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The invention results in a process of making a stronger, lighter concrete pole named Pylonflex, reinforced iron bars form a conic structural assembly to be placed in the pole mold. Four to five #5 sizes bars are placed longitudinally and joint by ¼″ size diameter continuous circular stirrups (drawings 041-042-043). The diameter of the structural form at the base varies (from 10″to 20″) and at the head (from 2″ to 8″). The structural assembly is attached by iron tie wire size {fraction (1/16)}″. Outlet boxes, electrical wiring conduct, 1½″ galvanize pipe light fixture support are attached to the structural assembly and placed in the pole mold. The structural iron bars assembly is placed symmetrically at 1½″ to 2″ thickness to the sides of the mold. The concrete mixture is being poured (100% capacity) and will remain at a dormant stage from 12 to 15 hours in order to obtain maximum strength 3000 psi. Any iron bars distributions similar to this assembly and mixing with the fiber reinforced cellular concrete are part of Pylonflex invention.

Rosenberg, Jean Gabriel (Miami, FL, US)
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International Classes:
C04B28/02; E04C3/34; E04H12/12; (IPC1-7): E04C3/34; E04H12/00
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What is claimed is:

1. I Jean Gabriel Rosenberg, claim to be the inventor of the New Engineering concept creating Pylonflex, the new revolutionary lightweight concrete Pole that offers great advantages such as: Brakeless pole (under shock or pressure). Safe pole (automobile bumper shock caused by traffic accident.). Excellent stability after installation. Better quality at competitive price. Better deflection. Faster time delivery Diversity (many colors to blend with environment) Aesthetics, a new challenge in the electrical engineering Industry. THE MATERIAL USED ARE: High performance lightweight concrete (FRCC) weighting about 75 lb/ft3is a mixture of fiber, expanded clay, fine sand, cement, water, thermoflex Additive and Regular reinforced iron bars joint by continuous spiral stirrups. Bars used are: #4, #5 and ¼″ see prototype drawings #0.4.1, 0.4.2 and 0.4.3. Finished existing compound in the market will be used to add colors and impermeability purposes.



[0001] Today the market supplies common pre cast or pre stress concrete poles. They are made with ordinary concrete, weighting 145 lb/ft3, heavy with costly operation procedures and reinforced by a pre-stress cable. To be transported and installed, they require special equipments and they break under shock or auto bumper caused by traffic accidents. Therefore, they are unsafe to install in some areas and they present some instability in their behaviors.


[0002] Through a new fiber reinforced cellular concrete (Thermoflex) license, Gabriel Rosenberg has created a new lightweight concrete pole (75 lb/ft3), where sand and gravel are replaced by fiber and expanded clay. Pre stress cables are being replaced by regular reinforced iron bars with a continuous stirrups of ¼″ at adjustable spaces. This research results in a lighter, stronger concrete pole, safer to install everywhere with better stability and no breakage under shock.

[0003] 0.31 Process of Making Pylonflex Pole

[0004] A) Regular reinforced iron bars form a conic structural assembly to be placed in the pole mold. Four to five #5 iron bars are placed longitudinally (10 ft to 73 ft) and joint by ¼″ size diameter continuous circular stirrups. The stirrups of different diameter sizes vary from the base of the pole to the head. The strength of the pole is proportional to the adjustable stirrup gaps or spaces. The diameter of the structural form at the base varies (from 10″ to 20″) and at the head (from 2″ to 8″).

[0005] B) The reinforced iron bars are placed longitudinally to support the weight at the head of pole such as transformers and utility lines and the stirrups are controlling the strength capacity of the pole. All reinforced materials used are deformed iron bars, ideal for the fiber. The structural assembly is attached by iron tie wire size {fraction (1/16)}″.

[0006] C) Outlet boxes, electrical wiring conduct, 1½″ galvanize pipe light fixture supports and others are attached to the structural assembly to be placed in the pole mold. Prototype drawings #041, #042, #043, demonstrate the conic distributions of the stirrups Gaps designed to obtain strength and pole classification.

[0007] D) The pole mold is being cleaned, greased and the structural iron bars assembly is placed symmetrically at 1½″ to 2″ thickness to the sides of the mold. The concrete mixture is being poured to cover the entire structural iron bars (100% capacity) and will remain at a dormant stage from 12 to 15 hours. Hot air is used to activate time curing process in order to obtain maximum strength.(3000 psi).

[0008] E) The prototype wet fiber cellular concrete mixture weights about 90 lbs/ft3, for a standard strength of 3200 psi.

[0009] The mixture is made of 26.5% of cement, 10.3% of water, 52.4% of expanded clay, 10.5% of fine crush sand, 0.5% of patented Thermoflex formula and 0.6% of fiber.

[0010] F) This concrete will stay in a dormant stage for 12 to 15 hours and will reach 3000 psi.

[0011] G) More iron bars distributions conform to this assembly mixing with the fiber reinforced cellular concrete to make poles are similar and part of this invention.


[0012] Annexed, we will find drawings showing the structural concept as follows: 5 # 5 are Being placed longitudinally and are being related by a continuous spiral stirrups ¼″ from bottom to head of the poles. See drawings # (0.4.1)-(0.4.2)-(0.4.3).


[0013] The research resulted in:


[0015] a) A lighter pole because gravel and sand are replaced by fiber. (Pylonflex weights 75 lbs./ft3, compared to pre-stress ordinary concrete that weighs 145 lbs./cubic ft.).

[0016] b) Better acceptable deflection because cellular concrete is able to use regular iron reinforced bars compared to regular pre-stress concrete, which uses cable.


[0018] a) Cable is used in pre-stress concrete. The testing shows that the pole breaks under extreme pressure or shock because the cable cannot handle heavy autoclave concrete.

