Lifting and leveling insert for a precast concrete slab

Abstract

An insert for lifting and leveling a precast concrete slab is provided. The insert includes a sleeve that extends through the concrete slab and has two distinct threaded portions on an inner surface of the sleeve. This configuration allows a lifting bolt to be positioned into an upper end of the sleeve to lift the concrete slab, and a different-sized leveling bolt to be positioned in the sleeve to selectively elevate or raise part of the concrete slab relative to a ground surface.

Claims

1. An insert for lifting and leveling a precast concrete slab, comprising: a sleeve configured to be embedded in a precast concrete slab, wherein said sleeve is formed from a continuous wire; an upper portion of said sleeve having an inner diameter configured to receive a lifting bolt to position said precast concrete panel; a lower portion of said sleeve having an inner diameter configured to receive a leveling bolt, said inner diameter of said lower portion is less than said inner diameter of said upper portion, and said lower portion defines a lower opening of said sleeve; and a plate having a plug engaged with said lower opening, wherein said plug is configured to disengage from said lower opening as said leveling bolt rotates in said lower portion.

2. The insert of claim 1, wherein said continuous wire has a substantially constant cross-sectional dimension along a total length of said continuous wire.

3. The insert of claim 1, further comprising at least one leg interconnected to an outer surface of said sleeve wherein a lower end of said at least one leg is aligned in a common plane with a lower surface of said plate.

4. The insert of claim 3, wherein said at least one leg is formed from a wire having a cross-sectional dimension that is substantially equal to a cross-sectional dimension of said continuous wire of said sleeve.

5. The insert of claim 1, wherein said plug is engaged with said lower opening with an interference fit, wherein said plug is plastic and has a non-threaded outer surface.

6. The insert of claim 1, wherein said upper portion defines an upper opening of said sleeve, and an upper plug is engaged with said upper opening to enclose a volume within said sleeve between said upper opening and said lower opening.

7. A method for manufacturing an insert for lifting and leveling a precast concrete slab, comprising: turning a continuous wire about a longitudinal axis to produce a first portion of a sleeve of said insert, said first portion having an inner diameter; turning said continuous wire about said longitudinal axis to produce a transition portion from said first portion to a second portion of said sleeve; turning said continuous wire about said longitudinal axis to produce said second portion, wherein an inner diameter of said second portion is distinct from said inner diameter of said first portion, and an outer diameter of said second portion is distinct from an outer diameter of said first portion; securing at least one leg to said sleeve, wherein said at least one leg is formed from a wire having a cross-sectional dimension that is substantially equal to a cross-sectional dimension of said continuous wire of said sleeve; and engaging a plug of a plate to one of said first portion or said second portion, wherein said plug and said plate are configured to disengage as a leveling bolt rotates through one of said first portion and said second portion and applies a force to said plug.

8. The method of claim 7, wherein said inner diameter of said first portion is smaller than said inner diameter of said second portion, and said plug has a non-threaded outer surface, is plastic, and is engaged to said first portion with an interference fit.

9. The method of claim 7, further comprising cutting said continuous wire after producing said second portion.

10. The method of claim 7, wherein said at least one leg is a plurality of legs that are equally spaced radially about said longitudinal axis.

11. The method of claim 7, wherein said continuous wire has said substantially constant cross-sectional dimension along a total length of said continuous wire.

12. The method of claim 7, further comprising engaging an upper plug with one of said first portion or said second portion to enclose a volume within said sleeve.

13. The method of claim 7, wherein said first portion comprises multiple turns of said continuous wire, and said second portion comprises multiple turns of said continuous wire.

