Dowel basket with non-metallic dowel bars and method of making same

Abstract

A dowel basket includes a metal frame with a plurality of non-metallic dowel bars having weld members secured to the dowel bars and welded to the metal frame. The dowel basket may provide wherein the weld members include weldable metal though pins extending through through-holes provided on opposed ends of each dowel bar and welded to loop wires of the metal frame, or weldable metal caps on opposed ends of each dowel bar welded to the metal frame, or weldable metal caps with at least one lug on opposed ends of each dowel bar welded to the metal frame. A method of forming a dowel basket including a metal frame with a plurality of non-metallic dowel bars comprises the steps of securing weld members to opposed ends of each of the dowel bars and welding each of the dowel bars to the metal frame via the weld members.

Claims

1. A dowel basket including a metal frame with a plurality of non-metallic dowel bars having weld members secured to the dowel bars and welded to the metal frame, wherein the weld members include weldable metal through pins extending through through-holes provided on opposed ends of each dowel bar and welded to loop wires of the metal frame, wherein the dowel bars have a longitudinal axis and wherein the through-holes extend perpendicular to the longitudinal axis of the dowel bar and entirely through the dowel bar.

2. The dowel basket according to claim 1 wherein each non-metallic dowel bar is formed of fiberglass, reinforced composite, or reinforced plastic.

3. The dowel basket according to claim 2 wherein the metal through pins are formed as cylindrical steel pins.

4. The dowel basket according to claim 3 wherein each cylindrical steel pin extends through the through-hole extending out an equal distance from opposite sides of the dowel bar.

5. The dowel basket according to claim 4 wherein each cylindrical steel pin is adhesively secured to the dowel bar.

6. The dowel basket according to claim 1 wherein the metal through pins are formed as cylindrical steel pins.

7. The dowel basket according to claim 6 wherein each cylindrical steel pin extends through the through-hole extending out an equal distance from opposite sides of the dowel bar.

8. The dowel basket according to claim 7 wherein each cylindrical steel pin is adhesively secured to the dowel bar.

9. The dowel basket according to claim 1 wherein each non-metallic dowel bar is formed of fiberglass.

10. The dowel basket according to claim 9 wherein the metal through pins are formed as cylindrical steel pins.

11. The dowel basket according to claim 10 wherein each cylindrical steel pin extends through the through-hole extending out an equal distance from opposite sides of the dowel bar.

12. The dowel basket according to claim 11 wherein each cylindrical steel pin is adhesively secured to the dowel bar.

13. A dowel basket including a metal frame with a plurality of fiberglass dowel bars having weld members secured to the dowel bars and welded to the metal frame, wherein the weld members include weldable metal caps with at least one lug on opposed ends of each dowel bar welded to the metal frame, wherein each weldable metal cap includes a pair of radially extending lugs on opposed sides of the cap, and wherein each weldable metal cap includes a pair of radially extending lugs on opposed sides of the cap.

14. A method of making a dowel basket including a metal frame with a plurality of non-metallic dowel bars comprises the steps of securing weld members to opposed ends of each of the dowel bars and welding each of the dowel bars to the metal frame via the weld members, wherein the weld members include weldable metal through pins extending through through-holes provided on opposed ends of each dowel bar and welded to loop wires of the metal frame, wherein the dowel bars have a longitudinal axis and wherein the through-holes extend perpendicular to the longitudinal axis of the dowel bar and entirely through the dowel bar.

15. The method of making a dowel basket according to claim 14 wherein the metal through pins are formed as cylindrical steel pins.

16. The method of making a dowel basket according to claim 15 wherein each cylindrical steel pin extends through the through-hole extending out an equal distance from opposite sides of the dowel bar.

17. The method of making a dowel basket according to claim 16 wherein each cylindrical steel pin is adhesively secured to the dowel bar.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic top plan view of a dowel basket with non-metallic dowel bars having weld members secured thereto in accordance with a first embodiment of the present invention;

(2) FIG. 2 is a schematic front elevation view of the dowel basket with non-metallic dowel bars of FIG. 1;

(3) FIG. 3 is a schematic front elevation exploded view a non-metallic dowel bar of FIG. 1;

(4) FIG. 4 is a schematic side elevation view of a portion of the dowel basket with non-metallic dowel bars of FIG. 1;

(5) FIG. 5 is a schematic side elevation view of a portion of a modified dowel basket with non-metallic dowel bars of FIG. 1;

(6) FIG. 6 is a schematic front elevation view of a dowel basket with non-metallic dowel bars having weld members secured thereto in accordance with a second embodiment of the present invention;

(7) FIG. 7 is a schematic side elevation view of a portion of the dowel basket with non-metallic dowel bars of FIG. 6;

(8) FIG. 8 is a schematic side elevation view of a portion of a modified dowel basket with non-metallic dowel bars of FIG. 6;

(9) FIG. 9 is a schematic side elevation view of a portion of a modified dowel basket with non-metallic dowel bars of FIG. 6;

(10) FIG. 10 is a schematic front elevation view of a dowel basket with non-metallic dowel bars having weld members secured thereto in accordance with a third embodiment of the present invention;

(11) FIG. 11 is a schematic front elevation exploded view a non-metallic dowel bar of FIG. 10;

(12) FIG. 12 is a schematic side elevation view of a portion of a modified dowel basket with non-metallic dowel bars of FIG. 10; and

(13) FIG. 13 is a schematic side elevation view of a portion of a modified dowel basket with non-metallic dowel bars of FIG. 10.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(14) The present invention provides a dowel basket 10 with non-metallic dowel bars 12 having weld members secured thereto, such as steel endcaps 14 shown in FIGS. 3-5, through weld pin 24 shown in FIGS. 6-9 or cap 14 with weld lugs 34 shown in FIGS. 10-13. The weld members allow for welding of the non-metallic dowel bars 12 to the loop wires 16 and/or rail wires 18 of the basket 10 to secure the dowel bars in place.

