Post-tension concrete leave out splicing system and method

A concrete construction, comprising:

• a first post-tensioned concrete slab, a second post-tensioned concrete slab, and a cavity-forming device,
• said first post-tensioned concrete slab and said second post-tensioned concrete slab having respective upper surfaces that are generally aligned,
• said first post-tensioned concrete slab including a plurality of first rebars installed therein, said first post-tensioned concrete slab being post-tensioned in at least a direction substantially parallel to said plurality of first rebars,
• said second post-tensioned concrete slab including a plurality of second rebars installed therein, said second post-tensioned concrete slab being post-tensioned in at least a direction substantially parallel to said plurality of second rebars,
• said first post-tensioned concrete slab and said second post-tensioned concrete slab being separated by a gap so that the concrete material of said first post-tensioned concrete slab is not in contact with the concrete material of said second post-tensioned concrete slab,
• said cavity-forming device forming a cavity,
• said cavity-forming device being installed in said first post-tensioned concrete slab, wherein said cavity contains a portion of one of said plurality of second rebars, and
• said cavity-forming device is not directly connected to said plurality of first rebars.

A concrete floor construction, comprising:

• a first post-tensioned concrete floor slab, a second post-tensioned concrete floor slab, and a cavity-forming device, said first post-tensioned concrete floor slab and said second post-tensioned concrete floor slab having respective upper surfaces that are generally aligned,
• said first post-tensioned concrete floor slab including a plurality of first rebars installed therein, said first post-tensioned concrete floor slab being post-tensioned in at least a direction substantially parallel to said plurality of first rebars,
• said second post-tensioned concrete floor slab including a plurality of second rebars installed therein, said second post-tensioned concrete floor slab being post-tensioned in at least a direction substantially parallel to said plurality of second rebars,
• said first post-tensioned concrete floor slab and said second post-tensioned concrete floor slab being separated by a gap so that the concrete material of said first post-tensioned concrete floor slab is not in contact with the concrete material of said second post-tensioned concrete floor slab,
• said cavity-forming device forming a cavity which together with said device form a volume,
• said cavity-forming device being installed in said first post-tensioned concrete floor slab, wherein one of said second rebars connects with said volume,
• said cavity being filled with a binding material which connects together said first post-tensioned concrete floor slab and said one of said second rebars,
• said gap having a longer dimension for one side-to-side and a shorter dimension for another side-to-side, said shorter dimension being twelve (12) inches or less and being shorter relative to said longer dimension, and
• said gap being filled with a strip of non-shrink material, wherein said strip has a compressive strength that is greater than or equal to a compressive strength of the concrete material of said first and second post-tensioned concrete floor slabs.

A method for making a concrete floor construction including a first post-tensioned concrete floor slab and a second post-tensioned concrete floor slab separated by a gap, comprising:

• forming said first post-tensioned concrete floor slab with a plurality of first rebars, said first post-tensioned concrete floor slab being post-tensioned in at least a direction substantially parallel to said plurality of first rebars, wherein said first post-tensioned concrete floor slab includes a cavity-forming device with a cavity having an opening towards an end of said first post-tensioned concrete floor slab;
• prior to pouring a second concrete floor slab, positioning one of a plurality of second rebars for said second concrete floor slab so that a portion of said one of said plurality of second rebars is inside said cavity;
• pouring said second concrete floor slab;
• forming the second post-tensioned concrete floor slab by tensioning said second concrete floor slab in at least a direction substantially parallel to said plurality of second rebars, thus forming said gap between said first post-tensioned concrete floor slab and said second post-tensioned concrete floor slab, wherein said gap has a longer dimension for one side-to-side and a shorter dimension for another side-to-side, said shorter dimension being shorter relative to said longer dimension;
• and
• after forming said second post-tensioned concrete floor slab, securely fixing said portion of said one of said plurality of said second rebars in the cavity.

A method for making a concrete floor construction including a first post-tensioned concrete floor slab and a second post-tensioned concrete floor slab separated by a gap, comprising:

• forming said first post-tensioned concrete floor slab, wherein said first post-tensioned concrete floor slab includes a first rebar installed therein, and an end portion of said first rebar extends into a space that will become said gap, said first post-tensioned concrete floor slab being post-tensioned in at least a direction substantially parallel to said first rebar;
• before a second post-tensioned concrete floor slab has been formed, positioning a cavity-forming device having a cavity at an end portion of said first rebar so that said end portion of said first rebar is inside said cavity, but not securely connecting said cavity-forming device to said end portion of said first rebar;
• pouring said second concrete floor slab such that the cavity forming device is positioned within an end of the second concrete floor slab;
• forming a second post-tensioned concrete floor slab by tensioning said second concrete floor slab in at least a direction substantially parallel to a second rebar installed within the second concrete floor slab, thus forming said gap between said first post-tensioned concrete floor slab and said second post-tensioned concrete floor slab, wherein said gap has a longer dimension for one side-to-side and a shorter dimension for another side-to-side, said shorter dimension being shorter relative to said longer dimension;
• and
• after forming said second post-tensioned concrete floor slab, securely fixing said end portion of said first rebar in the cavity.