14. A precast concrete panel with an apparatus for lifting and leveling the precast concrete panel, comprising: a precast concrete panel having an upper surface, a lower surface, and perimeter edges extending therebetween; a sleeve embedded in said precast concrete panel, said sleeve having a predetermined total length; an upper portion of said sleeve having a threaded inner surface defining an inner diameter adapted to receive a lifting bolt through said upper surface of said precast concrete panel to position said precast concrete panel; a lower portion of said sleeve having a threaded inner surface defining an inner diameter adapted to receive a leveling bolt through said upper surface of said precast concrete panel, and said lower portion defines an opening of said sleeve; and a plug of a plate engaged with said opening of said lower portion, wherein said plug and said plate are configured to disengage from said opening and extend away from said lower surface of said precast concrete panel as said leveling bolt rotates in said lower portion and contacts said plug.

15. The apparatus of claim 14, wherein said sleeve is formed from a continuous wire.

16. The apparatus of claim 14, wherein said plug is engaged to said opening of said lower portion with an interference fit wherein said plug is plastic and has a non-threaded outer surface.

17. The apparatus of claim 14, wherein said inner diameter of said lower portion is distinct from said inner diameter of said upper portion.

18. The apparatus of claim 14, wherein said upper portion has a length less than said predetermined total length of said sleeve, and said lower portion has a length less than said predetermined total length of said sleeve.

19. The apparatus of claim 14, further comprising at least one leg interconnected to an outer surface of said upper portion of said sleeve to support said sleeve in said precast concrete panel, and wherein each leg is made from a continuous wire, wherein said continuous wire of each leg has substantially the same cross-sectional dimension as a continuous wire of said sleeve.

20. The method of claim 7, wherein a top surface of said plate is planar, and only said plug is positioned on said top surface.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the disclosure and together with the general description of the disclosure given above and the detailed description of the drawings given below, serve to explain the principles of the disclosures.

(2) FIG. 1 is a front elevation view of an insert in accordance with an embodiment of the present invention;

(3) FIG. 2 is a cross-sectional view of the insert of FIG. 1 in accordance with an embodiment of the present invention;

(4) FIG. 3 is a cross-sectional view of the insert of FIG. 1 in a precast concrete slab in accordance with an embodiment of the present invention;

(5) FIG. 4 is an additional front elevation view of the insert of FIG. 1 in accordance with an embodiment of the present invention;

(6) FIG. 5 is a top plan view of the insert of FIG. 1 in accordance with an embodiment of the present invention;

(7) FIG. 6 is a perspective view of another insert made from coiled wire in accordance with an embodiment of the present invention;

(8) FIG. 7 is a front elevation view of the insert in FIG. 6 in accordance with an embodiment of the present invention;

(9) FIG. 8A is a top plan view of the insert in FIG. 6 in accordance with an embodiment of the present invention;

(10) FIG. 8B is a top plan view of the insert in FIG. 6 without an upper plug in accordance with an embodiment of the present invention; and

(11) FIG. 9 is a bottom plan view of the insert in FIG. 6 without a plate or bottom plug in accordance with an embodiment of the present invention.

(12) To assist in the understanding of the embodiments of the invention the following list of components and associated numbering found in the drawings is provided herein:

(13) TABLE-US-00001 Component No. Component 10 Insert 14 Sleeve 18 Leg 22 Leg Tip 26 Plate 30 First Threaded Portion 34 Lifting Bolt 38 Second Threaded Portion 42 Leveling Bolt 46 Precast Concrete Slab 50 Ground Surface 54 Insert Height 58 Leg Height 62 Plate Spacing 66 Leg Spacing 70 Leg Angle 74 Plate Width 76 Wire 78 Upper Portion 80 First Outer Diameter 82 Lower Portion 84 Second Outer Diameter 86 Upper Plug 88 Lower Plug

(14) It should be understood that the drawings are not necessarily to scale, and various dimensions may be altered. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

DETAILED DESCRIPTION

(15) The invention has significant benefits across a broad spectrum of endeavors. It is the Applicant's intent that this specification and the claims appended hereto be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed. To acquaint persons skilled in the pertinent arts most closely related to the invention, a preferred embodiment that illustrates the best mode now contemplated for putting the invention into practice is described herein by, and with reference to, the annexed drawings that form a part of the specification. The exemplary embodiment is described in detail without attempting to describe all of the various forms and modifications in which the invention might be embodied. As such, the embodiments described herein are illustrative, and as will become apparent to those skilled in the arts, and may be modified in numerous ways within the scope and spirit of the invention.

