REBAR INSTALLATION DEVICE AND

CORRESPONDING METHOD

PRIOR APPLICATION

[0001] The present application claims priority from U.S. provisional patent application No. 63/203.207, filed on July 13, 2021 , and entitled “REBAR INSTALLATION DEVICE AND CORRESPONDING METHOD”, the disclosure of which being hereby incorporated by reference in its entirety.

TECHNICAL FIELD

[0002] The technical field relates to rebar supports, and more particularly to rebar installation devices configured to support rebars within concrete forms when forming concrete structures, and to corresponding methods.

BACKGROUND

[0003] Concrete walls and other concrete structures are traditionally made by building a form. Unhardened concrete is poured into a form space defined by the form. Once the concrete hardens, form walls at least partially delimiting the form space are removed leaving a concrete wall or other concrete structure/structural member. Given the limitations in structural strength of concrete when subjected to certain types of loading such as tensile loading, it is known to provide reinforcement for the concrete. The reinforcement is typically accomplished by placing reinforcement bars or rebars (usually made from steel) within the form space defined by the form and at least partially delimited by the form walls. The precise positioning of the reinforcement bars within the form space is important and is selected to maximize the structural benefit and at the same time ensure other design criteria are met. Traditional rebar supports or chairs exist at varying heights to support single rebars and typically orient them in a single direction. This requires the use of a large number of supports or chairs to arrange and adequately support multiple layers of rebars. Moreover, numerous manual manipulations are usually needed to arrange the rebars within the form space in a substantially stable manner.

[0004] In view of the above, there is a need for a rebar installation device which would be able to overcome or at least minimize some of the above-discussed prior art concerns.

BRIEF SUMMARY

[0005] According to a general aspect, there is provided a rebar installation device, comprising: a rebar-engaging member defining a rebar-receiving cavity and comprising a distal portion and a proximal portion at least partially spaced apart from each other; the distal portion having an outer surface, an opposed inner surface and a first fastener-receiving opening extending therethrough between the inner and outer surfaces; the proximal portion having an inner surface, an opposed support-mounting surface and a second fastener-receiving opening extending therethrough between the inner and support-mounting surfaces; wherein the inner surfaces of the distal and proximal portions at least partially delimit the rebar-receiving cavity; and wherein the first and second fastener-receiving openings are in register with each other.

[0006] According to another aspect, there is provided a method of installing a rebar in a concrete structure form space at least partially delimited by at least one form wall, said method comprising: providing at least one rebar installation device as described herein; arranging the rebar in the concrete structure form space to extend substantially vertically or horizontally; engaging a portion of the rebar with the rebar-receiving cavity of said at least one rebar installation device; abutting the support-mounting surface of said at least one rebar installation device against a portion of said at least one form wall; engaging a mechanical fastener with the first fastener-receiving opening and the second fastener-receiving opening so as to maintain the portion of the rebar in the rebar-receiving cavity; and engaging a portion of the mechanical fastener with the portion of said at least one form wall to secure the rebar installation device thereto.

[0007] According to another aspect, there is provided a rebar installation device, comprising: an upper rebar-engaging body defining an upper rebar-receiving cavity; and at least two supporting members secured to or formed integral with the upper rebar- engaging body, said at least two supporting members being spaced apart from each other; wherein each of said at least two supporting members defines a lower rebar-receiving cavity; wherein the lower rebar-receiving cavities of said at least two supporting members are in register with each other.

[0008] According to another aspect, there is provided a method of installing upper and lower rebars in a concrete structure form space at least partially delimited by a form floor, said method comprising: providing a rebar installation as described herein; arranging the rebar installation device in the concrete structure form space with said at least two supporting members being supported on the form floor; engaging at least two spaced-apart portions of the lower rebar with the lower rebar receiving cavities of said at least two supporting members; and engaging at least a portion of the upper rebar with the upper rebar-receiving cavity.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Fig. 1 is a first perspective view of a rebar installation assembly comprising a rebar installation device in accordance with a first embodiment, comprising a rebar- engaging member defining a rebar-receiving cavity, first and second fastener receiving openings being formed therethrough, the rebar installation assembly further comprising a mechanical fastener and a rebar.

[0010] Fig. 2 is a is a second perspective view of the rebar installation device of Fig. 1.

[0011] Fig. 3 is a first perspective view of another rebar installation assembly comprising a rebar installation device in accordance with a second embodiment, comprising a rebar-engaging member defining a rebar-receiving cavity with first and second fastener-receiving openings therethrough, a proximal portion of the rebar- engaging member comprising two support-mounting members, the rebar installation assembly further comprising a mechanical fastener and a rebar.

[0012] Fig. 4 is another perspective view of the rebar installation device of Fig. 3.

[0013] Fig. 5 is a top elevational view of the rebar installation device of Fig. 3.

[0014] Fig. 6 is a side elevational view of the rebar installation device of Fig. 3.

[0015] Fig. 7 is a bottom perspective view of the rebar installation device of Fig. 3.

[0016] Fig. 8 is a first perspective view of another rebar installation assembly comprising a rebar installation device in accordance with a third embodiment, comprising an upper rebar-engaging body defining an upper rebar-receiving cavity and two lower rebar-receiving cavities at least partially delimited by two supporting members of the rebar installation device, the lower rebar-receiving cavity having a curved profile, the rebar installation assembly further comprising an upper rebar at least partially arranged within the upper rebar-receiving cavity and a lower rebar at least partially arranged within the lower rebar-receiving cavities.

