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US 2026/0250951 A1Published application
Welded Rebar for Load Transfer System
OwnerTheo Robert Seeleyinventor
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OwnerTheo Robert Seeleyinventor
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A new construction method for foundations or any structure using steel rebar by covering rebar with cured concrete or welding smaller rebar to the main rebar prior to being placed into service. This is to obtain advantages over common construction methods by changing the construction sequence and making an efficient system for load transfer. This is done by forming undulating steel bars or concrete on the load bearing rebar prior to placing into service. These can be inserted into borings, trenches, or forms along with granular fill and grout pipes to build designed structures. The grout can be injected at the time of installation, or at a later time. The grout could be additional Portland cement concrete or lower strength grout to complete the structure. The primary advantage is to have full strength steel and concrete in a structure without waiting for the concrete to cure.
A method for constructing steel reinforced structural elements consisting of first modifying steel rebars by welding bent smaller rebars to the load carrying rebar for the purpose of improving the load transfer between the load carrying rebar and surrounding lower strength materials this patent claims that by using rebars smaller than the load carrying rebar to interact with the surrounding lower strength materials where prior to being welded to the load carrying rebar the smaller rebars are bent at an angle between 20 and 70 degrees as measured from the alignment of the load carrying rebar and then bent back again to meet the load carrying rebar at an angle within the same range where a group of these smaller rebars when placed and welded around the load carrying rebar will form nodes that will transfer load to or from the load carrying rebar to the surrounding material that is weaker than cured Portland cement concrete the minimum diameter will be determined by the load carrying rebar and two of the smaller rebars such that when welded together the entire group forms the minimum diameter of the undulating shape then the maximum diameter of the nodes would be at least 1.5 times the minimum diameter;
It is claimed that the contact between the load bearing rebars and the low strength fill beyond the rebar nodes can be improved by filling the void space created by the said undulating smaller steel rebar with gravel or other small angular inert fill material so that when grouted along with the main body of fill the two fill materials, both inside and outside the nodes of undulating rebar will be fused into one fill mass thus further improving load transfer between the main load bearing rebar and the main body of grouted fill.
Dependencies are inferred from the claim text.