The present invention relates to reinforcement mesh, rolls of reinforcement mesh, reinforced concrete or other matrix structures, and related methods, uses, assemblies, and the like.

BACKGROUND OF THE INVENTION

It is usual when forming concrete structures to embed reinforcement members in the cement. The reinforcement members can take the form of synthetic or metal members or structures. A common method of reinforcing concrete for foundation structural or surfacing purposes (e.g. driveways, roading, footpaths, etc.) or flooring (e.g. in residences) is to imbed prefabricated mesh structures. These can be substantial and take the form of grids of steel rods. In some less demanding applications they can take the form of individual sheets of welded wire mesh. Typical of such prior art structures is the 665 standard (7.525 m ² net cover, 8.98 m ² gross cover) that measures 1.97 m by 4.56 m, formed from longitudinal and transverse wires defining 150 mm sized squares inwardly of the prominent free ends of both the longitudinal and transverse wires. Typically such wires are 5.3 mm in diameter and are welded to one another at welding nodes inwardly of the perimeter to form a grid. Additionally there is the Dl 47 diat is a 15 m ² sheet with 300 mm squares. This sheet is formed with 7.5 mm wire. Such expanses of steel mesh present a difficulty both in handling, owing to the free exposed ends, and in wastage.

In the concrete reinforcing systems of the prior art, a great deal of wastage occurs from the need to lap the ends of adjacent sheets, in respect of both the longitudinal and transverse edges, such that the lapping extends fully to allow the end parallel wires of the adjacent sheets to be placed next to each other. This therefore results in overlapping of at least whole squares of mesh as seen in Figure 1.

It is an object of the present invention to provide a more efficient use of grid or mesh structures for reinforcement purposes, or which at least provides the public with a useful choice.

SUMMARY OF THE INVENTION Accordingly, in a first aspect the present invention relates to a forged or tied knot noded mesh that preferably is able to be rolled and which preferably can be used more efficiently than has been with sheets of the prior art. Another aspect of the invention relates to a reinforcement mesh formed from intersecting longitudinal and transverse wires, each intersect inward of the perimeter defining a node, and suitable for use in reinforcing concrete for roads, paths, driveways or building construction or the like, the mesh comprising. spaced substantially parallel longitudinal wires having a diameter from about 2 to 3.85 mm, spaced substantially parallel transverse wires having a diameter from about 2 to 3.85 mm, and a knotting wire present on each of at least a majority of nodes for attachment of the intersecting transverse and longitudinal wires.

Another aspect of the invention relates to a reinforcement mesh formed from intersecting longitudinal and transverse wires, each intersect inward of the perimeter defining a node, and suitable for use in reinforcing concrete for roads, paths, driveways or building construction or the like, the mesh comprising spaced substantially parallel high tensile longitudinal wires, spaced substantially parallel medium tensile transverse wires, and a knotting wire present on each of at least a majority of nodes for attachment of the intersecting transverse and longitudinal wires

In some embodiments the transverse and longitudinal wires are of different tensile strength.

Another aspect of the invention relates to a reinforcement mesh formed from intersecting longitudinal and transverse wires, each intersect inward of the perimeter defining a node, and suitable for use in reinforcing concrete for roads, paths, driveways or building construction or the like, the mesh comprising. spaced substantially parallel longitudinal wires, spaced substantially parallel transverse wires, and a knotting wire present on each of at least a majority of nodes for attachment of the intersecting transverse and longitudinal wires, and wherein the tensile strength of the longitudinal wires is greater than that of the transverse wires.

Another aspect of the invention relates to a reinforcement mesh formed from intersecting longitudinal and transverse wires, each intersect inward of the perimeter defining a node, and suitable for use in reinforcing concrete for roads, paths, driveways or building construction or the like, the mesh comprising: spaced substantially mutually parallel longitudinal wires having an ultimate tensile strength of between 1235 to 1550 MPa, spaced substantially mutually parallel transverse wires having an ultimate tensile strength of between 700 to 1050 MPa, and a knotting wire present on each of at least a majority of nodes for attachment of the intersecting transverse and longitudinal wires.

The following embodiments may relate to any of the above aspects.

In some embodiments the transverse wires wrap about the terminal longitudinal wire.

In some embodiments the strength per metre of the reinforcement mesh is greater than about 40 kN/m.

In some embodiments the strength per metre of the reinforcement mesh is greater than about 70 kN/m.

In some embodiments the transverse wires are spaced closer together than the longitudinal wires. In some embodiments the openings are rectangular with the major rectangular access being transverse of the length of the mesh, the longitudinal wires extending along the length of the mesh.

In some embodiments the higher tensile wires are spaced at about 75 mm and the other wire is spaced at about 50 mm. In some embodiments the higher tensile wires are spaced at about 100 mm and the other wire is spaced at about 50 mm.

In some embodiments the higher tensile wires are spaced at about 125 mm and the other wire is spaced at about 75 mm.

