Set of components for tendon encapsulation process in active anchor plate in prestressed concrete

Abstract

This patent refers to improvements introduced in the encapsulation technique regarding the field of tendons with anchor plates and anchor tensors, applied in the construction system of prestressed concrete in its assembly, demoulding, tensioning and final finishing with obtaining anticorrosion protection of metal parts through a set of improved components applied to the current processes and an innovative process that will ensure the seal against entry of concrete cream into the greased system during the assembly of the system, in forms prior to concreting, which will also ensure their perpendicularity to the shape and bringing advantages that will increase the speed of installation, speed of calculation response, speed in the installation of hydraulic jacks for tensioning the pull rods, ease application and perfect fittings in the tools, improvement of the finishing process ensuring thus effective protection for durability, reuse of components, increased safety at work and elimination of all improper process that occurs in the preparation and fixing of the anchor plate and subsequent closing and finishing.

Claims

1. A set of components for a tendon encapsulation system, comprising: a flanged cap (1) having elongated shape, an anterior sleeve with truncated-cone shaped fixing tabs (1-A), a cylindrical shaped central body (1-B) and a truncated-cone shaped posterior end (1-C) fittable to an anchor plate (2), the flanged cap secured to the anchor plate by plastic double pull rod fasteners (3) and fittable to a tendon (C), the system comprising a hose (M), the anchor plate (2) having a taper-shaped posterior sleeve (2-A) with a female plug (2-A-1), and fittable to the flanged cap (1) by a mountable pocket form (4); a front of the double pull rod fasteners (3) having cylindrical shape, locking rings (3-A) and a fixed washer (3-B) and a back of the fasteners with locking rings (3-C) each with a lock (3-D) of ringed and truncated-cone shape with cuts forming locking wedges; the mountable pocket form (4) comprising two pluggable parts, a truncated-cone shaped hollow outer cover (4-A) with trapezoidal shaped internal guides (4-A-1) and a ring shaped leveling stopper (4-A-2) with sealing skirt (4-A-2-A) having cylindrical and conical shape and a core (4-B) having a hollow cylindrical shape with a removing ring (4-B-1), support ring (4-B-2) having the shape of a ring and a fitting bounce (4-B-3) also in the shape of ring and fittable on the anchor plate (2) and passing through the form (F); and a plug (5) made from concrete or mortar, having truncated-cone shape, closed on one side and with a sealing seal (5-B) adhered and closing the one side, fittable and adhered to an anchor niche (NF).

2. The set of components according to claim 1, wherein the plug (5) comprises a handle (5-C), having shape of an A, fixed in the other side.

3. The set of components according to claim 1, wherein the flanged cap comprises a fittable cap (6) having elongated shape with a truncated-cone-shaped anterior sleeve (6-A) and with a click type male fitting bounce (6-A-1), cylindrical-shaped central body (6-B) and a truncated-cone-shaped posterior end (6-C).

4. The set of components according to claim 1, wherein the pull rod fasteners comprise simple head tapping screw type pull rod fastener (7) complemented by a lock (3-D).

5. The set of components according to claim 1, wherein the pocket form comprises a monoblock pocket form (8).

6. The set of components according to claim 1 further comprising a pocket form removal tool (9) having an offset shaft lever shape, with a handle at a top part, two curves at an intermediate part and a U-shaped ear at a bottom part.

7. The set of components according to claim 1 wherein the plug (5) is filled with antioxidant grease (5-A).

8. A process for encapsulating an anchored tendon using the set of components of claim 1, comprising: removing excess of the hose from the tendon; installing the flanged cap having a posterior end onto the tendon proximate a position of the anchor plate; installing the anchor plate onto the tendon; installing a form onto the anchor plate using the plastic double pull rod fasteners; installing a sealing cap and the pocket form onto the anchor plate; pouring and curing concrete; removing the pocket form using a tool comprising an offset shaft lever shape, with a handle at a top part, two curves at an intermediate part and a U-shaped ear at a bottom part; tensioning the tendon and locking the tensioned tendon in the anchor plate with locking wedges; cutting the locked tendon; and installing the plug made from concrete or mortar, having the truncated-cone shape, closed on one side and filled with antioxidant grease, with a sealing seal adhered and closing an anchor niche made by the pocket form in the concrete.

