U.S. patent application number 16/361769 was filed with the patent office on 2020-09-24 for rough-in box for creating penetrations in poured concrete flooring and method of use.
This patent application is currently assigned to WALK SAFE INNOVATIONS, LLC. The applicant listed for this patent is WALK SAFE INNOVATIONS, LLC. Invention is credited to Gabriel McAuley, Donal O'Sullivan.
Application Number | 20200299980 16/361769 |
Document ID | / |
Family ID | 1000004331721 |
Filed Date | 2020-09-24 |
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United States Patent
Application |
20200299980 |
Kind Code |
A1 |
McAuley; Gabriel ; et
al. |
September 24, 2020 |
Rough-in Box for Creating Penetrations in Poured Concrete Flooring
and Method of Use
Abstract
A rough-in box kit (100) for creating a rough-in box (200) to
create a penetration in poured concrete flooring during the
construction of concrete buildings. The rough-in box kit (100)
includes a single unitary piece (1) having a flat section (5) with:
a top end; a bottom end opposite to the top end; an inside surface
(5a) located between the top end and the bottom end, and configured
to form an inside surface of the rough in box (200); and an outside
surface (5b) opposite to the inside surface (5a), and configured to
form an outside surface of the rough in box (200). The single
unitary piece (1) also has a top flange (3) connected to and
extending away from the top end of the flat section (5), and
perforations, through-holes, or slots (2) that are formed in the
flat section (5). The single unitary piece (1) is configured to be
bent at locations corresponding to and lining up with the
perforations, through-holes, or slots (2) so as to form the
rough-in box (200).
Inventors: |
McAuley; Gabriel; (Staten
Island, NY) ; O'Sullivan; Donal; (Douglaston,
NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
WALK SAFE INNOVATIONS, LLC |
New York |
NY |
US |
|
|
Assignee: |
WALK SAFE INNOVATIONS, LLC
New York
NY
|
Family ID: |
1000004331721 |
Appl. No.: |
16/361769 |
Filed: |
March 22, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04G 15/061
20130101 |
International
Class: |
E04G 15/06 20060101
E04G015/06 |
Claims
1. A rough-in box kit (100) for creating a rough-in box (200) to
create a penetration in poured concrete flooring during the
construction of concrete buildings, comprising: a single unitary
piece (1) having: a flat section (5) that has: a top end; a bottom
end opposite to the top end; an inside surface (5a) located between
the top end and the bottom end, and configured to form an inside
surface of the rough-in box (200); and an outside surface (5b)
opposite to the inside surface (5a), and configured to form an
outside surface of the rough-in box (200); and a top flange (3)
connected to and extending away from the top end of the flat
section (5); perforations, through-holes, or slots (2) that are
formed in the flat section (5); wherein the single unitary piece
(1) is configured to be bent at locations corresponding to and
lining up with the perforations, through-holes, or slots (2) so as
to form the rough-in box (200).
2. The rough-in box kit (100) of claim 1; wherein the top flange
has: a first extension (3a) that extends from the flat section (5)
at approximately a 90.degree. angle; and a second extension (3b)
that extends from the first extension (3a) at approximately a
90.degree. angle.
3. The rough-in box kit (100) of claim 2; wherein the perforations,
through-holes, or slots (2) are formed in the first extension
(3a).
4. The rough-in box kit (100) of claim 2 or 3; wherein the
perforations, through-holes, or slots (2) are not formed in a
distal end of the second extension (3b) opposite to and distal from
the first extension (3a).
5. The rough-in box kit (100) of one of claims 2-4; wherein the
perforations, through-holes, or slots (2) are formed in a proximal
end of the second extension (3b) adjacent and proximal to the first
extension (3a).
6. The rough-in box kit (100) of claim 2 or 3; wherein the
perforations, through-holes, or slots (2) are not formed in any
portion of the second extension (3b).
7. The rough-in box kit (100) of one of claims 1-5; wherein the
single unitary piece (1) additionally has: a bottom flange (4)
connected to and extending away from the bottom end of the flat
section (5) opposite to the top end of the flat section (5).
8. The rough-in box kit (100) of claim 7; wherein the bottom flange
extends from the flat section (5) at approximately a 90.degree.
angle.
9. The rough-in box kit (100) of claim 2; wherein the single
unitary piece (1) additionally has: a bottom flange (4) connected
to and extending away from a bottom end of the flat section (5)
opposite to the top end of the flat section (5); and wherein the
bottom flange (4) extends approximately parallel to the a first
extension (3a) of the top flange (3).
10. The rough-in box kit (100) of claim 7-9; wherein the
perforations, through-holes, or slots (2) are not formed in a
distal end of the bottom flange (4) opposite to and distal from the
flat section (5).
11. The rough-in box kit (100) of one of claims 7-9; wherein the
perforations, through-holes, or slots (2) are formed in a proximal
end of the bottom flange (4) adjacent and proximal to the flat
section (5).
12. The rough-in box kit (100) of claim 7-9; wherein the
perforations, through-holes, or slots (2) are not formed in any
portion of the bottom flange (4).
13. The rough-in box kit (100) of one of claims 1-12; wherein the
perforations, through-holes, or slots (2) form vertical arrays (2a)
in the flat section (5), each vertical array (2a) extending in a
vertical direction from the top end to the bottom end of the flat
section (5).
14. The rough-in box kit (100) of claim 13; wherein the vertical
arrays (2a) of perforations, through-holes, or slots (2) are spaced
apart from each other in a horizontal direction perpendicular to
the vertical direction so that the perforations, through-holes, or
slots (2) additionally form horizontal arrays (2b) in the flat
section (5) extending in the horizontal direction.
15. The rough-in box kit (100) of one of claims 1-14; wherein the
singe unitary piece (1) made of an aluminum alloy.
