rebox - brochure (141119)corkjoint.com/wp-content/uploads/2019/12/rebox-brochure.pdf · bars for...

PRODUCT DESCRIPTION

Rebox® is a prefabricated reinforcement bar connection system that is designed to allow for simple and fast continuity of steel reinforcement across construction joints in concrete.

The Rebox® system consists of Grade 500 steel reinforcement that is cut and bent accordingly to suit the project’s requirement, then factory assembled inside a special designed galvanised steel casing (box), which is then supplied to the construction site ready for immediate installation.

Once at site, the contractor fixes Rebox® directly to the formwork shutter or it can also be tied to the steel reinforcement at the location of the intended connection. Once Rebox® has been installed and the formwork system is completely closed, the concrete can be placed. The formwork is then stripped and the cover lid of Rebox® is easily removed to expose the lap reinforcement bars inside the casing. These bars are then re-bent out by the contractor (using a Rebox® Bar Bending Tool) to allow for connection of the main reinforcement bars for the connecting concrete element.

The back cover casing of Rebox® is left embedded in the first pour, providing a rebate or shear key for the second pour of concrete to connect into. The dimpled imprint on the back of the casing has been designed to provide a key for the first and second pours of concrete to bond to.

Rebox® is customised and designed to fully integrate and conform to the element where it is to be used, providing no site cutting or material wastage.

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REBOXREINFORCEMENT BAR CONNECTIONS SYSTEM

®


ADVANTAGES

Fast and simple to installEliminates the need of hacking concrete to expose lap reinforcement barsHelps fast track concrete pouring schedules providing savings in costs and timeDesign and installation of formwork is simplifiedNo wastage at site as the system is custom designed to suit the exact length of areaFully fabricated and assembled off-site in a factory controlled environmentCover & casing produced from pre-galvanised steel providing a strong and rigid box

Improves site safety as lap bars are only exposed/bent out when requiredProvides a rebate in the concrete to give added shear resistanceProduced to comply to the projects anchor and lap bar configurations and to bar diameter and spacing requirementsEnvironmentally friendly as eliminates the use of polystyrene block-outs that are used in conventional sitefabricated systemsCan be curved to suit radius requirementsAvailable with a joint waterstop system if needed

AREAS OF APPLICATION

Slab to wallSlab to slabSlab to lift core wallsWall to wallWall to column

For use in many areas for construction joint connections:

Slab to core wallsSlab to diaphragm wallPre-cast concrete elements for cast-in situ connectionsStair flights and landingsCorbels

Note : The products design and performance, its intended use, installation and final confirmation and approval for use, must be provided by the project’s Design Engineer and Project Manager.

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TECHNICAL FEATURES

Grade 500 steelAvailable in diameters of 10mm, 12mm, 13mm & 16mm. Larger diameters can be accommodated in our innovative Rebox® Bar Coupler System. Refer to CORKJOINT for further details.Anchor bar configurations and lap bar lengths are designed to suit the project’s specification requirements.

Steel reinforcement for anchor and lap bars:

Pre-galvanised steel to prevent corrosion.Front cover provided with a pre-punched window to aid in easy removal after concrete has been poured.Dimpled back cover provides additional bonding ability for the first and second pours of concrete to connect to.

Case & Cover:

Widths of 85mm, 120mm, 150mm, 190mm, 220mm & 250mmLengths of 1000mm up to 2400mm.Thickness (depth) 36mm.Custom widths, lengths and depths are available upon request based upon minimum order quantities.

Box sizes:

85mm

1000mm~2400mm

150mm

1000mm~2400mm

36mm

250mm

END ELEVATION VIEW OF CASE & COVER

36mm

190mm

36mm

220mm

RB190 RB220

RB250

ISOMETRIC VIEW OF CASE & COVER

RB85 RB150

36mm

85mm

36mm

120mm

36mm

150mm

RB85 RB120 RB150

Rebox® is custom produced to the connection requirements of the elements that are to be connected.There are many different types and configurations that can be produced to suit the project’s specification, some of the standard connections are stated below. Custom anchors types can also be produced if required.


