THERMAL BREAK FOR CONCRETE SLABS

Abstract

A thermal break system for cast-in-place concrete slabs is provided that includes a load-bearing structural foam barrier designed to separate an interior portion of concrete slab from an exterior portion of concrete slab. The thermal break system includes a plurality of reinforcing tension bars holes passing through the insulating barrier. In addition, reinforcing shear bars are inserted through the insulating foam at a non-horizontal angle and bent such that the shear bars are horizontal on either side of the insulating barrier.

Claims

1-4. (canceled)

5. A thermal break system prepared by a process comprising the steps of: forming, from a load-bearing, thermally insulating structural foam material, an insulating body such that the insulating body is sized and configured to separate a first area for an interior concrete slab from a second area for an exterior concrete slab; drilling a plurality of reinforcing tension rod holes through the insulating body; drilling a plurality of reinforcing shear rod holes through the insulation body at a non-horizontal angle; welding a washer to each of a plurality of reinforcing shear rods; bending each of the plurality of reinforcing shear rods at a first point to form a plurality of bent reinforcing shear rods; inserting the plurality of bent reinforcing shear rods through the plurality reinforcing shear rod holes in the insulating body such that the first point is aligned with a first side of the insulating body; bending, while inserted in the insulating body, the plurality of reinforcing shear rods at a second point, the second point being aligned with a second side of the insulating body, such that portions of the plurality of reinforcing shear rods extending from the first side of the insulating body and extending from the second side of the insulating body are substantially horizontal; and securing each of the washers to the insulating body.

6. A thermal break system for separating concrete slabs prepared by the process of claim 5.

7-15. (canceled)

16. A method for installing a thermally broken, cast-in-place concrete slab comprising: bending a plurality of reinforcing shear rods at a first point to form a plurality of bent reinforcing shear rods; inserting the plurality of bent reinforcing shear rods through a plurality of angled reinforcing shear rod holes in a load-bearing, thermally insulating structural foam body configured to separate an interior concrete slab from an exterior concrete slab such that the first point angle is aligned with a first side of the insulating body; bending, while inserted in the insulating body, the plurality of reinforcing shear rods at a second point, the second point being aligned with a second side of the insulating body, wherein a first portion of each of the plurality of reinforcing shear rods extends substantially horizontally from the first side of the insulating body and a second portion of each of the plurality of reinforcing shear rods extends substantially horizontally from the second side of the insulating body; inserting a plurality of reinforcing tension rods through a plurality of reinforcing tension rod holes in the insulating body such that a first portion of each of the plurality of reinforcing tension rods extends substantially horizontally from the first side of the insulating body and a second portion of each of the plurality of reinforcing tension rods extends substantially horizontally from the second side of the insulating body; and pouring concrete over the plurality of reinforcing tension rods and reinforcing shear rods on both the first side and the second side of the insulating body to form the exterior concrete slab and the interior concrete slab.

17. The method for installing a thermally broken, cast-in-place concrete slab according to claim 16, further including placing on both the first side and the second side of the insulating body a plurality of cross tension rods substantially perpendicular to the plurality of reinforcing tension rods.

18. The method for installing a thermally broken, cast-in-place concrete slab according to claim 17, further including securing each of the plurality of cross tension rods to one or more of the plurality of reinforcing tension rods.

19. The method for installing a thermally broken, cast-in-place concrete slab according to claim 17, further including securing each of the plurality of cross tension rods to one or more of the plurality of shear rods.

20. The method for installing a thermally broken, cast-in-place concrete slab according to claim 17, further including securing each of the plurality of cross tension rods to one or more of the plurality of reinforcing tension rods and to one or more of the plurality of shear rods.

21. (canceled)

22-42. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0046] For the purpose of illustrating the invention, the drawings show aspects of one or more embodiments of the invention. However, it should be understood that the present invention is not limited to the precise arrangements and instrumentalities shown in the drawings, wherein:

[0047] FIG. 1 is perspective view of a thermally broken cast-in-place concrete connection in accordance with an embodiment of the present invention;

[0048] FIG. 2 is a perspective view of the thermally broken cast-in-place concrete of FIG. 1 with the concrete in outline;

[0049] FIG. 3A is a perspective view of a thermal barrier with rebar installed in accordance with an embodiment of the present invention:

[0050] FIG. 3B is a top view of the thermal barrier structure of FIG. 3A;

[0051] FIG. 3C is a side view of the thermal barrier structure of FIG. 3A;

[0052] FIG. 3D is a front view of the thermal barrier structure of FIG. 3A;