16. The rough-in box kit (100) of one of claims 1-15, further
comprising: a lid (6) formed configured to supporting a weight of
at least approximately 2,000 pounds when placed on top of the
formed rough-in box (200).
17. The rough-in box kit (100) of claim 16; wherein the lid (6) is
formed of resin-impregnated fiberglass.
18. The rough-in box kit (100) of claim 17; wherein the
resin-impregnated fiberglass is impregnated with an epoxy
resin.
19. The rough-in box kit (100) of claim 17; wherein the lid (6)
comprises 18 to 40 fiberglass layer strands of fiber.
20. A rough-in box (200) comprising: the rough-in box kit (100) of
one of claims 16-19; wherein the single unitary piece (1) is bent
at locations corresponding to and lining up with the perforations,
through-holes, or slots (2) so as to form the rough-in box (200)
with the lid (6) being flush with a poured concrete floor.
21. The rough-in box (200) of claim 20, further comprising: a seal
arranged between the lid (6) and the top flange (3) to create a
waterproof or water-resistant seal when the lid (6) is arranged on
the top flange (3).
22. A method of constructing a penetration in a concrete floor
(300), comprising: bending the single unitary piece (1) of the
rough-in box kit (100) of one of claims 1-19 at locations
corresponding to and lining up with the perforations,
through-holes, or slots (2) so as to form a rough-in box (200);
placing the rough-in box (200) in a location on a formed deck
corresponding to a predetermined location for the penetration in
the concrete floor (300); pouring concrete around the rough-in box
(200) to form the concrete floor (300).
23. A method of constructing a penetration in a concrete floor
(300), comprising: bending a single unitary piece (1) so as to form
a rough-in box (200); placing the rough-in box (200) in a location
on a formed deck corresponding to a predetermined location for the
penetration in the concrete floor (300); placing a lid (6) on top
of the rough-in box (200); pouring concrete around the rough-in box
(200) to form the concrete floor (300).
24. The method according to claim 23; wherein one end (8a) of the
single unitary piece (1) is secured and affixed to an opposite end
(8b) of the single unitary piece (1) to form the rough-in box
(200).
25. The method according to claim 23 or 24, further comprising:
cutting a top flange (3) of the single unitary piece (1) at
multiple first locations; and cutting a bottom flange (4) of the
single unitary piece at multiple second locations; wherein the
single unitary piece (1) is bent along multiple bending lines (18)
so as to form a rough-in box (200), each bending line (18)
extending from one of the first locations to one of the second
locations.
26. The method according to claim 25, further comprising: wherein
each bending line (18) corresponds to an array of perforations,
through-holes, or slots (2) single unitary piece (1) so that the
single unitary piece (1) is bent along the arrays of perforations,
through-holes, or slots (2).
27. The method according to one of claim 23-26; wherein the
concrete is poured around the rough-in box (200) to form the
concrete floor (300) so that the lid (6) is flush with the poured
concrete floor.
28. A kit for a platform to securely hold a lid (6) over a
penetration in a concrete floor (300), comprising: multiple single
unitary pieces (12) having: a first extension (12a) extending along
a first plane; a second extension (12b) extending from an end of
the first extension (12a) along a second plane intersecting with
the first plane; and a third extension (12c) extending from an end
of the second extension (12b) opposite to the first extension (12a)
along a third plane approximately parallel to the first plane.
29. The kit according to claim 28: wherein a height of the second
extension (12b) extending between the first and third extensions
(12a, 12c) in a direction perpendicular to the first plane
corresponds to a thickness dimension of a lid (6).
30. The kit according to claim 28 or 29: wherein at least one of
the first and third extensions (12a, 12c) includes through holes
(19), each through hole (19) being configured to accept a screw or
bolt (13) so that the multiple single unitary pieces (12) can be
screwed or bolted to the concrete floor (300).
31. A platform for securely holding a lid (6) over a penetration in
a concrete floor (300), comprising: the multiple single unitary
pieces (12) of the kit according to one of claims 28-30; wherein
each single unitary piece (12) is arranged around an edge of the
penetration so that at least a portion of an end (12d) of each
single unitary piece (12) overlaps with at least a portion of an
end (12d) of an adjacent single unitary piece (12).
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates generally to a rough-in box
for creating penetrations in poured concrete flooring during the
construction of buildings, and a method of using the device.
2. Background
[0002] Currently there are a number of solutions for creating
penetrations in concrete slabs during the construction of
buildings. The penetrations may then be utilized for the
installation of plumbing, ducts, mechanical systems on or between
floors, for construction access, or any other purpose a penetration
may be used. One method to install plumbing or mechanical systems
through concrete floors is by cutting or chopping out holes in the
floor or drilling such holes after the concrete floor has been
placed. These holes are then used the as access for pipes, ducts,
conduits or any other purpose a penetration may be used. This
solution fails to meet the needs of the industry because it is time
consuming, labor intensive and wasteful of construction material
and results in damage to the structure of the building.
[0003] Another solution to provide slab penetrations includes the
on-site fabrication of plywood boxes. The plywood boxes are
constructed so as to be placed on the formed deck and exclude
concrete from the box (i.e., concrete is poured around the box,)
thus providing a penetration. The use of this method creates
several undesirable conditions. First, the plywood boxes must be
stripped from within the concrete slab after concrete placement for
fire safety reasons. This stripping requires additional labor,
generates hazardous debris, and the work of stripping is itself a
hazardous activity. Second, after the concrete is placed holes must
be covered with plywood. These covers are raised from the floor
surface and therefore constitute a tripping hazard. The raised
plywood covers also interfere with the use of any wheeled
conveyances such as manlifts, pallet jacks, and carts. Plywood
covers are also easily accidentally displaced during subsequent
construction activities. This creates both a fall hazard for
workers on the floor above the penetration and exposes workers
below to objects falling from the floor above. Additionally,
plywood covers have relatively limited strength, and this strength
can be further diminished as plywood is subject to deterioration
when exposed to water and other environmental conditions.
