Road structure – process – or apparatus – Traffic steering device or barrier
Reexamination Certificate
2002-12-27
2004-01-20
Pezzuto, Robert E. (Department: 3671)
Road structure, process, or apparatus
Traffic steering device or barrier
C052S295000, C256S013100
Reexamination Certificate
active
06679649
ABSTRACT:
FIELD
The invention relates generally to a slip formed barrier wall structure and method of construction, more particularly an improved barrier system and method that results in secure placement and retaining of reinforcement cage within barrier wall allowing for slip form process to take place without the need for a poured anchoring base footing or slab base.
BACKGROUND
In the past, continuously forming a concrete structure at grade level running generally horizontal was anchored by concrete footing structures incorporating anchoring points. Typical construction consists of first constructing concrete footings incorporating anchoring points, after the footings are complete the desired shaped concrete structure is then formed atop the footing using the anchoring points within the footings to secure the structure. Anchoring points typically are comprised of short elongated reinforcement bar with one end embedded into the footing and the other end extending upward from the concrete. The structure is connected to these anchoring points to prevent unwanted movement of the system. One process used to form this shaped structure that sits atop the footing is a process of continuously forming concrete structures generally known in the arts as slip forming, as disclosed in U.S. Pat. No. 5,533,888. Among other items the process encompasses a machine that includes a frame and a form. The frame holds a form that encloses an area having a cross sectional configuration corresponding to the predetermined cross sectional configuration of the concrete structure desired. The form is moved along at grade as the forward end of the form is being supplied with un-cured concrete. As the form moves it extrudes and shapes the concrete using processes that include preset vibrations and continuous forces. The un-cured concrete semi sets within the form as the form moves along at grade, the concrete is shaped in place and is free standing as it emerges out from the second end of the form creating a formed self supporting concrete barrier wall. It is also well known in the arts that concrete barrier walls constructed solely of concrete may not result in desired strengths of the wall. Commonly, the concrete wall structure is supplemented with reinforcing bar (rebar), when the concrete is formed and cured around the reinforcing bar the resultant structure has a more stable desirable structure and one that has good strength. One way currently used to strengthen a barrier wall is to position reinforcing members within the concrete wall during the slip form process. Today, one way this is accomplish is by simply pushing reinforcement rods into the un-cured concrete at the forward end of slip form equipment as it moves along the grade therefor resulting in embedded bars within the concrete. However, this process ends in inconstant wall strength and may even result in undesired wall strength. It is also well known in the arts to use the slip form process to form barrier walls that include a preformed reinforcement cage. First, the reinforcement cage is built, next the cage is secured in place which prevents movement of the cage as the slip form moves over the anchored reinforcement cage. Anchoring the cage is necessary to the slip form process, anchoring of the cage prevents movement of the cage during the slip form process. A well-anchored cage stays in place and results in creating a strong sturdy barrier wall. In many locations, specifications require the concrete construction to contain reinforcement bar structures molded within the concrete to assure desired structure strength. The reinforcement cage can be made up of a plurality of preformed reinforcement bars that are held together by several wire tie wraps, or the cage can be welded together, or any other similar method of fixing the members of the reinforcement bar in place to form the cage. If the cage is not anchored in place during the slip form process then the final slip formed structure will not net desired results. During the slip form process the slip form machine with it's mold structure moves along grade guided over the cage. As the mold moves concrete is added to create the wall shape, this practice exerts numerous loads and forces on the cage, for instance, pushing pulling and twisting. These loads applied to the cage will result in movement of the cage causing the cage to move out of it original location. Movement of the cage will place the cage in an unknown location within the mold. Unknown placement of the cage within the mold is considered unacceptable because it creates an unwanted inconsistently strong barrier wall. In some cases the reinforcement cage will not be totally embedded within the concrete therefore causing the reinforcement bar to be exposed to the elements when the concrete cures. The exposed reinforcement cage will then rust and degrade the structure at rapid rate. These varying loads are exerted on the reinforcement cage as a result of the slip forming process and the concrete that is supplied to the slip form equipment and the loads on the cage as the slip form mold is moved over the grade. Typically, to hold a reinforcement cage in place, a formed footing is constructed containing anchoring points such that the reinforcement cage can sit on the footing and be anchored securely to the anchoring points to prevent movement of the cage during slip forming.
Many slip formed barrier wall systems today use poured concrete footings that include anchor points to anchor the reinforcement bar cage during the slip forming process. The slip formed barrier wall sits on this footing and the reinforcement cage is anchored to the anchor ties on this footing. Footings are typically poured concrete structures that run substantially along the ground at grade. A footing typically includes a plurality of substantially vertically positioned anchoring bars that are placed in several locations within the concrete prior to curing. After the concrete footing cures the anchoring bars are fixed in place, embedded in the footing and then used as anchor points to tie the reinforcement cage prior to the slip forming process. The cage can be secured to the anchoring bars poured into the footing by tying the cage to the anchor bars, or the cage can be welded directly to the anchor bars or any other common way of attachment. The reinforcement cage can either be placed directly on the footing or can be placed on spacers that are in communication with both the footing and the reinforcement cage. Once the reinforcement cage is secured to the anchor bars the slip form apparatus and form is positioned over the reinforcement cage. The form moves along the grade as it is being supplied with concrete resulting in a barrier wall, effectively extruding a barrier wall that contains an embedded reinforcement cage.
This traditional way of construction has been found by the inventor to be time consuming, costly and not required. The traditional way of construction is burdensome and unnecessary to accomplish the result of the anchored barrier wall. Consequently, many contractors have attempted various alternative ways to anchor such walls including; securing wall structures to anchors embedded in concrete slabs; drilling holes in the cured footing and or concrete slabs and pouring in quantities of a hardening liquid securing agent creating an anchoring effect; forming a footer along the length of the proposed barrier wall that includes anchoring points and positioning the reinforcement bar or reinforcement cage on the footer. The inventor has a novel solution to overcome the problems of past barrier wall construction.
Further drawbacks in the design of such prior art will be manifested by the uneven quality of work done. For instance, in order for the wall system to work correctly, the quality of the footing must be the same or compatible to that of the wall. For example, the footings and footing anchors must be poured and allowed to set prior to the forming of the barrier wall. If the footing is not allowed to cure correctly the concrete will not possess it&ap
Law Offices of Michael Leccese, P.C.
Leccese, Esq. Michael
Pechhold Alexandra K.
Pezzuto Robert E.
SPS New England, Inc.
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