Abstract
A structural crack repair apparatus is disclosed. The apparatus includes at least one staple having an elongated torque plate, a pair of reinforcing rods and a pair of rotatable cam members provided on the torque plate and engaging the respective cam members. According to the method, the reinforcing rods are inserted in rod apertures provided in the surface on opposite sides of the crack. The cam members are selectively rotated to cause radial displacement of the reinforcing rods with respect to a geometric center of the cam members to cause tight engagement of the reinforcing rods with the interiors of the rod apertures.
Claims
1. A method of repairing a crack in a surface, comprising: providing at least one staple comprising an elongated torque plate, a pair of cam members rotatably carried by said torque plate and a pair of reinforcing rods engaging said pair of cam members, respectively; providing an excavation cavity in said surface in intersecting relationship to said crack; providing a pair of rod apertures in said surface on opposite sides of said crack; inserting said pair of reinforcing rods into said pair of rod apertures, respectively; causing radial displacement of said pair of reinforcing rods with respect to a geometrical center of said pair of cam members, respectively, by rotating said pair of cam members on said torque plate; and providing a cement material and filling said excavation cavity with said cement material after said pair of reinforcing rods have been radially displaced.
2. The method of claim 1 an excavation cavity in said surface in intersecting relationship to said crack and wherein said providing a pair of rod apertures in said surface on opposite sides of said crack comprises providing said pair of rod apertures in a rear surface of said excavation cavity.
3. The method of claim 2 further comprising providing an epoxy on said pair of reinforcing rods, respectively, prior to said inserting said pair of reinforcing rods into said pair of rod apertures, respectively.
4. The method of claim 1 further comprising placing an epoxy into said pair of rod apertures, respectively, prior to inserting said pair of reinforcing rods into said pair of rod apertures.
5. The method of claim 4 further comprising allowing said epoxy to at least partially cure prior to radially displacing said pair of reinforcing rods.
6. A method of repairing a crack in a surface, comprising: providing at least one staple including an elongated torque plate and a pair of reinforcing rods connected to opposing ends of the elongated torque plate, at least one of the reinforcing rods being movably connected to the elongated torque plate; forming at least one excavation cavity in the surface in intersecting relationship with the crack; forming a pair of rod apertures in the at least one excavation cavity on opposing sides of the crack; inserting the pair of reinforcing rods in the pair of rod apertures of the at least one excavation cavity, respectively; and moving at least one of the pair of reinforcing rods toward the other of the pair of reinforcing rods; and filling the at least one excavation cavity with cement after said reinforcing rod have been moved towards the other reinforcing rod.
7. The method of claim 6, further comprising the step of providing epoxy to at least one of the pair of reinforcing rods and the pair of rod apertures.
8. The method of claim 6 further comprising placing an epoxy into said pair of rod apertures, respectively, prior to inserting said pair of reinforcing rods into said pair of rod apertures.
9. The method of claim 8 further comprising allowing said epoxy to at least partially cure prior to moving at least one of the pair of reinforcing rods toward the other of the pair of reinforcing rod.
10. A method of repairing a crack in a wall surface of a pool, comprising: forming at least one excavation cavity in the wall surface in transverse and intersecting relationship to the crack; drilling a pair of spaced-apart rod apertures in the at least one excavation cavity on opposing sides of the crack; providing at least one staple including an elongated torque plate having opposing ends and a pair of spaced-apart reinforcing rods connected to the opposing ends of the elongated torque plate, at least one of the pair of spaced-apart reinforcing rods being movably connected to the elongated torque plate; inserting the pair of reinforcing rods in the pair of rod apertures of the at least one excavation cavity, respectively; moving at least one of the pair of reinforcing rods toward the other of the pair of reinforcing rods to minimize propagation of the crack; and filling the at least one excavation cavity with a non-shrinking cement after moving the at least one reinforcing rod toward the other reinforcing rod.
11. The method of claim 10, wherein said step of inserting the pair of reinforcing rods in the pair of rod apertures comprises positioning the pair of reinforcing rods approximately in the center of each of the pair of spaced-apart rod apertures, respectively.
12. The method of claim 10, further comprising the step of providing epoxy to at least one of the pair of reinforcing rods and the pair of rod apertures prior to the step of inserting the pair of reinforcing rods in the pair of rod apertures of the at least one excavation cavity, respectively.