[0017] Fig. 9 is another perspective view of the rebar installation device of Fig. 8 with the lower rebar engaged with the lower rebar-receiving cavities thereof.

[0018] Fig. 10 is a side elevational view of the rebar installation device of Fig. 8.

[0019] Fig. 11 is another perspective view of the rebar installation device of Fig. 8.

[0020] Fig. 12 is a first top perspective view of a rebar installation assembly comprising a variant of the rebar installation device of Figs. 8-11, whereby each supporting member of the rebar installation device comprises a rebar-maintaining protrusion shaped and dimensioned to maintain the lower rebar within the lower-receiving cavities.

[0021] Fig. 13 is another perspective view of the rebar installation device of Fig. 12 with the lower rebar engaged with the lower rebar-receiving cavities thereof.

[0022] Fig. 14 is a side elevational view of the rebar installation device of Fig. 12.

[0023] Fig. 15 is another perspective view of the rebar installation device of Fig. 12.

[0024] It will be appreciated that for simplicity and clarity of illustration, elements shown in the figures have not necessarily been drawn to scale. For example, the dimensions of some of the elements may be exaggerated relative to other elements for clarity. Nevertheless, for disclosure purposes, it should be understood that the relative proportions of the various elements as shown in the figures are disclosed.

DETAILED DESCRIPTION

[0025] In the following description, the same numerical references refer to similar elements. Furthermore, for the sake of simplicity and clarity, namely so as to not unduly burden the figures with several references numbers, not all figures contain references to all the components and features, and references to some components and features may be found in only one figure, and components and features of the present disclosure which are illustrated in other figures can be easily inferred therefrom. The embodiments, geometrical configurations, materials mentioned and/or dimensions shown in the figures are optional, and are given for exemplification purposes only.

[0026] Moreover, it will be appreciated that positional descriptions such as "above", "below", "forward", "rearward", "left", "right" and the like should, unless otherwise indicated, be taken in the context of the figures only and should not be considered limiting. Moreover, the figures are meant to be illustrative of certain characteristics of the rebar installation devices and are not necessarily to scale.

[0027] To provide a more concise description, some of the quantitative expressions given herein may be qualified with the term "about". It is understood that whether the term "about" is used explicitly or not, every quantity given herein is meant to refer to an actual given value, and it is also meant to refer to the approximation to such given value that would reasonably be inferred based on the ordinary skill in the art, including approximations due to the experimental and/or measurement conditions for such given value.

[0028] In the following description, an embodiment is an example or implementation. The various appearances of "one embodiment", "an embodiment" or "some embodiments" do not necessarily all refer to the same embodiments. Although various features may be described in the context of a single embodiment, the features may also be provided separately or in any suitable combination. Conversely, although the invention may be described herein in the context of separate embodiments for clarity, it may also be implemented in a single embodiment. Reference in the specification to "some embodiments", "an embodiment", "one embodiment" or "other embodiments" means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily all embodiments. [0029] It is to be understood that the phraseology and terminology employed herein is not to be construed as limiting and are for descriptive purpose only. The principles and uses of the teachings of the present disclosure may be better understood with reference to the accompanying description, figures and examples. It is to be understood that the details set forth herein do not construe a limitation to an application of the disclosure.

[0030] Furthermore, it is to be understood that the disclosure can be carried out or practiced in various ways and that the disclosure can be implemented in embodiments other than the ones outlined in the description above. It is to be understood that the terms "including", "comprising", and grammatical variants thereof do not preclude the addition of one or more components, features, steps, or integers or groups thereof and that the terms are to be construed as specifying components, features, steps or integers. If the specification or claims refer to "an additional" element, that does not preclude there being more than one of the additional element. It is to be understood that where the claims or specification refer to "a" or "an" element, such reference is not be construed that there is only one of that element. It is to be understood that where the specification states that a component, feature, structure, or characteristic "may", "might", "can" or "could" be included, that particular component, feature, structure, or characteristic is not required to be included.

[0031] The descriptions, examples, methods and materials presented in the claims and the specification are not to be construed as limiting but rather as illustrative only. Meanings of technical and scientific terms used herein are to be commonly understood as by one of ordinary skill in the art to which the invention belongs, unless otherwise defined. It will be appreciated that the methods described herein may be performed in the described order, or in any suitable order.

[0032] As used herein, the term “rebar” is generally intended to refer to a reinforcing bar, may be of any size, length, or shape. The rebar may be a bar, rod, or a mesh of wires, optionally comprising ridges. The rebar may be made of any material such as steel, fiberglass, or a composite material. In some aspects, rebar refers to main rebars or distribution/support bars. [0033] Referring now to the drawings, and more particularly to Fig. 1 and 3, there is shown a rebar installation assembly 10, 1010 comprising a rebar installation device 100, 1100 in accordance with first or second embodiments, the rebar installation assembly 10, 1010 further comprising a mechanical fastener 300 and a rebar 400, for instance at least partially made of steel.

First embodiment

[0034] In the first embodiment shown, the rebar installation device 100 comprises a rebar-engaging member 110 defining a rebar-receiving cavity 130 and comprising a distal portion 111 and a proximal portion 114 at least partially spaced apart from each other; the distal portion 111 having an outer surfacel 12, an opposed inner surface 113 and a first fastener-receiving opening 120 extending therethrough between the inner and outer surfaces. The proximal portion 114 has an inner surface 115, an opposed support-mounting surface 116 and a second fastener-receiving opening 121 extending therethrough between the inner and support-mounting surfaces 115, 116. The inner surfaces of the distal and proximal portions at least partially delimit the rebar-receiving cavity 130. The first and second fastener-receiving openings are in register with each other.