Type A Type B Type C

Type D Type E Type F

Type G Type H Type I

Type J Type K Type L

TYPES AND CONFIGURATIONS FOR ANCOR AND LAP BARS

Ordering is a simple and easy process via our Rebox® Scheduling Form which needs to be detailed with the following information:

For all orders, each individual box that is assembled is labelled with a Reference Identification Tag (refer below) for quick identification, at any time, of the box type and its specification.


When ordering, the following dimensions need to be detailed:

wall thickness

‘a’ ‘l’‘c’RB

slab

th

ickn

ess

concrete cover

Section/ Area

Structuralsection to

be connected

Thicknessof section

(mm)

Length of section /

area (mm)

Required spacing ofbar (mm)

Bardiameter

(mm)

Bar Type(refer to

typebelow)

Anchorlength

‘a’(mm)

Lap length

‘l’(mm)

Anchorlength

‘c’(mm)

Concrete cover(mm)

1A slab to wall 10,000top - 10bottom - 10

Type B 480100150slab - 200wall - 300

slab - 30wall - 30

top - 200bottom - 200

Anchor reinforcement typeBox lengthReinforcement spacingReinforcement diameterBox type and width

RB 85-12-200-1200-D

ORDERING AND SCHEDULING FORM

REBOX® IDENTIFICATION REFERENCE

ANCHOR AND LAP BAR DETAILING

Note : A full Rebox® Scheduling Form is available upon request or can be downloaded from our website at corkjoint.com.

Rebox® is supplied to the site ready for immediate installation. The complete box can be either nailed or screwed directly to the formwork shutter or can be tied with wire ties directly to the main reinforcement cage. The formwork is then positioned and the box is sandwiched between the formwork and the main reinforcement cage (refer Figure 1).

The concrete is then poured and the entire Rebox® is cast into the face of the element. Once the formwork is removed, the front case of the Rebox® is exposed ready for removal when required (refer Figure 2).

Once ready, strike the front cover, at the location of the pre-punched window, and insert the claw of a hammer or steel bar tool and remove the cover, exposing the reinforcement lap bars inside. The lap bars are then straightened using the Rebox® Bar Bender (refer Figure 3). The main reinforcement bars of the subsequent pour can be connected and placed into position as required (refer Figure 4).


INSTALLATION INSTRUCTIONS

Figure 1 Figure 2

Figure 3 Figure 4


The straightening of the steel reinforcement bars should be approached with care and consideration to using the correct technique. We recommend the use of our Rebox® Bar Bender (refer below photos). We do not recommend the use of steel pipes, tubes or other implements that are not at the correct diameters, due to when straightening of the bar, they can cause kinks or could apply incorrect re-bending forces.

Rebox® Bar Bender is a straight tube pipe that has a slightly larger internal diameter than the outer diameter of the steel reinforcement bar ribs that it is being placed over to straighten. One end of the tube is cut on an angle to aid in supporting the outside edge of the reinforcement during bending and also allows for a smooth continuous travel during straightening.

When first installing the Rebox® Bar Bender, the tool should be pushed onto the end of the lap reinforcement bar to be straightened, and as far along as possible, to the full length of the bar to where the bend radius is. Once inserted, the bar needs to be straightened in a continuous motion and as the bar straightens, the tool needs to be continually pushed (slid) along the bar towards the metal back cover of the box, and should end up touching the cover upon completion of the straightening.

The tool is then removed and the straightened steel reinforcement bar checked for alignment and length for lapping/connecting to the subsequent main reinforcement. All other bars are then straightened according to the same procedure.

Rebox® Bar Bender is available in the following sizes:

RBB-10 to suit 10mm diameter bar. RBB-12 to suit 12mm diameter bar. RBB-13 to suit 13mm diameter bar. RBB-16 to suit 16mm diameter bar.

