Concrete Reinforcement Elements and Structures

Abstract

A prong is configured for use with a concrete reinforcement element and includes first and second legs positioned opposite first and second sides of the prong and a bridge portion connecting distal ends the legs, where the bridge portion forms a first end of the prong. The legs extend from the bridge portion to a second end of the prong opposite the first end, and each of the legs has a proximal end at the second end of the prong. The proximal end of the first leg is bent toward the second leg, and the proximal end of the second leg is bent toward the first leg, such that the proximal ends of the legs overlap each other. Inner surfaces of the proximal ends of the legs define engagement surfaces configured to engage a tie wire, enabling the proximal ends to be connected to the tie wire.

What is claimed is: 
     
         1 . A concrete reinforcement mat comprising:
 a plurality of concrete reinforcement elements, each concrete reinforcement element comprising a tie wire having a length and a plurality of prongs connected along the length of the tie wire, each of the prongs being spaced from adjacent prongs, wherein each of the prongs comprises:
 a first leg and a second leg, with a bridge portion connecting the first leg and the second leg, wherein the bridge portion forms a first end of the prong distal from the tie wire, the first and second legs extending from the bridge portion to a second end of the prong opposite the first end, and wherein the second end of the prong is connected to the tie wire, wherein the prong extends outwardly away from a top side of the tie wire and has a prong length defined between the first and second ends, and wherein the prong is elongated such that a maximum spacing between the first and second legs is smaller than the prong length, 
 wherein each of the first and second legs has a proximal end at the second end of the prong, wherein the proximal end of the first leg extends on a first side of the tie wire and is bent toward the second leg to extend at least partially around an underside of the tie wire opposite the top side, and wherein the proximal end of the second leg extends on a second side of the tie wire opposite the first side and is bent toward the first side to extend at least partially around the underside of the tie wire, 
 wherein the second end of each prong is connected to the tie wire by welding, such that at least a portion of each of the proximal ends of the first and second legs is welded to the underside of the tie wire; and 
   a plurality of cross-wires connected to the plurality of concrete reinforcement elements by connection to the tie wires, such that the concrete reinforcement elements are all positioned in spaced relation and extending along a first direction, and the cross-wires are connected between the concrete reinforcement elements in spaced relation to each other and extend along a second direction transverse to the first direction.   
     
     
         2 . The concrete reinforcement mat of  claim 1 , wherein the prongs on each reinforcement element are not aligned with the prongs on adjacent reinforcement elements. 
     
     
         3 . The concrete reinforcement mat of  claim 1 , wherein the mat is configured such that an applied load sufficient to cause failure of one of the prongs when exerted on the bridge portion of the prong in a direction away from the tie wire is higher than a bond strength of the welding. 
     
     
         4 . The concrete reinforcement mat of  claim 1 , wherein the mat is configured such that an applied load sufficient to cause failure of one of the prongs when exerted on the bridge portion of the prong in a direction away from the tie wire is approximately equal to an applied load sufficient to cause fracture of the prong. 
     
     
         5 . The concrete reinforcement mat of  claim 1 , wherein the at least a portion of each of the proximal ends of the first and second legs welded to the underside of the tie wire defines a curved surface that is welded to the tie wire. 
     
     
         6 . The concrete reinforcement mat of  claim 1 , wherein the proximal ends of the first and second legs overlap each other, and wherein confronting surfaces of the proximal ends of the first and second legs contact each other while overlapping. 
     
     
         7 . The concrete reinforcement mat of  claim 1 , wherein the first and second legs of each prong are disposed at an acute angle to each other. 
     
     
         8 . The concrete reinforcement mat of  claim 1 , wherein the first end of each prong is a free end, such that the prong is secured only at the second end. 
     
     
         9 . The concrete reinforcement mat of  claim 1 , wherein each concrete reinforcement element further comprises a lock rod connected to the first end of each of the prongs of the respective concrete reinforcement element, such that each prong is secured only to the tie wire at the second end and to the lock rod at the first end. 
     
     
         10 . The concrete reinforcement mat of  claim 1 , wherein the bridge portion of each prong has a bend of at least 180° and a radius of curvature of about 0.5 inch. 
     
