the
concrete insert
without unduly reducing the strength of the concrete insert. The concrete
insert is typically formed
from a corrosion-resistant composite material. Any material that resists
corrosion and is capable
of bonding to both adhesives and concrete could be used such as a molded
thermoplastic material
reinforced with fibers of glass, carbon, or the like. When concrete insert 40
is molded, the major
surfaces 42 and 43 can be textured where the embedded fibers within the
concrete insert form
ridges in the major surfaces. Additionally, the mold may comprise
indentations, thereby forming
dimples on the exterior of the concrete insert during the molding process.
[00115] FIG. 1 illustrates that T-shaped planks 30 are rejoined by forming a
slot 60 in the
concrete deck 20, through metal clip 50, and partially into the T-shaped
planks 30. A circular
diamond saw blade is used to form slot 60. Epoxy 70 is inserted into slot 60
and then the concrete
insert 40 is inserted into the slot. When the epoxy dries, the epoxy bonds the
concrete insert to the
26
Date recue / Date received 2021-11-04
concrete T-shaped planks 30 and the concrete deck 20, thereby retaining the
concrete T-shaped
planks in place relative to each other.
[00116] The improved composite material 100 of the present disclosure and
method for
inserting the improved composite material into concrete in accordance with the
present disclosure
is an improvement over the concrete insert 40 illustrated in FIGS. 1 and 2 and
disclosed in US
Patent No. 6,312,541, and also is an improvement over the insert 80
illustrated in FIG. 13.
[00117] FIGS. 3-12 illustrate two non-limiting versions of the improved
composite material 100
in accordance with the present disclosure that are used to connect,
strengthen, and/or repair a
typical concrete deck 20 that is disposed above concrete T-shaped planks 30.
FIG. 3 does not
illustrate a metal clip 50 spanning a gap 25 between two T-shaped planks 30.
In practice, the metal
clips are spaced apart from one another along the longitudinal length or axis
G of gap 25. As
mentioned above, the metal clips secure together the two adjacently positioned
T-shaped planks
30. FIG. 3 illustrates a tooled joint or gap 25 formed in the concrete deck
20. The tooled joint
typically includes a sealant on the top portion of the tooled joint that
covers a gap 25 between the
two sections of the concrete deck; however, this is not required. Over time,
moisture leaks through
sealant and into gap 25, thereby resulting in moisture contacting a metal clip
(not shown) and
causing the metal clip to corrode, thereby compromising the structural
strength of the metal clip.
[00118] The first and second improved composite materials 100 of the present
disclosure are
configured to quickly, easily, and effectively connect, strengthen, and/or
repair the damaged
connection between the two adjacently positioned T-shaped planks. As also can
be appreciated,
the improved composite materials of the present disclosure can be used in
other concrete
connection and/or repair applications. As also can be appreciated, the
improved composite
materials of the present disclosure can be used as a substitute for metal
clips previously used to
connect two adjacently positioned T-shaped planks. As such, originally
installed T-shaped planks
can eliminate the use of metal clips that corrode over time and be substituted
for the improved
composite materials of the present disclosure. When originally installed T-
shaped planks use the
improved composite materials of the present disclosure, the improved composite
materials can be
installed by the same or similar process (as will be discussed below) when
repairing damaged
metal clips between T-shaped planks, or the concrete on the T-shaped planks.
and/or concrete slabs
can include pre-cut or preformed slots for the improved composite materials of
the present
disclosure.
27
Date recue / Date received 2021-11-04
[00119] Referring now to FIGS. 3-4A, there is illustrated a concrete deck 20.
A cut slot 120 is
cut into the concrete deck 20. Generally, the slot depth is greater than the
thickness of the concrete
deck 20 such that the slot depth fully penetrates through the complete
thickness of the concrete
deck 20 and only partially into the T-shaped planks 30 as illustrated in FIGS.