[0004] Another application where voids must be provided in concrete
slabs occurs when plumbing fixtures require voids or penetrations
in the concrete slab. These voids are typically formed by use of
steel boxes that are set prior to placing concrete. But these steel
boxes are not designed to be left in place, and instead designed to
be reused from floor to floor. Because these steel boxes need to be
reused on subsequent floors, they must be removed quickly once the
concrete has just set but has not developed full strength. This
requires workers to walk on fresh concrete which can leave
footprints and other indentations in the newly placed slab which
must be repaired. Also, the act of removing the boxes often damages
the concrete at the edges of the void requiring costly repair work.
Similar to the penetrations discussed above, these voids must be
covered with plywood. These plywood covers are subject to the same
problems and hazards cited in the paragraph above.
[0005] None of the forms described above are suitable for bearing
the weight of workers and construction vehicles/equipment/materials
without creating an uneven floor surface that constitutes a
tripping hazard for construction workers and which could hinder the
movement of wheeled devices. Moreover, none of the forms described
allow construction to continue without the need to remove or trim
the forms or covers placed over the forms before the placing of
concrete. Further, the strength of covers currently in use are
typically unable to support heavy loads with appropriate safety
factors and are subject to deterioration due to environmental
conditions and removal and misplacement due to construction
activities.
[0006] The typical current method of creating penetrations and
voids in concrete floors during the construction of buildings
involves using job plywood boxes or removable metal boxes generally
includes the following steps: [0007] (1) The boxes are lifted and
placed by crane on the floor that is being readied to be poured.
[0008] (2) The boxes are then carried and placed on the prearranged
spots on the deck. Depending on the size of the box this may
require two workers. [0009] (3) The box is tied to the rebar or
fastened to the deck to prevent the box from being moved or
dislodged during the concrete placement. [0010] (4) Steel plumbing
void forms are greased to facilitate removal from concrete. [0011]
(5) The concrete is placed to create the slab. [0012] (6) The
surface is screeded and trowelled to make it flat and level. [0013]
(7) Steel plumbing void forms are removed by prying from the slab
after the concrete is set but not fully hardened. This process
usually takes two workers. This process can cause damage to the
surface of the concrete with footprints and also to the edges of
the hole. [0014] (8) The surface of the concrete must be repaired
to remove the footprints and fix other surface damage resulting
from removal of the boxes. [0015] (9) During the pouring process,
some concrete often overflows into the boxes, and when the boxes
are removed the hardened concrete has to be removed from the box.
This cleaning process requires two workers to strike the box sides
with sledgehammers to loosen the concrete and then chip out the
remainder with a scraper or chisel. [0016] (10) Plywood
penetrations boxes are stripped and removed when the deck below the
concrete floor is stripped, creating additional debris and hazards.
[0017] (11) Debris from plywood boxes and steel plumbing boxes is
gathered and removed from the site [0018] (12) Before the supports
and formwork for the next floor can be erected, the open holes must
be covered to prevent injuries. Plywood covers are placed over the
hole and nailed to the concrete to act as a cover.
[0019] This method does not meet the needs of the industry because
it has many inherent problems and inefficiencies, some of which are
now discussed.
[0020] While formwork for the next floor are ongoing, stripping of
formwork on the floor below begins. This process involves heavy
traffic on the floor and often covers can be displaced. This
creates hazardous conditions for the workers and leads to increased
labor to repair and replace covers.
[0021] Once the plumbing, mechanical, or other penetrations in one
floor are covered, the erection of the support legs and deck form
for the next floor can begin. During the normal course of
construction activities the plywood hole covers can become
dislodged and sometimes discarded. To prevent injuries caused by
stepping through a hole or items falling on workers below, covers
must be replaced or refastened to the floor. This is a constant
maintenance item and it requires the ongoing expenditure of labor
hours.
[0022] The concrete contractor must maintain the covers for
approximately six floors until the general contractor assumes
control of the floor. Maintenance typically consists of daily
inspections of the penetration covers on each floor to ensure they
are still correctly positioned and fastened to the floor, and
refastening loose covers. Once the general contractor takes control
of the floor they generally remove the concrete contractor's covers
and replace them with a double plywood cover with chamfered sides
The old covers then need to be removed from the floor and
discarded. The new covers have many of the same disadvantages that
the previous covers had.
[0023] It would be desirable to have a device and method of using
the device to form an opening in concrete slab during the placement
of concrete which is capable of providing an upper surface that is
flush with the concrete floor, has the strength to support the
weight of workers and construction supplies, can remain in place
after construction, and has waterproofing and fireproofing
capabilities. This would eliminate the need to cover openings with
plywood, which creates a tripping hazard for construction workers
and impedes the movement of wheeled carts and trucks that are used
to move materials around the construction site. Still further, it
would be desirable to have a device and method that provides for
improved efficiency, increased safety, and reduced labor costs.
Therefore, there currently exists a need in the industry for a
device and associated method that provides for an opening in poured
concrete flooring, with an upper surface that is flush with the
surrounding floor, strong enough to support the weight of
construction materials and workers, waterproof, fireproof, and cost
effective. Therefore, there currently exists a need in the industry
for a device and method of use that solves all the problems
discussed above.
[0024] Specifically there is a need for a form that can be used to
enable penetrations to be created in a concrete floor while
concrete for the floor is being poured, that can permit work on the
floor to continue without the need for removal of materials and
which can remain in place even after the floor is completed, that
provides a fireproof and waterproof barrier, and that desirably can
easily accommodate different sized penetrations.