(16) Although the following text sets forth a detailed description of numerous different embodiments, it should be understood that the detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims. To the extent that any term recited in the claims at the end of this patent is referred to in this patent in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such claim term by limited, by implication or otherwise, to that single meaning.

(17) Various embodiments of the invention are described herein and as depicted in the drawings. It is expressly understood that although the figures illustrate inserts, sleeves, bolts, etc., the invention is not limited to these embodiments.

(18) Now referring to FIG. 1, a front elevation view of an insert 10 is provided. The insert 10 comprises a tubular sleeve 14 and legs 18 that extend from an outer surface of the sleeve 14. When the insert 10 is embedded in a precast concrete slab, the sleeve 14 is oriented to extend through the thickness dimension, or smallest dimension, of the slab. Thus, the legs 18 extend laterally into the slab to provide support and stability. The legs 26 may have optional plastic tips 28 disposed on the distal ends of the legs 26 to improve the safety for those who handle the insert 10.

(19) In addition, a plate 26 is positioned at one end of the sleeve 14. In practice, the plate 26 is substantially parallel with a lower surface of the precast concrete slab, and the plate 26 is oriented to contact a ground surface. The plate 26 is configured to selectively detach from the sleeve 14 and the precast concrete slab to elevate or lower the sleeve 14 and the precast concrete slab above the ground surface. With a precast concrete slab that has multiple insert systems 10, the particular elevation and orientation of the precast concrete slab can be controlled so that, for example, the precast concrete slab is flush with a road surface to repair a road.

(20) It will be appreciated that the sleeve 14 may be machined from a tubular structure or cast into a tubular structure, in some embodiments. It will be further appreciated that the sleeve 14 can be formed from coiled tubing that is turned about a longitudinal axis to form the sleeve 14. Complementary bolts configured to thread within coil tubing are also contemplated for embodiments of the present invention.

(21) Now referring to FIG. 2, a cross-sectional view of the insert 10 is provided. The sleeve 14 comprises a first threaded portion 30 and a second threaded portion 38. The first threaded portion 30 is positioned at the end of the sleeve 14 that is proximate to the top surface of the precast concrete slab. The first threaded portion 30 may extend only partially along the longitudinal length of the sleeve 14. In some embodiments, the first threaded portion 30 is disposed only on an upper half of the sleeve 14. In various embodiments, the first threaded portion 30 does not extend to the top edge of the sleeve 14.

(22) The sleeve 14 also comprises a second threaded portion 38, which like the first threaded portion 30, may extend only partially along the longitudinal length of the sleeve 14. In some embodiments, the second threaded portion 38 is disposed only on a lower half of the sleeve 14. In various embodiments, the second threaded portion 38 does not extend to the bottom edge of the sleeve 14. Further still, the first and second threaded portions 30, 38 may meet at a midpoint or other point of the sleeve 14 such that the portions 30, 38 are adjacent to each other. Various embodiments of the invention may include an unthreaded portion that is positioned between the threaded portions 30, 38, and in some embodiments, the unthreaded portion has a smaller diameter than the first threaded portion 30 to prevent a lifting bolt from extending further down the sleeve 14.

(23) As noted elsewhere herein, the first threaded portion 30 may have a larger diameter than the second threaded portion 38. In various embodiments, the first threaded portion 30 may have a diameter between approximately 2 and . In some embodiments, the first threaded portion 30 may have a diameter of approximately 1. In various embodiments, the second threaded portion 38 may have a diameter between approximately 1 and . In some embodiments, the second threaded portion 38 may have a diameter of approximately 1.