Description

(1) For a better understanding of this invention, attached hereto are the following figures:

(2) FIG. 1 shows the perspective view of the tendon covered with a hose with cap, anchor plate, pocket form, pull rod and form, identifying the individual details of each component and their formation together, allowing the visualization of the fittings and sequence assembled into the set of components of this invention placed before concreting;

(3) FIG. 2 shows the front perspective view of the flanged cap, one of the individual components of the set of components of this invention;

(4) FIG. 3 shows the top view of the flanged cap, one of the individual components of the set of components of this invention;

(5) FIG. 4 shows the rear view of (1-C) to (1-A) of the flanged cap, one of the individual components of the set of components of this invention;

(6) FIG. 5 shows the front view of the improved anchor plate, one of the individual components of the set of components of this invention;

(7) FIG. 6 shows the rear perspective view of the improved anchor plate, one of the individual components of the set of components of this invention;

(8) FIG. 7 shows the front perspective view of the pull rod, one of the individual components of the set of components of this invention;

(9) FIG. 8 shows the front perspective view of the pull rod lock, one of the individual components of the set of components of this invention;

(10) FIG. 9 shows the rear perspective view of the pull rod lock, one of the individual components of the set of components of this invention;

(11) FIG. 10 shows the longitudinal cross-sectional view of the pull rod lock, one of the individual components of the set of components of this invention;

(12) FIG. 11 shows the front view of the outer cover (anchor niche molding skirt) of the pocket form, one of the individual components of the set of components of this invention;

(13) FIG. 12 shows the rear perspective view of the outer cover (anchor niche molding skirt) of the pocket form, one of the individual components of the set of components of this invention;

(14) FIG. 13 shows the top view from (4-A-1) to (4-A-2) of the outer cover (anchor niche molding skirt) of the pocket form, one of the individual components of the set of components of this invention;

(15) FIG. 14 shows the front view of the pocket form core (guide), one of the individual components of the set of components of this invention;

(16) FIG. 15 shows the rear perspective view of the pocket form core (guide), one of the individual components of the set of components of this invention;

(17) FIG. 16 shows the rear view of the core (guide) from (4-B-1) to (4-B-2) of the pocket form, one of the individual components of the set of components of this invention;

(18) FIG. 17 shows the side perspective of the plug, one of the individual components of the set of components of this invention;

(19) FIG. 18 shows the side view of the plug, one of the individual components of the improved set of components of this invention;

(20) FIG. 19 shows the bottom view of the plug, one of the individual components of the set of components of this invention;

(21) FIG. 20 shows the side perspective of the plug without a handle, one of the individual components of the set of components of this invention;

(22) FIG. 21 shows the front perspective of the alternative of the fitting cap, one of the individual components of the set of components of this invention;

(23) FIG. 22 shows the front view from (6-A-1) to (6-C) of the alternative of the fitting cap, one of the individual components of the set of components of this invention;

(24) FIG. 23 shows the rear view from (6-C) to (6-A-1) of the alternative of the fitting cap, one of the individual components of the set of components of this invention;

(25) FIG. 24 shows the front view of the monobloc pocket form (assembled), one of the individual components of the set of components of this invention;

(26) FIG. 25 shows the front perspective of the pull rod alternative, one of the individual components of the set of components of this invention;

(27) FIG. 26 shows the perspective view of the hose-covered grease tendon of this invention positioned before concreting;

(28) FIG. 27 shows the perspective view of the hose-covered grease tendon and cap of this invention positioned before concreting;

(29) FIG. 28 shows the perspective view of the hose-covered grease tendon with cap and with an anchor plate of this invention positioned before concreting;

(30) FIG. 29 shows the perspective view of the hose-covered grease tendon with cap, with anchor plate and with the pocket form of this invention positioned before concreting;

(31) FIG. 30 shows the perspective view of the hose-covered grease tendon with cap, with anchor plate, with pull rods and with the pocket form of this invention;

(32) FIG. 31 shows the perspective of the hose-covered grease tendon with cap, with anchor plate, with pocket form and with the form placed before concreting;

(33) FIG. 32 shows the top view of the hose-covered grease tendon with cap, with anchor plate, with pull rods with pocket form and with the form of this invention placed after the concreting and before deforming;

(34) FIG. 33 shows the top view of the hose-covered grease tendon with cap, with anchor plate and with the pull rods with pocket form of this invention placed after the concreting and with the form removed (deformed);

(35) FIG. 34 shows the perspective view of the removal tool of this invention during the removal operation of the pocket form,

