Expansion joint splicing device and method

Abstract

A splice device and method for connecting reinforcing bars across adjacent concrete slabs in floor construction. The device includes a cylindrical body extending along a longitudinal axis with a threaded bore at a first end for fixedly attaching to a first rebar and a slot-shaped opening at a second end for receiving a second rebar. The slot opening permits both axial and lateral movement of the second rebar during construction. The device accommodates thermal expansion and contraction of the concrete slabs and structural frame during construction by allowing the second rebar to move within the cavity while maintaining a gap distance from the threaded end. After the building thermal envelope is completed and interior temperatures stabilize, the cavity is filled with a curable fill material through the inlet, which upon curing securely fixes the second rebar and structurally couples the adjacent concrete slabs.

1 . A method of coupling a first concrete slab and a second concrete slab, the method comprising:
 attaching a coupling device to a first rebar, the coupling device comprising:   a body defining a cavity extending along a longitudinal axis;   a bore at a first end configured to engage the first rebar to fixedly connect the coupling device to the first rebar; and   a slot-shaped opening at a second end opposite the first end, the slot having a width greater than a height to permit both lateral and axial movement of a second rebar extending therethrough;   embedding the coupling device and the first rebar in the first concrete slab such that the slot-shaped opening is positioned adjacent a side of the first concrete slab;   positioning the second rebar of a second concrete slab through the slot-shaped opening and into the cavity with an end of the second rebar spaced from the first end of the cavity to define a first gap distance configured to accommodate thermal expansion of the first concrete slab toward the second concrete slab;   pouring the second concrete slab with a second gap formed between the first concrete slab and the second concrete slab, the second gap having a gap width configured to accommodate thermal expansion of the second concrete slab toward the first concrete slab;   permitting thermal expansion and contraction of the first concrete slab and the second concrete slab during a construction phase, wherein the second rebar moves axially and laterally within the slot-shaped opening and the cavity in response to the thermal expansion and contraction; and   after completing a building thermal envelope, and stabilizing interior temperatures, filling the cavity with a curable fill material through an inlet in the coupling device such that, upon curing, the fill material retains the second rebar in the cavity.   
     
     
         2 . The method of  claim 1 , wherein the first rebar has a threaded end that is coupled to mating threads on the body. 
     
     
         3 . The method of  claim 1 , wherein the first gap distance is between about one inch and about four inches. 
     
     
         4 . The method of  claim 1 , wherein the first gap distance and the gap width are substantially equal to accommodate symmetric thermal expansion from both the first concrete slab and the second concrete slab. 
     
     
         5 . The method of  claim 1 , wherein the construction phase spans a period during which exterior ambient temperatures fluctuate causing the first concrete slab and the second concrete slab to undergo multiple cycles of thermal expansion and contraction prior to filling the cavity with the curable fill material. 
     
     
         6 . The method of  claim 1 , wherein completing the building thermal envelope comprises installing exterior walls, windows, and roofing to substantially isolate interior spaces from exterior temperature fluctuations. 
     
     
         7 . The method of  claim 1 , further comprising:
 placing a compressible material in the second gap to permit compression and expansion of the second gap during the construction phase; and   removing or compressing the compressible material prior to filling the second gap with fill material.   
     
     
         8 . The method of  claim 1 , wherein the slot-shaped opening has a height that is between a diameter of the second rebar and double the diameter of the second rebar. 
     
     
         9 . The method of  claim 1 , further comprising debonding a portion of the second rebar from the second concrete slab adjacent the slot-shaped opening to permit axial movement of the debonded portion during thermal expansion and contraction. 
     
     
         10 . A splice device for coupling a first concrete slab to a second concrete slab across a gap, the splice device comprising:
 a cylindrical housing having a longitudinal axis and defining an internal chamber;   a threaded end portion at a first end of the housing, the threaded end portion including internal threads configured for threaded engagement with a first reinforcing bar having corresponding external threads;   an open end portion at a second end of the housing opposite the threaded end portion, the open end portion defining a slot opening having a width and a height, wherein the width exceeds the height to permit both lateral displacement and axial displacement of a second reinforcing bar extending through the slot opening;   at least one port extending through a wall of the housing and communicating with the internal chamber;   wherein the internal chamber is configured to receive a portion of the second reinforcing bar through the slot opening while maintaining a first gap distance between an end of the second reinforcing bar and the threaded end portion to accommodate thermal expansion movement; and   wherein the internal chamber is configured to be filled with a curable fill material through the at least one port after thermal movement has stabilized.   
     