[0035] In the following description, unless otherwise specified, the terms inner and outer should be understood relatively to the rebar-receiving cavity.

[0036] In the following description, unless otherwise specified, the terms proximal and distal refer to a member or surface that is relative to a support or a wall to which the rebar installation device is configured to be mounted (for instance secured via the above-mentioned mechanical fastener 300). For example, the rebar installation device is configured to be mounted to a form wall of a concrete structure form space.

[0037] In the first embodiment of the rebar installation device, as represented in Figs. 1 and 2, the rebar-engaging member 110 of the rebar installation device 100 is substantially C-shaped. In the embodiment shown, the distal 111 and proximal 114 portions are substantially parallelepipedal (for instance substantially rectangular or square) and extend substantially parallel to each other. The distal and proximal portions (the inner surfaces thereof) at least partially delimit the rebar-receiving cavity 130.

[0038] In the embodiment shown, the rebar-engaging member 110 further comprises a connecting portion 117 connecting the distal 111 and proximal portions 114 to each other. For instance, the connecting portion 117 is substantially perpendicular to the distal and proximal portions.

[0039] Each of the proximal 114 and distal 111 portions comprise opposed first and second end portions; the connecting portion is secured to or formed integral with the first end portions of the proximal and distal portions. The second end portions of the proximal and distal portions are spaced apart from each other and at least partially delimit a rebar-engaging aperture opening into the rebar-receiving cavity 130.

[0040] The rebar-engaging member 130 is shaped and dimensioned so that the above-mentioned rebar 400 is engageable with the rebar-receiving cavity 130 via the rebar-engaging aperture. For instance, and as detailed below, when the rebar installation device is mounted (for instance secured) to a form wall, the rebar 400 may extend substantially vertically or horizontally.

[0041] In the embodiment shown, when the rebar 400 is engaged with the rebar receiving cavity 130, the rebar 400 is substantially perpendicular to the connecting 117, distal 111, and proximal 114 portions of the rebar-engaging member 110.

[0042] The rebar installation device 100 is shaped and dimensioned so that the rebar receiving cavity 130 may be configured to any size rebar by configuring the lengths and/or widths of the connecting 117, distal 111, and/or proximal 114 portions of the rebar-engaging member 110.

[0043] The rebar, also referred to as a reinforcing bar, may be of any size, length, or shape. The rebar may be a bar, rod, or mesh of wires, optionally comprising ridges. The rebar may be made of any material such as steel, fiberglass, or a composite material.

[0044] The support-mounting surface 116 of the proximal portion 114 of the rebar- engaging member 110 is configured to be abutted against the support or wall (for instance the above-mentioned form wall). The wall may be a form wall of the concrete structure form space.

[0045] The first 120 and second 121 fastener-receiving openings are formed in the second end portions of the proximal 114 and distal 111 portions of the rebar-engaging member 110, respectively (i.e., in the end portions of the proximal and distal portions of the rebar-engaging member opposed to the end portions secured to or formed integral with the connecting portion).

[0046] The first fastener-receiving opening 120 extends from the outer surface 112 through to the inner surface 113 of the second end portion of the distal portion 111 of the rebar-engaging member 110. The second fastener-receiving opening 121 extends from the inner surface 115 through to the support-mounting surface 116 of the second end portion of the proximal portion 114 of the rebar-engaging member 110. The openings may be substantially cylindrical. A thread (not represented) might be formed in a peripheral surface at least partially delimiting the first and second fastener receiving openings. The shape and dimensions of the first and second fastener receiving openings may be configured to fit any size of mechanical faster 300.

[0047] The mechanical fastener 300 may be any device that is used to mechanically join, fasten, maintain or affix, the rebar installation device 100 (for instance the proximal portion 114 thereof) to a support or wall. For example, the mechanical fastener may be a screw ora nail. The proximal 114 or the connecting 117 portions of the rebar-engaging member 110 may be configured to be of any length to control the distance between the rebar and the support or wall.

[0048] The mechanical faster 300 may be engaged with the first 120 and second 121 fastener-receiving openings and to protrude outwardly from the support-mounting surface 116 to further engage with a portion of the concrete structure form space ( e.g form wall). When engaged with the first and second fastener-receiving openings and extending between the distal and proximal portions of the rebar-engaging member 110, the above-mentioned rebar-engaging aperture is at least partially closed, thereby maintaining the rebar 400 in the rebar-receiving cavity 130 while securing the rebar installation device 100 to the concrete structure form space. As best shown in Fig. 1, the rebar 400 and the mechanical fastener 300 are substantially perpendicular to each other when engaged with the rebar installation device 100. The connecting portion 117 is substantially parallel and spaced apart from the mechanical fastener 300. In other words, when the mechanical fastener is engaged with the distal and proximal portions of the rebar-engaging member by being at least partially inserted in the first and second fastener-receiving openings thereof, the mechanical fastener 300 is substantially parallel to the connecting portion 117 so that the rebar-receiving cavity is at least partially delimited by the inner surfaces of the distal, proximal and connecting portions and the mechanical fastener 300.

[0049] Even though in the embodiment shown a single mechanical fastener is engaged with the distal end portions of the proximal and distal portions of the rebar- engaging member, it could also be conceived a rebar-installation device wherein an additional fastener-receiving opening would be formed in the connecting portion and would open into the outer surface of the distal portion and the support-mounting surface of the proximal portion for an additional mechanical fastener to be inserted therein and further secure the rebar installation device to the mounting surface (for instance to the form wall).