13. The method of claim 10 further comprising placing an epoxy into said pair of spaced-apart rod apertures, respectively, prior to moving at least one of the pair of reinforcing rods toward the other of the pair of reinforcing rods.
14. The method of claim 13 further comprising allowing said epoxy to at least partially cure prior moving at least one of the pair of reinforcing rods toward the other of the pair of reinforcing rods to minimize propagation of the crack.
15. The method of claim 10, wherein said step of forming at least one excavation cavity in the wall surface comprises cutting a plurality of excavation cavities in the wall surface in spaced-apart relationship to each other.
16. The method of claim 15, wherein each of said plurality of excavation cavities has an elongated, rectangular shape.
17. The method of claim 16, wherein the elongated torque plate has a rectangular shape.
18. The method of claim 10, wherein the at least one of the reinforcing rods that is movably connected to the elongated torque plate is connected to a circular cam member at a location offset from a center of the circular cam member, and the circular cam member is rotatably received in a circular cam-receiving aperture extending though at least one of the opposing ends of the elongated torque plate.
19. The method of claim 18, wherein the circular cam member includes at least one cam tool aperture extending through the circular cam member at a location offset from the center of the circular cam member.
20. The method of claim 18, further comprising the step of coating the torque plate and the at least one cam member with epoxy prior to the step of inserting the pair of reinforcing rods in the pair of rod apertures of the at least one excavation cavity, respectively.
21. The method of claim 18, wherein said step of moving at least one of the pair of reinforcing rods toward the other of the pair of reinforcing rods comprises rotating the circular cam member to move the at least one of the reinforcing rods connected to the circular cam member toward the other of the pair of reinforcing rods.
22. The method of claim 21, wherein said step of rotating the circular cam member comprises rotating the circular cam member to move the at least one of the reinforcing rods connected to the circular cam member from an outside position to an intermediate position.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The preferred embodiments of the invention will hereinafter be described in conjunction with the appended drawings provided to illustrate and not to limit the invention, where like designations denote like elements, and in which:
(2) FIG. 1 is a perspective view of a drained swimming pool, partially in section, with a fracture line or crack to be repaired in the side and bottom surfaces of the pool;
(3) FIG. 2 is a perspective view of the drained swimming pool of FIG. 1, with excavation cavities provided in the side and bottom surfaces of the pool in transverse relationship to the crack as a first step according to the crack repair method of the present invention;
(4) FIG. 3 is a perspective view of the pool of FIG. 2, illustrating a pair of rod apertures drilled from the rear or bottom of each excavation cavity into the surface as a second step according to the crack repair method of the present invention;
(5) FIG. 4 is a perspective view of the pool, illustrating in exploded view multiple, assembled staples of the structural crack repair apparatus of the present invention positioned for insertion into each corresponding pair of rod apertures as a third step according to the method of the present invention;
(6) FIG. 5 is a perspective view of the pool, illustrating in exploded view application of an epoxy to the reinforcing rods of each staple prior to insertion of the reinforcing rods into each corresponding pair of rod apertures as a fourth step according to the method of the present invention;
(7) FIG. 6 is a perspective view of the pool, illustrating the staples inserted in each corresponding pair of reinforcing rods in each excavation cavity as a fifth step according to the method of the present invention;
(8) FIG. 7 is a perspective view of the pool, illustrating in exploded view removable engagement of a cam-driving tool, ratchet and handle assembly (shown in phantom) with the cam member of each staple to facilitate rotation of the cam member and engagement of the reinforcing rods against the interiors of the rod cavities as a sixth step according to the method of the present invention;
(9) FIG. 8 is a perspective view of a staple, illustrating in exploded view a cam-driving tool (in solid lines) and a ratchet and handle assembly (in phantom) which may be conventional and is used to rotate each cam member on the torque plate element of the staple and cause secure engagement of the reinforcing rods against the interior surfaces of the rod apertures;
(10) FIG. 9 is a front view of a staple inserted in an excavation cavity in a surface, illustrating clockwise rotation of the cam members on the torque plate to cause rotation and radial displacement of the reinforcing rods into tight engagement with the interior surfaces of the respective rod apertures in which they are inserted;
(11) FIG. 10 is a top view of the staple of FIG. 9, prior to rotation of the cam members and reinforcing rods;
(12) FIG. 11 is a front view of the staple of FIG. 9, after rotation of the cam members on the torque plate and engagement of the reinforcing rods with the interior surfaces of the respective rod apertures;
(13) FIG. 12 is a top view of the staple of FIG. 11, after rotation of the cam members and reinforcing rods;
(14) FIG. 13 is a perspective view of an assembled staple of the structural crack repair apparatus according to the present invention;
(15) FIG. 14 is an exploded, perspective view of the staple of FIG. 13; and
(16) FIG. 15 is a perspective view of an assembled staple according to an alternative embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
(17) Shown throughout the Figures, the present invention is generally directed to a structural crack repair apparatus and method for repairing cracks in a surface. The apparatus incorporates a simple, low profile, and yet heavy-duty, design that facilitates ease of installation and prevents or minimizes the widening or propagation of cracks in a variety of surfaces.
