CONCRETE RODDER AND METHODS OF USE AND MANUFACTURE OF SAME

Abstract

Apparatus and method for screeding/rodding concrete (and method of manufacture of the same), comprising: a rigid base member configured to comprise a tight tolerance of levelness along its length, and a mounting structure for securely attaching a working layer; attachment of a preferably fiberglass working layer comprising a durable material deposited on the rigid base member and capable of being finished to a smooth surface suitable for advantageous direct contact with poured wet concrete.

Claims

1. An apparatus for rodding concrete, comprising: a rigid base member arranged for maintaining a tight tolerance of levelness along its length, adapted for connecting an additional working layer surface; and a working layer on said rigid base member, comprising a durable material capable of being finished to a smooth surface suitable for direct contact with poured wet concrete.

2. The apparatus of claim 1, wherein the working layer is finished with a material consisting of a cured fiberglass compound, attached to the rigid base member.

3. The apparatus of claim 1, wherein the working layer has been smoothed to a very smooth surface to conform to the tight tolerance of level needed along the length of the rigid base member.

4. The apparatus of claim 1, wherein the exterior surface of the working layer is a material that covers the length and width of the rigid base member, such that the working layer is adapted to provide a smooth and consistent surface that is in contact with the concrete being leveled.

5. The apparatus of claim 1, wherein the rigid base member comprises a wood 24 having routed along the length of its narrower surface one of a stepped surface, a groove, a dovetail, and a dado-fin cut, further comprising a fiberglass working layer attached along the routed narrower surface of said 24.

6. The apparatus of claim 5, wherein the rigid base member comprises an aluminum rod having a structure to provide a secure mounting for the fiberglass working layer, further comprising a fiberglass working layer attached along the narrower surface of said aluminum rod.

7. The apparatus of claim 5, wherein the rigid base member comprises a sturdy construction of plyboard or other processed structural wood, cut and glued to a similar size and shape as a wood 24, having routed along the length of its narrower surface one of a stepped surface, a groove, and a dovetail, further comprising a fiberglass working layer attached along the routed narrower surface of said construction.

8. The apparatus of claim 5 wherein the rigid base member has a dovetail groove routed along the length of its lower surface which contacts the working layer.

9. The apparatus of claim 6 wherein the working layer has a prominence extending outward from the unfinished side of the working layer, which connects to the rigid base member.

10. The apparatus of claim 1 further comprising optional endcaps attached adjacent the joint which connects the rigid base member to the working layer.

11. The apparatus of claim 10 wherein the optional endcaps have openings for fasteners to attach the endcaps to the rigid base member.

12. The apparatus of claim 10 wherein the endcaps are composed of metal.

13. A process of making a rodding tool comprising the steps of: one of constructing a metal rod and planing and routing a piece of dimensional lumber, to comprise one of a smooth surface, a stepped surface, a dovetail surface, and a grooved surface, to be adapted for; one of painting and layering a fiberglass layer along the length of the piece of dimensional lumber; and curing the fiberglass layer to a degree of hardness suitable for working the fiberglass covered dimensional lumber to perform the rodding of a concrete pour with the rodding tool.

14. The method of claim 13 further comprising the steps of: creating a mold having the desired length and shape for the fiberglass working layer; acquiring and preparing fiberglass material strips to desired length and width; pouring a fiberglass liquid component into the mold; laying individual strips of fiberglass material into the liquid component within the mold; pressing the entire length of the dovetail surface of the lumber into the mold to contact the combined liquid and fiberglass strips; holding the lumber in place to ensure the liquid component oozes into the dovetail surface; and allowing the fiberglass to harden and then removing the mold.

15. An improved efficiency method of rodding a freshly-poured concrete pour within a form having first and second ends to form a smooth concrete surface before drying and curing of the concrete, comprising the steps of: pouring freshly-mixed concrete into the form; standing near the first end of the form while holding an apparatus for rodding concrete, the apparatus comprising: a rigid base member arranged for maintaining a tight tolerance of levelness along its length, adapted for connecting an additional working layer surface; and a working layer on the rigid base member, comprising a durable material capable of being finished to a smooth surface suitable for direct contact with poured wet concrete; extending the user's arms to reach and engage in contacting relationship the durable material on the apparatus to the poured wet concrete; retracting the user's arms to pull the durable material partially within and along an upper surface of the poured wet concrete such that the concrete is smoothed by the durable material as it is pulled toward the user's feet; taking a step rearwardly toward the second end of the form; and repeating the previous three steps of the process a minimal number of times to achieve a sufficiently smooth surface able to be successfully bull floated with a substantially lesser degree of effort compared to had the surface been rodded using a completely wooden, or completely metal, apparatus.