[0050] The rebar installation device 100 may be made as a single piece or by connecting/securing different pieces or portions, such as by securing the distal 111 and proximal portions 114 of the rebar-engaging member 110 to the connecting portion 117. The device may be completely or partially made of any plastic or metal (e.g., steel), or any material that can support the rebar and in which a mechanical fastener can at least partially be inserted.

[0051] In some embodiments, a plurality of rebar installation devices 100 can be provided along a length of the reinforcement bar.

[0052] In the embodiment shown, the rebar installation device 100 has a plane of symmetry extending between the distal and proximal portions (i.e., between the inner surfaces thereof). In the embodiment shown, the plane of symmetry of the rebar installation device is substantially perpendicular to the connecting portion and to the mechanical fastener, when the mechanical fastener is at least partially inserted in the first and second fastener-receiving openings. For instance, as represented in Fig. 1, when the rebar is engaged in the rebar-receiving cavity, the plane of symmetry at least partially intersects the rebar 400.

[0053] It is appreciated that the shape and the configuration of the rebar installation device, as well as the shape and configuration of the distal, connecting and proximal portions thereof, can vary from the embodiment shown.

Second embodiment

[0054] For instance, referring now to figures 3 to 7, there is shown a second possible embodiment of the rebar installation device 1100.

[0055] Similar to the first embodiment, the rebar installation device 1100 comprises a rebar-engaging member 1110 defining a rebar-receiving cavity 1130 and comprising a distal portion 1111 and a proximal portion 1114 at least partially spaced apart from each other; the distal portion having an outer surface 1112, an opposed inner surface 1113 and a first fastener-receiving opening 1120 extending therethrough between the inner and outer surfaces. The proximal portion 1114 has an inner surface 1115, an opposed support-mounting surface 1116 and a second fastener-receiving opening 1121 extending therethrough between the inner and support-mounting surfaces. The inner surfaces of the distal and proximal portions at least partially delimit the rebar receiving cavity. The first and second fastener-receiving openings are in register with each other.

[0056] In the embodiment shown, the proximal portion comprises at least two support mounting members 1122 spaced apart from each other and forming at least partially the support-mounting surface 1116. The proximal portion defines a concrete-filling cavity 1140 at least partially delimited between the at least two support-mounting members.

[0057] In the second embodiment, as represented in Figs. 3 and 4, a distal portion of the rebar-engaging member 1110 of the rebar installation device 1100 is substantially C-shaped. In the embodiment shown, the distal 1111 and proximal 1114 portions are substantially parallelepipedal (for instance rectangular or square) and substantially parallel to each other, and at least partially delimit the rebar-receiving cavity 1130. The at least two support-mounting members 1122 are formed integral with or secured to a cavity-delimiting part of the proximal portion 1114 of the rebar-engaging member.

[0058] For instance, the second fastener-receiving opening 1121 extends at least partially along one of the support-mounting members 1122. In otherwords, the second fastener-receiving opening 1121 extends in the cavity-delimiting part of the proximal portion 1114 and in one of the support-mounting members 1122. It could also be conceived a rebar installation device wherein the one or more support-mounting members would be offset with respect to an end portion of the cavity-delimiting part of the proximal portion in which the second fastener-receiving opening is formed. It could also be conceived a rebar installation device comprising a single support-mounting member or more than two support-mounting members.

[0059] The one or more support-mounting members comprise a support-mounting surface forming at least partially the support-mounting surface 1116 of the proximal portion 1114.

[0060] When having two at least partially spaced-apart support-mounting members 1122, they delimit at least partially the above-mentioned concrete-filling cavity 1140, which may provide a greater surface area upon which the concrete can form. One of the support-mounting members 1122 is substantially aligned with the connecting portion 1117 extending between the distal 1111 and proximal 1114 portion. As mentioned above, the second support-mounting member 1122 comprises at least partially the second fastener-receiving opening 1121.

[0061] Similarly to the first variant, the first fastener-receiving opening 1120 extends from the outer surface 1112 through to the inner surface 1113 of the second end portion of the distal portion 1111 of the rebar-engaging member 1110 (i.e., opposed to the end portion secured to or formed integral with the connecting portion 1117). The second fastener-receiving opening 1121 extends from the inner surface 1115 of the second end portion of the proximal portion 1114 of the rebar-engaging member 1110 through to the support-mounting surface 1116 of one of the support-mounting members 1122. The openings may be substantially cylindrical. The size of the openings may be configured to fit any size mechanical faster 300. The mechanical fastener 1300 may be any device that is used to mechanically join, fasten, or affix, the rebar installation device 1100 to a support or wall via the second end portion of the proximal portion 1114 and/or via one of the support-mounting members. For example, the mechanical fastener may be a screw or a nail.

[0062] A rebar 400 is engaged in the rebar-receiving cavity 1130 via the rebar- engaging aperture at least partially delimited by the second end portions of the proximal and distal portions (i.e., at least partially delimited by the end portions of the proximal and distal portions opposed to the connecting portion). When in use, the rebar 400 may extend substantially vertically or horizontally. The rebar 400 is substantially perpendicular to the connecting 1117, distal 1111, and proximal 1114 portions of the rebar-engaging member 1110, as well as to the support-mounting member(s) 1122. The rebar-receiving cavity 1130 may be configured to any size rebar by configuring the lengths, and/or widths of the connecting 1117, distal 1111, and/or proximal 1114 portions of the rebar-engaging member.