     
         11 . The splice device of  claim 10 , wherein the internal chamber has a longitudinal length configured to maintain the first gap distance of between one inch and four inches when the second reinforcing bar is fully inserted through the slot opening. 
     
     
         12 . The splice device of  claim 10 , wherein the height of the slot opening is between a diameter of the second reinforcing bar and double the diameter of the second reinforcing bar. 
     
     
         13 . The splice device of  claim 10 , wherein the width of the slot opening is at least 1.5 times greater than the height to permit lateral displacement of at least one-quarter inch in each lateral direction perpendicular to the longitudinal axis. 
     
     
         14 . The splice device of  claim 10 , wherein the slot opening is rectangular with arcuate ends shaped to correspond to a cross-sectional profile of the second reinforcing bar. 
     
     
         15 . The splice device of  claim 10 , wherein the at least one port comprises an inlet and an outlet positioned on a same side of the housing to facilitate filling of the internal chamber with the curable fill material and venting of air from the internal chamber. 
     
     
         16 . The splice device of  claim 10 , wherein the internal chamber includes a plurality of axially spaced annular ridges extending inwardly from an interior surface of the housing, the ridges being configured to increase surface area for bonding with the curable fill material and the second reinforcing bar. 
     
     
         17 . The splice device of  claim 10 , further comprising a debonding sleeve configured to be positioned over a portion of the second reinforcing bar adjacent the slot opening, the debonding sleeve preventing bonding between the second reinforcing bar and the second concrete slab to permit axial movement during thermal expansion. 
     
     
         18 . The splice device of  claim 10 , wherein the open end portion includes an external flange extending radially outward from the housing, the flange being configured to abut against a side surface of the first concrete slab to position the slot opening adjacent the gap. 
     
     
         19 . The splice device of  claim 10 , wherein the internal chamber has a volume configured to receive the second reinforcing bar while retaining sufficient space for the curable fill material to surround and bond to both the second reinforcing bar and internal surfaces of the chamber after thermal movement has stabilized. 
     
     
         20 . A splice device for coupling a first concrete slab to a second concrete slab across a gap, the splice device comprising:
 a device for use at a gap between adjacent concrete slabs, the device comprising:   a body extending along a first longitudinal axis between a first end and a second end, the body defining:   a first opening including a first bore at the first end, the first bore being configured to receive a first rebar of a first concrete slab;   a second opening including a second bore at the second end, wherein the second bore comprises a slot configured to receive a second rebar of a second concrete slab, the slot having a width that is greater than a height to permit lateral movement of the second rebar relative to the body;   an inlet disposed along a second longitudinal axis, the second longitudinal axis extending in a first direction substantially perpendicular to the first longitudinal axis;   an outlet disposed along a third longitudinal axis, the third longitudinal axis extending in a second direction substantially perpendicular to the first longitudinal axis; and   a cavity extending along the first longitudinal axis, the cavity in fluid communication with the first opening, the second opening, the inlet, and the outlet,   wherein the cavity is configured to accommodate axial movement of the second rebar toward and away from the first end.   
     
     
         21 . The splice device of  claim 20 , wherein the first bore includes one or more threads on an inner surface configured to engage corresponding threads on the first rebar to fixedly connect the splice device to the first rebar. 
     
     
         22 . The splice device of  claim 20 , wherein the slot has a height that is between a diameter of the second rebar and double the diameter of the second rebar. 
     
     
         23 . The splice device of  claim 20 , wherein the slot is rectangular in geometry with arcuate ends shaped to correspond to a cross-sectional profile of the second rebar. 
     
     
         24 . The splice device of  claim 23 , wherein the slot includes an upper surface and a lower surface, each configured to contact an outer surface of the second rebar and provide sufficient strength to support the second concrete slab. 
     
     
         25 . The splice device of  claim 20 , wherein the body is formed of stainless steel and includes a coating material on an exterior surface to resist corrosion. 
     
     
         26 . The splice device of  claim 20 , wherein the body has a length along the first longitudinal axis of between about one foot and about three feet. 
     
     
         27 . The splice device of  claim 26 , wherein the body has a length of about eighteen inches. 
     
     
         28 . The splice device of  claim 20 , wherein the body has an outer diameter of between about two inches and about five inches, and wherein the cavity has an inner diameter of between about 1.5 inches and about four inches. 
     
     
         29 . The splice device of  claim 28 , wherein the body has an outer diameter of between about three inches and about 3.5 inches, and wherein the cavity has an inner diameter of between about two inches and about three inches. 
     
     
         30 . The splice device of  claim 20 , wherein the body has a wall thickness between the cavity and an exterior surface of the body of between about 0.3 inches and about 0.8 inches.