4 and 4A; however,
this is not required. When the cut slot 120 is not fully cut through the
complete thickness or width
of the top portion of the T-shaped planks, the base 122 of cut slot 120 is
generally spaced at least
about 0.1 in. from the bottom surface 36 of the top portions of the T-shaped
planks, typically
spaced about 0.1-5 in. (and all values and ranges therebetween) from the
bottom surface of the top
portions of the T-shaped planks, more typically spaced about 0.1-2 in. from
the bottom surface of
the top portions of the T-shaped planks. Depending on the location of the cut
slot 120, the cut slot
may or may not be cut through a pre-existing metal clip. In practice, the cut
slot is cut in a location
that does not include the metal clip since the metal clip can damage the
cutting blade and/or
increase cutting time for the slot when the blade contacts the metal clip;
however, this is not
required.
[00120] Cut slot 120 is generally cut by a saw blade (e.g., diamond tipped saw
blade, etc.);
however, the cut slot can be cut by other means. When the cut slot is cut by a
circular saw blade,
the two ends 60, 61 of the cut slot have a radius of curvature generally equal
to the radius of
curvature of the saw blade. As illustrated in FIGS. 3-5A, the cut slot is cut
in the concrete deck
20 such that the longitudinal length or axis of the slot traverses gap 25. As
illustrated in FIGS. 3-
4A, the cut slot is generally symmetrically oriented about gap 25; however,
this is not required.
The cut slot is cut generally straight along the longitudinal length of the
cut slot; however, this is
not required. The inside surfaces of the cut slot can be smooth or non-smooth.
Generally, the
inside surface of the cut slot is non-smooth to facilitate in the bonding of
the improved composite
material 100 in the slot. The longitudinal length of the cut slot is generally
equal to or greater than
the longitudinal length of the improved composite material. Typically, the
longitudinal length of
the slot is at least about 102% the longitudinal length of the improved
composite material, and
typically 110-130% the longitudinal length of the improved composite material.
[00121] Cut slot 120 is also cut at a nonparallel angle to longitudinal length
or axis of gap 25.
As illustrated in FIGS. 3-4A, the longitudinal length or axis of the cut slot
120 is cut at an angle
relative to the longitudinal length or axis of gap 25. Generally, the
longitudinal length or axis of
the cut slot is cut at an angle of about 10-170 to the longitudinal length or
axis of the gap, typically
28
Date recue / Date received 2021-11-04
at an angle of about 20-1600, more typically about 30-1500, and even more
typically about 45-
135 (e.g., 900).
[00122] The width of the cut slot is generally uniform along the longitudinal
length of the slot;
however, this is not required. As illustrated in FIGS. 5 and 5A, the depth and
width of the slot is
greater than the depth and width of the improved composite material so the
improved composite
material can be easily inserted into the cut slot and an adhesive 70 can also
be inserted into the cut
slot to bond the improved composite material to the wall of the cut slot.
Generally, the cut slot
width in the concrete is about 105-200% (and all values and ranges
therebetween) the width of the
improved composite material, typically about 110-250% the width of the
improved composite
material, and even more typically about 150-200% the width of the improved
composite material.
The cut slot width may or may not be constant along the longitudinal length of
the cut slot.
[00123] FIGS. 3-4A illustrate that the depth of cut slot 120 is generally
uniform, excluding the
curved slot ends; however, this is not required. FIGS. 4 and 4A also
illustrate that the depth of cut
slot 120 is greater than the depth or height of the improved composite
material; however, this is
not required. Generally, the depth of cut slot is generally at least 100% the
depth or height of the
improved composite material, typically about 100-200% (and all values and
ranges therebetween)
the depth or height of the improved composite material, more typically about
105-150% the depth
or height of the improved composite material, and even more typically about
10%-125% the depth
or height of the improved composite material. As illustrated in FIGS. 4 and
4A, when the depth
or height of the improved composite material is less than the depth of the cut
slot, the top surface
of the improved composite material is positioned below the top surface of the
concrete deck 20.
In such an arrangement, adhesive 70 can be positioned completely about the
outer surfaces (e.g.,
top, bottom and side surfaces) of the improved composite material. The
adhesive is generally a
two-part, 100% solids epoxy adhesive that is thixotropic in nature; however,
other or additional
types of adhesives can be used. The adhesive can be fully or partially
inserted into the cut slot
before, during, or after the improved composite material is inserted into the
cut slot. The viscosity
of the adhesive is generally selected to be easily poured and/or packed into
the cut slot; however,
this is not required. Adhesives having viscosities that are too large to allow
the flow of the
adhesive into the cut slot can result in the improper bonding of the improved
composite material
in the cut slot.