[0019] b) Pylonflex, on the other hand, is reinforced by regular iron bars and secured by continuous circular stirrups providing a much stronger resistance under extreme shock.

[0020] c) In addition, Pylonflex will not break, during testing, but will show maximum bending moment due to the use of the ordinary iron bars.

[0021] A Fire Proof Pole with an Excellent Insulation Factor.

[0022] Both Pylonflex and regular pre-stress concrete provide excellent insulation, However, Pylonflex has a greater coefficient factor (R19) and will not produce flame, smoke nor reduce in volume under fire, confirming the absence of toxic elements.

[0023] Pole Easy to Transport and Install.

[0024] Pylonflex is lighter and uses reinforced regular iron bars instead of cables, thus, it has an improved deflection. It is easier to transport and install and does not require special care. Pylonflex can be installed at 5′ maximum depth instead of 7′ required by new DOT regulations.

[0025] Pole with Better Stability.

[0026] Pylonflex provides greater stability because of its weight advantage. After installation, it will not suffer from any descending movement and it is more resistant to high wind pressure especially associated with hurricane force winds. It is designed to support and hold cable pressure at the head of the pole and to sustain vertical loads such as transformers, lights, etc.

[0027] The Technical Specifications of Pylonflex

[0028] Adjustable Density is from 3000 psi to 7000 psi, and weighs respectively 73 lbs./ft3 to 90 lb/ft3.

[0029] Dimensions are twelve inches base and four inches top. The length ranges from 12 ft to 45 ft as needed. As shown in detail drawings 0.4.1.-0.4.2.-0.4.3.

[0030] Elements of the reinforced iron bars five regular reinforced iron bars of ⅝″ are attached with continuous circular stirrups of ¼″.(0.4.1.-0.4.2-0.4.3.)

0.6 Advantages of Using Pylonflex

[0031] No breakage under extreme pressure or shock

[0032] Excellent stability under wind shear

[0033] Better deflection with the use of iron bars

[0034] Fungi and toxic free

[0035] Easy transportation and installation

[0036] Overall lower production costs

[0037] Quality versus cost at sale

[0038] Creation of diversity and aesthetics

[0039] Faster time delivery

[0040] Protection of the environment

0.7 Safer Environment

[0041] The materials that go into the reinforced cellular concrete poles are inorganic. They undergo no changes during the process. Ordinary sand and gravel are being replaced by fiber, fine sand and expanded clay. Pylonflex manufacturing protects the environment and does not produce dust. Pylonflex manufacturing plant can be located anywhere and will fit in any environment.

[0042] Pylonflex is a non-corrosive light poles, it will maintain its colors for many years after installation. No polluted elements are included in pylonflex concrete mixture.

0.8 Strong and Secure with Better Stability

[0043] Pylonflex can support heavy load with a better stability. Its rigidity will prevent twisting under heavy hurricane wind (210 mph). It is the only concrete pole that uses regular reinforced bars and can be installed everywhere. It will not break under automobile bumper shock caused by traffic accident and it is secure to install in a high volume traffic area. Tests performed on Pylonflex show no breaking point due to extra charge load but resume to a maximum flexure or bending moment. Pylonflex will support itself better than any other concrete pole because of the weight difference. Pylonflex, using a new high performance concrete, weighting half of the ordinary concrete (73 lbs/ft3), will not show any download movement after installation. Consequently, it will maintain its rigidity and stability under heavy wind pressure.

0.8 Delivery, Transportation and Installation

[0044] Pylonflex process curing time is about six times shorter than any ordinary concrete pole. Hot steam air can be used to activate time delivery purpose. No necessary heavy or special equipments are needed for transportation and installation. Pylonflex ,by its concept, will accept deflection without cracking or breaking.

0.9 Qualities and Cost Efficiency

[0045] Pylonflex will create diversity and custom colored poles as desired. Made of a new high performance concrete, we will produce high quality poles. We will fabricate a wide range of variety of style and colored poles at competitive price. We will offer DOT approved poles for electrical utility lines and traffic signals.

1.0 The Materials Used in Pylonflex Pole

[0046] All materials used in manufacturing Pylonflex light poles are tested and proven durable and accepted by the Miami Dade County approved laboratory. Here are the materials and quantities used to a standard concrete of 3200 psi:

[0047] CEMENT: The cement used is conformed to ASTM C-150 type I, Type III. 26.5%

[0048] FIBER: Polypropylene fiber is being used replacing the autoclaves gravels and sand.

[0049] Polypropylene fiber is tested and approved by the Miami Dade laboratory. 100 g/ft3

[0050] WATER: Water has to be well filtered in order to eliminate alkaline or polluted organic elements into the manufacturing process.10.3%

[0051] EXPANDED CLAY is chosen as filler for adjustable density. 52.4%

[0052] FINE SAND is chosen as filler for adjustable density. 10.5%

[0053] PATENTED THERMOFLEX FORMULA LICENSE: The patented formula allows expansion and activates uniformly distributed fiber into cellular concrete. 125 g/ft3

[0054] IRON BARS: 4 to 5 #5 bars surrounding with continuous ¼″ bars stirrup are used in Pylonflex poles.

1.1 Batching and Curing Procedures

[0055] The mixture is put in a fast speed mixer tank for about 10 minutes before placing in a dormant stage in a pole mold for 12 to 15 hours. The next day the pole is placed in a controlled steam area or outside storage area, to continue curing process before being delivered. A compressive strength of 3200 psi is reached within 12 to 16 hours. It is a fast curing manufacturing process. Pylonflex, has a shorter timedelivery opposed to the pre-stress concrete pole that requires 28 days to obtain maximum strength.