In some embodiments the higher tensile wires are spaced at about 175 mm and the other wire is spaced at about 100 mm.

In some embodiments the longitudinal wire and transverse wires are of substantially the same diameter (i.e. plus or minus 20%). Preferable the longitudinal and transverse wires are the same diameter.

In some embodiments the wires are about 2.5 to 2.8 mm in diameter. In some embodiments the wires are about 2.8 to 3.15 mm in diameter. In some embodiments the ultimate tensile strength of the longitudinal wire is at least about 1235, 1250, 1300, 1350, 1400,1450, 1500, or 1550 MPa.

In some embodiments the ultimate tensile strength of the transverse wire is at least about 700, 710, 720, 730, 740, 750, 760, 770, 780, 790, 800, 810, 820, 830, 840, 850, 860, 870, 880, 890, 900, 910, 920, 930, 940, 950, 960, 970, 980, 990, 1000, 1010, 1020, 1030, 1040 or 1050 MPa.

In some embodiments the transverse wires are a medium tensile wire having a tensile strength of between about 700 to 1050 MPa, and more preferably between about 950 to 1050 MPa.

In some embodiments the higher tensile wire has an ultimate tensile strength of about 1050 to 1235 MPa.

In some embodiments die higher tensile wire has an ultimate tensile strength of about 1235 to 1550 MPa.

In some embodiments the lower tensile wire has an ultimate tensile strength of about 800 to 950 MPa. In some embodiments the lower tensile wire has an ultimate tensile strength of about 950 to 1050 MPa.

In a furdier embodiment the ultimate tensile strength of the transverse wire is less than that of die longitudinal wires. Preferably die longitudinal wire is a high tensile wire and the transverse wire is a medium tensile wire. Preferably the medium tensile wire has an ultimate tensile strengtii less than about 1050 MPa and more than about 950 MPa. Most preferably the medium tensile wire has an ultimate tensile strength of between about 800 to about 950 MPa.

In some embodiments the wires have a diameter of about 2.00, 2.05, 2.10, 2.15, 2.20, 2.25, 2.30, 2.35, 2.40, 2.45, 2.50, 2.55, 2.60, 2.65, 2.70, 2.75, 2.80, 2.85, 2.90, 2.95, 3.0, 3.05, 3.1, 3.15, 3.20, 3.25, 3.30, 3.35, 3.40, 3.45, 3.50, 3.55, 3.60, 3.65, 3.70, 3.75, 3.80 or 3.85 mm. In some embodiments the wires are of about 2.8 mm in diameter with, for example, the higher tensile wires being, for example, of about 1235 MPa ultimate tensile strength and about 864 MPa lower characteristic yield strengdi while the other wire set is of about 800 MPa ultimate tensile strength and about 560 MPa lower characteristic yield strengdi.

In some embodiments the wires are of about 3.15 mm in diameter with, for example, the higher tensile wires being, for example, of about 1235 MPa ultimate tensile strength and about

864 MPa lower characteristic yield strength whilst die other wire set is of about 800 MPa ultimate tensile strength and about 560 MPa lower characteristic yield strength. In some embodiments the mesh is of such wires all of 2.5 mm diameter with longitudinal wires being the higher tensile wires being spaced at, for example, 100 mm spaced longitudinal wire and 50 mm spaced transverse wire.

In some embodiments the mesh is formed by wires all of 2.8 mm diameter with longitudinal wires being the higher tensile wires being spaced at, for example, 75 mm (if for example house foundations or floors) or about 125 mm (if for footpaths and driveways) with transverse medium tensile steel spaced respectively at 50 mm and 75 mm.

In some embodiments the mesh is formed by wires all of 3.15 mm diameter with longitudinal wires being the higher tensile wires being spaced at, for example, 100 mm or 4 inches (if for example house foundations or floors) or about 175 mm or 7 inches (if for footpaths and driveways) with transverse medium tensile steel spaced respectively at 50 mm and 100 mm.

In one embodiment the transverse wire is more workable than the longitudinal wire. As used herein the term "workable" means that the wire has an increased ability to undergo inelastic deformations with litde or no reduction in load carrying capacity. In some embodiments die transverse wires are better able to be wound than die longitudinal wires about a tight winding access and to remain wound i.e. has less resilience and/or tendency to break.

In some embodiments the, or each, knotting wire is formed as forged or tied knots.

In some embodiments the short knotting wire is present at most crossings of the spaced longitudinal and spaced transverse wires. More preferably the short knotting wire is present at each crossing of a longitudinal and transverse wire.

In some embodiments the, or each, knotting wire have an ultimate tensile strength of between about 380 to 500 MPa.

In some embodiments the diameter of die, or each, knotting wire is between about 2.5 to 2.8 mm.

In some embodiments the mesh is in a roll form with die longitudinal wire winding about the roll.

In some embodiments the load capability of the mesh per square meter is substantially the same in longitudinal and transverse directions. In some embodiments the mesh is absent any protruding wire ends.