29
Date recue / Date received 2021-11-04
[00124] The adhesive is inserted into the cut slot prior to the full drying or
curing of the
adhesive. Generally, the 80%+ (e.g., 80-100% and all values and ranges
therebetween) drying
and/or curing time for the adhesive after the improved composite material is
inserted into the cut
slot and the adhesive is properly positioned in the cut slot to secure the
improved composite
material in the cut slot is at least about 0.25 hours, typically about 0.25-10
hours (and all values
and ranges therebetween), and more typically about 1-5 hours. The bonding
strength of the
improved composite material to the concrete is generally about 1.5-4 MSI (and
all values and
ranges therebetween).
[00125] As illustrated in FIGS. 4-4A, the improved composite material is
positioned in the cut
slot so that it is generally symmetrically oriented (40-50 to 40-50%) about
the longitudinal axis of
gap 25; however, this is not required. Generally, the improved composite
material is positioned
in the cut slot so that about 30-70% (and all values and ranges therebetween)
of the improved
composite material is positioned on one side of the longitudinal axis of gap
25 and the remainder
of the improved composite material on the other side of the longitudinal axis
of the gap.
[00126] Referring now to FIGS. 5-11, the first and second versions of the
improved composite
material 100 are illustrated as formed of multiple layers. As can be
appreciated, improved
composite material 100 can be formed of a single layer of fiber that is coated
and/or saturated with
an adhesive.
[00127] In one non-limiting configuration of the improved composite material,
the improved
composite material includes a first fiber system and an adhesive material
(e.g., resin material). As
illustrated in FIGS. 5 and 6, the first fiber system of the first version of
the improved composite
material is illustrated as being formed of a plurality of fiber layers 106,
110, 112. The fiber layers
forming the first fiber system can have 1) the same or different fiber volume
and/or fiber strands,
2) the same or different types of fibers, 3) the same or different tensile
strength and/or tensile
modulus, and/or have the same or different fiber layer thicknesses, 4) the
same or different layer
thickness or width, and/or 5) the same or different fiber orientation. In one
non-limiting
configuration, the first fiber system includes or is fully formed of carbon
fibers. The fibers forming
the first fiber system have a tensile strength of at least about 350 KSI and a
tensile modulus of at
least about 10 MSI.
[00128] FIG. 6 illustrates a non-limiting first version of the improved
composite material
formed of five layers having certain layer thicknesses, wherein the first
fiber system is formed of
Date recue / Date received 2021-11-04
three fiber layers 106, 110, 112, and a layer of dielectric insulating
material 117, 119 is positioned
on each side of the first fiber system. Fiber layer 106 of the first fiber
system can have a thickness
that is the same or greater than the thickness of all other layers of the
improved composite material;
however, this is not required. Fiber layers 110 and 112 of the first fiber
system have generally the
same thickness. In one non-limiting arrangement, the thickness or width of
fiber layer 106 of the
first fiber system is greater than the thickness of all other layers of the
improved composite
material. In one non-limiting arrangement, the thickness or width of fiber
layers 110 and 112 of
the first fiber system is generally the same and is less than the thickness of
fiber layer 106 (e.g.,
width ratio of 0.1:1 to 1:1 and all values and ranges therebetween); however,
this is not required.
In one non-limiting arrangement, the thickness or width of dielectric
insulating material layers 117
and 119 is generally less than the thickness of fiber layers 106 (e.g., width
ratio of 0.02:1 to 0.6:1
and all values and ranges therebetween), and is generally less or the same as
the thickness of fiber
layers 110, and 112 (e.g., width ratio of 0.1:1 to 1:1 and all values and
ranges therebetween);
however, this is not required. In one non-limiting specific configuration, the
thickness or width of
the fiber layer 106 of the first fiber system is about 0.04-0.2 in. (and all
values and ranges
therebetween), the thickness or width of each of fiber layers 106, 110 of the
first fiber system is
about 0.015-0.039 in. (and all values and ranges therebetween), and the
thickness or width of
dielectric insulating material layers 117 and 119 is 0.05-0.014 (and all
values and ranges
therebetween).
