Method of forming concrete and an apparatus for transferring loads between concrete slabs

Abstract

An apparatus for forming concrete includes a form having a slot configured to closely receive a plate. The slot is defined by one or more annular surfaces having central axes perpendicular to a direction in which the slot receives the plate. A method for forming same includes providing a sheet of form material; disposing a release layer on the sheet; cutting the sheet into a plurality of forms having a predetermined form height; and cutting a slot in each of each of the plurality of forms. Another apparatus for forming concrete includes a plate having a first portion and a second portion. A coating is disposed on the first portion. When disposed in a joint defined by a first volume of concrete and a second volume of concrete, the first volume of concrete adheres only to the coating and the second volume of concrete adheres only to the second portion. A method for forming concrete includes providing a plate having a coated first portion and a second 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. The plate remains in the cured concrete.

1 . Apparatus for forming concrete comprising a form having a slot configured to closely receive a plate, wherein said slot is defined by one or more annular surfaces having central axes perpendicular to a direction in which said slot receives the plate.  
   
   
       2 . Apparatus of  claim 1 , wherein said form has a side surface and a back surface with which said annular surfaces define proximal intersections and distal intersections configured to contact corresponding proximal portions and distal portions of a plate.  
   
   
       3 . Apparatus of  claim 1 , wherein said form has a back surface, a top surface and a chamfer interposed therebetween defining an angle relative to said top surface ranging from 10° to 89°.  
   
   
       4 . Apparatus of  claim 1 , further comprising a release layer on said form.  
   
   
       5 . Apparatus of  claim 4 , wherein said release layer is constructed of phenolic paper, kraft paper, acrylic, latex, melamine, Formica®, foil, oil, high density overlay, metal or combinations thereof.  
   
   
       6 . Apparatus of  claim 1 , wherein said form is constructed of oriented strand board, dimensional lumber, particle board, metal, plastic, cardboard, fiber board, polyurethane foam, Styrofoam® or combinations thereof.  
   
   
       7 . Apparatus of  claim 1 , wherein said form has a width ranging from 0.125 to 3.000 inches.  
   
   
       8 . Apparatus of  claim 1 , wherein said form has a top surface width ranging from 0.125 to 0.875 inch.  
   
   
       9 . Method of making an apparatus for forming concrete comprising: 
 providing a sheet of form material;    disposing a release layer on the sheet;    cutting the sheet into a plurality of forms having a predetermined form height; and    cutting a slot in each of each of the plurality of forms.    
   
   
       10 . Method of  claim 9 , wherein the slot is defined by one or more annular surfaces having central axes perpendicular to a direction in which the slot receives a plate.  
   
   
       11 . Method of  claim 9 , wherein each of the plurality of forms has a side surface and a back surface with which the annular surfaces define proximal intersections and distal intersections configured to contact corresponding proximal portions and distal portions of a plate.  
   
   
       12 . Method of  claim 9 , wherein each of the plurality of forms has a back surface and a top surface, further comprising cutting a chamfer between the back surface and the top surface in each of the plurality of forms.  
   
   
       13 . Apparatus for transferring a load between a first concrete slab and a second concrete slab, defining a joint, comprising: 
 a plate having a first portion and a second portion; and    a coating disposed on said first portion;    whereby, when disposed in the joint;    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.    
   
   
       14 . Apparatus of  claim 13 , wherein said coating has a thickness of about 0.03 inches.  
   
   
       15 . Apparatus of  claim 13 , wherein said coating slides relative to said plate, said coating slides relative to the first concrete slab or combinations thereof.  
   
   
       16 . Apparatus of  claim 13 , wherein, when disposed in the joint, said plate defines a rhombus or rectangle having opposite corners aligned with the joint when disposed therein.  
   
   
       17 . Apparatus of  claim 13 , wherein, when disposed in the joint, said plate defines a rhombus or rectangle in a plane perpendicular to the joint and having sides aligned with and perpendicular to the joint.  
   
   
       18 . Apparatus of  claim 13 , wherein said plate is shear formed.  
   
   
       19 . Apparatus of  claim 13 , further comprising a form having a slot configured to closely receive said second portion.  
   
   
       20 . Apparatus of  claim 19 , wherein said form is constructed of oriented strand board, dimensional lumber, particle board, metal, plastic, cardboard, fiber board, polyurethane foam, Styrofoam® or combinations thereof.  
   
   
       21 . Apparatus of  claim 19 , wherein said form has a back surface, a top surface and a chamfer interposed therebetween defining an angle relative to said top surface ranging from 10° to 89°.  
   
   
       22 . Apparatus of  claim 19 , wherein said form has a width ranging from 0.125 to 3.000 inches.  
   
   
       23 . Apparatus of  claim 19 , wherein said form has a top surface width ranging from 0.125 to 0.875 inch.  
   
   
       24 . Apparatus of  claim 19 , wherein said slot defines one or more annular surfaces having central axes perpendicular to a direction in which said slot receives said second portion.  
   
   
       25 . Apparatus of  claim 24 , wherein said form has a side surface and a back surface with which said annular surfaces define proximal intersections and distal intersections configured to contact corresponding proximal portions and distal portions of said plate.  
   
   
       26 . Apparatus of  claim 19 , further comprising a release layer on said form.  
   
   
       27 . Apparatus of  claim 26 , wherein said release layer is constructed of phenolic paper, kraft paper, acrylic, latex, melamine, Formica®, foil, oil, high density overlay, metal or combinations thereof.  
   
   
       28 . Method of forming concrete comprising: 
 providing a plate having a coated first portion and a second 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.    
   
   
       29 . Method of  claim 28 , further comprising: 
 pouring a second volume of concrete adjacent to the cured concrete and on the second portion; and    curing the second volume of concrete and defining a second cured concrete.