16. The method of claim 15, wherein the number of pulls to achieve the sufficiently smooth surface are reduced by approximately one third as compared to the number of pulls necessary to achieve the same result with prior art methods.

17. The method of claim 15, wherein the substantially lesser degree of effort to successfully bull float comprises approximately 50% less effort when compared with the effort necessary to successfully bull float using prior art methods.

18. The method of claim 15, wherein the finished surface on the working layer consists of fiberglass.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0044] FIG. 1A is a perspective view of the rigid base member prior to application of the working layer, showing an example of routing a box-joint-type pattern, or a stepped pattern, in a narrow side suitable for securely attaching the working layer;

[0045] FIG. 1B is a perspective view of an alternate rigid base member prior to application of the working layer, showing example of routing a different pattern, such as a dove-tail joint pattern, in the narrow side suitable for securing attaching the working layer;

[0046] FIG. 2A is a perspective view of the rigid base member of FIG. 1A, where the working layer has also been added, and wherein the working layer has slightly rounded corners for easier concrete rodding;

[0047] FIG. 2B is a perspective view of the alternate rigid base member of FIG. 1B, where the working layer has also been added;

[0048] FIG. 3A is a perspective view of another alternative rigid base member comprising a metal rod, showing an example of a mounting area, such as grooves or fins, suitable for securely attaching the working layer;

[0049] FIG. 3B is a perspective view of the alternative rigid base member of FIG. 3A where the working layer has been added with slightly rounded lower edges;

[0050] FIG. 4 is a perspective view of a rodder in accordance with an aspect and embodiment of the disclosure and in use as a rodding tool in a typical application;

[0051] FIG. 5 is a flowchart showing the general steps involved in manufacturing a rodding tool in accordance with the disclosure;

[0052] FIG. 6 is a flowchart showing specific steps involved in manufacturing a rodding tool using a wood 24 and fiberglass in accordance with the disclosure;

[0053] FIG. 7 is a flowchart showing specific steps involved in using the improved concrete rodding tool in a typical application;

[0054] FIG. 8 is a flowchart showing specific steps involved in a method of manufacturing a rodding tool in accordance with the disclosure;

[0055] FIG. 9A is a perspective view of another embodiment of a rigid base member prior to application of a working layer, showing an example of routing an inverted dovetail groove along the rigid base member, suitable for attaching the working layer;

[0056] FIG. 9B is a perspective view of the rigid base member of FIG. 9A, with the working layer also added;

[0057] FIG. 10A is a perspective view of the rodding tool with an optional endcap which can be attached adjacent the end of the rodding tool;

[0058] FIG. 10B is a perspective view of the rodding tool with the optional endcap attached to the rodding tool.

DETAILED DESCRIPTION

[0059] Referring to FIGS. 1A-2B, 2A-2B, 3A-3B, 9A-9B, in accordance with one or more aspects of the disclosure, there is provided an apparatus comprising: a rodding assembly 100, 100, 100, 200 comprising a rigid base member 102, 102, 102, 200 further comprised of one of a 24 piece of lumber, aluminum, or other suitable wood, metal, or plastic member, adapted with a mounting geometry 104, 104 104, 204 such as a routed box, or stepped, joint portion, and a working layer 106, 106, 106, 206, which working layer is adapted to be securely attached to the rigid base member as with painting, coating, or otherwise forming in a form or mold, fluid fiberglass material.

[0060] In accordance with an embodiment of the disclosure shown in FIG. 4, it is noted that any of the rodding assemblies of this disclosure, e.g., rodding assembly 100 of FIGS. 1A-1B, 100 of FIGS. 2A-2B, 100 of FIGS. 3A-3B, and 200 of FIGS. 9A-9B, may be so used as shown in FIG. 4, and each is intended to be used with a narrow side (e.g., 106) down, providing a secure handhold broader surface (e.g., 108) on the upper narrow wood (or other suitable material) portion (e.g., 102), for the worker in moving and pulling the wet concrete as part of the rodding process. Thus, the design of this tool allows the worker skilled in the art to utilize the same motion and process for rodding that has previously been learned.