[00129] The fibers layers 106, 110, and 112 of the first fiber system can be
optionally connected
together by a mechanical connection (stitching, stitching, staples, clips,
pins, hook and loop
fastener, etc.), melted bond, and/or adhesive. One or more of the fiber layers
106, 110, and 112 of
the first fiber system can be formed by a fabric layer (woven or unwoven
fabric layer), fiber
rovings, or fibers. The fibers in the one or more fiber layers 106, 110, and
112 can be oriented
parallel or non-parallel to fibers in one or more of the other fiber layers.
The composition, size,
and thickness of the fibers in the one or more of the fiber layers 106, 110,
and 112 can the same or
different from the fibers in one or more other fiber layers. In one non-
limiting embodiment, the
composition of at least 70% (e.g., 70-100% and all values and ranges
therebetween) of the fibers
of fiber layers 106, 110, and 112 are formed of carbon fibers. In another non-
limiting embodiment,
outer layers 117, 119 are partially or fully formed (e.g., 51-100% and all
values and ranges
therebetween) of a resin or plastic material.
31
Date recue / Date received 2021-11-04
[00130] As illustrated in FIG. 7, the cross-hatching of layer 106 illustrates
that the orientation
of the fibers in the fiber layer 110 are non-parallel to the longitudinal axis
of the improved
composite material; however, this is not required. The parallel lines of layer
112 illustrate the
orientation of the fibers in the fiber layer 112 is parallel to the
longitudinal axis of the improved
composite material; however, this is not required. In the non-limiting
embodiment of FIG. 7, the
orientation of the fibers in the fiber layers 106, 112 is parallel to the
longitudinal axis of the
improved composite material, and the orientation of the fibers in the fiber
layer 110 are non-
parallel to the longitudinal axis of the improved composite material. Outer
layer 117, 119 may or
may not include fibers. If outer layers 117, 119 do include fibers, the
orientation of the fibers in
layers 117, 119 can be parallel to the longitudinal axis of the improved
composite material.
[00131] As illustrated in FIGS. 5A and 10, the second version includes a first
fiber system that
is formed of a single layer 121 of fibers, and a layer 117, 119 of dielectric
insulating material
positioned on each side of the first fiber system. The first fiber system can
be formed of a single
fabric layer, a single layer of fiber rovings, or a single layer of fibers.
The composition, size,
and/or shape of the fibers in the first fiber system can be the same as
described above with regard
to the first version of the improved composite material. The two outer layers
117, 119 are the
layers of dielectric insulating material, and such layers generally have the
same thickness or width
and the thickness or width of each of the two outer layers is generally less
than the thickness of
layer 121 of the first fiber system; however, this is not required. In one non-
limiting embodiment,
the thickness or width of layer 121 of the first fiber system is at least 1.05
times (e.g., 1.05-500
times and all values and ranges therebetween) the thickness of each of the two
outer layers 117,
119. In one non-limiting embodiment, the thickness or width of the layer 121
is about 0.02-0.5 in.
(and all values and ranges therebetween), and the thickness or width of
dielectric insulating
material layers 117 and 119 is 0.05-0.014 (and all values and ranges
therebetween).
[00132] An adhesive can optionally be applied to the one or more fiber layers
of the first or
second version of the improved composite material prior to or at the same time
as the forming of
the two outer layers are the layers of dielectric insulating material. The
adhesive (when used) is
used to partially or fully bond together one or more of the fiber layers,
and/or to partially or fully
saturate one or more of the fiber layers. The one or more fiber layers of the
first fiber system can
optionally be pressed together until the adhesive dries/cures to facilitate in
the partial or full
bonding together one or more of the fiber layers, and/or to facilitate in the
partial or full saturation
32
Date recue / Date received 2021-11-04
of the one or more of the fiber layers. A vacuum can optionally be applied
during the pressing and
drying/curing steps of the adhesive; however, this is not required. Generally,
the adhesive is
allowed to dry/cure and harden prior to the improved composite material being
placed in the cut
slot.