(24) FIG. 2 also shows the lifting bolt 34 and the leveling bolt 42. The lifting bolt 34 is configured to engage the first threaded portion 30, and the leveling bolt 42 is configured to engage the second threaded portion 38. Just as the first threaded portion 30 has a larger diameter than the second threaded portion 38, the lifting bolt 34 has a larger diameter than the leveling bolt 42. This allows the leveling bolt 42 to be first inserted through the top end of the sleeve 14, through the sleeve 14, and into the second threaded portion 38. Then, the lifting bolt 34 may be inserted into the first threaded portion 30. Alternatively, during operation of the insert 10, the lifting bolt 34 may be used and then discarded before the leveling bolt 42 is inserted through the sleeve 14 into the second threaded portion 38. The lifting bolt 34 may have a connection feature such as an aperture, a ring, an eyelet, etc. that allows a separate device such as a crane to selectively interconnect to the lifting bolt 34.

(25) It will be appreciated that in preferred embodiments, the lifting bolt 34 and the leveling bolt 42 are shorter than the predetermined distance between both ends of the sleeve 14 or the thickness of the precast concrete slab. However, it will also be appreciated that in other embodiment, one or both of the lifting bolt 34 and the leveling bolt 42 may have a length that is equal to or greater than the predetermined distance.

(26) Now referring to FIG. 3, a cross-sectional view of the insert 10 is provided where the insert 10 is elevated above a ground surface 50. As shown, the insert 10 has been embedded in a precast concrete slab 46, and the sleeve 14 is oriented such that a longitudinal dimension of the sleeve 14 extends through a thickness of the precast concrete slab. The lifting bolt has been utilized to position the precast concrete slab 46 over a ground surface 50, and has been subsequently removed. Next, the leveling bolt 42 is driven into the plate 26 such that the plate 26 detaches from the lower end of the sleeve 14 and the bottom surface of the slab 42. The leveling bolt 42 elevates the sleeve 14 and the precast concrete slab 46 above the plate 26 and the ground surface 50 by a predetermined height. Lastly, grout can be pumped underneath the precast concrete slab 46 to set the precast concrete slab 46 at the predetermined height. The precast concrete slab 46 may have separate apertures that extend through the thickness of the precast concrete slab 46 to provide access underneath the precast concrete slab 46 for the grout.

(27) The sleeve 14 of the insert 10 extends substantially between the top and bottom surfaces of the precast concrete slab 46. However, it will be appreciated that in other embodiments, the length of the sleeve 14 may be shorter or longer than the thickness of the precast concrete slab 46. For instance, a top end of the sleeve 14 may be short of the top surface of the precast concrete slab 46, a bottom end of the sleeve 14 may be short of the bottom surface of the precast concrete slab 46, or both ends may be short. Further still, in some embodiments, a tubular spacer may be positioned between an end of the sleeve 14 and a surface of the precast concrete slab 46.

(28) Another feature of the insert 10 is a plug, which interconnects the plate 26 to the sleeve 14 of the insert 10. The plug can interconnect the plate 26 to the sleeve 14 in a variety of ways. In some embodiments, the plug is a plastic portion that engages part of the second threaded portion 38 of the sleeve 14. When the leveling bolt 42 is engaged, the plug is driven out of the sleeve and the leveling bolt 42 drives the plate 26 into the ground surface 50. In various embodiments, the plug may interconnect to the sleeve 14 through an interference fit, which again, may be forced out of the sleeve 14 during engagement of the leveling bolt 42.

(29) Now referring to FIG. 4, a front elevation view of the insert 10 with dimensions is provided. The sleeve 14 also has an insert height 54 and a leg height 58. The insert height 54 may be any height to accommodate any size precast concrete slab. In some embodiments, the insert height 54 is approximately 7. An optional leg height may extend between the end of a leg and the top of the sleeve 14. In some embodiments, the leg height 58 is approximately .