(18) Referring initially to FIG. 6, an illustrative embodiment of the structural crack repair system of the present invention is generally indicated by reference numeral 1. In an exemplary application of the invention, the system 1 includes at least one staple 5, and typically multiple staples, which span a crack 35 in the wall 33 and floor 34 of a swimming pool 32. The staples 5 prevent further widening and propagation of the crack 35 along the wall 33 and floor 34. While application of the invention will be hereinafter described with respect to repair of the crack 34 in the swimming pool 32, it is understood that the system 1 can be used to repair cracks in a wide variety of surfaces, structural bodies and the like having various configurations and compositions. The structural details of each staple 5, as well as a typical manner of installation, will be hereinafter further described.
(19) Referring next to FIGS. 13-15, each staple 5 typically includes a torque plate 2 having an elongated shaft 4. A circular cam-receiving aperture 3 extends through each end portion of the shaft 4. Accordingly, each cam-receiving aperture 3 is adapted to receive a cam member 7 in such a manner that the cam member 7 can rotate freely in the corresponding cam-receiving aperture 3. In an alternative embodiment of the staple 5a illustrated in FIG. 15, the torque plate 2a includes an elongated, rectangular plate member 4a and the cam-receiving apertures 3 extend through the respective end portions of the plate member 4a.
(20) As particularly illustrated in FIG. 14, each cam member 7 typically includes a circular cam body 10. A pair of spaced-apart cam tool apertures 9 extend through the cam body 10 for purposes which will be hereinafter described. An offset aperture 8 extends through each cam body 10 in offset or eccentric relationship with respect to the geometric center of the cam body 10. As illustrated in FIG. 12, in the assembled staple 5, each offset aperture 8 receives the reduced diameter tip 13 of an elongated reinforcing rod 12, which is typically steel. Accordingly, as illustrated in FIG. 13, the reinforcing rods 12 extend from the respective cam members 7, in spaced-apart relationship to each other.
(21) Referring next to FIGS. 1-12, in typical application of the system 1 according to the structural crack repair method of the present invention, multiple staples 5 are used to repair a fracture line or crack 35 in the wall 33 and floor 34 of a swimming pool 32. The crack 35 is shown in the untreated condition in FIG. 1. As illustrated in FIG. 2, in a first step according to the method of the invention, multiple excavation cavities 36, each of which typically has an elongated, rectangular shape, are cut in the wall 33 and floor 34 in spaced-apart relationship to each other and in transverse and intersecting relationship to the crack 35. The dimensions of each excavation cavity 36 depend on the length of the staples 5 which are to be used in the repair process. For example, in the event that the length of each of the staples 5 is 3.0 inches, each excavation cavity 36 has dimensions of typically 5.02.5 inches; if the length of each staple 5 is 6.0 inches, then each excavation cavity 36 has dimensions of typically 82.5 inches. The depth of each excavation cavity 36 is greater than the thickness of the torque plate 2 of each staple 2. Each excavation cavity 36 is thoroughly cleaned to remove debris therefrom.
(22) As illustrated in FIG. 3, a pair of spaced-apart rod apertures 38 is next drilled into rear surface of each excavation cavity 36 cut in the swimming pool wall 33 and the bottom surface of each excavation cavity 36 cut in the swimming pool floor 34. The locations of the rod apertures 38 may first be marked by using the assembled staple 5, with the cam members 7 inserted in the respective cam-receiving apertures 3, as a template. Accordingly, with the cam members 7 positioned in the respective cam-receiving apertures 3 in such a manner that the cam tool apertures 9 located at the inside position and the offset aperture 8 located at the outside position of each cam member 7, as illustrated in FIG. 13, the rod apertures 38 correspond to the locations of the respective offset apertures 8. Alignment means (not illustrated), such as indentations or markings, for example, may be provided in the torque plate 2 and circular cam members 7 to ensure proper orientation of the staple 5 prior to marking the locations of the rod apertures 38. The rod apertures 38 may be formed using a 0.75 inch masonry bit, for example. A typical depth for each rod aperture 38 is at least 3.25 inches for a 3.0 inch reinforcing rod and at least 6.25 inches for a 6.0 inch reinforcing rod 12. After drilling, debris is cleaned from the rod apertures 38 using compressed air, a brush or the like.
(23) As illustrated in FIG. 4, the reinforcing rods 12 are next assembled on each staple 5. As illustrated in FIG. 14, this is facilitated by inserting the reduced-diameter tip of each reinforcing rod 12 in the offset aperture 8 of each cam member 7, as heretofore described. As illustrated in FIG. 5, a two-part, free-flowing, non-sag epoxy 17 is then applied from an epoxy container 16 to each reinforcing rod 12. Alternatively, the epoxy 17 may be applied directly to each rod aperture 38. A small quantity of epoxy 17 may be used to secure the reduced-diameter tip 13 of each reinforcing rod 12 in the corresponding offset aperture 8 of the cam member 7.
(24) As illustrated in FIGS. 6 and 10, the reinforcing rods 12 of each staple 5 are next inserted into the respective rod apertures 38 of each excavation cavity 36 until the torque plate 2 is flush with the rear or bottom wall of the excavation cavity 36. The epoxy 17 is then allowed to cure for a period of time, depending on the particular epoxy used.
(25) As illustrated in FIGS. 7 and 8, the reinforcing rods 12 of each staple 5 are next forced inwardly toward each other by rotation of the cam members 7 in the respective cam-receiving apertures 3. As illustrated in FIG. 8, this is carried out using a cam-driving tool 20, which may be conventional. Such a cam-driving tool 20 typically includes a pair of spaced-apart pegs 21 and an offset or eccentric rod aperture 22. A nut 23 is provided on the cam-driving tool 20 for engagement by the socket 27 of a ratchet 26. A handle 28 engages the ratchet 26 for rotation of the cam-driving tool 20.
(26) The cam-driving tool 20 engages each cam member 7 by inserting the pegs 21 of the cam-driving tool 20 in the respective cam tool apertures 9 of the cam member 7 and inserting the reduced-diameter tip 13 of the reinforcing rod 12, which protrudes from the offset aperture 8, into the rod aperture 22 of the cam-driving tool 20. As illustrated in FIGS. 9 and 10, the cam tool apertures 9 of each cam member 7 are initially located at the inside position and the offset aperture 8 of each cam member 7 is located at the outside position. By operation of the cam-driving tool 20, each cam member 7 is rotated in the clockwise direction, as indicated by the curved arrows in FIG. 9. This causes rotation of the offset aperture 8 of each cam member 7 from the outside position of FIG. 9 to the upper position of FIG. 11, thereby facilitating radial displacement of the reinforcing rods 12 toward each other in the respective rod apertures 38. Accordingly, prior to rotation of the cam members 7, the reinforcing rods 12 are positioned in approximately the center of each rod aperture 38, as illustrated in FIG. 10. After rotation of the cam members 7, the reinforcing rods 12 engage the inner surface of the respective rod apertures 38 at a force of approximately 60 torque-pounds of resistance, as illustrated in FIG. 12. This substantially reinforces each staple 5 in the corresponding excavation cavity 36.
(27) A light coating of epoxy (not illustrated) is then coated over the entire surface of the torque plate 2 and cam members 7 of each staple 5. Finally, each excavation cavity is filled in using a non-shrinking cement (not illustrated), thereby covering the torque plate 2, cam members 7 and reduced-diameter rod tips 13 of each staple 5.
(28) While the preferred embodiments of the invention have been described above, it will be recognized and understood that various modifications can be made in the invention and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the invention.