[0063] The concrete-filling cavity 1140 may be a substantially similar size, smaller, or larger, than the rebar-receiving cavity 1130. The concrete-filling cavity may increase the surface area upon which the concrete can form, thereby enhancing stability and strength of the resulting concrete structure.

[0064] The support-mounting surface 1116 of the proximal portion (at least partially defined by the support-mounting surfaces of support-mounting members 1122 in the embodiment shown) is abutted against the support or wall. The wall may be a form wall of the concrete structure form space.

[0065] In the embodiment shown, the support-mounting members extend substantially transversally (for instance substantially perpendicular) to a distal portion (or cavity delimiting portion) of the proximal portion and/or to the distal portion. In the embodiment shown, a length of at least one of the proximal 1114 and distal 1111 portions of the rebar-engaging member 1110 may be substantially equal to a length of at least one of the first and second support-mounting members 1122. The length of the first and second support-mounting members 1122 may also be modified to control the distance of the rebar from the support or wall. Therefore, the length of the first and second support-mounting members 1122 may be shorter or longer than the length of the proximal 1114, distal 1111, and/or connecting 1117 portions of the rebar-engaging member. Alternatively, the connecting 1117 portion of the rebar-engaging member 1110 may be configured to be any length to adjust to the dimensions of the rebar at least partially engaged in the rebar-receiving cavity.

[0066] The mechanical faster 300 may be engaged in the first fastener-receiving opening 1120, then into the second 1121 fastener-receiving opening and to protrude outwardly from the support-mounting surface 1116 (for instance at least partially defined by the support-mounting surface of the second support-mounting member 1122), to further engage with a portion of the concrete structure form space ( e.g form wall). When engaged with the first and second fastener-receiving openings and extending between the distal and proximal portions of the rebar-engaging member 1110, the above-mentioned rebar-engaging aperture is at least partially closed, thereby maintaining the rebar in the rebar-receiving cavity while securing the rebar installation device to the concrete structure form space. As best shown in Fig. 3, the rebar 400 and the mechanical fastener 300 are substantially perpendicular to each other when engaged with the rebar installation device 1100. The connecting portion 1117 of the rebar-engaging member 1110 and first support-mounting member 1122 are substantially parallel and spaced apart from the mechanical fastener 300.

[0067] Even though in the embodiment shown a single mechanical fastener is engaged with the distal end portions of the proximal and distal portions of the rebar- engaging member and with one of the support-mounting members, it could also be conceived a rebar-installation device wherein an additional fastener-receiving opening would be formed in the connecting portion and into the other one of the support mounting members and would open into the support-mounting surface of the other one of the support-mounting members for an additional mechanical fastener to be inserted therein and further secure the rebar installation device to the mounting surface (for instance to the form wall).

[0068] The rebar installation device 1100 may be made as a single piece or by connecting/securing different pieces, such as by securing the distal 1111 and proximal 1114 portions of the rebar-engaging member 1110 to the connecting portion 1117. Furthermore, the support-mounting member(s) 1122 may be secured to the cavity delimiting part of the proximal portion 1114 of the rebar-engaging member 1110. The device 1100 may be completely or partially made of any plastic or metal, or any material that can support the rebar.

[0069] In some embodiments, a plurality of rebar installation devices 1100, 100 can be provided along a length of the reinforcement bar.

[0070] It is appreciated that the shape and the configuration of the rebar installation device, as well as the shape, the configuration, the relative arrangement and/or the number of the proximal and distal portions, and the support-mounting members thereof, can vary from the embodiment shown.

Method of installing a rebar in a concrete structure - first and second embodiments

[0071] According to another aspect of the disclosure, there is provided a method of installing a rebar in a concrete structure form space at least partially delimited by at least one form wall.

[0072] The method according to embodiments of the present disclosure may be carried out with a rebar installation device 100, 1100 such as those described above.

[0073] In the embodiment shown, the method comprises providing at least one rebar installation device 100, 1100; arranging the rebar 400 in the concrete structure form space to extend substantially vertically or horizontally; engaging a portion of the rebar 400 with the rebar-receiving cavity 130, 1300 of said at least one rebar installation device 100; abutting the support-mounting surface 116, 1116 of said at least one rebar installation device 100, 1100 against a portion of said at least one form wall; engaging a mechanical fastener 300 with the first fastener-receiving opening 120, 1120 and the second fastener-receiving opening 121, 1121 so as to maintain the portion of the rebar 400 in the rebar-receiving cavity 130, 1130; and engaging a portion of the mechanical fastener 300 with the portion of said at least one form wall to secure the rebar installation device 100, 1100 thereto.

[0074] The steps of the method described herein can be performed in various orders. For example, the step of abutting the support-mounting surface 116, 1116 may be performed prior to engaging the rebar 400 with the rebar-receiving cavity 130, 1130. Furthermore, the rebar 400 may be engaged with the rebar-receiving cavity 130, 1130 and the mechanical fastener 300 may be partially engaged to secure the rebar in the rebar-receiving cavity. The support-mounting surface 116, 1116 may then be abutted to the form wall prior to completely engaging the mechanical fastener 300 to the form wall.

[0075] In some embodiments, a plurality of rebar installation devices can be installed along a length of the reinforcement bar. As detailed above, in the embodiments shown, the rebar installation device is use in forming concrete structures.