[00133] When the outer layer of the improved composite material is formed of a
non-fiber layer
(e.g., resin layer, plastic layer, polymer layer, etc.), the outer layers can
be applied after the
adhesive has dried/cured, before the adhesive has dried/cured, or at the same
time as the adhesive
if applied to the first fiber system. When the adhesive is a resin material,
the same material for the
adhesive can optionally be used to form the outer layers.
[00134] When the outer layers of the improved composite material are formed of
a non-fiber
layer, the outer layers can optionally be textured to improve the bonding
strength of the improved
composite material to the concrete when placed in the cut slot with the
material used to connect
the improved composite material to the concrete.
[00135] The improved composite material has a top edge 102, a bottom edge 103,
a first end
113, and a second end 115. The first and second ends are illustrated as having
a curved surface
between the top and bottom edges; however, one or both of the ends can be
straight or include
some other shape. As illustrated in FIGS. 7-8, a majority (e.g., 50.01-90% and
all values and
ranges therebetween) of the top edge of the first version of the improved
composite material is
illustrated as being generally parallel to the bottom edge; however, this is
not required. As
illustrated in FIGS. 9 and 11, less than a majority (e.g., 0-45% and all
values and ranges
therebetween) of the top edge of the second version of the improved composite
material is
illustrated as being non-parallel to the bottom edge.
[00136] As illustrated in FIGS. 7-8, the top edge of the first version of the
improved composite
material that is parallel or generally parallel to the bottom edge is
illustrated as having a
longitudinal length that is greater than a longitudinal length of the bottom
edge; however, this is
not required. Generally, the length of the bottom edge of the first version of
the improved
composite material that is parallel or generally parallel to the top edge is
about 10-99% (and all
values and ranges therebetween) of the length of the top edge, typically about
25-95% of the length
of the top edge, and more typically about 50-95% of the length of the top
edge.
[00137] As illustrated in FIGS. 9 and 11, the second version of the improved
composite material
has a top edge and a bottom edge formed of curved surfaces. As such, very
little of the top edge
33
Date recue / Date received 2021-11-04
of the second version of the improved composite material is parallel to the
bottom edge of the
second version of the improved composite material. In one non-limiting
embodiment, the radius
of curvature of the end portions 141, 143 of top edge of the second version of
the improved
composite material is 20-80 in. (and all values and ranges therebetween). In
one non-limiting
embodiment, the radius of curvature of the bottom edge 145 of the second
version of the improved
composite material is 10-50 in. (and all values and ranges therebetween). In
one non-limiting
embodiment, the radius of curvature of the bottom edge 145 of the second
version of the improved
composite material is less than the radius of curvature of the end portions
141, 143 of top edge of
the second version of the improved composite material. The radius of curvature
of the two bottom
side ends 161, 163 is about 3-20 in. (and all values and ranges therebetween),
and typically about
5-10 in. The longitudinal length of the improved composite material is
generally 5-40 in. (and all
values and ranges therebetween), and typically about 12-20 in.
[00138] As illustrated in FIGS. 3-11, the top edge 102 of the first and second
versions of the
improved composite material include a recessed portion 151 and optionally two
curved end
portions 153, 155. The longitudinal length of the recessed portion 151 is
generally 5-60% (and all
values and ranges therebetween) the longitudinal length of the top edge of the
first and second
versions of the improved composite material, and typically longitudinal length
of the recessed
portion is 10-40% the longitudinal length of the first and second versions of
the top edge of the
improved composite material. The maximum depth of the recess portion is
generally 5-60% (and
all values and ranges therebetween) the maximum height of the first and second
versions of the
improved composite material, and typically maximum depth of the recessed
portion is 10-40% the
maximum depth of the first and second versions of the improved composite
material. The recess
portion of the first version of the improved composite material is illustrated
as having a generally
constant depth along 20-95% (and all values and ranges therebetween) the
longitudinal length of
the recess portion, and typically the recess portion has a generally constant
depth along 60-95%
the longitudinal length of the recess portion. The recess portion of the
second version of the
improved composite material is illustrated as having a generally arcuate or
curved profile along
50-100% (and all values and ranges therebetween) the longitudinal length of
the recess portion. In
one non-limiting embodiment, the maximum height of the improved composite
material is about
1-10 in. (and all values and ranges therebetween), and typically about 2-4 in.