In some embodiments the longitudinal and transverse wires are not interwoven. In one embodiment the forged or tied knot noded mesh is absent outstands of wire.

In some embodiments the higher tensile steel wire runs longitudinally of the mesh and the mesh has such longitudinal wires in the roll with the transverse wires extending length wise of the roll. In some embodiments the wire tying the grid together is a soft tensile wire preferably of the same diameter. Preferably the diameter is between 2.5, 2.6, 2.7 or 2.8 mm, more preferably 2.5 mm. Preferably the ultimate tensile strength is about 380, 390, 400, 410, 420, 430, 440, 450, 460, 470, 480, 490, or 500 MPa.

In some embodiments die tie is substantially as herein described widi reference to any one or more of the accompanying drawings.

In some embodiments the free ends of each transverse wire is wound about a longitudinal high tensile wire.

In a further aspect die invention consists in a concrete matrix reinforced by steel mesh, where the mesh has one or more of the following characteristics: a) the mesh is not welded b) there are longitudinal and transverse wires defining nodes that, away from the perimeter, are tied by a separate length of wire c) the longitudinal and transverse wires define rectangular forms as opposed to square forms d) the mesh has been sourced from a roll e) the mesh has a similar tensile loading capability both longitudinally and transversely, not withstanding the fact that the longitudinal wires are of higher tensile steel than the transverse wires f) die spacing of the transverse wires is closer than for the longitudinal wires, and g) the transverse wires finish with a wrap by such transverse wire of a flanking longitudinal wire.

Preferably the mesh has any one or more of the characteristics hereinafter described but need not be tied to such characteristics.

Preferably die mesh has all of characteristics (a) to (g). In a further aspect die invention consists in, as a roll, a reinforcement mesh as previously defined. In a further aspect the invention consists in a reinforcement mesh without protruding wire ends, defining rectangular openings and having in one direction high tensile wire and in the orthogonal direction medium tensile wire.

In still a further aspect, the present invention consists in a use of (at least in part) knotted mesh of any of the kinds previously described in accordance with the present invention for the purpose of concrete reinforcement.

In still further aspects the invention is a method of reinforced concrete construction (whether floors, paths, building, or the like, or not) which comprises or includes lapping or associating sheets of mesh of any of the kinds of the present invention so as to provide (A) with tying, clipping, or like, or not, and/ or (B) with subsequently imposed concrete to act in compression or shear, a reinforcement link between sheets to carry tensile forces, and embedding the mesh sheets in the wet concrete composition and allowing set.

In some embodiments there is some lapping. Preferably there is tying, clipping or the like. There can be both. In still further aspects the invention is the outcome of such a method.

In yet a further aspect of the present invention consists in reinforced concrete that is relied upon the use of mesh in accordance with the present invention.

In yet a further aspect the present invention consists in reinforcement mesh substantially as hereinafter described with reference to any one or more of the accompanying drawings.

In yet a further aspect of the present invention consists in rectangular mesh forms of wire at least substantially tied one to another by knots provided by wire in addition to those extending longitudinally and transversely.

In some embodiments there are much fewer high tensile wires than there are transverse medium tensile wires in the expanse of mesh and likewise for any square meter of mesh.

Reference hereinbefore with reference to "longitudinal" or "longitudinally" and "transverse" or "laterally" preferably refers to longitudinal and transverse of an elongate mesh form with the roll involving the longitudinal expanse being rolled such that the transverse wires run length wise of the resulting roll. The term "comprising" as used in this specification means "consisting at least in part of.

When interpreting statements in this specification which include that term, the features, prefaced by that term in each statement, all need to be present but other features can also be present. Related terms such as "comprise" and "comprised" are to be interpreted in the same manner. As used herein, the term "concrete" refers to all types of cementitious matrix (whether including Pordand cement or not) irrespective of aggregate(s) used.

As used herein "substantially the same" means within 20% (and more preferably within 10%) (and most preferably within 5%). The term "comprising" as used in this specification and claims means "consisting at least in part of". When interpreting statements in this specification and claims which include that term, the features, prefaced by that term in each statement, all need to be present but other features can also be present. Related terms such as "comprise" and "comprised" are to be interpreted in the same manner. To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from die scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting. Preferred forms of the present invention will now be described with reference to the accompanying drawings

BRIED DESCRIPTION OF THE DRAWINGS

The invention will now be described by way of example only and with reference to the drawings in which: Figure 1 shows a mesh of prior art generally formed by having horizontal and vertical wires of 5.3 mm or 4.0 mm diameter welded to one another,

Figure 2 shows a mesh of the prior art that when placed adjacent to each other must overlap their edges until the end parallel wires are adjacent,

Figure 3 shows a mesh of the present invention having wider placed longitudinal and transverse wires suitable for, for example, footpaths and driveways,

