CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to pending U.S. Provisional Patent Application No. 62/189,950 filed on July 8, 2015 which is incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The present invention generally relates to a barrier system and, more particularly, to a greener and more cost-effective high-strength, durable and weather resistant barrier and fencing system.

BACKGROUND

[0003] State Departments of Transportation (DOT) are required to use federally approved materials for highway guardrail systems. These materials are very expensive when new as they must be manufactured according to the rigorous standards set by the American Association of State Highway and Transportation Officials (AASHTO) in order to obtain DOT approval for highway guardrail use. ASSHTO is tasked with setting the standards for quality, strength, durability, and weather resistance of highway guardrail materials to make them incredibly strong with a nearly infinite lifespan once installed. The stated mission of AASHTO is to advocate transportation-related policies and provide technical services to support states in their efforts to efficiently and safely move people and goods.

[0004] As part of that ongoing effort, AASHTO promulgates standards for highway guardrail systems in its AASHTO-AGC-ARTBA Joint Subcommittee on New Highway Materials Task Force 13 Report, entitled "A Guide to Standardized Highway Barrier Hardware." This Guide specifies the standards for each component that may be used in approved guardrail systems, which standards generally consist of detailed drawings of acceptable materials, along with detailed specifications and the intended use for each. The standards wherein AASHTO regulates guardrail panel specified for DOT approval include, but are not limited to: (i) the type of steel used in the manufacturing of highway guardrail; (ii) the required thicknesses of the specified steel used to produce highway guardrail; (iii) the thickness of the corrosion resistant coating applied to guardrail barrier structural materials; and (iv) the lengths, widths, exact hole punching and other dimensions for DOT guardrail to be approved for installation on US highways.

[0005] All standard highway guardrail panels are equally bound by AASHTO standards when newly manufactured. AASHTO approved W-beam guardrails must, for example, be 31 1 (12.25 inches) in width and have a specific cross-section where the shape resembles the letter "VV" by exhibiting two waves on the outer surface. Thrie- beam guardrails have three waves instead of two, and measure 508 mm (20 inches) in width. The metal specified in the guardrail specifications is the same AASHTO M 270 / M 270M grade steel set forth above.

[0006] The thickness of these guardrails is designed specifically for impact resistance and absorption, thereby requiring a much stronger barrier than is needed in other applications, such as agricultural fencing. U.S. Patent No. 8, 127,419 to Calton teaches a system and method for converting used guardrail, formerly AASHTO- approved, into other barrier applications such as agricultural fencing. The guardrail in those applications are standard guardrail sections, which generally come in 12-gauge or 10-gauge metal, ranging from 2.67 mm (0.105 inches) thickness to 3.43 mm (0.135 inch) thickness steel. That guardrail is also galvanized per AASHTO requirements.

[0007] Although the system and methods set forth in U.S. Patent No. 8, 127,419 offer a beneficial and ultimately green solution to providing high-quality barrier systems from used, or repurposed, guardrail, the supply of even used AASHTO-approved guardrail is severely limited and generally fails to meet the demand. As such, many farmers and other users who prefer used guardrail find themselves in the position of having to purchase new guardrail designed for the higher-duty highway impact barrier

applications required by AASHTO. This represents a tremendous waste of materials and energy because the AASHTO materials are far greater in thickness and coating than required for other applications.

[0008] As a result of agricultural sector growth, there now exists a strong demand for materials needed to construct affordable, permanent, efficient, safe, humane facilities, which coincide with the performance offered by DOT approved used highway guardrail panel. However, the national supply of salvaged DOT approved highway guardrail panel remains insufficient to keep pace with the projected demand of our nation's growing agriculture sector. With continued reinstallation of used highway guardrail on state DOT roadside projects, the supply of used highway guardrail being made available to the agricultural sector is decreasing, just as the need for such high performance material is increasing.

[0009] Barrier system panels compatible with the strength, durability, and weather resistance of standard DOT guardrail panel would be useful so long as it could be reconfigured and manufactured to be commensurate in price and physical profile with salvaged DOT guardrail panel. Yet no existing systems have met this need for thinner W-beam and Thrie-beam-guardrail-shaped panel materials using the more suitable, pre- galvanized coil for the production process.

SUMMARY OF THE INVENTION

[0010] It is an object of the invention to provide an improved livestock containment system which provides an environmentally sound solution incorporating recycled DOT approved guard rail material and purposefully manufactured guard rail material interchangeably.

[0011] A particular feature of the invention is the ability to provide a solution with an improved manufacturing process without reliance on used guard rail availability.