[0061] Referring to FIGS. 1A-1B, 2A-2B, 3A-3B, and 9A-9B, the mounting geometry 104, 104, 104, 204, respectively may be realized with any of a number of different shapes (rectangular box, or stepped, cut 104, dove-tail cut 104, 204, or dado-cut-fins/otherwise formed grooves 104), with the effect to provide a secure mounting point for the working layer 106, 106, 106, 206.

[0062] Referring specifically to FIG. 2A, the working layer 106 is securely attached to the rigid base member 102, utilizing the mounting geometry 104 in the form of a rectangular box, or stepped, cut, to provide the secure attachment.

[0063] Referring specifically to FIG. 2B, the working layer 106 is securely attached to the rigid base member 102, utilizing the mounting geometry 104 in the form of a dove-tail joint cut, to provide the secure attachment.

[0064] Referring to FIGS. 2A, 2B, 3B, 9B, the external shape of the working layer 106, 106, 106, and 206 generally conforms to the original shape of the wood 24, other dimensional wood, or other suitable base member 102, 102, 102, 202, providing a familiar shape of the tool to the worker.

[0065] Referring to FIGS. 2A, 2B, 3B, and 9B it will be appreciated that the lower edge 107, 107, 107, 207 may be squared off as shown in FIG. 2B (107), or slightly rounded as shown in FIGS. 2A (107) and 3B (107).

[0066] Alternatively, as shown in FIGS. 3A and 3B, the rigid base member 102 may comprise a metal 24 (such as aluminum), while preserving the secure handhold 108 (or 108 of FIGS. 1A-1B, 108 of FIGS. 2A-2B, or 208 of FIGS. 9A-9B), 108 for the worker and a mounting geometry 104 (e.g., cut or molded dado fins or grooves) to provide secure attachment to the working layer 106.

[0067] FIG. 5 describes in general terms the process for creating the assembly for the improved rodding tool 100, 100, 100, 200, comprising the steps of: [0068] create rigid base member with high degree of straightness (e.g., out of wood or aluminum) 110; [0069] provide means of securely attaching a working layer (e.g., with box or dove-tail joint) 112; and [0070] add the working layer (e.g., by forming or painting fiberglass onto the base member) 114.

[0071] FIG. 6 describes steps to create an embodiment, comprising a wood 24 as the rigid base member 102, a straight and routed mounting geometry 104, 104, 204, and a fiberglass working layer 106, 106, 206, comprising the steps of: [0072] select 24 with moderate straightness 116; [0073] plane narrow edge of 24 for straightness within tolerance 118; [0074] route narrow edge of 24 to create box or dove-tail joint 120; [0075] coat narrow edge of box or dove-tail joint with fiberglass compound. Shape to conform to width of 24 122; [0076] cure and add layers as needed until desired thickness and coverage is achieved 124; [0077] measure straightness of fiberglass and sand as required 126; and [0078] coat surface for smoothness 128.

[0079] It will be appreciated that a rodding tool 100, 100, 100, 200 in accordance with this disclosure provides the concrete installer with a tool that is physically less strenuous to manipulate through wet concrete than an unmodified wood 24, and provides a working surface in contact with the concrete that requires fewer additional finishing steps, helping to maintain flatness for demanding applications.

[0080] In an unforeseen way, fiberglass added to the bottom of the base member 102, 102, 102, 202 as described herein significantly eases the rodding/pulling of the concrete. This aspect of the invention facilitates the rodding process significantly, which heretofore has been a very strenuous labor.

[0081] In another embodiment, referring now specifically to FIGS. 9A and 9B, the connecting groove 204 of the improved rodding tool 200 may be shaped like a dovetail and machined out of the rigid base member 202, with the working layer 206 having a corresponding prominence 205 extending outward from the unfinished surface of the working layer which attaches it to the rigid base member 202. A benefit of this alternative shape is that it is easier to machine into the rigid base member 202, thereby reducing manufacturing costs and improving efficiency. The improved rodding tool 200 will have a broad surface 208 on the side suitable as a handhold for a worker using the tool to rod a freshly poured concrete surface.