Figure 4 is a cross sectional view of a mesh system of Figure 3, Figure 5 is a isometric view of the wire system of Figure 3, Figure 6 is a knotting wire to bind longitudinal and transverse wires, Figure 7 is a mesh forming machine used to produce the mesh of the present invention, Figure 8 is a mesh of the present invention having a closer formed longitudinal and transverse wires suitable for use in, for example, house foundations,

Figure 9 is a cross sectional view of the mesh system of Figure 8, Figure 10 is an isometric view of the mesh system of Figure 8, and Figure 11 shows a side view of the mesh of the present invention rolled into a roll form for storage prior to unrolling and use.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to a concrete matrix reinforced by steel mesh, where the steel mesh has one or more of the following characteristics:

1. not welded

2. has longitudinal and transverse wires defining nodes, that away from the perimeter, are tied by a separate length of wire,

3 the longitudinal and transverse wires define rectangular forms as opposed to square forms,

4 the mesh has been sourced from a roll,

5. the mesh has a similar tensile loading capability both longitudinally and transversely, not withstanding the fact that the longitudinal wires are of a higher tensile steel than the transverse wires, 6. the spacing of the transverse wires is closer together than the spacing of the longitudinal wires and, 7 the transverse wires finish with a wrap by having a flanking longitudinal wire that flanks the end of the transverse wires.

The invention may also relate to the reinforcement mesh that is formed from space parallel longitudinal wires and space transverse wires that are connected together by short knotting wires, preferably one for each crossing of a longitudinal wire by transverse wire, where the tensile strength of the mesh is substantially the same longitudinally as it is transversely

Figuie 1 shows the general form of the prior art reinforcement meshes that generally consist of 5 3 mm diameter wires with 150 mm centres that are welded to one another to form a rigid sheet These sheets are generally sized to 1.97 m by 4.56 m and are thus difficult to store and use owing to their size and weight. Conventional sheets with using 5.3 mm diameter wire with 150 mm centres comprise about 1353 cm ³ of steel per square meter and for conventional sheets with 300 mm centres.

Figure 2 shows the overlapping between two adjacent sheets of the prior art. The transverse wires 1 must be overlapped with the terminal transverse wires of the adjacent sheet as shown in Figure 2. The purpose of the lap is to generate the full tensile strength of the reinforcement (the lapped section has at least as higher strength as the parent reinforcement material) The lap length is typically detailed to be at least long enough to generate this full capacity. Owing to this lapping, that could potentially be on all four sides of a sheet, the effective cover of each sheet is reduced by around 20%.

Also, welding of conventional mesh can adversely affect the strength and ductility of the wires. Ductility is defined as the ability to undergo inelastic deformations with little or no reduction in load carrying capacity. The reinforcement mesh of the present invention does not have this problem since it does not use welding to fix the transverse and longitudinal wires to each other.

New Zealand standard NZS 3101 provides a series of requirements for the lapping lengths need in reinforcing mesh, both when considering and when ignoring the presence of the transverse wires. A number of the requirements are proportional to the spacing of the wires.

Widi conventional welded wire mesh, each square is typically 150 mm, requiring a minimum lap length of 240 mm. This means that the effective cover of a 8.98 m ² standard sheet (4.56 m x 1.97 m) is 7.52 m ² . The actual size of a standard sheet, including overhangs, is 4.56 m x 1.97 m, which comprises 14 high wires at 150 mm centres and 31 across wires at 150 mm centres. This lapping results in approximately 20% decrease in effective cover.

Figures 1 and 2 also show that the sheets of the prior art, owing to the overhanging nature of the transverse 1 and longitudinal wires 2 beyond the terminal transverse 3 and longitudinal 4 wires, can be dangerous as the ends of the wires aie sharp and can cause injury.

Figures 3 to 5 show a sheet of mesh of the present invention having transverse 1 and longitudinal 2 wires that are held to each other by shoit knotting wires 5 The terminal longitudinal wire 4 is placed such that there is no o\ erhanging of the transverse wires 1 beyond that of the terminal longitudinal wire 4. The terminal longitudinal wire 4 is held to the sheet by the 1 transverse wires 1 coiling around the terminal longitudinal wire 4

An advantage of the reinforcement mesh of the present invention over the prior art conventional mesh is that it achieves the same strength per metre as conventional mesh, but uses less wire. This is achieved as the strength of the wire of the reinforcement mesh of the present invention wire is considerably higher

Therefore the ratio of gross/nett coverage areas for the reinforcement mesh of the present invention is higher than for conventional mesh Figure 6 shows a short knotting wire 5 that can be used to attach the transverse 1 and longitudinal 2 wires to each other. It should be appreciated that various designs can be used as knots to attach the transverse 1 and longitudinal 2 wires. Shown in Figure 7 is the sort of machine that could be used to make a mesh of the present invention. The advantage of using knotting wire is that they allow some slip under an applied load, allowing the transverse wires to slide on the longitudinal wires. This is advantageous, especially for early age shrinkage control in concrete. In comparison, welded knots are rigid, with the transverse wires locked to the longitudinal wires. The mesh of Figures 3 to 5 generally have a diameter of about 2.00, 2.05, 2.10, 2.15, 2.20,