Third and fourth embodiments

[0076] Referring now to Figs. 8-15, there is shown two variants of a rebar installation assembly 20, 1020 comprising a rebar installation device 200, 1200 in accordance with third and fourth embodiments, the rebar installation assembly 20, 1020 further comprising an upper rebar 400’ and a lower rebar 400, for instance at least partially made of steel.

[0077] In the third and fourth embodiments shown (respectively in Figures 8 to 11 and Figures 12 to 15), the rebar installation device 200 comprises an upper rebar-engaging body 205, 1205 defining an upper rebar-receiving cavity 210, 1210 (or upper rebar supporting cavity 210, 1210); and at least two supporting members 230, 1230 secured to or formed integral with the upper rebar-engaging body 205, 1205. The at least two supporting members 230, 1230 are spaced apart from each other. Each of the at least two supporting members 230, 1230 defines a lower rebar-receiving cavity 220, 1220 (or lower rebar-supporting cavity 220, 1220). The lower rebar-receiving cavities 220, 1220 of the at least two supporting members 230, 1230 are substantially in register with each other.

[0078] In the embodiments shown, the upper rebar-engaging body 205, 1205 comprises two upper rebar-engaging members 206, 1206 and an upper portion 207, 1207 between the parallel upper rebar-engaging members and connecting the upper rebar-engaging parallel members 206, 1206 to each other, thereby at least partially delimiting the upper rebar-receiving cavity 210, 1210. In the embodiment shown, the two upper rebar-engaging members 206, 1206 are slightly inclined with respect with a vertical direction when the rebar installation device is supported on a substantially horizontal plane, the two upper rebar-engaging members 206, 1206, as best shown in Figs. 10 and 14, being inclined in two opposed directions with respect to the vertical direction. For instance, each upper rebar-engaging member 206, 1206 defines an acute angle with the vertical direction. For instance, the angle defined between the upper rebar-engaging member and the vertical direction is comprised between about 45° and about 5°. Moreover, as best shown in Figs. 11 and 12, the two upper rebar- engaging members 206, 1206 substantially converge toward each other at junctions between the upper rebar-engaging members 206, 1206 and the upper portion 207, 1207. In the embodiment shown, the upper portion 207, 1207 comprises two substantially inclined parts, so that the upper portion 207, 1207 is substantially V- shaped, a concavity being defined by the upper portion 207, 1207 at least partially delimiting the upper rebar-receiving cavity 210, 1210.

[0079] An upper rebar 400’ is engaged with the upper rebar-receiving cavity 210, 1210 or is at least partially supported by the upper portion 207, 1207. The upper rebar receiving cavity 210, 1210 may be configured to be any shape or size to fit any rebar. For example, the upper rebar-receiving cavity may be substantially triangular or round shaped. The upper rebar 400’, also referred to as a reinforcing bar, main bar, or distribution bar, may be any size, length, or shape. The upper rebar 400’ may be a bar, rod, or mesh of wires, optionally comprising ridges. The upper rebar 400’ may be made of any material such as steel, fiberglass, or a composite material.

[0080] The at least two supporting members 230, 1230 are formed integral with or secured to the upper rebar-engaging body 205, 1205 (for instance with the upper rebar-engaging members 206, 1206 thereof). The supporting members 230, 1230 are substantially parallel to each other and extend substantially in a vertical direction when the rebar installation device is supported on a substantially horizontal plane. The supporting members 230, 1230 may comprise a flat bottom surface allowing the device to sit on the base or form bottom wall or floor of a concrete structure form delimiting at least partially a concrete structure form space.

[0081] Each supporting member 230, 1230 comprises a lower rebar-receiving cavity 220, 1220, whereby the lower rebar-receiving cavities 220, 1220 are substantially in register with each other (i.e. , substantially aligned for a lower rebar to be received in both cavities). In the embodiment shown, the lower rebar-receiving cavities 220, 1220 open towards opposed directions. As best shown in Figs. 8, 9, 12, and 13, a lower rebar 400 is engageable in the lower rebar-receiving cavities 220, 1220. The lower rebar 400 is substantially perpendicular to the supporting members 230, 1230. In the embodiment shown, the lower rebar 400 is substantially parallel to the upper portion 207, 1207 (for instance to a portion thereof) of the upper rebar-engaging body 205, 1205. When in use, the lower and upper rebars, 400 and 400’, respectively, are spaced apart from each other and are substantially parallel to each other, as shown in Figures 8, 10, 12, and 14. The lower rebar-receiving cavities 220, 1220 may be configured to be any shape or size to fit any rebar.

[0082] For example, in the third embodiment of the rebar installation device 200, the cavity may be substantially round as shown in Figs. 8-11. For instance, a portion of each of the supporting members 230 is substantially bent to form a concavity delimiting at least partially the corresponding lower rebar-receiving cavity. Moreover, each of the supporting members 230 comprises a rebar-maintaining protrusion 240 at least partially delimiting a rebar-engaging aperture 221 opening into the lower rebar receiving cavity 220. As best shown in Fig. 10, when the rebar installation device 200 is supported on a substantially flat supporting surface, a height H of a bottom portion of the lower rebar-receiving cavity 220 is smaller than a height H2 of the corresponding rebar-maintaining protrusion 240. For instance, the height H of the bottom portion of the lower rebar-receiving cavity 220 is smaller than about 99% of the height H2 of the corresponding rebar-maintaining protrusion 240; for instance smaller than about 95%, for instance smaller than about 90%.