(15) The non-metallic dowel bar 12 is preferably a fiberglass dowel bar 12, but may be a reinforced composite, a reinforced plastic or any non-weld-able material.

(16) The present invention utilizes a standard wire metal frame for the basket 10 and it is noteworthy that the National Concrete Consortium has had a goal for more than a decade of standardizing basket frame designs. The basket 10 of the invention preferably conforms to these recommendations:

(17) The basket 10 includes loop wires 16, in a J, U or V style, extending between the upper rail wire 18 and the lower rail wire 18 at each dowel bar 12 location, and the loop wire is generally about 0.243 in. min. diameter. The basket 10 includes longitudinally extending basket rail wire 18, an upper rail wire 18 and lower rail wire 18 on each side, which should be about 0.306 in. min. diameter. Spacer or tie wires 20, as needed, are used in the basket structure 20 and should be about 0.177 in. dia. (7 gauge). The FIG. 1 also show a conventional expansion joint filler 22 for context but this is not part of the invention.

(18) The first embodiment of the present invention is shown in FIGS. 1-5 and provides weldable metal caps 14, preferably a steel caps 14 on opposed ends of the dowel bar 12 and secured thereto by adhesive, friction fit, swedging, or the like. The weldable caps 14 are received within the metal frame of the dowel basket and can be welded in position by tack welding to the loop wires 16 and/or to the upper rail wire 18.

(19) FIG. 3 shows a “step down” at the ends of the dowel 12 receiving the caps 14 so that the outer perimeter of the caps 14 aligns with the portion of the dowel 12 between the caps 14 whereby the dowel 12 with caps 14 presents a uniform thickness (as does a conventional dowel bar). The caps 14 will have an outer diameter that is determined by the associated frame, namely the loop wires 16, to accommodate welding. The caps 14 need only extend far enough along the bar 12 to allow for tack welding to the to the loop wires 16 and/or to the upper rail wire 18. The diameter of the dowel bar 12 is determined by the associated strength needed for the dowel bar 12 in operation across the joint.

(20) It may be more cost effective if the caps 14 are fit onto corresponding dowel bars 12 that are uniform outer diameters (no step down as shown), however the embodiment shown may yield advantages for automating the assembly process (because the equipment does not need to accommodate the stepdown as shown).

(21) FIG. 4 shows the first embodiment used with J shaped loop wires 16, while FIG. 5 shows the first embodiment is easily utilized with U or A shaped loop wires 16.

(22) The second embodiment of the present invention is shown in FIGS. 6-9 and provides weldable metal though pins 24, preferably a steel pins 24 extending through through-holes provided on opposed ends of the dowel bar 12 and secured thereto by adhesive or a friction fit. The weldable metal though pins 24 are received on the metal frame of the dowel basket 10 adjacent the loop wires 16 and can be welded in position by tack welding to the loop wires 16.

(23) In assembly, the dowel bar 12 with predrilled holes for the pins 24 is preferably placed on the frame of the basket 10, the holes aligned to be horizontal, and then the through pins 24 placed through horizontal holes to lock the dowel bar 12 in place with the dowel bar 12 further secured by welding each pin 24 to the associated loop wire 16.

(24) FIG. 7 shows the second embodiment used with A shaped loop wires 16, FIG. 8 shows the second embodiment used with J shaped loop wires 16, and FIG. 9 shows the second embodiment is easily utilized with U (or A in phantom) shaped loop wires 16.

(25) The third embodiment of the present invention is shown in FIGS. 10-13 and provides weldable metal caps 14 with weld lugs 34, preferably a steel caps 14 and steel lugs 34 on opposed ends of the dowel bar 12 and secured thereto by adhesive, friction fit, swedging, or the like. The weldable caps 14 with weld lugs 34 are received within the metal frame of the dowel basket and can be welded in position by tack welding to the loop wires 16 and/or to the upper rail wire 18. The weld lugs 34, like locking pins 24, provide a welding location, if desired, and can further secure the dowel 12 in position in assembly.

(26) The dowel bar 12 may be sized to have an outer diameter match the outer diameter of the cap 14 as shown, or may be uniform in diameter. In this embodiment it is likely the dowel bar 12 in practice would be of uniform diameter throughout. The weld lugs 34 must accommodate the assembly process and thus may extend less distance from the outer diameter of the dowel bar 12 than the locking pin 24, because the lugs 34 will typically be in position while the dowel bar 12 is being placed into position. Additionally the lug 34 may only be on one side of the cap 14 to better accommodate assembly.

(27) All three embodiments of the present invention permits fiberglass, fiber composite, reinforced plastic, or other non-metallic dowel bars 12 to be supported in the dowel basket frame 10 and welded in position in a cost effective, efficient and effective manner

(28) While this invention has been particularly shown and described with references to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention.