Reinforcing Bar Clip

The present application claims priority to U.S. Provisional Application No. 63/643,538, filed May 7, 2024, the entire contents of which are herein incorporated by reference.

The present disclosure relates to a clip configured to support reinforcing bar proximate an induced crack.

In some embodiments, the disclosure provides a crack control assembly for concrete. The assembly includes rebar that bonds to the concrete and extends along a rebar axis. A clip extends substantially parallel to the rebar axis. The clip includes a first end connected to the rebar at a first location along the rebar axis and a second end coupled to the rebar at a second location along the rebar axis, spaced from the first location. The clip extends generally parallel to the rebar and above the rebar to enhance the effective interlock of the concrete proximate the clip.

In some embodiments, the disclosure provides a method of enhancing the effective interlock strength of concrete in a concrete slab. The method includes positioning rebar at a height above the ground surface, so that the rebar extends along a rebar axis. The method further includes positioning the clip against the rebar, so that that a first end of the clip is positioned at a first location along the rebar axis and a second end of the clip is positioned at a second location along the rebar axis spaced from the first location. The method further includes moving the clip with respect to the rebar to thereby cause deformation of a portion of the clip. The method further includes at least partially surround the rebar with the clip to thereby couple the clip to the rebar, and pouring concrete over the rebar and the clip.

Before any embodiments are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of supporting other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. Terms of degree, such as “substantially,” “about,” “approximately,” etc. are understood by those of ordinary skill to refer to reasonable ranges outside of the given value, for example, general tolerances associated with manufacturing, assembly, and use of the described embodiments.

illustrates a grid of reinforcing bar (rebar)supported by bolsters. The rebaris positioned in spaced apart rows and columns. The rebarcan be spaced apart 16 inches, 24 inches or other suitable distance. The illustrated bolstersare positioned in a square, such that each bolstersupports seven rebars. The bolsterscan be cut to length to allow for multiple sizes, shapes and configurations. In other configurations, more or fewer pieces of rebarare supported by each bolster.

The illustrated rebaris non-metallic and includes a fiber reinforced polymer. Some examples of fiber-reinforced polymer reinforcing bar are disclosed in U.S. Pat. Nos. 9,688,030; 10,682,818; and 11,919,254, the contents of which are herein incorporated by reference. The rebaris cut to length and positioned in the bolstersprior to concrete being poured.

illustrate the bolstersin greater detail. The bolstersinclude an elongate baseand a plurality of upwardly extending protrusions. The illustrated elongate baseincludes a horizontal componentthat is configured to rest on a ground surface and a vertical componentthat extends upwardly from the horizontal component. In the illustrated embodiment, the vertical componentis positioned in the center of the horizontal component. In other embodiments, the vertical componentcan be positioned closer to one side of the horizontal componentthan to the other side of the horizontal component.

The horizontal componentincludes a plurality of aperturesextending therethrough.illustrate the apertureon one side of the vertical component. However, as shown in, the aperturesalternate between opposite sides of the vertical componentalong the length of the bolster. In some embodiments, one of the aperturesis positioned 6″ from an end of the bolsterand the aperturesalternate sides every 24″ thereafter. The aperturespermit one or more fasteners to retain the bolsterin position while the cement is being poured. In some embodiments, a stake is pressed through one of the aperturesinto a ground surface by an operator. In other embodiments, a nail, bolt or screw extends through the apertureand into the surface below the bolsterto retain the bolsterin position.

The upwardly extending protrusionextends upward from the vertical componentand includes a first projectionand a second projectionthat define a recesstherebetween. The recessis sized to receive the rebartherein. The first and second projections,are configured to retain the rebarin the recess. In some embodiments, the first and second projections,form an interference fit with the rebarso as to retain the rebarwithin the recess. The recessretains the rebarat the desired height while the cement is being poured. The upwardly extending protrusionhas a height that corresponds with the desired position of the rebarwithin the poured concrete.

The bolsterscan be made from a recycled material, such as one or more polymeric materials. The bolstersmay be provided in a variety of lengths and can be cut to length if desired. For example, the bolstersmay be available in 10 foot, 12 foot, 14 foot and 16 foot lengths. The illustrated bolstersare shown by way of example. Other shapes, sizes and configurations of bolsterscan be utilized to support the rebarat the desired height.

Concrete can form cracks upon expanding or contracting due to temperature changes. One way to address this challenge is to cut the concrete at set intervals to induce a crack. At each of those cut locations, some type of reinforcement can be utilized to ensure effective interlock between the two sides of the crack. For example, in a 6 inch thick concrete slab, a saw may cut 0.5-1 inch deep to induce a crack and the rebarmay be spaced apart 18 inches on center.

In some embodiments, the bolstersare positioned every four feet to induce a crack every four feet. The upwardly extending protrusionsof the bolsterscan help to induce a crack because the concrete is not joined together proximate vertical componentof the bolster. Instead, the concrete is joined to either side of the upwardly extending protrusionsand above the upwardly extending protrusions. Above the bolster, the concrete is bonded for a lesser height than at locations spaced from the bolster. The bolstereffectively weakens the bond of the concrete, so a crack is more likely to form proximate the bolster. A saw cut may also be made above the bolstersto further induce a crack.

illustrate a clipthat can be utilized to enhance the interlock across the induced cracks. The clipincludes a first end portion, a second end portion, and an elongate middle portionbetween the first end portionand the second end portion. The clipcan be made of a flexible wire that is bent to shape. The clipis generally symmetrical such that the second end portionis substantially a mirror-image of the first end portion. The side viewsillustrate the first end portion, but the description of the first end portionequally applies to the second end portion.

The first end portionincludes a first bent portion, a first curved portionand a first vertical portion. The first bent portionincludes a first end positioned a first distance X away from the first vertical portionand a second end positioned a second distance Y away from the vertical portion. The first bent portionextends toward the first vertical portionsuch that the first distance X is greater than the second distance Y. The first distance X is greater than the diameter of the rebarand the second distance Y is less than the diameter of rebar.

The first curved portionincludes a first end coupled to the second end of the first bent portion, a middle portion and a second end coupled to a lower end of the first vertical portion. The first end of the first curved portionis spaced apart the second distance Y from the vertical portion. The middle portion is spaced apart a third distance Z from the vertical portion. The third distance Z is greater than the second distance Y. The third distance Z is equal to, slightly greater or slightly less than the diameter of the rebar. While the illustrated bends at the first end of the first curved portionand the middle portion of the first curved portionare exemplary. Other suitable angles can be utilized.

The first vertical portionincludes a first end coupled to the second end of the first curved portionand a second end coupled to the elongate middle portion. The first vertical portionextends along a first height H. The second end of the first bent portion, which is spaced from the first vertical portionthe second distance Y, is positioned a second height Habove the first end of the first vertical portion. The first height His sufficient so that the elongate middle portionis positioned at the desirable location within the poured concrete. In different applications, the first height Hdiffers within a range of heights to properly position the elongate middle portionat the desired height within the poured concrete.

The second height His less than the first height H. In some embodiments, the second height His approximately half of the first height. The second height His greater than the diameter of the rebar. In the illustrated embodiment, the second height His between about two and three times the diameter of the rebar.

The elongate middle portionextends along a length L between the first end portionand the second end portion. In some embodiments, the length L is approximately 10 inches. In other embodiments, other lengths can be utilized.

As noted above, the second end portionis substantially a mirror image of the first end portion. The second end portionincludes a second bent portion, a second curved portionand second vertical portion. The second bent portionincludes a first end positioned the first distance X away from the second vertical portionand a second end positioned the second distance Y from the second vertical portion. The second bent portionextends toward the second vertical portionsuch that the first distance X is greater than the second distance Y. The first distance X is greater than the diameter of the rebarand the second distance Y is less than the diameter of rebar.

The second curved portionincludes a first end coupled to the second end of the second bent portion, a middle portion and a second end coupled to a lower end of the second vertical portion. The first end of the second curved portionis spaced apart the second distance Y from the second vertical portion. The middle portion is spaced apart a third distance Z from the vertical portion. The third distance Z is greater than the second distance Y. The third distance Z is equal to, slightly greater than or slightly less than the diameter of the rebar. The angles between the bends at the first end of the second curved portionand the middle portion of the second curved portionare exemplary. Other suitable angles can be utilized.

The second vertical portionincludes a first end coupled to the second end of the second curved portionand a second end coupled to the elongate middle portion. The second vertical portionextends along the first height H. The second end of the second bent portion, which is spaced from the second vertical portionthe second distance Y, is positioned the second height Habove the first end of the second vertical portion. The first height Hcan be adjusted so that the elongate middle portionis positioned at the desirable location within the poured concrete.

illustrate an assembly including the rebar, the bolsterand the clip. The bolsteris positioned on a ground surface. In the exemplary embodiment of, the ground surfaceis denoted as zero inches and the concrete slab has an upper surfaceabout six inches above the ground surface. In other configurations, other thicknesses of slabs can be poured.

The illustrated elongate basehas an overall height of between one and two inches and the upwardly extending protrusionextends to just over three inches. Other sizes, shapes and configurations of the bolsterare possible in other configurations. The rebaris positioned in the recessand such that the rebaris positioned at approximately three inches above the ground surface. In the example of, the rebaris retained at a generally central location along the thickness of the concrete slab. In other configurations, the rebarcan be positioned closer to a lower surface or an upper surface of the slab if desired.

The horizontal componentincludes aperturesthat alternate on opposite sides of the vertical componentalong the length of the bolster. The vertical componentin the illustrated configuration is substantially centered above the horizontal component.

After the rebaris positioned in the recess, the clipis connected to the rebaron opposite sides of the bolster. The clipis installed by positioning the clipabove and perpendicular to the bolster. The clipis pressed against the rebarsuch that the first and second vertical portionsandcontact the rebar. The clipis then lifted upward such that the rebarpresses against the first and second bent portionsandcausing the first and second curved portionsandto deform. The clipcontinues to slide against the first and second vertical portionsand. After the rebarhas moved past the first ends of the first and second curved portions,toward the middle portions of the first and second curved portions,, the first and second curved portionsandmove back to the undeformed position. The rebaris thereby retained between the first and second curved portionsandand the first and second vertical portionsandas shown in.

After the clipsare coupled to the rebarat the desired spacing, the concrete is then poured. The clipsare sized to fit tightly onto the rebarsuch that elongate middle portionremains above the rebarduring the pour. The clipsare positioned such that the elongate middle portionis positioned in the upper portion of the concrete slab. In the illustrated embodiment, the rebar is positioned in the upper one third of the concrete slab. Specifically, in the illustrated embodiment, the elongate middle portionis positioned at about four and one half inches above the ground and about one and one half inches below the upper portion of the slab. Optionally, a saw cut between one half and one inch thick is cut above the bolster. The optional saw cut would be generally parallel to the bolsterto weaken the concrete proximate the bolsterand the optional saw cut. The clipsenhance the effective interlock of the concrete proximate the bolsterand the optional saw cut.

illustrate an alternative clipthat can be utilized in place of clip. Only the differences between the clipand the clipwill be discussed in detail. The remaining discussion of clipis applicable to clipunless noted otherwise. The illustrated clipis coupled to rebar. Like the clip, the clipenhances the interlock across the induced cracks. Also, like the clip, the length of the clipis variable depending upon the desired application.

Clipincludes a first end portion, a first elongate middle portion, a first central portion, a second central portion, a second elongate middle portionand a second end portion. The clipcan be made of a flexible wire that is bent to shape. In some embodiments, the clipcan be made from a wire having a smaller diameter than the clip. For example, the clipcan be made from ⅜″ diameter wire and the clipcan be made from ¼″ diameter wire. In other embodiments, other sizes of wire can be utilized.

