Apparatus for and method of forming concrete and transferring loads between concrete slabs

Abstract

An embodiment configured according to principles of the invention includes a plate defining a hexagon having a base parallel with joint between concrete slabs. Another embodiment includes a hexagon-shaped plate having an elastomer-coated first portion and a second portion, and a form having a slot configured to closely receive the second portion. A further embodiment includes a plate having compressive and/or resilient edge banding disposed on a plate edge that is not parallel to the joint. Apparatuses and methods for retro-fitting existing concrete stabs for transferring a load with a new adjacent concrete slab also are disclosed.

1 . Apparatus for transferring a load between a first concrete slab and a second concrete slab, defining a joint, comprising: 
 a plate or dowel; and    edge banding disposed on a surface of the plate or dowel.    
   
   
       2 . Apparatus of  claim 1 , wherein said surface is not parallel to the joint.  
   
   
       3 . Apparatus of  claim 1 , wherein said edge banding is compressible and/or resilient.  
   
   
       4 . Apparatus of  claim 1 , wherein said edge banding is constructed of a natural polymer, a synthetic polymer or combination thereof.  
   
   
       5 . Apparatus of  claim 1 , wherein said edge banding is configured according to a pre-determined slab size, concrete composition, shrinkage expectation, other emplacement consideration or combinations thereof.  
   
   
       6 . Apparatus of  claim 1 , wherein said edge banding has a thickness that ranges from 0.025 to 0.25 inches.  
   
   
       7 . Apparatus of  claim 1 , wherein said plate has a first portion and a second portion, said edge banding being disposed on said first portion, further comprising an elastomer coating disposed on said first portion and said edge banding; 
 whereby: 
 when disposed in the joint, the first concrete slab contacts only said elastomer coating and the second concrete slab adheres only to said second portion; and  
 the first concrete slab may move relative to said plate.  
   
   
   
       8 . Apparatus of  claim 7 , wherein said elastomer coating is configured to slide relative to said plate, the first concrete slab or combination thereof.  
   
   
       9 . Apparatus of  claim 7 , wherein said edge banding is configured to slide relative to said plate, said elastomer coating or combination thereof.  
   
   
       10 . Apparatus of  claim 1 , wherein said plate has a first portion, further comprising a second edge said edge banding being disposed on said first portion, further comprising a second edge banding disposed on a surface of said second portion.  
   
   
       11 . Apparatus of  claim 10 , wherein said second edge banding is configured to slide relative to said plate, a second concrete slab or combination thereof.  
   
   
       12 . Apparatus for forming concrete comprising: 
 a form having a slot configured to closely receive a plate;    a plate having a first portion and a second portion; and    a coating and/or edge banding disposed on said first portion;    wherein: 
 said coating at least initially adheres to said plate; and  
 said coating and/or edge banding has a thickness configured to prevent said first portion from passing through said slot.  
   
   
   
       13 . Apparatus of  claim 12 , wherein, when disposed in a joint defined by a first concrete slab and a second concrete slab, said coating slides relative to said plate, said coating slides relative to a concrete slab adhered thereto or combinations thereof.  
   
   
       14 . Apparatus of  claim 12 , whereby, when disposed in a joint defined by a first concrete slab and a second concrete slab; 
 the first concrete slab contacts only said coating and the second concrete slab adheres only to said second portion; and    the first concrete slab may move relative to said plate.    
   
   
       15 . Method of forming concrete comprising: 
 providing a plate having a first portion and a second portion and edge banding disposed on a surface of the first portion;    providing a form having a slot configured to closely receive the second portion;    inserting the second portion in the slot;    positioning the form to receive concrete;    pouring a volume of concrete on the form and the first portion;    curing the volume of concrete and defining cured concrete; and    removing the form from the cured concrete,    wherein the plate remains in the cured concrete.    
   
   
       16 . Method of  claim 15 , further comprising pouring a second volume of concrete on the second portion.  
   
   
       17 . Method of  claim 15 , further comprising: 
 disposing an elastomer coating on the first portion and the edge banding;    whereby: 
 when disposed in a joint defined by a first concrete slab and a second concrete slab, the first concrete slab contacts only the coating and the second concrete slab adheres only to the second portion; and  
 the first concrete slab may move relative to the plate.  
   
   
   
       18 . Method of  claim 17 , wherein the elastomer coating is configured to slide relative to the plate, the first concrete slab or combination thereof.  
   
   
       19 . Method of  claim 17 , wherein the edge banding is configured to slide relative to the plate, the elastomer coating or combination thereof.  
   
   
       20 . Method of  claim 15 , wherein a second edge banding is disposed on a surface of the second portion.  
   
   
       21 . Method of  claim 20 , wherein said second edge banding is configured to slide relative to the plate, a second concrete slab or combination thereof.  
   
   
       22 . Method of locating a plate in a form for forming concrete comprising: 
 providing the form with a slot configured to closely receive a plate having a first portion and a second portion; and    coating and/or edge banding the first portion;    wherein: 
 the coating at least initially adheres to the plate; and  
 the coating and/or edge banding has a thickness configured to prevent the first portion from passing through said slot.  
   
   
   
       23 . Method of installing a load transfer apparatus in a concrete slab comprising: 
 developing a recess in the concrete slab; and    introducing a first portion of a load transfer apparatus in the recess;    wherein the first portion has edge banding and/or an elastomer coating.    
   
   
       24 . Method of  claim 23 , wherein the load transfer apparatus defines a plate, a square bar, a round bar or combinations thereof.  
   
   
       25 . Method of  claim 23 , wherein said developing a recess comprises boring a hole and/or plunge-cutting a slot.  
   
   
       26 . Method of  claim 23 , further comprising disposing an epoxy in the recess prior to said introducing a first part of a load transfer apparatus.  
   
   
       27 . Method of adapting an existing concrete stab and a freshly-poured concrete stab for transferring a load therebetween comprising: 
 installing a first portion of a load transfer apparatus in the existing concrete slab according to  claim 23;  and    pouring a volume of concrete on a second portion of the toad transfer apparatus.