[0083] For example, in the fourth embodiment of the rebar installation device 1200, the cavity is substantially V-shaped as shown in Figs. 12-15. In the embodiment shown, the lower rebar-receiving cavity 1220 is at least partially delimited by a portion of a corresponding one of the upper rebar-engaging members 1206 (a substantially vertical portion thereof, when the rebar installation device 1200 is supported on a substantially horizontal supporting surface), and by a portion of the corresponding supporting member 1230. In the embodiment shown, each of the supporting members comprises a supporting part 1235 forming at least partially the above-mentioned flat bottom surface 1236 and an opposed rebar-guiding part 1237. In the embodiment shown, the rebar-guiding part 1237 of the supporting member is dividable into an inner portion 1238 (or cavity-delimiting portion) and an outer portion 1239. In the embodiment shown, the inner 1238 and outer portions 1239 are inclined with respect to each other and are connected to each other at a rebar-maintaining protrusion 1240. In some embodiments, the V-shaped lower rebar-receiving cavity 1220 is formed by a fold formed by the supporting member 1230.

[0084] In other words, the rebar-maintaining protrusion 1240 (or peak 1240) formed by the supporting member 1230 forms a junction between the inner 1238 and outer 1239 portions of the rebar-guiding part 1237 of the supporting member 1235 and is shaped and dimensioned to guide and maintain the lower rebar 400 within the lower rebar receiving cavity 1220. As best shown in Fig. 14, the inner portion 1238 extends downwardly from the rebar-maintaining protrusion 1240 towards the lower rebar receiving cavity 1220 and thus contributes to the guiding of the lower rebar 400 towards the lower rebar-receiving cavity 1220 and upper rebar-engaging member 1206. In the embodiment shown, the angle created between the inner portion 1238 and upper rebar-engaging member 1206 is less than 90°, for instance comprised between about 80° and about 5°, for instance comprised between about 70° and about 5°, for instance comprised between about 60° and about 5°, for instance comprised between about 50° and about 5°, for instance comprised between about 45° and about 5°. Moreover, as best shown in Fig. 14, the inner portion 1238 substantially converges toward the upper rebar-engaging member 1206 such that the lower rebar-receiving cavity 1220 is substantially V-shaped. Furthermore, as best shown in Fig. 14, when the rebar installation device 1200 is supported on a substantially flat supporting surface, a height H of a bottom portion of the lower rebar-receiving cavity 1220 is smaller than a height H2 of the corresponding rebar-maintaining protrusion 1240. For instance, the height H of the bottom portion of the lower rebar-receiving cavity 1220 is smaller than about 99% of the height H2 of the corresponding rebar-maintaining protrusion 1240; for instance smaller than about 95%, for instance smaller than about 90%.

[0085] In other words, the rebar-maintaining protrusion 240, 1240 or peak 240, 1240 is shaped and dimensioned to tightly secure the lower rebar 400 in the lower rebar- receiving cavity 220, 1220 and prevent the lower rebar 400 from displacing out of the lower rebar-receiving cavity 220, 1220. As detailed above, and without being limitative, the peak 1240 (rebar-maintaining protrusion 1240) might be formed by a fold of the supporting member 1230 (of the rebar-guiding part 1237 thereof, in the embodiment shown).

[0086] The lower rebar 400, also referred to as a reinforcing bar, main bar, or distribution bar, may be any size, length, or shape. The lower rebar 400 may be a bar, rod, or mesh of wires, optionally comprising ridges. The lower rebar 400 may be made of any material such as steel, fiberglass, or a composite material. The lower rebar 400 extends through both of the lower rebar-receiving cavities 220, 1220, thereby providing added support for the lower rebar 400 (i.e. , more points of contact). In some aspects, the device is configured such that the lower rebar 400 positioned in the lower rebar receiving cavities 220, 1220 is elevated with respect to the base or form bottom wall or floor of a concrete structure. In some aspects, the height (H) (Figs. 10 and 14), as measured from the base or form bottom wall or floor of a concrete structure to the bottom of the lower rebar receiving cavities 220, 1220, is at least 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2.0 inches.

[0087] In some embodiments, the height (H’) (Figs. 10 and 14), as measured from the base or form bottom wall or floor of a concrete structure to the bottom of the upper rebar receiving cavities 210, 1210, is dependent from a length of the upper rebar- engaging members 206, 1206. Therefore, the height (H’) may be configured to be at any height by lengthening or shortening the upper rebar-engaging members 206, 1206.

[0088] In some aspects, the rebar installation device defined herein is used in replacement of or in combination of commonly used spacers to elevate the rebars from the base or form bottom wall or floor of a concrete structure.

[0089] In some embodiments, the rebar installation device defined herein is used to arrange one or a plurality of rows, levels, or layers of rebars. For example, a first row of rebars may be arranged by engaging at least two spaced-apart portions of a lower rebar 400 in the lower rebar-receiving cavities 220, 1220 of at least two rebar installation devices 200, 1200. A plurality of assembled lower rebars may be arranged in parallel to form a first layer of rebars. A second row of rebars may then be arranged directly on top of the first layer of rebars and substantially perpendicularly to the first layer of rebars, as typically done in concrete form or structure. A third row of rebars (e.g., upper rebars 400’) may then be arranged in the upper rebar-receiving cavities 210, 1210 of the rebar installation devices 200, 1200, in a substantially parallel direction with respect to the lower rebars 400 and vertically spaced apart therefrom. Additional layers of rebars can then be arranged directly over the upper rebars 400’ in a substantially perpendicular fashion.