(36) FIG. 35 shows the perspective view of the hose-covered grease tendon with cap, with anchor plate, with cut pull rods, with pocket form removed and with the tendon of this invention;

(37) FIG. 36 shows the top view of the hose-covered grease tendon with cap, with anchor plate, with cut pull rods, with pocket form removed, with anchor niche formed, with locking wedge and cut tendon from this invention placed after the concreting and release of the calculating engineer;

(38) FIG. 37 shows the perspective view of the hose-covered grease tendon with cap, with anchor plate, with cut pull rods, with locking wedge, with cut tendon and with the plug of this invention;

(39) FIG. 38 shows the top view of the hose-covered grease tendon with cap, with anchor plate, with cut pull rods, with formed niche, with locking wedge, with cut tendon and with the plug adhered in the niche of this invention placed after the concreting; and

(40) FIG. 39 shows the block diagram of the novel encapsulation process sequence of this invention.

(41) The set of components of this invention used in conventional encapsulation processes or in the process claimed herein is formed by the following items:

(42) Flanged cap (1) made of plastic or other suitable material, having elongated shape with an anterior sleeve with truncated-cone shape fixing tabs (1-A) (with perfect contact between the cap and anchor plate, thus allowing the use of conventional anchor plates) and cylindrical-shaped central body (1-B) and truncated-cone-shaped posterior end (1-C) (to facilitate penetration of the often-shredded tendon) attachable to the anchor plate (2), fastened by the double pull rod fastener (3) and attachable to the set of tendon (C), grease (G) and hose (M);

(43) Metal anchor plate (2) with tapered shape posterior bounce (2-A) with a with click type female plug (2-A) (for a perfect coupling of the fitting cap with the anchor plate, avoiding the concrete cream penetration on the tendon) and fastened by the double pull rod fasteners (3) engageable in the flanged cap (1) and by the mountable pocket form (4);

(44) Double pull rod fastener (3) having predominantly cylindrical shape, with the front equipped with locking rings (3-A) and fixed washer (3-B) and the back equipped with locking rings (3-C) in plastic or other suitable material and with lock (3-D) of ringed and truncated-cone shape with cuts forming locking wedges (to prevent wire tips that can generate corrosion on the surface of prestressed concrete) and fasteners of the cap set (1) and anchor plate (2) in the form (F);

(45) Mountable pocket form (4) in plastic or other suitable material with two fitting parts with truncated-cone-shaped hollow outer cover (4-A) with trapezoidal-shaped internal guides (4-A-1) and ring-shaped stopper (4-A-2) with sealing skirt (4-A-2-A) having cylindrical and conical shape (improving the system lock and preventing concrete cream to penetrate the system between the pocket form and anchor plate) and core (4-B) having a hollow cylindrical shape with a removing ring (4-B-1) (protrusion with a fitting that adapts itself to a tool that will remove it from the concrete), support ring (4-B-2) having the shape of a ring and a fitting bounce (4-B-3) also in the shape of ring (the use of the mountable pocket form is due to the fact that its manufacture is simpler and allows the interchangeability of the outer cover favoring the environment and being able to be replaced by a monobloc pocket form of same design and functionality of the object required in this invention) engageable in the anchor plate (2) and passing through the form (F); and

(46) Plug (5) in concrete or mortar, having truncated-cone shape, closed on one side and filled with antioxidant grease (5-A) (the same as the tendon), with sealing seal (5-B) adhered and closing the open side (which protects the grease in an internal space of the plug, same space that breaches the tip of the tendon at the time of its application) and handle (5-C) having the shape of an A in plastic or other suitable material fixed in the closed and fitting side adhered to the anchor niche (NF). See FIGS. 2 to 19.

(47) Alternatively, one could adopt the plug (5) without the handle (5-C). See FIG. 20.

(48) Alternatively one could adopt the fitting cap (6) in plastic or other suitable material with elongated shape, with truncated-cone-shaped anterior sleeve (6-A) and with click type male fitting bounce (6-A-1) (for a perfect fit into the groove (2-A-1) of the anchor plate (2)), cylindrical-shaped central body (6-B) and truncated-cone-shaped posterior end (6-C). See FIGS. 21, 22 and 23.

(49) Alternatively, one could adopt the pocket form monoblock (8) in plastic or other suitable material of the same mountable pocket form constructiveness (4), but with single monoblock body. See FIG. 24.