2.25, 2.30, 2.35, 2.40, 2.45, 2.50, 2.55, 2.60, 2.65, 2.70, 2.75, 2.80, 2.85, 2.90, 2.95, 3.0, 3.05, 3.1, 3.15, 3.20, 3.25, 3.30, 3.35, 3.40, 3.45, 3.50, 3.55, 3.60, 3.65, 3.70, 3.75, 3.80, 3.85 mm, and useful ranges may be selected between any of these values (for example, about 2 to about 3.85, about 2 to about 3.70, about 2 to about 3.5, about 2 to about 3.4, about 2.1 to about 3.85, about 2.1 to about 3.7, about 2.1 to about 3.6, about 2.1 to about 3.5, about 2.3 to about 3.85, about 2.3 to about 3.70, about 2.3 to about 3.6, about 2.3 to about 3.5, about 2.4 to about 3.85, about 2.4 to about 3.70, about 2.4 to about 3.6, about 2.4 to about 3.5, about 2.5 to about 3.85, about 2.5 to about 3.7, about 2.5 to about 3.6, about 2.5 to about 3.5, about 2.2 to about 2.3, about 2.2 to about 2.5, about 2.2 to about 2.7, about 2.2 to about 2.9, about 2.2 to about 3.1, about 2.2 to about 3.3, about 2.2 to about 3.5, about 2.3 to about 2.5, about 2.3 to about 2.7, about 2.3 to about 2.9, about 2.3 to about 3.1, about 2.3 to about 3.3, about 2.3 to about 3.5, about 2.4 to about 2.6, about 2.4 to about 2.8, about 2.4 to about 3, about 2.4 to about 3.2, about 2.4 to about

3.4, about 2.5 to about 2.6, about 2.5 to about 2.8, about 2.5 to about 3, about 2.5 to about 3.2, about 2.5 to about 3.4, about 2.6 to about 2.7, about 2.6 to about 2.9, about 2.6 to about 3.1, about 2.6 to about 3.3, about 2.6 to about 3.5, about 2.7 to about 2.9, about 2.7 to about 3.1, about 2.7 to about 3.3, about 2.7 to about 3.5, about 2.8 to about 3, about 2.8 to about 3.2, about 2.8 to about 3.4, about 2.9 to about 3, about 2.9 to about 3.2, about 2.9 to about 3.4, about 3 to about 3.1, about 3 to about 3.3, about 3 to about 3.5, about 3.1 to about 3.3, about 3.1 to about

3.5, about 3.2 to about 3.4, about 3.3 to about 3.4 or about 3.4 to about 3.5 mm). As seen in Figures 8 to about 10 are mesh sheets of the present invention having a slightly smaller spacing between the transverse 1 and/or longitudinal 2 wires. Such a mesh would be suitable for, for example, house foundations and floors. As shown for the mesh system of Figures 3 to 5, the mesh system of Figures 8 to 10 has a terminal longitudinal wire 4 that is affixed to the transverse wires 1. Various methods can be used to fix the transverse 1 and terminal longitudinal wire 4 such as the end portion of a transverse wire 1 are wrapped about the terminal longitudinal wire 4. It should be appreciated that other methods could be used to attach the terminal longitudinal wire 4 to the transverse wires 1.

In one aspect of the invention the transverse wires 1 are less brittle than the longitudinal wires 2. In a further embodiment of the invention the transverse wires 1 are more malleable than the longitudinal wires 2.

In one embodiment the transverse wires 1 are more workable than the longitudinal wires 2. As used herein the term "workable" means has an increased ability to undergo inelastic deformations with litde or no reduction in load carrying capacity.

In a furdier embodiment the tensile strength of the transverse wires 1 is less than that of the longitudinal wires 2.

Preferably the tensile strength of the longitudinal wire 2 is 1235, 1250, 1300, 1350, 1400,1450, 1500, or 1550 MPa, and useful ranges may be selected between any of these values (for example, about 1235 to about 1250, about 1235 to about 1300, about 1235 to about 1350, about 1235 to about 1400, about 1235 to about 1450, about 1235 to about 1500, about 1235 to about 1550, about 1250 to about 1300, about 1250 to about 1350, about 12350 to about 1400, about 1250 to about 1450, about 1250 to about 1500, about 1250 to about 1550, about 1300 to about 1350, about 1300 to about 1400, about 1300 to about 1450, about 1300 to about 1500, about 1300 to about 1550, about 1350 to about 1400, about 1350 to about 1450, about 1350 to about 1500, about 1350 to about 1550, about 1400 to about 1450, about 1400 to about 1500, about 1400 to about 1550, about 1450 to about 1500, about or 1450 to about 1550 MPa).

