Rebar Support Assembly

Abstract

The present invention is directed toward a rebar support assembly utilized in structural construction beams. The assembly may include a frame having chair portion, a cage portion, an intermediate portion, and/or a header portion. Each portion may include one or more rebar receptacles designed to support a segment of reinforcement bar in a predetermined location and orientation. For example, the receptacles may be configured to orient the rebar in a generally horizontal and/or a generally vertical position. The assembly may be configured as a unitary structure, or may be modular to customize the rebar support for a job site. In use, the assembly is positioned on the supporting surface of the concrete pour area and rebar segments are coupled to the receptacles. Concrete is then poured over/around the assembly.

1 . A rebar support assembly for a reinforced concrete element, the assembly comprising:
 a chair portion operable to support the frame on a supporting surface;   a cage portion oriented above the chair portion;   a first receptacle operable to support a first reinforcement bar in a first orientation; and   a second receptacle operable to support a second reinforcement bar in a second orientation different form the first orientation,   wherein the assembly positions and supports the reinforcement bars during the formation and curing of a concrete structural element.   
   
   
       2 . The support assembly of  claim 1 , wherein:
 the first receptacle orients the first reinforcement bar generally parallel to the supporting surface; and   the second receptacle orients the second reinforcement bar generally perpendicular to the supporting surface.   
   
   
       3 . The support assembly of  claim 2 , wherein
 the cage portion comprises a plurality of the first receptacles; and   the chair portion comprises a plurality of the second receptacles.   
   
   
       4 . The support assembly of  claim 1 , wherein:
 the chair portion comprises a chair frame including:
 a pair of exterior chair support members, and 
 an interior chair support member extending between the pair of exterior chair support members; 
   the cage portion comprises a cage frame including:
 a pair of exterior cage support members, and 
 an interior cage support member extending between the pair of exterior cage support members; 
   the first receptacle is disposed on the interior chair support member; and   the second receptacle is disposed on the exterior cage support members.   
   
   
       5 . The support assembly of  claim 1 , wherein:
 at least one of the receptacles comprises a resilient clip including a receiving portion configured to flex from a first, normal position to a second, expanded position; and   the receiving portion is biased toward the normal position.   
   
   
       6 . The support assembly of  claim 1  further comprising a header portion oriented above the cage portion, the header portion including a first header receptacle operable to receive a reinforcement bar and orient the bar generally parallel to the supporting surface. 
   
   
       7 . The support assembly of  claim 6 , wherein the header portion further comprises a second header receptacle operable to receive a reinforcement bar and orient the bar generally perpendicular to the supporting surface. 
   
   
       8 . The support assembly of  claim 6  further comprising an intermediate portion disposed between the header portion and the cage portion, the intermediate portion including a an intermediate receptacle operable to receive a reinforcement bar and orient the bar generally parallel to the supporting surface. 
   
   
       9 . The support assembly of  claim 1  further comprising an intermediate portion disposed between the chair portion and the cage portion, the intermediate portion including a intermediate receptacle operable to receive a reinforcement bar and orient the bar generally parallel to the supporting surface. 
   
   
       10 . The support assembly of  claim 1  further comprising a fastener socket operable to receive a fastener that couples the assembly to a concrete form. 
   
   
       11 . The support assembly of  claim 1 , wherein:
 the assembly further comprises:
 a first fastener socket disposed on the chair portion, and 
 a second fastener socket disposed on the cage portion; and 
   the fastener sockets receive a fastener capable of securing the assembly to a concrete form.   
   
   
       12 . The support assembly of  claim 1 , wherein:
 the second receptacle is disposed on the chair portion, the second receptacle being operable to support the second reinforcement bar in a generally perpendicular to the supporting surface;   the assembly further comprises a header portion oriented above the cage portion, the header portion including a header receptacle operable to receive a reinforcement bar and orient the bar generally perpendicular to the supporting surface,   a reinforcement bar extending from the second receptacle to the header receptacle.   
   
   
       13 . The support assembly of  claim 1 , wherein the chair portion releasably engages the cage portion. 
   
   
       14 . The support assembly of  claim 1 , wherein the frame is formed from thermoplastic material. 
   
   
       15 . A concrete beam rebar support assembly comprising:
 a chair portion operable to support the assembly over a supporting surface;   a cage portion in communication with the chair portion, the cage portion comprising an open web to permit the flow of concrete therethough; and   a receptacle operable to receive a reinforcement bar and couple the bar to the assembly,   wherein the support assembly is adapted to support and position one or more reinforcement bars during the pouring and curing of a concrete beam.   
   
   
       16 . The rebar support assembly of  claim 15 , wherein the assembly comprises a unitary structure formed from a thermoplastic material. 
   
   
       17 . The rebar support assembly of  claim 15 , wherein:
 at least one of the receptacles comprises a resilient clip including a receiving portion configured to flex from a first, normal position to a second, expanded position; and   the receiving portion is biased toward the normal position.   
   
   
       18 . A method of forming a reinforced concrete beam, the method comprising:
 (a) providing a plurality of support assemblies, each support assembly including:
 a chair portion operable to support the frame on a supporting surface, the chair portion including a first chair rebar receptacle operable to receive a reinforcement bar such that it is oriented generally parallel to the supporting surface, and 
 a cage portion oriented above the chair portion, the cage portion comprising:
 a pair of generally vertical support members oriented in spaced relation, 
 a generally horizontal support member extending between the pair of generally vertical support members, and 
 a cage rebar receptacle operable to receive a reinforcement bar such that it is oriented in generally parallel to the supporting surface; 
 
   (b) orienting the support assemblies in spaced, parallel relation on a supporting surface;   (c) inserting a first reinforcement bar into a plurality of chair rebar support members such that extends at least from a first assembly to a second assembly;   (d) directing uncured concrete around the assembly.   
   
   
       19 . The method of  claim 18 , wherein:
 the chair assembly further comprises a second chair rebar receptacle operable to receive an reinforcement bar and orient the bar generally perpendicular to the supporting surface;   the assembly further comprises a header portion including:
 a first header rebar receptacle operable to receive an reinforcement bar and orient the bar generally parallel to the supporting surface, and 
 a second header rebar receptacle operable to receive an reinforcement bar and orient the bar generally perpendicular to the supporting surface; 
   the second chair rebar receptacle is generally aligned with the second header rebar receptacle; and   the method further comprises (e) inserting a second reinforcement member into both the chair second receptacle and the header second receptacle.   
   
   
       20 . A rebar support system for a reinforced concrete beam, the system comprising a plurality of rebar support assemblies, each system comprising:
 a chair portion operable to support the frame on a supporting surface, the chair portion including:
 a first chair receptacle operable to receive a reinforcement bar and orient the bar generally parallel to the supporting surface, 
 a second chair receptacle operable to receive a reinforcement bar and orient the bar generally perpendicular to the supporting surface; and 
   a cage portion oriented above the chair portion, the cage portion comprising a cage receptacle operable to receive a reinforcement bar and orient the bar generally parallel to the supporting surface.