Prefabricated modular rebar modules and methods of using the same

Abstract

There is provided a reinforcing steel structure for use in a concrete building wall. The structure includes one or more prefabricated, welded cages having vertical reinforcing bars. A plurality of continuous ties extends around the vertical reinforcing bars and a plurality of shear ties extends generally horizontally between the vertical reinforcing bars. Each welded cage is sized and shaped for shipping and said structure can be formed onsite from a plurality of said cages lapped together. Concrete is added to the reinforcing steel structure to form a concrete building wall. There is also provided a reinforcing steel structure for use in a concrete building transfer or raft slab. The structure includes one or more prefabricated, welded beams. The prefabricated, welded beams have a top beam layer and a bottom beam layer, each having horizontal reinforcing bars, and a plurality of continuous ties extending generally vertically around the top and bottom beam layers. Each welded beam is sized and shaped for shipping and said structure can be formed onsite from a plurality of said beams lapped together. Concrete is added to the reinforcing steel structure to form a concrete building slab.

1 - 8 . (canceled) 
     
     
         9 . A reinforcing steel structure for use in a concrete building transfer or raft slab, the structure comprising:
 one or more prefabricated, welded beams comprising:
 a top beam layer having horizontal reinforcing bars, 
 a bottom beam layer having horizontal reinforcing bars, and 
 a plurality of continuous ties extending generally vertically around the top beam layer and the bottom beam layer; and 
   wherein each welded beam is sized and shaped for shipping and said structure can be formed onsite from a plurality of said beams lapped together.   
     
     
         10 . The reinforcing steel structure of  claim 9 , wherein the structure further comprises:
 a plurality of prefabricated, welded beams lapped together;   a top slab layer comprising a plurality of horizontal reinforcing bars oriented generally perpendicularly to the horizontal reinforcing bars of the top beam layer;   a bottom slab layer comprising a plurality of horizontal reinforcing bars oriented generally perpendicularly to the horizontal reinforcing bars of the bottom beam layer;   wherein the structure can be formed onsite by installing the bottom slab layer, installing the plurality of welded beams on the bottom slab layer and installing the top slab layer on the plurality of welded beams.   
     
     
         11 . The reinforcing steel structure of  claim 9 , wherein each of the one or more prefabricated, welded beams further comprises a plurality of shear ties extending generally vertically between the horizontal reinforcing bars of the top beam layer and the horizontal reinforcing bars of the bottom beam layer. 
     
     
         12 . The reinforcing steel structure of  claim 11 , wherein each of the one or more prefabricated, welded beams further comprises the plurality of shear ties being oriented with the hook ends connected to the horizontal reinforcing bars of the top layer slab. 
     
     
         13 . The reinforcing steel structure of  claim 12 , wherein the plurality of shear ties further comprise two or more parallel rows of shear ties extending along a length of the one or more prefabricated, welded beams. 
     
     
         14 . The reinforcing steel structure of  claim 9 , wherein each of the one or more prefabricated, welded beams have dimensions equal to or less than 12 feet by 12 feet by 60 feet. 
     
     
         15 . The reinforcing steel structure of  claim 9  for use in a concrete transfer slab or a concrete raft slab. 
     
     
         16 . A method of constructing a reinforcing steel structure for use in a concrete building slab, comprising:
 providing a plurality of prefabricated, welded beams at a worksite, the welded beams comprising:
 a top beam layer having horizontal reinforcing bars, 
 a bottom beam layer having horizontal reinforcing bars, and 
 a plurality of continuous ties extending generally vertically around the top beam layer and the bottom beam layer; 
   installing a bottom slab layer comprising a plurality of horizontal reinforcing bars;   installing the plurality of prefabricated, welded beams adjacent to one another on the bottom slab layer; and   installing a top slab layer comprising a plurality of horizontal reinforcing bars on the plurality of welded beams to form a reinforcing steel structure; and   adding concrete to the reinforcing steel structure to form a concrete building slab.