[0012] These and other embodiments, as will be realized, are provided in a guardrail-shaped barrier system comprising at least one guardrail section made of rolled metal with a thickness ranging from 0.80 mm (0.032 inches) to 2.6 mm (0.102 inches), wherein the rolled metal is galvanized before entering a roll forming mill.

[0013] Yet another embodiment is provided in a method of providing a guardrail- shaped barrier system comprising the steps of: providing a coil of galvanized steel, wherein the steel has a thickness of from 0.80 mm to 2.6 mm; slitting the coil into at least two scalp coils; cutting at least one scalp coil of said scalp coils into a specified length thereby forming a sized strip; punching the sized strip with at least one mounting hole; and rolling sized strip into a guardrail-shape forming a rail.

[0014] Yet another embodiment is provided in a method of providing a guardrail- shaped barrier system comprising the steps of: providing a coil of galvanized steel, wherein the steel has a thickness of from 0.80 mm to 2.6 mm; slitting the coil into at least two scalp coils; rolling the scalp coil into a guardrail-shaped form; and cutting the guardrail-shaped form into a length thereby forming a rail.

BRIEF DESCRIPTION OF FIGURES

[0015] Fig. 1 is a flow chart representation of an embodiment of the invention.

[0016] Fig. 2 is a schematic representation of an embodiment of the invention.

[0017] Fig. 3 is a schematic representation of an embodiment of the invention.

DESCRIPTION

[0018] The invention provides an affordable, high-strength, and durable barrier system useful in many applications, primarily agricultural fencing capable of preventing the passage of livestock according to one embodiment of the invention. The barrier system is an environmentally responsible, multi-functional, weather-resistant, reinforced barrier system employing roll-formed W-beam and Thrie-beam profiled guardrail materials which is galvanized prior to roll forming.

[0019] The present invention accomplishes the foregoing objects by reconfiguring the dimension of the thickness and method of construction of prior art systems and methods, allowing increased affordability in a barrier system commensurate with the strength, durability, and weather resistance of standard approved DOT guardrail materials in applications not requiring DOT materials approval. More specifically, the present invention provides a barrier system comprising W-beam profile and Thrie-beam profile steel beams with thicknesses within the range of 0.80 mm (0.032 inches) to 2.6 mm (0.102 inches) and constructed from pre-galvanized steel sheet in steel coil form. [0020] The invention is directed to lighter-duty applications, such as agricultural fencing. By contrast to the guardrail taught in U.S. Patent No. 8, 127,419, the invention uses much thinner guardrail. In this way, the invention saves a great deal of wasted raw materials by not requiring the much thicker metal found in AASHTO-approved guardrail. The invention also saves a great deal of refined materials by avoiding the hazardous galvanization process during production. Additionally, by using much less metal and zinc, the invention ultimately saves a great deal of energy in the

manufacturing process.

[0021] It is also expected that due to increased demand upon a lessening supply of salvaged DOT guardrail materials, the remaining product to which those end users have access may also now be too expensive to be employed. Providing for the production of a guardrail shaped panel, commensurate in performance, and with the ability to seamlessly integrate with pre-existing systems built with standard salvaged DOT guardrail panel, is a currently standing, and crucial need. This need is expected to grow with the increased demand of American agriculture.

[0022] An object of the invention is therefore to provide a system and method of providing a fencing and barrier panel manufactured to perform the same duties as salvaged DOT-approved guardrail materials, yet produced from a gauge, or thickness, of steel which is less than that required by DOT standards to redirect automobile traffic, while still sufficient in strength and durability to perform alternative barrier-system duties as set forth in U.S. Pat. No. 8,127,419.

[0023] A further object of the invention is to provide for the wider availability of materials so that local and national agriculture infrastructure may be offered both the salvaged DOT guardrail materials and a product manufactured specifically for the purpose of affordable W-beam- and Thrie-beam-shaped-guardrail panel barrier systems. Thereby, the accessibility of product would provide greater availability and affordability for current and future sustainable growth in many sectors while positively influencing the revitalization, functionality and safety of currently established livestock containment systems.

[0024] Another aspect of producing a lighter gauge guardrail animal containment panel is the effect of increased efficiency in shipping. Transporting these lighter gauge panels, which weigh approximately ½ that of a standard recycled DOT guardrail panel, means the per-foot transportation costs are greatly reduced as the linear footage of fencing transported per single truckload can be vastly increased. Thus, the design and method of production reduces demand for consumables needed for manufacture and also transport by reducing heavy vehicle road usage as fewer trucks will be required for shipping from warehouse to destination.