SUMMARY OF THE INVENTION
[0025] The present invention advantageously fills the
aforementioned deficiencies by providing a rough-in box for
creating penetrations in concrete flooring along with a method of
use which creates a penetration in the flooring while providing a
flush surface with the floor which can support the weight of
workers and equipment, can remain in place post construction, and
provides waterproofing and fire proofing capabilities. The present
invention further provides a method using such boxes.
[0026] The present invention provides a structure for forming
openings in poured concrete slab flooring, which is made up of the
following components: one or more boxes, for example two boxes,
forming an opening of a desired shape. Rectangular side walls can
be used for forming a box having the shape of a rectangular prism,
and curved side walls can be used for forming a circular or
elliptical box.
[0027] In a particularly useful embodiment, each box has four
sides, and an optional top lid. The top lid is strong enough to
permit workmen and their equipment to move across it without risk.
The strength required of the top depends on the particular
situation in which the box is being used. Conveniently, the box is
formed on site from pre-formed side pieces. It is desirable that
the top piece is customized for a particular location. To
facilitate on-site assembly of a box, the side pieces are designed
to be easily bent to the preferred configuration. A flange is
provided at the top of the side profile which serves to support the
top of the box flush with the concrete. This configuration is
typically used for ducts and other mechanical systems that go
vertically from floor to floor, but is equally applicable to any
slab opening that must be protected during construction.
[0028] In another embodiment, typically used to form a void for the
connection of plumbing fixtures on a floor, one or several boxes
can be configured to accommodate the required void. In plan view
these boxes may take a linear shape, the shape of the letter T or
L, or a cruciform shape. Where the sides of the boxes abut, there
will be an opening in the wall of each box to allow access between
the two boxes for subsequent plumbing installation. The top side of
each box will be removable. When the desired configuration has been
created, the device is placed in the required position on the deck
of the floor. Concrete is poured onto the deck and cured. The top
sides of the boxes will sit flush with the floor surface to allow
for pallet jacks and other wheeled carts to be moved over the
covered openings without hindrance and without the need for plywood
coverings which create tripping hazards.
[0029] While the above embodiment describes multiple rough-in boxes
being used to create a given shape, it should be appreciated that
the same shape could be formed by connecting multiple rough-in box
kits to form a single rough-in box with one of the above-mentioned
shapes.
[0030] Another embodiment of the present invention will serve as a
hole cover for penetrations that have been conventionally formed in
a concrete slab or any hole in any floor that needs to be covered
securely. In this embodiment, as shown in FIGS. 17-19, a frame of
bent steel sections 12 is fastened in the opening and provided with
a top lid 6 with sufficient strength to allow construction
activities to safely proceed.
[0031] In still another embodiment of the present invention a steel
frame is made to mount over steel pour stops typically used in
steel framed buildings where the slabs are placed on top of metal
deck forms. This steel frame is fitted with a lid of sufficient
strength to allow construction activities to safely proceed. This
version of the invention is suitable for steel framed buildings and
provides a flush hole cover.
[0032] The present invention may also have one or more of the
following. The boxes may be constructed to be water tight to
prevent water traveling through the floor penetration. The boxes
may be constructed entirely or partially of a fireproof material.
The boxes may also incorporate intumescent material as a means of
fireproofing the penetration. Similarly, the method associated with
the present invention may also include one or more of the following
steps: installing waterproofing devices, installing fireproofing
devices.
[0033] The present invention is unique when compared with other
known devices and solutions because the invention provides a
structure: (1) which creates a slab pass-through and a void space
for plumbing, mechanical, or other access and which can remain in
place after the concrete cures (2) which optionally has a closed
top that is flush with the slab floor and can support the weight of
construction workers and material; (3) and which optionally
provides waterproofing and fireproofing protection. Similarly, the
associated method is unique in that it: (1) eliminates the time and
labor of constructing and installing wooden covers on-site; (2)
eliminates the time and labor removing forms from cured concrete;
and (3) eliminates obstructions and tripping hazards at the
construction site.
[0034] The present invention is unique in that it is structurally
different from other known devices or solutions. More specifically,
the present invention is unique due to the presence of: (1) a top
lid which is flush with surrounding concrete and significantly
stronger than current materials: (2) rectangular or square shaped
structures for both the pass through section and plumbing connector
as well as full penetration sections for shafts or mechanical
systems; and (3) rigid construction that can support the weight of
workers and material. Furthermore, the process associated with the
aforementioned invention is likewise unique and different from
known processes and solutions. More specifically, the present
invention process owes its uniqueness to the fact that it achieves
as good or better results than conventional methods in fewer steps,
less time, less labor, less cost, and has safety advantages.
[0035] Among other things, it is an object of the present invention
to provide plumbing boxes and mechanical boxes for creating
penetrations in concrete flooring and methods of use that does not
suffer from any of the problems or deficiencies associated with
prior solutions.
[0036] It is still further an objective of the present invention to
create a device that is more economical to produce, easier to
manufacture, easier to ship to the work site, easier to install and
of sufficient durability to remain in place after construction is
complete.
[0037] Further still, it is an objective of the present invention
to create a device that is amenable to mass production in a variety
of standard dimensions frequently encountered in the industry,
thereby enabling the device to be more easily commercialized.
[0038] In a preferred aspect of the present invention, the boxes
are comprised of components that allow accurate on-site bending at
increments that allow easy field fabrication of appropriate size
rough-in boxes for the desired penetrations. Typically, the
components forming the side walls of the box and are bent into
shape as described below. The tops of these wall members provide a
flange on which the cover may be placed.
[0039] The side walls may be formed of any strong, tough material
which may vary in accordance with the particular application or
circumstances under which the rough-in box is to be used. For
example, the side walls may be made from metal alloys, fiberglass,
and heavy duty plastics, or any combination thereof. Examples of
heavy duty plastics include polyethylene, polyvinyl, and
polypropylene. In one particular embodiment, the side walls are
made from an aluminum alloy, such as the aluminum 5000 series, and
may have a thickness in the range of 0.03 to 0.1, for example,
0.050 inches. In another embodiment, the side walls are made from
galvanized steel (e.g., 22 ga galvanized steel). Other properties
such as weight can be relevant to the choice of material for the
side walls of the rough-in box.