The maximum depth
of the recess portion 151 is about 0.1-3 in. (and all values and ranges
therebetween), and typically
34
Date recue / Date received 2021-11-04
about 0.2-1 in. Generally, the ratio of the maximum depth of the recess
portion 151 to the
maximum height of the improved composite material is 0.1:1 to 0.9:1 (and all
values and ranges
therebetween), and typically 0.15:1 to 0.3:1. Generally, the ratio of the
maximum longitudinal
length of the recess portion 151 to the maximum longitudinal length of the
improved composite
material is 0.1:1 to 0.7:1 (and all values and ranges therebetween), and
typically 0.2:1 to 0.4:1. In
another non-limiting embodiment, the longitudinal length of the recess portion
151 is generally
the same or less than the longitudinal length of the linear portion of the
bottom edge of the first
version of the improved composite material of FIGS. 7 and 8, or is generally
the same or less than
the longitudinal length of the curved central portion of the bottom edge of
the second version of
the improved composite material of FIGS. 9 and 11. In one specific non-
limiting configuration,
the longitudinal length of the recess portion 151 is less than the
longitudinal length of the linear
portion of the bottom edge of the first version of the improved composite
material of FIGS. 7 and
8, or is less than the longitudinal length of the curved central portion of
the bottom edge of the
second version of the improved composite material of FIGS. 9 and 11.
[00139] As illustrated in FIGS. 3-11, the ends 113, 115 of the improved
composite material are
illustrated as being rounded; however, this is not required. Such rounding of
the ends facilitates
in reducing cracking the concrete at or near the ends of the improved
composite material. In one
non-limiting arrangement, the radius of curvature of the ends, when one or
both ends are rounded,
is about 0.1-1 (and all values and ranges therebetween), and generally about
0.15-0.5, and typically
0.2-0.3 in.
[00140] Once the improved composite material has been fully formed (e.g.,
adhesive cured, all
mechanical connections applied, etc.) the improved composite material can be
cut to a desired size
and shape. The thickness of the improved composite material can be uniform or
vary along the
longitudinal length of the improved composite material. When fully formed, the
improved
composite material has a tensile strength along the x-y axis or longitudinal
axis of at least about
55 KSI, a compressive strength along the x-y axis or longitudinal axis of at
least about 45 KSI, a
compressive strength through the z axis or thickness of at least about 5.5
KSI, a shear strength
through the z axis or thickness of at least about 11 KSI, and/or an inter
laminar shear along the x-
y axis or longitudinal axis of at least about 1.1 KSI.
[00141] One non-limiting method in accordance with the present disclosure
includes: 1) cutting
a slot in the concrete such that the slot crosses the longitudinal axis of the
gap 25 between the T-
Date recue / Date received 2021-11-04
shaped planks 30; 2) optionally forming a V-shaped top opening 181 in the cut
slot; 3) optionally
cleaning the cut slot of debris prior to inserting the improved composite
material in the cut slot; 4)
optionally inserting an adhesive on one or both sides of the improved
composite material prior to
inserting the improved composite material into the cut slot; 5) inserting the
improved composite
material into the cut slot; 6) inserting an adhesive in the cut slot to secure
the improved composite
material in the cut slot; and 7) allowing the adhesive to dry and/or cure;
[00142] FIGS. 12 illustrates a comparison of the improved composite material
to a prior art
Biscuit in FIG. 13. As illustrated in FIG. 12, the improved composite
material is configured to
better fit in the cut slot at the base of the improved composite material as
compared to the prior art
Biscuit . The improved fit reduces the amount of stress concentration between
the base of the
improved composite material and the cut slot, thereby reducing the incidence
of cracking in
adhesive used to secure the improved composite material in the cut slot and
also reducing the
incidence of crack formation in the concrete. The lower profile of the
improved composite material
as a result of the recess portion 151 allows the backer rod 170 to be placed
over the improved
composite material without having to cut the backer rod at each prior art
Biscuit location. When
a V-shaped opening 181 is optionally formed in the top portion of the cut
slot, such V-shaped
opening facilitates in the placement of the backer rod and the proper
application of the sealant over
the backer rod.