[0025] The fact that the lighter gauge, pre-galvanized panels can also be produced at nearly ½ the weight per foot also provides the reasonable option to increase the manufactured length of panels or rails beyond the 7.9 m (26 feet) length commonly employed. The potential of longer panels per unit could additionally increase the efficiency of installation within the variety of applications where non-ASHTO W- and Thrie- beam guardrail panel may be effectively applied.

[0026] The consistent production of a more affordable guardrail panel or rail that seamlessly merges with pre-existing recycled highway guardrail means that builders of animal storage, sorting and handling facilities will be able to continue their positive growth without concerns of being unable to source and/or afford sufficient materials when their businesses demand growth cycles requiring affordable, readily accessible guardrail panel materials. Consistent availability to W-beam and Thrie-beam guardrail panel also means that businesses and individuals constructing larger facilities will no longer be solely dependent upon a historically diminishing and/or inconsistent supply of salvaged DOT highway guardrail materials.

[0027] The unique design of the W-beam and Thrie-beam profiles set forth herein require no additional costs when integrating these new panels with the formerly available salvaged DOT panels, as the two systems integrate interchangeably although their construction method and physical thicknesses differ significantly. Therefore, livestock handling facilities having previously installed salvaged DOT highway guardrail materials will experience no additional costs while integrating the new, lighter gauge panel with preexisting guardrail designs.

[0028] Moreover, considering the various factors, such as scrap prices, which determine the pricing of reclaimed highway guardrail panel. The instant invention assures that the market which currently consumes the national surplus of used, recycled, DOT guardrail panel will continue to consume 100% of the useable product made available from Departments of Transportation nationwide with the end result being that both recycled, surplus DOT highway guardrail panel, and new, lighter gauge W-beam and Thrie-beam, guardrail will remain both affordable and available to a growing variety of end users.

[0029] The advent of a new, affordable, consistent product, which seamlessly integrates with standard recycled guardrail panel, will be a significant benefit for the continued growth and stability of industries which have grown increasingly conscious of and dependent upon the availability and performance of W-beam- and Thrie-beam- guardrail panel.

[0030] According to another aspect of the invention, an environmentally responsible, multifunctional, weather-resistant, reinforced barrier system is adapted from

manufactured W-beam and Thrie-beam profile guardrail materials comprising:

[0031] In one aspect of the invention, a guardrail-shaped barrier system is provided comprising at least one guardrail section made of rolled metal with a thickness ranging from about 0.80 mm (0.032 inches) to 2.6 mm (0.102 inches) and more preferably about 0.94 mm (0.037 inches) to about 2.55 mm (0.100 inches), wherein the rolled metal is galvanized before roll forming. The guardrail-shaped barrier system can be w-beam- shaped or thrie-beam-shaped. The guardrail-shaped barrier system can also be of any length, or it may be of non-standard lengths of at least 3.05 m (10 feet) to no more than 12.5 m (41 feet). In one embodiment the length is less than 3.81 m (12.5 feet) in length and in another embodiment greater than 7.9 m (26 feet) in length. In one embodiment the length is at least 3.81 m (12.5 feet) to no more than 7.9 m (26 feet) in length

[0032] In another aspect of the invention, a method is provided for a guardrail- shaped barrier system comprising the steps of: providing a galvanized master-coil of steel, wherein the steel ranges from about 0.80 mm (0.032 inches) to 2.62 mm (0.103 inches) and preferably 0.94 mm (0.037 inches) to about 2.55 mm (0.100 inches) in thickness; slitting the master-coil of steel into at least two narrower-width coils referred to as coil scalps; cutting the narrower-width coils scalps into a series of desired length members; punching each of the desired length members with at least one mounting hole; and rolling each of the desired length members into a W-beam guardrail or Thrie- beam guardrail-shaped form.

[0033] In this method, the narrower-width scalp coils can be 472.2 - 477.5 mm (18.6-18.8 inches) in width before roll-forming into w-beam, 731 .5-736.6 mm (28.8-29 inches) in width, before being rolled into thrie-beam. It is also possible that the desired length members are less than 3.81 m (12.5 feet) in length or greater than 7.9 m (26 feet) in length.

[0034] The resulting barrier system provides an excellent wind break for livestock during winter months and during storms because the materials used are weather- resistant, multi-functional and reinforced so as to provide an environmentally

responsible solution.

[0035] The invention will be described with reference to the figures forming an integral, non-limiting, part of the disclosure. In the various figures similar elements will be numbered accordingly.