[0040] The top lid needs to be strong enough to provide a working
surface on the floor while construction is being carried out. As
such, the top lid must be capable of supporting a concentrated
weight of approximately 2,000 pounds and a uniformly distributed
load of approximately 100 pounds per square foot. The lid can be
made from a broad range of materials including fiber reinforced
plastics, engineered wood, or heavy duty plastics, or a combination
thereof. In one embodiment, the top lid can be made of resin
impregnated fiberglass with the density of fibers being determined
by the weight that the closure has to bear. Generally, the number
of piles or layers of fibers will affect the flexural strength of
the lid as will be further discussed below. The resins used to
impregnate the fiberglass may include epoxy resins as well as other
types of thermosetting plastics such as polyester or vinyl-ester
resins and thermoplastics. The lids may be custom made to have a
fixed size for particular sized penetrations. If required, the lid
can be supported by one or more struts stretching across the box
from an opening or vertical slot in one wall to an opening or
vertical slot in the opposite wall.
[0041] In another aspect, the present invention provides a method
for constructing a floor containing penetrations which comprises:
assembling the walls of a box as described above, locating such
boxes on a floor deck, placing a lid being made of a material
stronger than that of the sidewalls and being capable of supporting
a weight of approximately 2,000 pounds on the top of said box,
pouring concrete to form a floor around said boxes, performing work
on said floor after pouring the concrete, and subsequently removing
said top, leaving the remaining parts of the box in situ in the
concrete, and installing plumbing or electrical fittings within
said box.
[0042] In a further embodiment, the walls of the box, irrespective
of whether the walls are a fixed size or the wall lengths are
adjustable, are provided with one or more grooves into which fire
proofing or fire retardant can be injected or inserted.
[0043] In a yet further embodiment of the invention, the box
components or the lid are provided with elements from which a guard
rail may be provided to surround the perimeter of the
penetration.
[0044] To comply with safety regulations, the upper surface of the
lid should be a bright color (yellow and orange being typical) and
should be provided with a non-slip upper surface and be clearly
marked with the word "HOLE".
[0045] In a preferred embodiment, the box may be made to the
required size by bending a single unitary piece along lines of
perforations located at increments along the single piece.
[0046] In one embodiment of the invention there is provided a
rough-in box kit (100) for creating a rough-in box (200) to create
a penetration in poured concrete flooring during the construction
of concrete buildings. The rough-in box kit (100) includes a single
unitary piece (1) having a flat section (5) with: a top end; a
bottom end opposite to the top end; an inside surface (5a) located
between the top end and the bottom end, and configured to form an
inside surface of the rough in box (200); and an outside surface
(5b) opposite to the inside surface (5a), and configured to form an
outside surface of the rough in box (200). The single unitary piece
(1) also has a top flange (3) connected to and extending away from
the top end of the flat section (5), and perforations,
through-holes, or slots (2) that are formed in the flat section
(5). The single unitary piece (1) is configured to be bent at
locations corresponding to and lining up with the perforations,
through-holes, or slots (2) so as to form the rough-in box
(200).
[0047] In another embodiment, the top flange has a first extension
(3a) that extends from the flat section (5) at approximately a
90.degree. angle, and a second extension (3b) that extends from the
first extension (3a) at approximately a 90.degree. angle.
[0048] In yet another embodiment, the perforations, through-holes,
or slots (2) are formed in the first extension (3a).
[0049] In a further embodiment, the perforations, through-holes, or
slots (2) are not formed in a distal end of the second extension
(3b) opposite to and distal from the first extension (3a).
[0050] In yet a further embodiment, the perforations,
through-holes, or slots (2) are formed in a proximal end of the
second extension (3b) adjacent and proximal to the first extension
(3a).
[0051] In another embodiment, the perforations, through-holes, or
slots (2) are not formed in any portion of the second extension
(3b).
[0052] In yet another embodiment, wherein the single unitary piece
(1) additionally has a bottom flange (4) connected to and extending
away from the bottom end of the flat section (5) opposite to the
top end of the flat section (5).
[0053] In a further embodiment, the bottom flange extends from the
flat section (5) at approximately a 90.degree. angle.
[0054] In yet a further embodiment, the single unitary piece (1)
additionally has a bottom flange (4) connected to and extending
away from a bottom end of the flat section (5) opposite to the top
end of the flat section (5). The bottom flange (4) extends
approximately parallel to the a first extension (3a) of the top
flange (3).
[0055] In another embodiment, the perforations, through-holes, or
slots (2) are not formed in a distal end of the bottom flange (4)
opposite to and distal from the flat section (5).
[0056] In yet another embodiment, the perforations, through-holes,
or slots (2) are formed in a proximal end of the bottom flange (4)
adjacent and proximal to the flat section (5).
[0057] In a further embodiment, the perforations, through-holes, or
slots (2) are not formed in any portion of the bottom flange
(4).
[0058] In yet a further embodiment, the perforations,
through-holes, or slots (2) form vertical arrays (2a) in the flat
section (5), each vertical array (2a) extending in a vertical
direction from the top end to the bottom end of the flat section
(5).
[0059] In another embodiment, the vertical arrays (2a) of
perforations, through-holes, or slots (2) are spaced apart from
each other in a horizontal direction perpendicular to the vertical
direction so that the perforations, through-holes, or slots (2)
additionally form horizontal arrays (2b) in the flat section (5)
extending in the horizontal direction.
[0060] In yet another embodiment, the singe unitary piece (1) made
of an aluminum alloy.