(30) The plate 26 is disposed at the bottom end of the sleeve 14 on the bottom surface of the precast concrete slab. There is a spacing 62 between the plate 26 and the legs 18 of the insert 10, which are discussed further below. In some embodiments, the plate spacing 62 is approximately .

(31) Like with other dimensions discussed herein, the spacing from the end of one leg 18 to the end of another leg 18 may be any size to accommodate the dimensions and needs of a particular insert 10 and precast concrete slab. In some embodiments, the leg spacing 66 is approximately 9. Further, the legs 18 in some embodiments may be diameter wire. In addition, the legs 18 in some embodiments may have a proximal end that is interconnected to the outer surface of the sleeve 14 and a distal end that extends downward toward the lower end of the sleeve 14. Specifically, in some embodiments, the distal end of the legs 18 lies in a common plane with the lower end of the sleeve 14 and the plate 26.

(32) Now referring to FIG. 5 a top plan view of the insert 10 with dimensions is provided. The insert 10 has four legs 18 arrayed about the sleeve 14. The legs 18 are equally spaced about the sleeve 14, and the angle 70 between the legs 18 in this embodiment is approximately 90 degrees. It will be appreciated that legs 18 in other embodiments of the invention may have more or fewer than four legs 18, and the configuration of the legs 18 may also be different. For example, the legs 18 may be arrayed asymmetrically about the sleeve 14.

(33) Lastly, the plate 26 in FIG. 5 is square has a width 74 that is a 6. However, it will be appreciated that the plate may have other shapes, dimensions, and materials to allow the leveling bolt to thread through the second threaded portion of the sleeve 14 and drive the plate into the ground surface to raise the precast concrete slab.

(34) Now referring to FIG. 6, a perspective view of another insert 10 is provided. In this embodiment, the insert 10 has a sleeve 14 made from a coiled wire, which can be less expensive and faster to produce than other types of sleeves that require milling, threading, etc. The sleeve 14 in this embodiment comprises an upper portion 78 and a lower portion 82 and a transition portion disposed therebetween. The upper portion 78 has a first outer diameter 80 that is larger than a second outer diameter 84 of the lower portion 82. Since the sleeve 14 is made from a continuous wire with a constant thickness, the upper portion 78 has an inner diameter that is larger than an inner diameter of the lower portion 82 by the same distance that the first outer diameter 80 is larger than the second outer diameter 84.

(35) To manufacture the sleeve 14 in FIG. 6, first, the lower portion 82 is produced by turning a wire about an axis and at the outer diameter 84. The wire is coiled for a predetermined length along the axis, and then the diameter of the wire transitions from the outer diameter 84 of the lower portion 82 to a larger outer diameter 80 of the upper portion 78. The wire is coiled for another predetermined length along the axis, and the wire is then cut, which leaves the sleeve 14 with two different-sized outer diameters 80, 84 made from a continuous wire. The next wire sleeve 14 can be made in reverse to minimize waste and increase production speed. The upper portion 78 is created first, and then the wire transitions from the outer diameter 80 of the upper portion 78 to the outer diameter 84 of the lower portion 82. Multiple sleeves 14 made from continuous wire can be manufactured in this alternating process.

(36) After forming the sleeve 14, other components can be added to the sleeve 14 to make the insert 10. Legs 18 can be bent and manufactured into a predetermined shape and then connected to the sleeve 14, for example, by welding. The legs 18 further secure the insert 10 to the precast concrete slab. Specifically, in this embodiment, legs 18 are connected to the upper portion 78 and evenly arranged about a central axis of the sleeve 14. It will be appreciated that any number of legs 18, more or less than four, can be connected to the sleeve 14 in any configuration and/or orientation.