[0090] As represented, in the embodiment shown, the rebar installation device 200, 1200 is at least partially formed of substantially cylindrical or tubular members, for instance at least partially made of steel; some of the cylindrical or tubular members are substantially curved to form concavities defining at least partially the upper bar receiving cavity 210, 1210 and/or the lower bar-receiving cavities 220, 1220. The rebar installation device 200, 1200 may be made as a single piece or by connecting/securing different pieces. The device may be completely or partially made of any plastic or metal (e.g., steel), or any material that can support the rebar. In some aspects, the device is completely or partially made of a substantially resilient material or of a material allowing relative flexibility or temporary deformation of parts thereof. For example, as shown in Figs. 12-15, the lower rebar 400 may be engaged with the supporting members 230, 1230 or rebar-maintaining protrusions 240, 1240 (peaks 240, 1240) of the device 200, 1200, such that when the device is twisted or rotated towards the lower rebar 400, as described below, the lower rebar 400 is displaced over the peak 240, 1240 and into each lower rebar-receiving cavity 220, 1220 and is locked into place. In some cases, the resiliency of the device - for instance of the supporting member thereof, for instance the rebar-guiding part 1237 thereof - allows for the device to temporarily bend and ease the displacement of the lower rebar 400 over the peak 240, 1240 and into the corresponding lower rebar-receiving cavity 220, 1220.

[0091] In some embodiments, a plurality of rebar installation devices can be provided along a length of the reinforcement bar.

Method of installing a rebar in a concrete structure - third and fourth embodiments [0092] According to another aspect of the disclosure, there is provided a method of installing upper and lower rebars 400’, 400 in a concrete structure form space at least partially delimited by a form bottom wall (or form floor).

[0093] The method according to embodiments of the present disclosure may be carried out with a rebar installation device 200, 1200 such as the ones described above.

[0094] In the embodiment shown, the method comprises providing a rebar installation device 200, 1200 according to the present disclosure; arranging the rebar installation device 200, 1200 in the concrete structure form space with said at least two supporting members 230 being supported on the form bottom wall (or form floor); engaging at least two spaced-apart portions of the lower rebar 400 with the lower rebar-receiving cavities 220, 1220 of said at least two supporting members 230, 1230; and engaging at least a portion of the upper rebar 400’ with the upper rebar-receiving cavity 210, 1210.

[0095] A plurality of bar installation devices 200, 1200 can be installed along a length of the upper and lower reinforcement bars.

[0096] For instance, the method comprises arranging the lower rebar in the concrete structure form space. For instance, the method comprises arranging the lower rebar on holding pieces supported on the form bottom wall (or form floor), for the lower rebar to be spaced apart from the form bottom wall (or form floor). The method then comprising arranging one or more rebar installation devices in the concrete structure form space in the vicinity of the lower rebar. For instance, the rebar installation device is arranged so that the supporting members thereof are on both sides of a portion of the lower rebar. The rebar installation device is then rotated about an axis substantially perpendicular to the form floor (for instance about a substantially vertical axis), to engage the portion of the lower rebar with the lower rebar-receiving cavities at least partially delimited by the supporting members. For instance, the upper rebar-engaging body 205 (for instance the upper portion 207 thereof) is shaped and dimensioned to be easily handled by a user, so as to easily rotate the rebar installation device. In the embodiment shown, considered from above (i.e., from a side of the upper portion opposed to the supporting members), the rebar device is rotated in a clockwise direction to engage the lower rebar with the lower rebar-receiving cavities. A rebar device which would be rotated in an anti-clockwise direction could also be conceived.

[0097] Once the lower rebar is engaged with the lower rebar-receiving cavities at least partially defined by the supporting members, the upper rebar can be engaged with the upper rebar-receiving cavity. The lower and upper rebars, 400 and 400’, respectively, are spaced apart from each other and are substantially parallel to each other.

[0098] In some embodiments, the method comprises installing a plurality of rows, levels, or layers of rebars in a concrete structure form space using the rebar installation device defined herein. The method comprises providing the rebar installation device defined herein; arranging the rebar installation device in the concrete structure form space with said at least two supporting members 230, 1230 being supported on the form floor; engaging at least two spaced-apart portions of the lower rebar 400 (e.g., main bar) with the lower rebar-receiving cavities 220, 1220 of said at least two supporting members 230, 1230; engaging at least a portion of the upper rebar 400’ (e.g., distribution bar) with the upper rebar-receiving cavity 210, 1210. In some aspects, additional rebars are arranged over the lower 400 and/or upper 400’ rebars in a substantially perpendicular orientation.

[0099] In some aspects, the method comprises engaging the at least two spaced-apart portions of the lower rebar (e.g., main bar) with the supporting members 230, 1230 or rebar-maintaining protrusions 240, 1240 (peaks 240, 1240) of the device 200, 1200, twisting or rotating the device towards the lower rebar 400 such that the lower rebar 400 is displaced over the peak 240, 1240 and is locked into place in each lower rebar receiving cavity 220, 1220.

[00100] As detailed above, in the embodiments shown, the rebar installation device is use in forming concrete structures.

[00101] Several alternative embodiments and examples have been described and illustrated herein. The embodiments of the invention described above are intended to be exemplary only. A person of ordinary skill in the art would appreciate the features of the individual embodiments, and the possible combinations and variations of the components. A person of ordinary skill in the art would further appreciate that any of the embodiments could be provided in any combination with the other embodiments disclosed herein. It is understood that the invention may be embodied in other specific forms without departing from the central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein. Accordingly, while the specific embodiments have been illustrated and described, numerous modifications come to mind. The scope of the invention is therefore intended to be limited by the scope of the appended claims.