[0061] In a further embodiment, the rough-in box kit (100) further
includes a lid (6) formed configured to supporting a weight of at
least approximately 2,000 pounds when placed on top of the formed
rough-in box (200).
[0062] In yet a further embodiment, the lid (6) is formed of
resin-impregnated fiberglass.
[0063] In another embodiment, the resin-impregnated fiberglass is
impregnated with an epoxy resin.
[0064] In yet another embodiment, the lid (6) comprises 18 to 40
fiberglass layer strands of fiber.
[0065] In a further embodiment, there is provided a rough-in box
(200) including the rough-in box kit (100) where the single unitary
piece (1) is bent at locations corresponding to and lining up with
the perforations, through-holes, or slots (2) so as to form the
rough-in box (200) with the lid (6) being flush with a poured
concrete floor.
[0066] In yet another embodiment, the rough-in box (200) further
includes a seal arranged between the lid (6) and the top flange (3)
to create a waterproof or water-resistant seal when the lid (6) is
arranged on the top flange (3).
[0067] In another embodiment, there is provided a method of
constructing a penetration in a concrete floor (300). The method
includes bending the single unitary piece (1) of the rough-in box
kit (100) of one of claims 1-19 at locations corresponding to and
lining up with the perforations, through-holes, or slots (2) so as
to form a rough-in box (200). Then the rough-in box is placed (200)
in a location on a formed deck corresponding to a predetermined
location for the penetration in the concrete floor (300). Next,
concrete is poured around the rough-in box (200) to form the
concrete floor (300).
[0068] In yet another embodiment, there is provided a method of
constructing a penetration in a concrete floor (300). The method
includes bending a single unitary piece (1) so as to form a
rough-in box (200). Then the rough-in box (200) is placed in a
location on a formed deck corresponding to a predetermined location
for the penetration in the concrete floor (300). Next a lid (6) is
placed on top of the rough-in box (200). After that, concrete is
poured around the rough-in box (200) to form the concrete floor
(300).
[0069] In a further embodiment, one end (8a) of the single unitary
piece (1) is secured and affixed to an opposite end (8b) of the
single unitary piece (1) to form the rough-in box (200).
[0070] In yet a further embodiment, the method further includes
cutting a top flange (3) of the single unitary piece (1) at
multiple first locations, and cutting a bottom flange (4) of the
single unitary piece at multiple second locations. The single
unitary piece (1) is then bent along multiple bending lines (18) so
as to form a rough-in box (200), each bending line (18) extending
from one of the first locations to one of the second locations.
[0071] In another embodiment, each bending line (18) corresponds to
an array of perforations, through-holes, or slots (2) single
unitary piece (1) so that the single unitary piece (1) is bent
along the arrays of perforations, through-holes, or slots (2).
[0072] In yet another embodiment, the concrete is poured around the
rough-in box (200) to form the concrete floor (300) so that the lid
(6) is flush with the poured concrete floor.
[0073] In a further embodiment, there is provided a kit for a
platform to securely hold a lid (6) over a penetration in a
concrete floor (300). The kit includes multiple single unitary
pieces (12), each having a first extension (12a) extending along a
first plane, a second extension (12b) extending from an end of the
first extension (12a) along a second plane intersecting with the
first plane, and a third extension (12c) extending from an end of
the second extension (12b) opposite to the first extension (12a)
along a third plane approximately parallel to the first plane.
[0074] In yet a further embodiment, a height of the second
extension (12b) extends between the first and third extensions
(12a, 12c) in a direction perpendicular to the first plane
corresponds to a thickness dimension of a lid (6).
[0075] In another embodiment, at least one of the first and third
extensions (12a, 12c) includes through holes (19), each through
hole (19) being configured to accept a screw or bolt (13) so that
the multiple single unitary pieces (12) can be screwed or bolted to
the concrete floor (300).
[0076] In another embodiment, there is provided a platform for
securely holding a lid (6) over a penetration in a concrete floor
(300). The platform includes the multiple single unitary pieces
(12). Each single unitary piece (12) is arranged around an edge of
the penetration so that at least a portion of an end (12d) of each
single unitary piece (12) overlaps with at least a portion of an
end (12d) of an adjacent single unitary piece (12).
[0077] It is noted that the features of the above-described
embodiments are not exclusive to each other, and that any one of
the above embodiments/features can be combined with one or more of
the other embodiments/features to arrive at further
embodiments.
[0078] The present invention will now he described more fully
hereinafter with reference to the accompanying drawings, which are
intended to be read in conjunction with both this summary, the
detailed description, and any preferred and/or particular
embodiments specifically discussed or otherwise disclosed. This
invention may, however, be embodied in many different forms and
should not be construed as limited to the embodiments set forth
herein. Rather, these embodiments are provided by way of
illustration only so that this disclosure will be thorough,
complete, and will fully convey the scope of the invention to those
skilled in the art.
BRIEF DESCRPTION OF THE DRAWINGS
[0079] FIG. 1 shows an embodiment of the rough-in box 200 along
with basic components of the box (single unitary pieces 1 and lids
6) as they will be provided to a job.
[0080] FIG. 2 shows a perspective view of the side profile of a
single unitary piece 1 of kit 100 for a rough-in box 200 in an
unassembled state. This single unitary piece 1 can be provided in
various lengths to suit the application.
[0081] FIGS. 3a and 3b show the method by which the single unitary
piece 1 is cut in specific locations so that it can be bent into
the box shape required for the application.
[0082] FIG. 4 shows the side profile of the single unitary piece 1
with a single 90 degree bend.
[0083] FIG. 5 shows an embodiment of a the side profile of the
single unitary piece 1 with a 90 degree bend.
[0084] FIG. 6 shows the side profile of the single unitary piece 1
with a second 90 degree bend.