[00143]
The lower profile of the improved composite material (compared to the prior
art
Biscuit ) ensures that sufficient qualities of adhesive material can be
positioned on the top edge
of the improved composite material to avoid the adhesive from popping out of
the cut slot.
[00144] As illustrated in FIGS. 12 and 13, the top edge of the improved
composite material is
positioned lower than the top edge of the prior art Biscuit . Generally, the
top edge of the
improved composite material is positioned 0.5- in. below the top surface of
the concrete surface.
Such a configuration allows for easy insertion of the backer rod and the
application of the sealant
over the backer rod. As also illustrated in FIGS. 12 and 13, the bottom
profile of the improved
composite material better conforms to the shape of the cut slot as compared to
the prior art
Biscuit .
[00145] FIGS. 14-18 illustrate the testing methods and results of the degree
of strain and
deflection of the improved composite material as compared to the prior art
Biscuit .
[00146] To compare the improved composite material to the prior art Biscuit ,
a series of
36
Date recue / Date received 2021-11-04
vertical load application tests were conducted. A set of concrete tee flanges
were joined together
by the improved composite material and the prior art Biscuit . The tee stems
rested on a rolling
support to allow the flanges to rotate, while having steel channel supports on
top of the end of the
tees connected to the base of the test fixture. The steel channels mimicked
how the weight and
connections to adjacent tees do not allow for a three-point bend to occur over
the flange joints.
Vertical load was applied from two hydraulic cylinders up to 8,000 lbs. over a
load head to
distribute the load through an area equal to the average vehicles tire contact
area. The deflection
was measured on each side of the joint connection using string potentiometers
to compare the
stiffness of the improved composite material to the prior art Biscuit .
[00147] The improved composite material and the prior art Biscuit had strain
gauges installed
on both sides. The strain gauges were used to measure the stress locally and
the direction of stress
in the improved composite material as compared to the prior art Biscuit .
[00148]
Strain gauges in the horizontal direction in the prior art Biscuit have the
strain in
tension, but in the improved composite material in the same location the
strain is in compression.
Compressive strain in those locations in the improved composite material is an
improvement
because tensile loads cause the concrete to fail/crack, allowing
water/contaminates to go through
the deck. Also, the strain values in the improved composite material are lower
at the same load
applied to the prior art Biscuit .
[00149] Strain gauges were also placed on the top surface of the concrete tees
beside the cut
slot as illustrated in FIG. 14. FIGS. 15-18 illustrate that the improved
composite material is more
flexible than the prior art Biscuit , but the improved composite material is
stiffer than a welded
steel connection. The improved composite material allows for more deflection
in the vertical
direction than the prior art Biscuit , thereby giving the joint more
flexibility to move without
cracking the concrete.
[00150] It will thus be seen that the objects set forth above, among those
made apparent from
the preceding description, are efficiently attained, and since certain changes
may be made in the
constructions set forth without departing from the spirit and scope of the
disclosure, it is intended
that all matter contained in the above description and shown in the
accompanying drawings shall
be interpreted as illustrative and not in a limiting sense. The disclosure has
been described with
reference to non-limiting and alternate embodiments. Modifications and
alterations will become
apparent to those skilled in the art upon reading and understanding the
detailed discussion of the
37
Date recue / Date received 2021-11-04
disclosure provided herein. This disclosure is intended to include all such
modifications and
alterations insofar as they come within the scope of the present disclosure.
It is also to be
understood that the following claims are intended to cover all of the generic
and specific features
of the disclosure herein described and all statements of the scope of the
disclosure, which, as a
matter of language, might be said to fall therebetween.
38
Date recue / Date received 2021-11-04
