Pre-cast concrete column and method of fabrication

Abstract

A column cage may comprise a plurality of column grids. The column grids may be formed with a plurality of longitudinal rebars. Also, the column grid may have a plurality of transverse rebars attached atop the plurality of longitudinal rebars. The transverse rebars may be attached to the longitudinal rebars. Four vertically extending rebars may be charged through the plurality of column grids at the four corners of column grids. The column grid may be held firmly to the vertically extending charged rebars with wire ties. Additionally, adjacent column cages may be connected to each other with a swedged on coupler.

1 . A concrete column comprising:
 a plurality of prefabricated grids disposed parallel to each other and spaced apart from each other, the prefabricated grids being vertically aligned to each other, each of the prefabricated grids having a rectangular configuration defining four corners;   four rebars charged through the prefabricated grids and respectively disposed adjacent the four corners of the prefabricated grids; and   concrete encapsulating the prefabricated grids and at least a portion of the four rebars.   
     
     
         2 . The concrete column of  claim 1  wherein each of the prefabricated grids have first, second, third and fourth rebars disposed parallel to each other and spaced apart from each other, and each of the prefabricated grids have fifth, sixth, seventh and eighth rebars disposed transverse to the first, second, third and fourth rebars, attached to the first, second, third and fourth rebars and spaced apart from each other. 
     
     
         3 . The concrete column of  claim 1  consisting essentially of:
 a first rebar charged through the prefabricated grids adjacent an intersection of the first and fifth rebars;   a second rebar charged through the prefabricated grids adjacent an intersection of the fourth and eighth rebars;   a third rebar charged through the prefabricated grids adjacent an intersection of the first and fourth rebars; and   a fourth rebar charged through the prefabricated grids adjacent an intersection of the fifth and eighth rebars.   
     
     
         4 . The concrete column of  claim 1  wherein the plurality of prefabricated grids is expanded to a total length greater than thirty feet. 
     
     
         5 . The concrete column of  claim 4  wherein the plurality of prefabricated grids is expanded to a total length up to a length of the four rebars. 
     
     
         6 . A concrete structure comprising:
 a first concrete column comprising:
 a plurality of prefabricated grids disposed parallel to each other and spaced apart from each other, the prefabricated grids being vertically aligned to each other, each of the prefabricated grids having a rectangular configuration defining four corners; 
 four rebars charged through the prefabricated grids and respectively disposed adjacent the four corners of the prefabricated grids; and 
 concrete encapsulating the prefabricated grids and at least a portion of the four rebars; and 
   a second concrete column comprising:
 a plurality of prefabricated grids disposed parallel to each other and spaced apart from each other, the prefabricated grids being vertically aligned to each other, each of the prefabricated grids having a rectangular configuration defining four corners; and 
 four rebars charged through the prefabricated grids and respectively disposed adjacent the four corners of the prefabricated grids; 
   four couplers attached to corresponding rebars of the first and second concrete columns.   
     
     
         7 . The concrete structure of  claim 6  wherein the four couplers are swedged on couplers. 
     
     
         8 . The concrete structure of  claim 6  wherein less rebar couplers are used to interconnect the first and second concrete columns compared to prior art concrete columns of similar size fabricated by column grids comprising a plurality of rebars held together by wire ties. 
     
     
         9 . The concrete structure of  claim 7  wherein the swedged on couplers each have an inner diameter sized and configured to be press fit onto the rebars of the first and second concrete columns.