(37) Plugs 86, 88 can help prevent cement or concrete from entering the interior of the sleeve 14 as the insert 10 is encased in a precast concrete slab. The top plug 86 shown in FIGS. 6 and 7 is insertable into the sleeve 14 to close the upper opening of the sleeve 14. The top plug 86 can be threadably secured or even secured with an interference or friction fit to the sleeve 14. After the precast concrete slab has cured, the top plug 86 can be removed to provide access to the interior of the insert 10 for lifting and leveling bolts. Similarly, the lower plug 88 shown in FIG. 7 can connect to the lower opening of the sleeve 14 using, for example, a threadable connection or an interference fit. In other embodiments, the plate 26 can directly provide a threadable connection or an interference fit. The lower plug 88 can be secured to the plate 26 by inserting a screw or bolt from a bottom surface of the plate 26, through the plate 26, and into the lower plug 88. During operation, a leveling bolt can drive the lower plug 88 out of the sleeve 14. To aid with this functionality, the top surface of the lower plug 88 can have a concave shape to center and stabilize the leveling bolt as the leveling blot drives the lower plug 88 out of the sleeve 14.

(38) Specialized lifting and leveling bolts can interact with the coiled wire sleeve 14 to position the insert 10 and raise and lower the insert 10 above a surface. The lifting bolt is configured to threadably connect to the inner surface of the upper portion 78. The lifting bolt has threads with a crest and root profile that compliments the shape of the inner surface of the upper portion 78, which is defined by a coiled wire. Thus, one can thread the lifting bolt into the upper portion 78 and use a hoist system that connects to the lifting bolt to lift and position the precast concrete slab. Similarly, the leveling bolt is configured to threadably connect to the inner surface of the lower portion 82, and the leveling bolt has a crest and root profile that compliments the shape of the inner surface of the lower portion 82, which is defined by a coiled wire. Therefore, one can rotate the leveling bolt through the lower portion 82 to contact the leveling bolt against the plate 26 and drive the plate 26 into the surface. As a result, the leveling bolt and insert raise the precast concrete slab above the surface.

(39) Now referring to FIGS. 8A, 8B, and 9, various views of the insert 10 are provided. FIG. 8A is a top plan view of the insert 10 that shows the upper plug 86 closing the interior volume of the sleeve. FIG. 8B is also a top plan view of the insert 10, but with the upper plug and plate removed so that the interior of the sleeve is visible. As depicted, the upper portion 78 has a larger inner diameter than the lower portion 82. FIG. 9 is a bottom plan view of the insert 10 with the plate and plugs removed.

(40) The invention has significant benefits across a broad spectrum of endeavors. It is the Applicant's intent that this specification and the claims appended hereto be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed.

(41) The phrases at least one, one or more, and and/or, as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions at least one of A, B, and C, at least one of A, B, or C, one or more of A, B, and C, one or more of A, B, or C, and A, B, and/or C means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B, and C together.

(42) Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, and so forth used in the specification, drawings, and claims are to be understood as being modified in all instances by the term about.

(43) The term a or an entity, as used herein, refers to one or more of that entity. As such, the terms a (or an), one or more and at least one can be used interchangeably herein.

(44) The use of including, comprising, or having, and variations thereof, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Accordingly, the terms including, comprising, or having and variations thereof can be used interchangeably herein.

(45) It shall be understood that the term means as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C. 112(f). Accordingly, a claim incorporating the term means shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials, or acts, and the equivalents thereof, shall include all those described in the summary of the invention, brief description of the drawings, detailed description, abstract, and claims themselves.

(46) The foregoing description of the invention has been presented for illustration and description purposes. However, the description is not intended to limit the invention to only the forms disclosed herein. In the foregoing Detailed Description for example, various features of the invention are grouped together in one or more embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the invention.

(47) Consequently, variations and modifications commensurate with the above teachings and skill and knowledge of the relevant art are within the scope of the invention. The embodiments described herein above are further intended to explain best modes of practicing the invention and to enable others skilled in the art to utilize the invention in such a manner, or include other embodiments with various modifications as required by the particular application(s) or use(s) of the invention. Thus, it is intended that the claims be construed to include alternative embodiments to the extent permitted by the prior art.