In one embodiment the transverse wires 1 are formed from a medium tensile wire having a tensile strength of less than about 1050 MPa and preferably more than about 950 MPa. In some embodiment the tensile strength of the transverse wire 1 is about 700, 710, 720,

730, 740, 750, 760, 770, 780, 790, 800, 810, 820, 830, 840, 850, 860, 870, 880, 890, 900, 910, 920, 930, 940, 950, 960, 970, 980, 990, 1000, 1010, 1020, 1030, 1040, 1050 MPa, and useful ranges may be selected between any of these values (for example, about 700 to about 1050, about 750 to about 1050, about 780 to about 1050, about 700 to about 1000, about 750 to about 1000, about 780 to about 1000, about 700 to about 900, about 750 to about 900, about 780 to about 900, about 800 to about 810, about 800 to about 830, about 800 to about 850, about 800 to about 870, about 800 to about 890, about 800 to about 910, about 800 to about 930, about 800 to about 950, about 800 to about 970, about 800 to about 990, about 800 to about 1010, about 800 to about 1030, about 800 to about 1050, about 810 to about 830, about 810 to about 850, about 810 to about 870, about 810 to about 890, about 810 to about 910, about 810 to about 930, about 810 to about 950, about 810 to about 800, about 810 to about 990, about 810 to about 1010, about 810 to about 1030, about 810 to about 1050, about 820 to about 840, about 820 to about 860, about 820 to about 810, about 820 to about 900, about 820 to about 920, about 820 to about 940, about 820 to about 960, about 820 to about 980, about 820 to about 1000, about 820 to about 1020, about 820 to about 1040, about 830 to about 840, about 830 to about 860, about 830 to about 880, about 830 to about 900, about 830 to about 920, about 830 to about 940, about 830 to about 960, about 830 to about 980, about 830 to about 1000, about 830 to about 1020, about 830 to about 1040, about 840 to about 850, about 840 to about 870, about 840 to about 890, about 840 to about 910, about 840 to about 930, about 840 to about 950, about 840 to about 970, about 840 to about 990, about 840 to about 1010, about 840 to about 1030, about 840 to about 1050, about 850 to about 870, about 850 to about 890, about 850 to about 910, about 850 to about 930, about 850 to about 950, about 850 to about 970, about 850 to about 990, about 850 to about 1010, about 850 to about 1030, about 850 to about 1050, about 860 to about 880, about 860 to about 900, about 860 to about 920, about 860 to about 940, about 860 to about 960, about 860 to about 980, about 860 to about 1000, about 860 to about 1020, about 860 to about 1040, about 870 to about 880, about 870 to about 900, about 870 to about 920, about 870 to about 940, about 870 to about 960, about 870 to about 980, about 870 to about 1000, about 870 to about 1020, about 870 to about 1040, about 880 to about 890, about 880 to about 920, about 880 to about 940, about 880 to about 960, about 880 to about 980, about 880 to about 1000, about 880 to about 1020, about 880 to about 1040, about 890 to about 900, about 890 to about 920, about 890 to about 940, about 890 to about 960, about 890 to about 980, about 890 to about 1000, about 890 to about 1020, about 890 to about 1040, about 900 to about 910, about 900 to about 930, about 900 to about 950, about 900 to about 970, about 900 to about 990, about 900 to about 1010, about 900 to about 1030, about 900 to about 1050, about 910 to about 930, about 910 to about 950, about 910 to about 970, about 910 to about 990, about 910 to about 1010, about 910 to about 1030, about 910 to about 1050, about 920 to about 940, about 920 to about 960, about 920 to about 980, about 920 to about 1000, about 920 to about 1020, about 920 to about 1040, about 930 to about 940, about 930 to about 960, about 930 to about 980, about 930 to about 1000, about 930 to about 1020, about 930 to about 1040, about 940 to about 950, about 940 to about 970, about 940 to about 990, about 940 to about 1010, about 940 to about 1030, about 940 to about 1050, about 950 to about 970, about 950 to about 990, about 950 to about 1010, about 950 to about 1030, about 950 to about 1050, about 960 to about 980, about 960 to about 1000, about 960 to about 1020, about 960 to about 1040, about 970 to about 980, about 970 to about 1000, about 970 to about 1020, about 970 to about 1040, about 980 to about 990, about 980 to about 1010, about 980 to about 1030, about 980 to about 1050, about 990 to about 1010, about 990 to about 1030, about 990 to about 1050, about 1000 to about 1020, about 1000 to about 1040, about 1010 to about 1020, about 1010 to about 1040, about 1020 to about 1030, about 1020 to about 1050 or about 1040 to about 1050 MPa). It should be appreciated that common wires are of a circular cross section. In some embodiments the wires are of about 2 8 mm in diameter with, for example, the higher tensile wires being, for example, of about 1235 MPa tensile strength and about 864 MPa yield strength whilst the other wire set is of about 800 MPa tensile strength and about 560 MPa yield strength. In some embodiments the wires are of about 3.15 mm in diameter with, for example, the higher tensile wires being, for example, of about 1235 MPa tensile strength and about 864 MPa yield strength whilst the other wire set is of about 800 MPa tensile strength and about 560 MPa yield strength.

