Reinforcement bar support

Abstract

The proposed support is preferably constructed from high-compression concrete and may be custom-dimensioned according to project requirements. The support may have one or more bearing pads at one or more heights which may include one or more anchoring arms. The support may include a bore sized to accommodate a range of rebar sizes. A length of pre-cut angled rebar may be may be cast in place or may be secured within the bore by epoxy or other means at the time of manufacture or in the field. To maximize stability and overcome low soil-bearing capacity, the bottom surface area of the support is preferably larger than the bearing pad surface area. At least two opposing sides of the support include at a shear-key to anchor the support within the finished slab.

1 . A support structure comprising:
 a body having a bottom surface and a top surface, and wherein the body has at least one inclusion between the top surface and the bottom surface for vertically anchoring the support structure in a finished concrete slab.   
     
     
         2 . The support structure recited in  claim 1  wherein the area of the bottom surface is greater than the area of the top surface. 
     
     
         3 . The support structure recited in  claim 2  wherein the shape of the support structure is at least one of frusto-pyramidal and frusto-conical. 
     
     
         4 . The support structure recited in  claim 2  and further comprising an anchoring structure. 
     
     
         5 . The support structure recited in  claim 4  wherein the anchoring structure a has a first end, a second end, and a midsection extending between the first and second ends. 
     
     
         6 . The anchoring structure recited in  claim 5  wherein the midsection includes at least one bend. 
     
     
         7 . The anchoring structure recited in  claim 5  wherein at least one of the first and second ends of the anchoring structure has a circumference which is greater than the circumference of the midsection. 
     
     
         8 . The support structure recited in  claim 4  wherein the anchoring structure is a bore extending into the support structure. 
     
     
         9 . The anchoring structure recited in  claim 8  and further comprising a support member having a first end, a second end, wherein the support structure includes at least one bend and wherein the first end of the support member is supported within the bore. 
     
     
         10 . The support structure recited in  claim 4  wherein the length of the bottom surface exceeds the width of the bottom surface. 
     
     
         11 . The support structure recited in  claim 10  wherein the top surface of the support structure comprises at least a first section at a first height relative to the bottom surface, and a second section at a second height relative to the bottom surface, and wherein the height of the first section exceeds the height of the second section. 
     
     
         12 . A process for manufacturing a support structure comprising the steps of:
 providing a form having a floor and a side wall, and having a height, length, and width which correspond to a set of desired support dimensions;   placing a first bearing pad insert, having at least one of a support groove and a through bore, onto the floor of the form;   performing at least one of inserting a dowel into a through bore on the bearing pad insert, the size of the dowel corresponding with the dimensions of the support bore to be formed in the support structure, and inserting an inverted anchoring arm into a support groove on the bearing pad insert;   placing a first shear key insert within the form;   pouring a concrete mixture into the form and allowing the concrete mixture to set; and   after allowing the support structure to cure completely, removing the support structure from the form.   
     
     
         13 . The process recited in  claim 12 , and further comprising the step of lining the form with a non-stick liner prior to installing the shear key insert. 
     
     
         14 . The process recited in  claim 12 , and further comprising the step of coating the liner with a releasing agent prior to pouring the concrete mixture. 
     
     
         15 . The process recited in  claim 12 , and further comprising the step of applying a sealant between the bearing pad insert and the form prior to pouring the concrete mixture. 
     
     
         16 . The process recited in  claim 12  and wherein the pouring a concrete mixture into the form step includes the steps of pouring a succession of concrete layers and smoothing each layer before the subsequent layer is poured. 
     
     
         17 . The process recited in  claim 12  and further comprising the step of selecting a second bearing pad insert which includes at least one of a support groove and a through bore and placing the second bearing pad insert into the form on top of a step insert provided adjacent the side wall. 
     
     
         18 . The process recited in  claim 12 , and further comprising the steps of:
 providing a high-strength reinforcing member which has been right-angle cut to a specified length and has been angled to form a first end and a second end;   applying a cement to the first end of the reinforcing member; and   inserting the first end of the reinforcing member into the support bore to fix the reinforcing member into the support structure.   
     
     
         19 . A process for using a support structure comprising the steps of:
 determining the site designated for concrete slab placement;   placing a support structure having a body with a top surface and a bottom surface, the top surface including at least one of an anchoring arm and an elevated support member, atop at least one of grade and decking; and   pouring concrete to a level over the support structure to form a concrete slab.   
     
     
         20 . The process recited in  claim 19  and further comprising the steps of securing at least one of a component of a reinforcing mat or a component of a post-tension cable to at least one of the anchoring arm and elevated support member.