[0082] In another embodiment, referring now to FIGS. 10A and 10B, there may be optional endcaps 160, preferably composed of a metal, each of which attaches to an end of the improved rodding tool 100 (as shown in FIG. 10B). Each such endcap 160 covers a connecting joint mounting geometry 104, 204 attaching the working layer 202, 222 and the rigid base member 220. The optional endcaps 160 may have a plurality of holes 162 through, or defined in, them which permit them to be attached with fasteners 164, possibly flat-head screws, to partially pass through the holes thereby attach the end caps to the improved rodding tool. The endcaps may be approximately 1.51.51.5 in length and may serve to protect the ends of the board if it were to brush up against a curb or other hard surface, which could potentially disturb the connection between the working layer and the rigid base member. The endcaps also serve other functions such as reducing the need for sanding of the edge of the rodding tool, and preventing the smooth fiberglass layer from becoming rough at the edges.

[0083] Through significant testing by the Applicant, in accordance with another aspect of the disclosure, referring now to FIG. 7, there is provided an improved efficiency method of rodding a freshly-poured concrete pour within a form having first and second ends to form a smooth concrete surface before drying and curing of the concrete, comprising the steps of: [0084] pouring freshly-mixed concrete into a form 130; [0085] standing in or near the freshly-poured concrete near the first end of the form while holding an apparatus for rodding concrete 132, the apparatus comprising: [0086] a rigid base member 102, 102, 102, 202 arranged for maintaining a tight tolerance of levelness along its length, adapted for connecting an additional working layer surface; and [0087] a working layer 106, 106, 106, 206 on the rigid base member, comprising a durable material capable of being finished to a smooth surface suitable for direct contact with poured wet concrete; [0088] extending the user's arms to reach and engage in contacting relationship the durable material on the apparatus to the poured wet concrete 134; [0089] retracting the user's arms to pull the durable material partially within and along an upper surface of the poured wet concrete such that the concrete is smoothed by the durable material as it is pulled toward the user's feet 136; [0090] taking a step rearwardly toward the second end of the form 138; and [0091] repeating the previous three steps of the process a minimal number of times 140, if at all, to achieve a sufficiently smooth surface able to be successfully bull floated with a substantially lesser degree of effort compared to had the surface been rodded using a completely wooden, or completely metal, apparatus.

[0092] The improved efficiency method of this aspect of the disclosure is such that wherein the number of pulls to achieve the sufficiently smooth surface may be reduced by approximately one third as compared to the number of pulls necessary to achieve the same result with an average skilled and strength person, or person, using prior art methods.

[0093] Further, the method of this aspect of the disclosure is such that wherein the substantially lesser degree of effort to successfully bull float comprises approximately 50% less effort when compared with the effort necessary to successfully bull float by an average skilled and strength person using prior art methods.

[0094] In accordance with another aspect of the disclosure, referring how to FIG. 8, there is provided an improved efficiency method of producing the improved rodding tool of the present disclosure, comprising the steps of: [0095] creating a mold having the desired length and shape for a fiberglass working layer 142; [0096] acquiring and preparing fiberglass material strips to a desired length and width 144; [0097] pouring a fiberglass liquid component into the mold, where the liquid component may further comprise a resin 146; [0098] laying individual strips (for example eight, or preferably eight such strips) of fiberglass material into the liquid component within the mold 148; [0099] compressing the entire length of the dovetail cut portion of the rigid base member into the mold to contact combined liquid and fiberglass strips 150; [0100] holding in place the rigid base member to ensure the fiberglass liquid component oozes into the mounting geometry (e.g., the dovetail groove 204 of FIG. 9A) 152; and [0101] allowing the fiberglass to harden and removing the mold 154.

[0102] The liquid component may include a resin material or other binding agent to facilitate the attachment of the fiberglass to the working layer. It is also possible for the rigid base member, or blank 24 or other structure which is made into the rigid base member, to be premanufactured out of wood or aluminum with the dovetail (or other shape) groove already in place to expedite the manufacturing process. The fiberglass material strips may be sequentially layer into the resin material already in the mold, and may be 8 by 1.5. As the strips are pressed into the mold, it may be necessary to work out any bubbles which form in the process, and to release the trapped air.

[0103] While preferred embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that many changes and modifications may be made without departing from the invention in its broader aspects. For example, it will be appreciated that one of ordinary skill in the art may mix and match the various components of the various embodiments of the invention without departing from the true spirit of the invention as claimed. Thus, for example, it will be appreciated that any of the structures 104, 104, 104, 204 may be formed into any type of base member 102, 102, 102, 202, 220 material without departing from the true spirit of the invention as claimed. The appended claims are therefore intended to cover all such changes and modifications as fall within the true spirit and scope of the invention.