In some embodiments the mesh is of such wires all of 2.5 mm diameter with longitudinal wires 2 being the higher tensile wires being spaced at, for example, 100 mm spaced longitudinal wire and 50 mm spaced transverse wire

In some embodiments the mesh is of such wires all of 2.8 mm diameter with longitudinal wires 2 being the higher tensile wires being spaced at, for example, 75 mm (if for example house foundations or floors) or about 125 mm (if for footpaths and driveways) with transverse medium tensile steel wires spaced respectively at 50 mm and 75 mm.

In some embodiments the mesh is of such wires all of 3 15 mm diameter widi longitudinal wires 2 being the higher tensile wires being spaced at, for example, 100 mm or 4 inches (if for example house foundations or floors) or about 175 mm or 7 inches (if for footpaths and driveways) with transverse medium tensile steel wires spaced respectively at 50 mm and 100 mm.

In one embodiment the load capability of a square meter of mesh is substantially the same in both longitudinal and transverse directions

An advantage of the current invention is that mesh can be rolled up to form a roll as diat shown in Figure 11. This allows the mesh to be easily stored at retail outlets as well as provides for easier transport and deployment at the construction scene. The clear advantage of a rolled up reinforcement mesh is that it can simply be laid down and then rolled out to form the reinforcement mesh prior to the pouring of the concrete.

In one embodiment the mesh may be coated with a substance such as to be galvanised. Such mesh may have a standard layer of galvanisation or may have a very thin layer of galvanisation applied to the "bright wire". Such a light coating provides more corrosion resistance for specific construction applications and may reduce the amount of concrete coverage required over the top of the present invention. Such a light coating also provides aesthetic wire as well as being easier and more preferable to handle. With the sheets of the present invention, because they employ a terminal longitudinal wire 4, the terminal longitudinal wires 4 of each adjacent sheet are merely placed adjacent to each other and then attached to each other by the use of, for example, ties or the like.

As shown in Figure 11 , rolls in accordance with the present invention can be, for example, 30 m long with a roll length (i.e. die expanse of the transverse wires being, for example, 1.8 m). A 30 m by 1.8 m roll with no protruding wires or only protrusions of longitudinal wires at the end of die roll is able to cover 54 square meters and can be used with little in the way of lapping. Strips edgewise can be clamped one to another by appropriate clamping arrangements substantially as hereinafter described with or without reference to any one or more of the accompanying drawings.

In some embodiments that need for extensive lapping of both transverse and longitudinal end wires as seen with the prior art sheets previously mentioned is reduced, as long as the lapping meets the requirements of the current building code. In one embodiment, the use of reinforcement mesh of the present invention without lapping can be achieved using a joining mechanism that is sufficiendy strong and ductile. In those embodiments that do not use lapping o f the edges of the reinforcement mesh, they can lead to at least about 10—20% more efficient coverage.

In some alternative embodiments some degree of lapping may be required. However, the clear advantage of the reinforcement mesh of the present invention is that, even with some degree of lapping, the reinforcement mesh of the present invention uses less steel per square meter of coverage yet retains the same reinforcement strength.

It is envisaged that rolls can be provided up to, for example, about 2.4 m wide without introducing unnecessarily hand difficulties at manufacture, distribution, or retail. It is also important in so far as die end user is concerned that the rolls can be rolled out as appropriate and cut. Another example of the rolls is that they are larger than conventional mesh, and thus result in less end laps per linear metre of run.

It should be appreciated that one advantage of eth present invention is that the rolls can be provided in any length. For example, the width could be of any length up to a maximum width of the manufacturing machine. Typically the maximum width is about 2.4 m, and so rolls of any width up to this could be produced. As the reinforced mesh is "extruded" through the machine, the roll can be of any length. This is an advantage because if there are no connection points in the length direction, then there is no need to attach one reinforced mesh to the next. A problem with conventional reinforcement mesh is that they are produced in set sizes of, for example, 1.97 m by 4.56 m. This means connection of adjacent mesh is unavoidable, which brings with it the issues of lapping and a reduction of effective coverage.

When in use the roll is transported to the site of use and unrolled. The roll can of course be cut to an appropriate si2e to fit the area to be concreted. Once the concrete is poured, which will be to a height appropriate to the end use of the concreted area, will of course sit at the bottom of the concrete. The reinforced mesh can be raised up by using a hook that when pressed into the concrete will hook the mesh and can be used to raised it up through the concrete, such that the mesh sits within the concrete. In some embodiments the mesh is raised so that it is about halfway up through the concrete. In other embodiments a "bar chair" is attached to the mesh to raise it of the ground.

Therefore, once the concrete is poured the mesh will sit within the concrete.

It will be appreciated that the amount that the mesh is raised from the ground (and thus where the mesh sits within the concrete) can be adjusted to account for the desired positioning of the mesh in the concrete. Where in the foregoing description reference has been made to elements or integers having known equivalents, then such equivalents are included as if they were individually set forth.