[0085] FIG. 7 shows the single unitary piece 1 side profile with
the top and bottom flanges 3, 4 partially trimmed at one of the two
ends 8a, 8b (e.g., left end 8a in FIGS. 7-9) and the resulting tab
11 bent at 90 degrees ready to overlap and attach to the other
opposite end 8a, 8b of the single unitary piece 1 to form a closed
box.
[0086] FIG. 8 shows the tab 11 referenced in FIG. 7 overlapping the
opposite end of the single unitary piece 1 so that the opposite
ends of the single unitary piece 1 (in this case the tab end and
the opposite end) are ready to be attached to each other by screws
13 or other means.
[0087] FIG. 9 is a perspective view of the single unitary piece 1
bent into a completed rectangular rough-in box 200.
[0088] FIG. 10 shows the completed box 200 with a lid 6 attached,
with an enlarged a detail showing an optional corner piece 10 that
may be applied to protect the corner of the lid.
[0089] FIG. 11 shows a completed rough-in box 200 with optional
corner pieces 10 and a lid 6 with a handle 9.
[0090] FIG. 12 shows a lid 6 being installed onto the top of the
completed rectangular rough-in box 200.
[0091] FIG. 13 shows a plan view of the rough-in box 200 completed
without the lid 6.
[0092] FIG. 14 shows a side view of the completed rectangular
rough-in box 200.
[0093] FIG. 15 shows a side view of the rough-in box kit 100 in
FIG. 2 along an end of the kit.
[0094] FIG. 16 shows cross sectional view of part of the rough-in
box 200 after concrete has been poured.
[0095] FIG. 17 shows cross sectional view of one of the steel
sections 12 of FIG. 18.
[0096] FIG. 18 shows a plan view of a version of the invention
designed to cover a hole in an existing slab. This is comprised of
steel sections 12 surrounding the perimeter of the hole fastened to
the surrounding slab that support a cover.
[0097] FIG. 19 a perspective view of one of the steel sections 12
of FIG. 18.
[0098] FIG. 20 shows examples of fire rated rubber seals 14.
[0099] FIG. 21 shows a non-slip or slip resistant surface 15.
[0100] FIG. 22 shows a lid 6 with hydraulic hinges 16.
[0101] FIG. 23 shows an example of a handle 9 for the lid 6.
[0102] FIG. 24 shows examples of the different types of screw heads
that can be used to effectively lock the lid 6 to the rough-in box
200.
[0103] FIGS. 25 and 26 show an optional deployable safety rail
system 17.
[0104] FIG. 27 is a plan view of the metal rough-in box 200 in
place.
[0105] FIG. 28 shows a cross-section through the metal rough-in box
200 with the concrete deck poured.
[0106] FIG. 29 shows a cross-section through the metal rough-in box
200 prior to concrete placement.
[0107] FIG. 30 is a plan view of a configuration 400 of multiple
single unitary pieces 1 attached together to form a frame for a
single depression of penetration.
[0108] FIG. 31 is a cross sectional view through line A-A of the
configuration 400 of FIG. 30.
[0109] FIG. 32 is a side view of the configuration 400 in FIG.
30.
[0110] FIG. 33 shows an embodiment with a slot 46 in the side walls
of the rough-in box 200 to receive expandable foam
fireproofing.
DETAILED DESCRIPTION OF THE INVENTION
[0111] The present invention is directed to a mechanical rough-in
and plumbing box 200 for creating penetrations in concrete flooring
and a method of use.
[0112] FIG. 1 shows that these components--single unitary pieces 1
and lids 6--are capable of being flat packed such that they fit
together when stacked on top of one another. This saves space when
transporting and storing the components. Thus, the components can
be delivered with fewer trucks, and take up less storage space at
the jobsite.
[0113] In the embodiment of the present invention in FIG. 2, the
rough-in box 200 is formed from a single unitary piece 1, which can
be supplied in a single stock length to form rough-in boxes 200 of
differing sizes and dimensions. The single unitary piece 1 is
supplied with perforations, through-holes, or slots 2 in increments
across their width. By snipping the top and bottom flanges 3, 4 of
the single unitary piece 1 at locations corresponding to and lining
with the perforations, through-holes, or slots 2, the profile may
be bent or cut at any of the incremental lengths that correspond to
the spacing of the perforations, through-holes, or slots 2, as
shown in FIG. 3 and further shown in FIGS. 4, 5, 6, and 7. This
feature allows the single unitary piece 1 to be formed into
virtually any shape by varying the lengths between the bends and
the angle of bends. The profile is fastened into a closed shape by
trimming a short length of the flanges 3, 4 of one end 8a, 8b
(e.g., left end 8a in FIGS. 7-11) of the single unitary piece 1 to
form a tab 11, and then bending the resulting tab 11 (FIG. 7) to
match the opposite end 8a, 8b (e.g., right end 8b in FIGS. 7-11) of
the single unitary piece 1 and securing the two ends 8a, 8b by
screws 13 or some other means. Should the shape of the desired
rough-in box 200 exceed the longest length of the single unitary
piece 1 supplied, a second single unitary piece 1 can be spliced to
the first in a manner similar to that described above wherein a tab
11 is created by trimming the flanges 3, 4 of the piece 1 allowing
the end 8a, 8b of one piece 1 to lie flat on the corresponding
opposite end 8a, 8b of the second piece 1. The pieces 1 can then be
spliced or affixed together with screws 13 or other appropriate
means.
[0114] Preferably, the perforations, through-holes, or slots 2 are
formed along vertical arrays 2a from the top of the single unitary
piece 1 to the bottom of the bottom of the single unitary piece 1.
