Tool for forming a cavity in a modular pavement slab and method of fabricating pavement slabs

A forming tool for forming a cavity in a modular pavement slab fabricated using a form, the forming tool comprising:

• an elongate body defining a longitudinal axis and having a proximal end positionable against a surface of the form, an opposite distal end, a longitudinal bore extending from the proximal end, and a riser bore defining an axis that is noncollinear to the longitudinal axis, the riser bore comprising a riser bore coupling surface;
• a fastener extending into the longitudinal bore of the elongate body, the fastener being coupled to the elongate body and configured for releasable connection to the form;
• a riser comprising a riser coupling surface, the riser coupling surface being releasably connected to the riser bore coupling surface;
• and
• an end plate positioned against the distal end of the elongate body, wherein the end plate is coupled to the fastener to releasably connect the elongate body to the surface of the form.

A forming tool for forming a cavity in a modular pavement slab fabricated using a form, the forming tool comprising:

• an elongate body defining a longitudinal axis and having a proximal end positionable against a surface of the form, an opposite distal end, a longitudinal bore extending from the proximal end, and a riser bore defining an axis that is noncollinear to the longitudinal axis, the riser bore comprising a riser bore coupling surface;
• a fastener extending into the longitudinal bore of the elongate body, the fastener being coupled to the elongate body and configured for releasable connection to the form;
• and
• a riser comprising a riser coupling surface, the riser coupling surface being releasably connected to the riser bore coupling surface;
• said elongate body further comprising a second riser bore defining a second axis that is noncollinear to the longitudinal axis, the second riser bore comprising a second riser bore coupling surface,
• said forming tool further comprising a second riser having a second riser coupling surface releasably connected to the second riser bore coupling surface,
• wherein the elongate body, the first riser and the second riser each comprises a tapered sidewall.

A form for forming a modular pavement slab having a top surface and pluralities of long and short cavities alternatingly formed around a periphery of the modular pavement slab, said form comprising:

• a first header comprising an inner surface and an outer surface, the inner surface configured to define at least a portion of the periphery of the modular pavement slab during formation of the modular pavement slab;
• a plurality of short forming tools coupled to the inner surface of the first header, each short forming tool comprising:
• a first elongate body defining a first longitudinal axis and having a first length, the first elongate body comprising a first riser bore defining a first riser bore axis that is noncollinear to the first longitudinal axis;
• a first fastener coupled to the first elongate body, the first fastener extending through the first header and releasably coupled thereto;
• and
• a first riser coupled to the first riser bore,
• each short form tool being configured such that the first riser extends to a vertical position corresponding to the top surface of the modular pavement slab;
• and
• a plurality of long forming tools coupled to the inner surface of the first header and disposed alternatingly with the plurality of short forming tools, each long forming tool comprising:
• a second elongate body defining a second longitudinal axis and having a second length that is longer than the first length, the second elongate body comprising second and third riser bores, the second riser bore defining a second riser bore axis that is noncollinear to the second longitudinal axis, and the third riser bore defining a third riser bore axis that is noncollinear to the second longitudinal axis;
• a second fastener coupled to the second elongate body, the second fastener extending through the first header and releasably coupled thereto;
• a second riser coupled to the second riser bore;
• and
• a third riser coupled to the third riser bore,
• each long form tool being configured such that the second and third risers extend to a vertical position corresponding to the top surface of the modular pavement slab.

A method of forming a modular pavement slab having a plurality of cavities formed around a periphery of the modular pavement slab, said method comprising:

• positioning a first header of a modular pavement slab for receiving a paving material;
• coupling a plurality of forming tools to an inner surface of the first header, each forming tool comprising an elongate body defining a longitudinal axis, the elongate body comprising at least one riser bore defining a riser bore axis that is noncollinear to the longitudinal axis;
• coupling a riser to each respective riser bore of the plurality of forming tools;
• pouring a paving material into the modular pavement slab form and allowing the paving material to set to define the modular pavement slab;
• removing each respective riser from the plurality of forming tools;
• and
• removing the plurality of forming tools from the modular pavement slab.