Although the invention has been described by way of example and with reference to particular embodiments, it is to be understood that modifications and/or improvements may be made without departing from the scope or spirit of the invention.

EXAMPLES

1. Reinforcement mesh for foundations or floors

This example describes a reinforcement mesh of the present invention for use in footpaths. A mesh manufacturing machine as shown in Figure 7 is fed with 3.15 mm wire for both the transverse and longitudinal wires to produce a reinforcement mesh 1.8 m wide

(transverse) and 30 m long (longitudinal) having the longitudinal wires spaced 100 mm and the transverse wires spaced 50 mm. The wire used for the longitudinal wire is high tensile wire with

- an ultimate tensile strength of about 1235 MPa and a yield strength of about 864 MPa. The wire used for the transverse wire is medium tensile wire having an ultimate tensile strength of about 800 MPa and a yield strength of about 560 MPa. This results in a reinforcement mesh having a strength of about 71 kN/m. Short knotting wires are used at every intersect of longitudinal and transverse wires, except for the terminal intercepts about the periphery of each mesh sheet, that have a diameter of 2 5 mm and a length of about 32 mm.

A mesh of these dimensions has a volume of steel per square meter of mesh of about 1105 cm', compared to 1353 cm for a conventional welded wire mesh that uses 5.3 mm diameter transverse and longitudinal wires spaced at 150 mm.

The manufacturing of this reinforcement mesh produces a roll that can be easily transported to the site of use. The roll is unrolled over the area to be concreted Where the area to be concreted has a width and/or length greater than that of a single roll, then two rolls are used, that are connected to each other along the terminal longitudinal or transverse wires where needed.

Following the concreting the a wire hook is used to pull the mesh into the middle of the concrete so that the reinforcement mesh sits halfway between the bottom and the top of the concrete. 2. Reinforcement mesh for footpaths and driveways

This example describes a reinforcement mesh of the present invention for use in footpaths and driveways. A mesh manufacturing machine as shown in Figure 7 is fed with 3.15 mm wire for both the transverse and longitudinal wires to produce a reinforcement mesh 1.8 m wide (transverse) and 30 m long (longitudinal) having the longitudinal wires spaced 175 mm and the transverse wires spaced 100 mm. The wire used for the longitudinal wire is high tensile wire with an ultimate tensile strength of about 1235 MPa and a yield strength of about 864 MPa. The wire used for the transverse wire is medium tensile wire having an ultimate tensile strength of about 800 MPa and a yield strength of about 560 MPa. This results in a reinforcement mesh having a strength of about 40 kN/m. Short knotting wires are used at every intersect of longitudinal and transverse wires, except for the terminal intercepts about the periphery of each mesh sheet, that have a diameter of 2 5 mm and a length of about 32 mm.

A mesh of these dimensions has a volume of steel per square meter of mesh of about 579 cm ¹ , compared to 765 cm ³ for a conventional welded wire mesh that uses 5 3 mm diameter transverse and longitudinal wires spaced at 300 mm.

The manufacturing of this reinforcement mesh produces a roll that can be easily transported to the site of use. The roll is unrolled over the area to be concreted using bar chairs to raise the mesh up from the ground such that after concreting the mesh sits about midway in the height of the concrete. Where the area to be concreted has a width and/or length greater than that of a single roll, then two rolls are used, that are connected to each other along the terminal longitudinal or transverse wires where needed.

3. Reinforcement mesh for footpaths and driveways This example describes a reinforcement mesh of the present invention for use in footpaths and driveways. A mesh manufacturing machine as shown in Figure 7 is fed with 2.5 mm wire for both the transverse and longitudinal wires to produce a reinforcement mesh 1.8 m wide (transverse) and 30 m long (longitudinal) having the longitudinal wires spaced 100 mm and the transverse wires spaced 50 mm. The wire used for the longitudinal wire is high tensile wire with an ultimate tensile strength of about 1235 MPa and a yield strength of about 864 MPa. The wire used for the transverse wire is medium tensile wire having an ultimate tensile strength of about 800 MPa and a yield strength of about 560 MPa.

Short knotting wires are used at every intersect of longitudinal and transverse wires, except for the terminal intercepts about the periphery of each mesh sheet, that have a diameter of 2.5 mm and a length of about 32 mm.

A mesh of these dimensions has a volume of steel per square meter of mesh of about 736 cm ³ , compared to 765 cm for a conventional welded wire mesh that uses 5.3 mm diameter transverse and longitudinal wires spaced at 300 mm.

The manufacturing of this reinforcement mesh produces a roll that can be easily transported to the site of use. The roll is unrolled over the area to be concreted. Where the area to be concreted has a width and/or length greater than that of a single roll, then two rolls are used, that are connected to each other along the terminal longitudinal or transverse wires where needed.

Following the concreting the a wire hook is used to pull the mesh into the middle of the concrete so that the reinforcement mesh sits halfway between the bottom and the top of the concrete.