Load transfer system

A method for constructing steel reinforced structural elements consisting of first modifying steel rebars by placing concrete on said rebars and allowing the concrete to cure prior to placing the modified rebars into service in an excavation or confined space;

• wherein said rebars with the cured concrete have undulating shape that alternates from a minimum covered zone that transitions to a maximum covered zone which transitions back to a minimum covered zone with said undulations repeating along a length of the rebars and leaving a portion of said rebars unmodified;
• the minimum covered zone has a concrete cover thickness of at least 1.5 inches and the maximum covered zone has a concrete cover that is at least 1.5 times of the thickness of the concrete cover of the minimum cover zone, and the transition between the minimum and maximum covered zone has a slope at an angle between 20 and 45 degrees as measured from an alignment of the rebar within the concrete;
• prior to placing the modified rebars into service, the concrete is allowed to cure to a minimum unconfined compressive strength of 2000 pounds per square inch (PSI) then said modified rebar may be placed into service;
• wherein the second step of constructing the structural elements is to place the modified rebar in the excavation or other confined space and then surrounding the modified rebar with granular fill material to completely fill a space between the modified rebars and the limits of the excavation or confined space, the granular fill consisting of sand, gravel, cobbles, boulders, and possibly demolition concrete or slag from metal refining to completely fill the space between the modified rebars and the excavation or other confined space prior to grouting, then to complete the structural elements the modified rebars include a grouting system to grout the entire surrounding space to ensure that the granular fill and the modified rebar will function as a complete structural element;
• and connecting the unmodified portion of the rebars with other structures including at least one of a pile cap, grade beam, structural foundations, structural slabs, walls, columns, or tie back anchors.