     
         11 . The concrete reinforcement mat of  claim 1 , wherein the proximal ends of the first and second legs of each prong each have a bend portion, and wherein the bend portion of each of the first and second legs is bent to an angle of at least 90° and not exceeding 135°. 
     
     
         12 . The concrete reinforcement mat of  claim 1 , wherein the concrete reinforcement mat is configured for use with a reinforced concrete pipe comprising a concrete wall defining a central passage, such that the concrete reinforcement mat is embedded within the concrete wall. 
     
     
         13 . A concrete reinforcement mat comprising:
 a plurality of concrete reinforcement elements, each concrete reinforcement element comprising a tie wire having a length and a plurality of prongs connected along the length of the tie wire, each of the prongs being spaced from adjacent prongs, wherein each of the prongs comprises:
 a first leg and a second leg, with a bridge portion connecting the first leg and the second leg, wherein the bridge portion forms a first end of the prong distal from the tie wire, the first and second legs extending from the bridge portion to a second end of the prong opposite the first end, and wherein the second end of the prong is connected to the tie wire, wherein the prong extends outwardly away from a top side of the tie wire and has a prong length defined between the first and second ends, and wherein the prong is elongated such that a maximum spacing between the first and second legs is smaller than the prong length, 
 wherein each of the first and second legs has a proximal end at the second end of the prong, wherein the proximal end of the first leg extends on a first side of the tie wire and is bent toward the second leg to extend at least partially around an underside of the tie wire opposite the top side, and wherein the proximal end of the second leg extends on a second side of the tie wire opposite the first side and is bent toward the first side to extend at least partially around the underside of the tie wire, 
 wherein the first and second legs of each prong are disposed at an acute angle to each other, and the proximal ends of the first and second legs overlap each other, such that confronting surfaces of the proximal ends of the first and second legs contact each other while overlapping, 
 wherein the second end of each prong is connected to the tie wire by welding, such that at least a portion of each of the proximal ends of the first and second legs is welded to the underside of the tie wire, and wherein the at least a portion of each of the proximal ends of the first and second legs welded to the underside of the tie wire defines a curved surface that is welded to the tie wire; and 
   a plurality of cross-wires connected to the plurality of concrete reinforcement elements by connection to the tie wires, such that the concrete reinforcement elements are all positioned in spaced relation and extending along a first direction, and the cross-wires are connected between the concrete reinforcement elements in spaced relation to each other and extend along a second direction transverse to the first direction.   
     
     
         14 . The concrete reinforcement mat of  claim 13 , wherein the prongs on each reinforcement element are not aligned with the prongs on adjacent reinforcement elements. 
     
     
         15 . The concrete reinforcement mat of  claim 13 , wherein the mat is configured such that an applied load sufficient to cause failure of one of the prongs when exerted on the bridge portion of the prong in a direction away from the tie wire is higher than a bond strength of the welding. 
     
     
         16 . The concrete reinforcement mat of  claim 13 , wherein the mat is configured such that an applied load sufficient to cause failure of one of the prongs when exerted on the bridge portion of the prong in a direction away from the tie wire is approximately equal to an applied load sufficient to cause fracture of the prong. 
     
     
         17 . The concrete reinforcement mat of  claim 13 , wherein the first end of each prong is a free end, such that the prong is secured only at the second end. 
     
     
         18 . The concrete reinforcement mat of  claim 13 , wherein each concrete reinforcement element further comprises a lock rod connected to the first end of each of the prongs of the respective concrete reinforcement element, such that each prong is secured only to the tie wire at the second end and to the lock rod at the first end. 
     
     
         19 . The concrete reinforcement mat of  claim 13 , wherein the bridge portion of each prong has a bend of at least 180° and a radius of curvature of about 0.5 inch. 
     
     
         20 . The concrete reinforcement element of  claim 13 , wherein the proximal ends of the first and second legs of each prong each have a bend portion, and wherein the bend portion of each of the first and second legs is bent to an angle of at least 90° and not exceeding 135°.