(50) Alternatively, one could adopt a simple head tapping screw type pull rod fastener (7) in plastic or other suitable material with the use of the flanged cap (1) or with the fitting cap (6), as long as it's with the aid of the lock (3-D). See FIG. 25.

(51) Alternatively, the conventional anchor plate, without bouncing for click, can be used in this invention system by fixing the flanged cap (1) using the pull rod fasteners (3) or (7), getting the same quality as the encapsulation process with the components here claimed.

(52) Additionally, the tool (9) has an offset shaft lever shape and tubular cross-section, with handle at the top part, two long radius curves at the intermediate part and a U-shaped ear at the bottom part.

(53) It is not recommended the adoption of the components here claimed with conventional pocket form and/or conventional cap by the possibility of entry of concrete cream into the encapsulation process.

(54) The novel encapsulation process of this invention is given in the following sequence:

(55) a) After the release of the tendon (C) covered with a hose (M) the exceeding hose (M) is cut from the tendon (C), grease (G) and hose (M) and install first the flanged cap (1) by moving it up next to the point that will be fixed, with the posterior end (1-C) facing the opposite side of the tensioning point;

(56) b) Insert the anchor plate chosen between the anchor plate (2) and the conventional one:

(57) c) Insert the pocket form chosen between the mountable (4) or the pocket form (8) monoblock with the removing ring (4-B-1) facing the hole (O) of the form (F) to the tensioning point;

(58) d) Pass the tip of the tendon in the hole (O) of the form (F) (which is the space intended to secure the anchor plate (2)) and secure the pull rod fasteners (3) manually or by means of their own tool on the anchor plate connected with pocket form, in the design angle, in the form;

(59) e) Fit the anterior sleeve (1-A) of flanged cap (1) on the posterior bounce (2-A) of the anchor plate (2) with the fixing tabs fastened to the anchor plate (thus ensuring a good seal to prevent the entry of concrete cream and also its possible movement during concreting);

(60) f) After making sure that everything is properly secured and fitted, the concreting of the element to be used in accordance with technical norms and engineering determinations begins;

(61) g) Once the curing time has elapsed and the concrete strength has been reached as established by the Structural Calculus Designer, the tensioning face deformation of the concrete begins;

(62) h) Without the forms, all the pocket form appear in position, ready to begin their removal, which are ergonomically and securely removed with the removing tool (9) with the contributor standing and turned to the same direction as the pocket form, pulling it back, usually in the continuity of the slab, until detachment of the pocket form occurs, positioning the removal end of the tool on the removing ring of the pocket form, penetrating the bounce at the opening of the tool itself with a little effort downwards and then effecting the pulling, which will culminate in total detachment of the pocket form without damaging or ruining it, allowing later manual removal of the piece (and, if necessary, its next reuse) and releasing the anchor niche (NF) formed;

(63) i) With the release of the anchor niche (NF) it is possible to fit the hydraulic jack (MH) and locking wedges (CT) (which will ensure entrapment of the tendon (C) together with the tensioning energy required to keep the prestressed concrete element stressed, generally zeroing out the efforts of the own tensile stresses on concrete);

(64) j) With the anchor niche (NF) without deformations (thanks to the design that minimizes deformations of the pocket form), the hydraulic jack nozzle fits perfectly in this niche;

(65) k) Approved by the estimating engineer, the stress/strain of the tendon (C) and its energy trapped by the locking wedges (CT) through the anchor plate, the excess cut of the tendon (C) is released with appropriate cutter and maintained the end of the tendon (C) exposed with a short distance from the anchor plate ready to receive treatment (and avoid pathology, as this is the most delicate point of the entire length of the tendon and must take care and attention necessary to avoid corrosion and the tendon to come off the anchor plate);

(66) l) With the aid of the handle (5-C), the plug (5) is applied with the grease trapped and the seal (5-B) adhered into the sealant adhesive solution (epoxy, polyurethane or other suitable adhesive available on the market) and then the plug (5) is directed to the anchor niche (NF), cleaned and its ready to receive it, applying it until its full penetration, causing the end of the tendon (C) to break the seal (5-B) so that the grease occupies the empty space and allows the adhesive to squeeze between the plug (5) and the concrete of the anchor niche of the prestressed concrete element; and

(67) m) Release the face of the concrete, already prestressed and properly protected, for subsequent finishing application, as specified in architectural design.

(68) The components of the set of components in this invention may be applicable individually or together in currently existing processes.

(69) The encapsulation process of this invention may use only part of the set of components claimed herein associated with conventional components.