[0053] FIG. 3E is a rear view of the thermal barrier structure of FIG. 3A;

[0054] FIG. 4 is perspective view of a thermally broken cast-in-place concrete connection in accordance with another embodiment of the present invention;

[0055] FIG. 5 is a perspective view of the thermally broken cast-in-place concrete of FIG. 4 with the concrete in outline;

[0056] FIG. 6A is a perspective view of a thermal barrier with rebar installed in accordance with an embodiment of the present invention:

[0057] FIG. 6B is a top view of the thermal barrier structure of FIG. 6A;

[0058] FIG. 6C is a side view of the thermal barrier structure of FIG. 6A;

[0059] FIG. 6D is a front view of the thermal barrier structure of FIG. 6A;

[0060] FIG. 6E is a rear view of the thermal barrier structure of FIG. 6A;

[0061] FIG. 7A is a perspective view of the thermal barrier structure without rebar installed;

[0062] FIG. 7B is a cutaway view of the thermal barrier structure of FIG. 7A;

[0063] FIG. 7C is another cutaway view of the thermal barrier structure of FIG. 7A;

[0064] FIG. 8A is a cutaway side view of the thermal barrier structure showing a partially installed reinforcement shear bar:

[0065] FIGS. 8B-8C depict the installation of a reinforcement shear bar in the thermal barrier structure; and

[0066] FIG. 9 is a perspective view of a pre-fabricated thermal break system in accordance with an embodiment of the present invention.

DESCRIPTION OF THE DISCLOSURE

[0067] A thermal break system for thermally isolating concrete slabs is provided that is easy to install and results in a structurally secure concrete slab construction. The system may be compiled in a kit or package that can be delivered to a construction site and that includes the components necessary to install the thermal break system.

[0068] At a high level, the thermally isolating system includes a thermally insulating harrier, such as a section of load-bearing structural foam, that is sized to be positioned between an exterior concrete slab and an interior concrete slab of a main structure. The thermally insulating barrier includes sets of holes therethrough. A first type of sets of holes are sized and configured to accommodate reinforcing tension bars that will pass through the foam barrier and be embedded in both the interior and exterior concrete slabs when poured. A second type of sets of holes are sized and configured to accommodate reinforcing shear bars that will also pass through the foam barrier and be embedded in both the interior and exterior concrete slabs. The reinforcing shear bars, however, are inserted through the barrier prior to being sent to the construction site and are angled within the foam barrier such that the reinforcing shear bars enter the foam on the interior concrete slab side at, for example, a higher point than the reinforcing shear bars exit the foam barrier on the exterior concrete slab side. In addition, washers may be welded to the reinforcing shear bars and then, after the shear bars are inserted into the barrier, secured to the foam to prevent twisting of the bars. During fabrication of the system, the reinforcing shear bars are passed through the angled holes and then bent at the exit point so that the reinforcing shear bars are substantially horizontal on both sides of the barrier. Upon arrival at a construction site, reinforcing tension bars are inserted through the pre-drilled tension bars holes and then concrete is poured on both sides of the barrier to form the interior and exterior concrete slabs.

[0069] Turning to the figures, and in particular FIGS. 1-3E, a thermally broken cast-in-place concrete slab 100 includes an exterior slab 104, an interior slab 108, and an insulating barrier 112, which provides a thermal break between interior slab 108 and exterior slab 104. Running through insulating barrier 112 are reinforcing tension bars 116 (e.g., 116a-116b) and reinforcing shear bars 120 (e.g., 120a-120c), which continue on either side of barrier 112 and are embedded in both interior slab 108 and exterior slab 104, thereby providing structural integrity for exterior slab 104. In addition, reinforcing cross tension bars 124 (e.g., 124a, 124c, 124d, 124e, 124i) may be embedded in either interior slab 108 or exterior slab 104 in an orientation running perpendicular to tension bars 116 and shear bars 120. The reinforcement bars may be of any size suitable for the intended construction project, and preferably for typical construction projects reinforcing tension bars 116 will be #5 or #6 rebars and reinforcing shear bars 120 will be #3 or #4 rebars.

[0070] Barrier 112 is preferably made of load-bearing structural foam having an R-value of about 2 per inch and will have a length to approximately match the widths of the concrete slabs to be thermally separated. The height of barrier 112 will similarly preferably approximately match the height of the concrete slabs to be separated, and the thickness may be any suitable thickness that provides sufficient insulating properties while also allowing for adequate structural integrity of concrete slab 104. The load-bearing structural foam of barrier 112, as a thermal break between concrete slabs as described herein, additionally adequately handles all the compression forces typically exerted by concrete slabs that are part of structures, which eliminates the need for having steel compression struts that pass through the thermal break. Material from which barrier 112 is made may be 500-280 Structural Thermal Break Material from Armatherm of Acushnet, Mass.