Length of Rebox® Bar Bender suits most lap length bar requirements but special lengths are available upon request.

The tool is painted orange, comes with a comfortable hand grip on one end and is clearly marked so it can be checked for its appropriate size and use with the steel reinforcement bar diameter that is to be straightened.

STRAIGHTENING OF BARS

DISCLAIMER

The information and the recommendations relating to the application and end use of this product are given in good faith and are based on the information provided by the manufacturer of the product and/or theCompany’s current knowledge and experience in connection with the product when properly stored, handled and applied under normal conditions and no liability of final function at the job site is assumed. In practice, the differences in materials substrates and actual site conditions are such that no warranty in respect ofmerchantability of or fitness for particular purpose, nor any liability arising out of any legal relationshipwhatsoever, can be inferred either from this information, or from any written and/or oral recommendations, or from any other advise offered by the Company. The Company also has no express or implied knowledge of any particular purpose for which the product is required and any such information given will not be taken into account in the supply of this product. No responsibility or liability by the Company will be accepted for misuse, misreading or derivation from recommended guidelines in respect of this product and the user shalldetermine the suitability of the product for his intended use and assume all risks and liability in connection therewith. The information contained in our brochure may change at any time without notice. Any use of this product; Rebox® in any application should be approved as suitable for use/application by the Design Engineer and Project Manager.

HEALTH AND SAFETY INFORMATION

Rebox® should be stored in a location that prevents it from being damaged by force and should be kept under cover in a dry location to prevent any corrosion. The product is supplied to the end-user on pallets and fully shrink wrapped, to help protect during delivery and storage.

STORAGE

Rebox® is manufactured and assembled under a full Quality Assurance System. A Mill Test Certificate is available upon request for the steel reinforcement bar that is installed in the production of the boxes.

Upon delivery, the product needs to be checked and verified by the end user that it complies fully to the project’s specification and design requirements and that final approval for use is to be given by the project’s engineer. The product also needs to be checked for any damage and if so, reported immediately to CORKJOINT for inspection prior to the product being installed/used. Once delivery of the product has been accepted,the ownership and full liability for its use, passes to the end user. For full product warranty and liability conditions pertaining to the product,refer to CORKJOINT’s Limited Product Warranty, which is available upon request.

QUALITY ASSURANCE

DELIVERY CONDITIONS

Effective Date: 14 NOVEMBER 2019

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Short lengths of Rebox® are light-weight and can be handled by one person, longer boxes can be heavy and should be lifted by two people or by lifting apparatus equipment. Protective gloves should be worn when handling the boxes, when removing box covers and during reinforcement bar straightening. Once the reinforcement bars have been straightened, extra care should be taken as the exposed bars, prior to lapping to the main reinforcement, can be harmful or cause serious injury to the human body if impact is to take place.

CORKJOINT (MALAYSIA) SDN BHD383102-H

No. 51, Jalan BRP 8/2,Bukit Rahman Putra Industrial Park,47000 Sungai Buloh, Selangor, MALAYSIA

+603 6148 8010/ +603 2711 0117

+603 6148 8020

CORKJOINT (SINGAPORE) PTE LTD 200716724-K

No. 10 Buroh Street #02-26 & 27, West Connect Building,SINGAPORE 627564

+65 6455 9331

+65 6455 8535 [email protected] / [email protected]

Unit 2, 18 Farrow Circuit Seaford Rise,South Australia 5169, AUSTRALIA

+61 432 423 103

THAILAND REGIONAL FOREIGN OFFICEP.O. Box 133 Bangna Post Office,Bangkok 10260, THAILAND

+66 949 023 133

[email protected]

CORKJOINT (MALAYSIA) SDN BHD0100562101046

CORK JOINTING SYSTEMS AUSTRALIA

rebox - brochure (141119)corkjoint.com/wp-content/uploads/2019/12/rebox-brochure.pdf · bars for...

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