[0036] The method of producing W- or Thrie-beam profile rails will be described with reference to Fig. 1 . In Fig. 1 a coil of steel is provided at 10 and the coil is galvanized by being coated with a permanent corrosive-resistant zinc coating at 12 thereby forming a master coil. This master coil is slit into narrower width coil at 14 thereby forming coil scalps wherein the coil scalps are at the target final dimensions which are preferably 304 mm (12 inches) to 317 mm (12.5 inches) and most preferably about 31 1 mm (12.25 inches) for W-beam or about 501 .6 mm (19.75 inches) to 514.3mm (20.25 inches) and more preferably about 508 mm (20 inches) for Thrie-beam-guardrails. The coil scalps are then placed into the W- or Thrie-beam-guardrail roll-forming line and rolled into the desired shape at 16 thereby forming a ribbon. The ribbon is cut into the specified lengths at 18 thereby forming rails which are preferably at least 4.1 m (13.5 feet) in length to no more than 7.9 m (26 feet) in length. These rails are optionally punched with proper holes per the customer order at 20 wherein the holes can be formed prior to rolling, prior to ribbon formation or as shown for simplicity in Fig. 1 . The rails are assembled at 22 forming a barrier. In some embodiments co-linear rails are overlapped resulting in a post separation of about 0.30 m (1 foot) less than the length of the rail. Alternatively, the coil can be cut to length at 18', to form sized strip, and then rolled into the desired shape at 16'. The sheet of pre-galvanized steel, having been cut-to-length and properly punched per customer application, is passed through a rolling-mill which shapes this prepared sheet into the W- or the Thrie-beam-guardrail profile. When the roll-forming process is complete, the panel is in the appropriate profile, and ready for stacking and shipment.

[0037] An embodiment of the invention will be described with reference to Fig. 2 wherein a barrier, generally represented at 100, utilizing W-beams, 102, is illustrated. In the barrier co-linear W-beams, referenced as 102a and 102b for the purposes of discussion, are overlapped an overlap distance, D, with at least one attachment element, 104, such as threaded bolts and mating nuts, which extend through aligned holes of the overlapped rails and secure the co-linear rails together and optionally, and preferably, to a post, 106. The overlap distance is preferably at least about 152 mm (6 inches) to no more than about 457 mm (18 inches) with about 304 mm (12 inches) being preferable. An overlap distance of less than about 152 mm may provide insufficient strength and an overlap distance of more than about 457 mm provides insufficient additional strength to justify the material use.

[0038] An embodiment of the invention will be described with reference to Fig. 3 wherein a barrier, generally represented at 200, utilizing Thrie-beams, 202, is illustrated. In the barrier co-linear Thrie-beams, referenced as 202a and 202b for the purposes of discussion, are overlapped an overlap distance, D, with at least one attachment element, 204, such as threaded bolts and mating nuts, which extend through aligned holes of the overlapped rails and secure the co-linear rails together and optionally, and preferably, to a post, 206. The overlap distance is preferably at least about 152 mm (6 inches) to no more than about 457 mm (18 inches) with about 304 mm (12 inches) being preferable. An overlap distance of less than about 152 mm may provide insufficient strength and an overlap distance of more than about 457 mm provides insufficient additional strength to justify the material use.

[0039] An advantage of the instant process is that the steel sheet has been previously galvanized, and rolled into a master coil. That master-coil of pre-galvanized sheet steel is then slit into thinner coil scalps. The galvanization has been applied before rolling. There are many beneficial factors to this process which does not require galvanizing facilities to be present. Guardrail roll-forming facilities do not require the storage and/or heating of multiple tons of zinc in a large, hazardous, hot molten metal vats which are commonly used for coating the finished highway guardrail product with a corrosion resistant finish. Additionally, in order to manufacture the steel product described herein, the final roll-forming facilities do not require the burning of tens of large volumes of fuel, typically commonly natural gas, needed to maintain a zinc hot- dipping tank at ~880 degrees Fahrenheit for dipping. This also means that for the purposes of manufacturing the product described herein, the roll forming facilities will not be required to commercially store massive amounts of zinc, fuel such as propane, or the multiple sulfuric and/or hydrochloric acids and other potentially harmful chemicals needed to clean and/or prep the materials before and during manufacture.

[0040] Although formed from a pre-galvanized, roll-formed sheet steel in the range of about 0.94 mm (0.037 inches) to about 2.62 mm (0.103 inches) thickness W-beam and Thrie-beam profile guardrail materials, the profiles maintain nearly all of the same weather-resistant properties, durability and extreme strength found in the same materials which were salvaged from former highway use.

