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PRODUCT DESCRIPTIONRebox® 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.

REBOX®

REINFORCEMENT BAR CONNECTION SYSTEM

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ADVANTAGES

• Fast and simple to install • Eliminates the need of hacking concrete to expose lap reinforcement bars • Helps fast track concrete pouring schedules providing savings in costs and time • Design and installation of formwork is simplified • No wastage at site as the system is custom designed to suit the exact length of area • Fully fabricated and assembled off-site in a factory controlled environment • Cover & casing produced from pre-galvanised steel providing a strong and rigid box • Improves site safety as lap bars are only exposed/bent out when required • Provides a rebate in the concrete to give added shear resistance • Produced to comply to the projects anchor and lap bar configurations and to bar diameter and spacing requirements • Environmentally friendly as eliminates the use of polystyrene block-outs that are used in conventional site fabricated systems • Can be curved to suit radius requirements • Available with a joint waterstop system if needed

AREAS OF APPLICATIONFor use in many areas for construction joint connections:• Slab to wall • Slab to core walls• Slab to slab • Slab to diaphragm wall• Slab to lift core walls • Pre-cast concrete elements for cast-in situ connections• Wall to wall • Stair flights and landings• Wall to column • Corbels

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85mm

1000mm~2400mm

150mm

1000mm~2400mm

36mm

55mm

36mm

85mm

36mm

120mm

36mm

150mm

36mm

190mm

36mm

220mm

36mm

250mm

TECHNICAL FEATURESSteel reinforcement for anchor and lap bars:• Grade 500 steel • Available 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.

Box sizes:• Widths of 55mm, 85mm, 120mm, 150mm, 190mm, 220mm & 250mm• Lengths of 1000mm up to 2400mm. • Thickness (depth) 36mm.• Custom widths, lengths and depths are available upon request based upon minimum order quantities.

Case & Cover:• 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.

END ELEVATION VIEW OF CASE & COVER

RB55 RB85 RB120 RB150

RB190 RB220

RB250

ISOMETRIC VIEW OF CASE & COVER

RB85 RB150

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TYPES AND CONFIGURATIONS FOR ANCOR AND LAP BARSRebox® 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

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ANCHOR AND LAP BAR DETAILINGWhen ordering, the following dimensions need to be detailed:

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

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

REBOX® IDENTIFICATION REFERENCEFor 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.

RB 85-12-200-1200-D

Anchor reinforcement type Box length Reinforcement spacing Reinforcement diameter Box type and width

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 10,000 top - 10bottom - 10

Type B 150 480100slab - 200wall - 300

slab - 30wall - 30

top - 200bottom - 200

wall thickness

‘a’ ‘l’‘c’RB

slab

thi

ckne

ss

concrete cover

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INSTALLATION INSTRUCTIONSRebox® 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).

figure 1 figure 2

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).

figure 3 figure 4

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).

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STRAIGHTENING OF BARSThe 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.

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STORAGERebox® 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.

QUALITY ASSURANCERebox® 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.

DELIVERY CONDITIONSUpon 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.

HEALTH AND SAFETY INFORMATIONShort 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.

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 the Company’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 of merchantability of or fitness for a particular purpose, nor any liability arising out of any legal relationship whatsoever, can be inferred either from this information, or from any written and / or oral recommendations, or from any other advice offered by the Company. No responsibility or liability by the Company will be accepted for misuse, misreading or derivation from the recommended guidelines in respect of this product and the user shall determine the suitability of the product for his intended use and assume all risks and liability in connection therewith. The information contained in this brochure may change at any time without notice.

Effective Date: 06 June 2016

CORKJOINT (MALAYSIA) SDN BHD 383102-H CORKJOINT (SINGAPORE) PTE LTD 200716724-KNo. 51, Jalan BRP 8/2, Bukit Rahman Putra Industrial Park 10, Admiralty Street, #03-82 North Link Building47000 Sungai Buloh, Selangor Darul Ehsan, Malaysia Singapore 757695Tel +603 2633 0117 Tel +65 6455 9331Fax +603 6148 8020 Fax +65 6455 8535

info@corkjoint .comwww.corkjo int .com © Corkjoint 2016. All Rights Reserved.