[0071] Barrier 112 includes a plurality of tension bar holes for accommodating reinforcing tension bars 116. Tension bar holes pass generally straight through the barrier at a single height so that reinforcing tension bars 116 remain generally parallel with the lengthwise direction of the slabs. Tension bar holes are pre-drilled prior to shipment to a construction site based on the needs of the slabs to be constructed. In addition, a plurality of reinforcing shear bar holes for accommodating reinforcing shear bars 120 are drilled through barrier 112. Reinforcing shear bar holes pass through barrier 112 at an angle, preferably about a 45 degree angle, sloping downward from an interior side 132 to an exterior side 128 of barrier 112 for cantilever conditions. (Alternatively, reinforcing shear bar holes may slope upward from an interior side 132 to an exterior side 128 of barrier 112 for simple span conditions.) In addition, barrier 112 includes washers 136 (e.g., 136a-136c) on one side of the reinforcing shear bar. Washers 136 are welded onto shear bars 120 prior to insertion and then secured to barrier 112 when shear bars 120 are inserted, and serve to prevent twisting of installed reinforcement shear bars 120.

[0072] In operation, distal ends of reinforcing tension bars 116 and reinforcing shear bars 120 are designated as the ends that will be embedded in interior concrete slab 108. Then proximate ends of reinforcing tension bars 116 are fed through the reinforcing tension bar holes of barrier 112 such that the distal ends protrude through interior side 132 a distance that reinforcing tension bars 116 will be embedded in interior concrete slab 108. In a preferred embodiment, tension bars 116 are inserted through barrier 112 at the construction site.

[0073] To fabricate the thermal break system, washers 136 are welded to reinforcing shear bars 120 so that washers 136 can later be secured to barrier 112. Then reinforcing shear bars 120 are bent at points that correspond to the points where reinforcing shear bars 120 will enter exterior side 128 of barrier 112, at an angle appropriate for the angle through which reinforcing shear bars will pass through barrier 112. Then bent reinforcing shear bars 120 are fed through barrier 112. Reinforcing shear bars 120 are then bent a second time at another point, pivoting until the proximal ends are again parallel with their distal ends and with reinforcing tension bars 116. This post-insertion bending during the fabrication process is preferable due to properties of barrier 112, which is made of load-bearing structural foam that is not conducive to having a bent bar fed through an angled hole. Washers 136 that are welded to shear bars 120 are then secured to barrier 112 with, for example, screws passing through pre-drilled holes in washers 136, which serve to prevent twisting of shear bars 120. In addition, washers 136 may provide a supporting element for assisting with the bending of reinforcing shear bar 120 while the angled portion resides within barrier.

[0074] The assembled thermal break system is then delivered to the construction site and installed where the concrete slabs are to be constructed. Once barrier 112 is in place, tension bars 116 are inserted through the pre-drilled holes, and cross tension bars 124 may be added. Cross tension bars 124 may be tied to reinforcing tension bars 116 and/or reinforcing shear bars 120 in interior slab 108 and exterior slab 104. Then concrete is poured to form thermally broken cast-in-place concrete slab 100 without the need for plates to sandwich the insulating material, steel compression struts passing through the thermal break, or articulating elements protruding through the insulating material and into the concrete slabs.

[0075] In another exemplary embodiment, shown in FIGS. 4-7C, a thermally broken cast-in-place concrete slab 200 includes an exterior slab 204, an interior slab 208, and an insulating barrier 212, which provides a thermal break between interior slab 208 and exterior slab 204. Running through insulating barrier 212 are reinforcing tension bars 216 (e.g., 216a-216d) and reinforcing shear bars 220 (e.g., 220a-220e), which continue on either side of barrier 212 and are embedded in both interior slab 208 and exterior slab 204, thereby providing structural integrity for exterior slab 204. In addition, reinforcing cross tension bars (not shown) may be embedded in either interior slab 208 or exterior slab 204 in an orientation running perpendicular to tension bars 216 and shear bars 220. The reinforcement bars may be of any size suitable for the intended construction project, and preferably for typical construction projects reinforcing tension bars 216 will be #5 or #6 rebars and reinforcing shear bars 220 will be #3 or #4 rebars.