[0041] Although not illustrated, various additional embodiments are possible using the invention similar to what is described and illustrated herein. For example, the barrier system is also suitable for use in many other non-highway applications such as agricultural bale feeders, bunk feeders, fencing, cribbing, cattle shades and snow drift catches.

[0042] The invention allows the production of W-beam and Thrie-beam shaped profile panels in lengths that are not customarily available. Due to a solid, long-standing national standard of dimensions for highway guardrail provided by AASHTO, the vast majority of lengths of the salvaged guardrail panels being used as affordable fencing and barrier material has been produced in only limited lengths of 41 15 mm (13.5 feet) for 3810 mm (12.5 foot) span of fence or 7925 mm (26 foot) lengths for 7620 mm (25 foot) span of fence. Until now, these two lengths have been the only two options made available to consumers. However, it is expected that within the variety of applications where reuse of the highly durable reclaimed guardrail material is common, there can be developed consistent needs for panels produced at additionally specified lengths. For example: livestock containment facilities consistently prefer longer beams of guardrail shaped panel to more efficiently and economically contain their animals. The

introduction of a longer length guardrail shaped panels would benefit the facility if this new type of panel was able to merge seamlessly with any presence of pre-existing cattle containment systems constructed out of standard salvaged highway guardrail panel.

[0043] For the purposes of the present invention a W-beam is approximately sinusoidal with two peaks separated equally from the ends with a separation between peaks of about 194 mm and a height of about 83 mm.

[0044] For the purposes of the present invention a Thrie-beam is approximately sinusoidal with three peaks separated equally with a height of about 83 mm.

[0045] As described above, many non-highway applications may also benefit from customizable lengths of W-beam and Thrie-beam guardrail panel for differing

applications so that standard highway-configured guardrails are not suitable for aftermarket re-tasking. The present invention addresses these deficiencies by providing a system and method by reconfiguring guardrail shaped materials and advancing that method by offering additional resources to expand the use of these reclaimed materials in a variety of alternative applications not requiring DOT approval. In this way, state DOTs are able to continue to recoup nearly twice as much in selling the used materials for reuse rather than recycling. In addition, farmers and other alternative users are able to afford and use these very high quality materials once reconfigured for different lengths and dimensions. And finally, the provision of a variety of cost-effective products which are designed to merge with the re-tasked materials bolsters a market atmosphere further avoiding the potential environmental damage from placing this galvanized material in landfills where zinc, a mild toxin, leeches into the surrounding soil.

[0046] The steadily increasing demand for W-beam- and Thrie-beam-shaped livestock system containment panels are shaped by several influences generally accepted by livestock handlers. First, contained animals inevitably make contact with their containment systems, and the gently faced curvature of a W-beam and Thrie-beam corrugated profiles greatly reduces the negative effects of those inevitable impacts. Second, the rigidity provided by the W-beam and Thrie-beam guardrail configurations have proven to be an excellent business investment, as the employment of such durable fencing panel effectively eliminates future repairs to the fencing system. This remarkable product thus eliminates almost all unintended future waste once installed. This permanence effect is in huge contrast to the repeated cycles of the necessary removal and replacements where wood and/or uncoated steel has been used as the primary containment structure material. Third, animal handlers have noted a significant calming effect facilitated by guardrail shaped barrier systems when used to contain large livestock. Animal handling professionals deduce this calming effect is due to the reduction of the contained animal's ability to perceive potentially stressful influences which may be outside the containment pen. Cattle remain much calmer when they cannot see beyond their immediate containment area.

[0047] This calming effect has many benefits. Calmer animals can be directed in smooth, uninterrupted traffic patterns. Accidents, even fatalities, of cattle handlers are much less likely when the livestock remain calm. Furthermore, animals contained in corrals built with guardrail-shaped panels simply fair better. During the process of necessary sorting, any overexcitement of livestock tends to create circumstances where the animals are much more likely to injure themselves or other animals. Thus, the calming effect induced by guardrail panel eliminates a great deal of potential

overexcitement, emotional pressure and therefore reducing animal injury.

[0048] Even in the reduced cases of animal overexcitement, corrugated W-beam and Thrie-beam profile of guardrail barriers provide a containment construction material with sufficient strength to retain the strong and heavy livestock. Therefore, it is to be expected that if present and future livestock handling facilities have consistent, affordable access to W-beam and Thrie-beam profile guardrail materials, these facilities will be enabled to continue to provide safer facilities for both livestock and their handlers. For human handlers must, at times, engage the livestock.

[0049] The invention has been described with reference to preferred embodiments without limit thereto. One of skill in the art would realize additional improvements and embodiments which are not specifically set forth but which are within the metes and bounds of the claims appended hereto.