The first end portionincludes a lower curved portionsized to engage the rebarand a generally vertical portion. The second end portionis generally L-shaped and includes a free end portionangled away from the rebar, a middle portionextending toward the rebar and an upper endextending away from the rebar. The first end portionand the second end portioncooperate to clip onto the rebarand to maintain a tight interference fit with the rebar. The rebarslides along the generally vertical portionof the first end portionuntil the rebarabuts the middle portionof the second end portion. Then, further movement causes the second end portionto deflect away from the first end portion. While the rebaris seated in the lower curved portionof the first end portion, the second end portionabuts the rebarto maintain a tight engagement between the clipand the rebar.

The first central portionincludes a substantially vertical portionand a lower curved portionthat connects to the second central portion. The second central portionincludes an inwardly bent portionand an outwardly extending portion. The lower curved portionis sized to receive the rebar.

The first central portionand the second central portioncooperate to clip onto the rebarand to maintain a tight interference fit with the rebar. The rebarslides along the substantially vertical portionof the first central portionuntil the rebarabuts the inwardly bent portionof the second central portion. Further movement causes the second central portionto deflect to permit the rebarto move downward into the lower curved portion. The inwardly bent portionretains the rebarwithin the lower curved portionto maintain a tight engagement between the clipand the rebar.

The first elongate middle portionextends along a first length Land the second elongate middle portionextends along a second length L. In the illustrated embodiment, the first length Lis greater than the second length L. One of both of the first length Land the second length Lcan be within a range of lengths in various embodiments. The first elongate middle portionand the second elongate middle portionare spaced apart a sufficient distance to permit free movement of the rebarbetween the elongate middle portions,. The user can grasp the first elongate middle portionwith one hand and the second elongate middle portionwith the other hand and pull upwards to attach the clipto the rebar. The tight engagement between the clipand the rebarmaintains the clipin position above the rebarto enhance the effective interlock of the concrete.

In some configurations, a crack control assembly for concrete includes rebar that is configured to bond to the concrete. The rebar extends along a rebar axis. The assembly also includes a clip that extends substantially parallel to the rebar axis. The clip includes a first end coupled to the rebar at a first location along the rebar axis and a second end coupled to the rebar at a second location along the rebar axis, spaced from the first location. The clip extends generally parallel to the rebar and above the rebar. The clip enhances the effective interlock of the concrete proximate the clip.

In some configurations, the assembly also includes a bolster positioned on a ground surface. The bolster extends along an elongate axis and positions the rebar at a desired height above the ground surface.

In some configurations, the bolster is configured to weaken interlock in the concrete adjacent the bolster to thereby induce cracks to form in the concrete above the bolster.

In some configurations, the first end of the clip includes a first flexible portion, and the second end of the clip includes a second flexible portion. The first and second flexible portions are configured to deform to permit the clip to be coupled to the rebar.

In some configurations, the clip is configured to be coupled to the rebar without the use of tools.

In some configurations, a method of enhancing the effective interlock strength of concrete in a concrete slab includes positioning rebar at a height above a ground surface, such that the rebar extends along a rebar axis. The method also includes positioning a clip against the rebar, such that a first end of the clip is positioned at a first location along the rebar axis and a second end of the clip is positioned at a second location along the rebar axis spaced from the first location. The method further includes moving the clip with respect to the rebar to thereby cause deformation of a portion of the clip. The method additionally includes at least partially surround the rebar with the clip to thereby couple the clip to the rebar, and pouring concrete over the rebar and the clip.

In some configurations, the method includes positioning the rebar at a height above the ground surface includes coupling the rebar to a bolster on a ground surface.

In some configurations, the method includes, cutting the concrete above the bolster after the concrete has at least partially hardened.

In some configurations, the method includes cutting the concrete above the bolster after the concrete has at least partially hardened.

In some configurations, the method includes inducing a crack proximate the clip and the optional bolster with the optional bolster and the optional saw cut.