[0076] Barrier 212 is preferably made of load-bearing structural foam having an R-value of about 2 per inch and will have a length to approximately match the widths of the concrete slabs to be thermally separated. The height of barrier 212 will similarly preferably approximately match the height of the concrete slabs to be separated, and the thickness may be any suitable thickness that provides sufficient insulating properties while also allowing for adequate structural integrity of concrete slab 204. The load-bearing structural foam of barrier 212, as a thermal break between concrete slabs as described herein, additionally adequately handles all the compression forces typically exerted by concrete slabs that are part of structures, which eliminates the need for having steel compression struts that pass through the thermal break.

[0077] In addition, washers 236 (e.g., 236a-236e) may be included on one side of reinforcing shear bar holes, as can be seen in FIGS. 6B, 6C, and 6E, by welding, for example. Washers 236 that are attached to shear bars 220 can be secured to barrier 212 when shear bars 220 are inserted, thus preventing twisting of installed reinforcement shear bars 220.

[0078] Turning to FIGS. 7A-7C, barrier 212 includes a plurality of tension bar holes 214 (e.g., 214a-214d) for accommodating reinforcing tension bars 216. Tension bar holes 214 pass generally straight through barrier 212 at a single height so that reinforcing tension bars 216 remain generally parallel with the lengthwise direction of the slabs. A plurality of reinforcing shear bar holes 218 (e.g., 218a-218e) for accommodating reinforcing shear bars 220 are also included in barrier 212. Reinforcing shear bar holes 218 pass through barrier 212 at an angle, sloping downward from an interior side 232 to an exterior side 228 of barrier 212 for cantilever conditions. (Alternatively, reinforcing shear bar holes 218 may slope upward from an interior side 232 to an exterior side 228 of barrier 212 for simple span conditions (not shown).)

[0079] FIGS. 8A-8C are cut-away views of barrier 212 that has been cut to size for forming a thermal break for a concrete slab. Tension bar holes 214 (e.g., 214a-214d) are pre-drilled for accommodating tension bars to be inserted at the construction site. Additionally, shear bar holes 218 (e.g., 218a-218e) are drilled where reinforcing shear bars will be inserted. As can be seen in FIG. 7C, shear bar holes 218 pass through barrier 212 at an angle (in a preferred embodiment, at a 45 degree angle).

[0080] In operation, distal ends of reinforcing tension bars 216 and reinforcing shear bars 220 are designated as the ends that will be embedded in interior concrete slab 208. Then proximate ends of reinforcing tension bars 216 are fed through the reinforcing tension bar holes of barrier 212 such that the distal ends protrude through interior side 232 a distance that reinforcing tension bars 216 will be embedded in interior concrete slab 208. In a preferred embodiment, tension bars 216 are inserted through barrier 212 at the construction site.

[0081] To fabricate a prefabricated thermal break system 250 (shown in FIG. 9), washers 236 (e.g., 236e as shown in FIG. 8A) are welded to reinforcing shear bars 220 and then reinforcing shear.sup.- bars 220 are bent at points 240 (e.g., point 240e in FIG. 8A), which correspond to the point where reinforcing shear bars 220 will enter exterior side 228 of barrier 212, at an angle appropriate for the angle through which reinforcing shear bars will pass through barrier 212. Then bent reinforcing shear bars 220 are fed through barrier 212. Reinforcing shear bars 220 are then bent a second time at points 244 (e.g., 244e in FIG. 8B), pivoting until the proximal ends are again parallel with their distal ends, i.e., generally horizontal. This bending during the installation process is necessitated by properties of barrier 212, which is made of load-bearing structural foam that is not conducive to having a bent bar fed through an angled hole. Washers 236 are then secured to barrier 212 with, for example, screws passing through pre-drilled holes in washers 236, which serve to prevent twisting of shear bars 220. In addition, washers 236 may provide a supporting element for assisting with the bending of reinforcing shear bar 220 while angled portion 221 resides within barrier 212.

[0082] The assembled thermal break system 250 is then delivered to the construction site and installed where the concrete slabs are to be constructed. Once barrier 212 is in place, reinforcing tension bars 216 are inserted through pre-drilled holes 214 and cross tension bars may be added. Cross tension bars may be tied to reinforcing tension bars and/or reinforcing shear bars in interior slab and exterior slab. Then concrete is poured to form thermally broken, cast-in-place concrete slab 200 without the need for plates to sandwich the insulating material, steel compression struts passing through the thermal break, or articulating elements protruding through the insulating material and into the concrete slabs.

[0083] Exemplary embodiments have been disclosed above and illustrated in the accompanying drawings. It will be understood by those skilled in the art that various changes, omissions, and additions may be made to that which is specifically disclosed herein without departing from the spirit and scope of the present invention.