This allows the single unitary piece 1 to be bent along straight
lines to form the corners of the rough-in box 200. The vertical
arrays 2a are spaced apart from each other at fixed increments
along the width of the single unitary piece 1. Preferably the
distance between adjacent vertical arrays 2a is constant. In one
embodiment, the constant distance between the vertical arrays 2a is
from 0.5 inches to 6.0 inches. Preferably, the constant distance
between the vertical arrays 2a is from 0.5 inches to 3.0 inches.
More preferably, the constant distance between the vertical arrays
2a is from 0.5 inches to 2.0 inches. Most preferably, the constant
distance between the vertical arrays 2a is from 0.5 inches to 1.5
inches. In a particularly preferred embodiment, the constant
distance between vertical arrays 2a is approximately 1.0
inches.
[0115] In another embodiment, the vertical arrays 2a of
perforations 2 are spaced so that the perforations 2 also line up
with each other horizontally to form horizontal arrays 2b that are
perpendicular to the vertical arrays 2a.
[0116] Preferably, each perforation, through-hole, or slot 2 is
formed in an oval or rectangular shape with its longest dimension
extending along the same direction of the vertical array 2a in
which it is arranged. This further facilitates bending the single
unitary piece 1 to form the rough-in box 200.
[0117] The single unitary piece 1 consists of a flat section (web)
5, a top flange 3 which is shaped to support the box lid 6 flush
with the surface of the concrete 300 (see FIG. 16), and a lower
flange 4 that enhances the strength of the single unitary piece 1
and allows the finished box 200 to be securely fastened to the deck
form. The flat section (web) 5 has an inside surface 5a and an
outside surface 5b, with the inside surface 5a forming an inside
surface of the final rough-in box 200 and the outside surface 5b
forming an outside surface of the final rough-in box 200.
[0118] The rough-in box 200 is formed by snipping the flanges 3, 4
at locations corresponding to the perforations, through-holes, or
slots 2, and bending the single unitary piece 1 along the
perforations, through-holes, or slots 2 as required to attain the
finished shape desired. Once the shape is attained the box 200 is
fastened by securing the web tab 11 from one end 8a, 8b of the
profile to the opposite end 8a, 8b.
[0119] In one embodiment, the profile of the rough-in box may be
snipped and bent at very small intervals thereby creating a chorded
circular shape.
[0120] There is no need to have a bottom surface on the rough-in
box 200 as that would hinder the installation of plumbing, ducts,
or other mechanical systems between floors. Thus, only a lid 6
needs to be opened so that these systems can be passed up from the
floors below.
[0121] Once the side walls 7 of the rough-in box 200 are formed and
the ends 8a, 8b joined together, the lid 6 is attached to the
rough-in box 200. Each side wall 7 of the rough-in box has a top
flange 3 to provide support for the lid 6 so that the lid 6 can is
supported by each of the side walls 7 of the rough-in box 200.
[0122] The lid 6 is load bearing to permit workmen, equipment,
vehicles, and materials to move over the lid 6 without risk of the
lid 6 collapsing and caving in. Therefore, the lid 6 needs to be
made from a strong enough material to provide a working surface on
the floor while construction is being carried out. In one
embodiment, the lid 6 is designed to support a weight of at least
approximately 2,000 pounds concentrated load and approximately 200
pounds per square foot uniform load. The lid 6 can be made from
fiberglass or from heavy duty plastics such as polyethylene,
polyvinyl, and polypropylene. Additionally, in some embodiments,
the lid 6 can be made from engineered wood. It is also possible
that the lid 6 is made from a combination of fiberglass, heavy duty
plastic, and/or engineered wood.
[0123] In one embodiment, the lid 6 can be made from resin
impregnated fiberglass with the density of fibers being determined
by the weight that the lid 6 has to bear. The resins used to make
the lid 6 can include epoxy resins as well as other types of
thermosetting plastics such as polyester or vinyl-ester resins and
thermoplastics.
[0124] A fire rated rubber seal 14, such as the one shown in FIG.
20, can be added to the lid 6 for water resistance. The shape of
the seal 14 should correspond to the shape of the lid 6 so that the
seal 14 added to the under surface of the lid 6 of the rough-in box
200 to create a tight seal with the top flange 3 of the side walls
7 when the rough-in box 200 is closed. Waterproofing the rough-in
box 200 allows sheetrock and other water-sensitive materials to be
stored on floors below without worry of damage.
[0125] Optionally, compressed fireproofing can be embedded into the
side walls 7 of the rough-in box 200. As shown in FIG. 33, a slot
46 can be left into the side walls of the rough-in box 200 to
receive expandable foam fireproofing. Alternatively, an expandable
fireproofing material--for example, expandable foam fireproofing
material--can be affixed to the inside surface 5a of the single
unitary piece 1 which will form an inside surface of rough-in box
200. After the rough-in box 200 is assembled and put into place, a
worker can pull off a tape that will expose the expandable
fireproofing material (e.g., expandable foam fireproofing). When
the tape is removed, the fireproofing material will expand until it
meets a solid barrier--for example, air conditioner ducts--such
that when a duct is passed through the rough-in box 200, the
fireproofing material is adhered to the surface of the duct. The
fireproofing material can be an intumescent tape or any equivalent
thereof. Intumescent materials that can be included in the tape
include, for example, polyphosphates (such as ammonium
polyphosphate) and materials that react with such phosphates such
as pentaerythritol and melamine, or silicate-containing
materials
[0126] If desired, the lid 6 can be supported by a strut (not
shown) stretching across the box from an opening or vertical slot
in one wall to an opening or vertical slot in an opposite wall to
provide additional load bearing strength.
[0127] As shown in FIG. 22, the lid 6 may be equipped with
hydraulic hinges 16 to control the speed at which the lid 6 opens
and also to keep the lid 6 in a vertical open position when the lid
6 is opened by a worker working on the hole.
[0128] The lid can also be equipped with a lanyard or tether 20.
The lanyard or tether 20 will provide positive attachment between
the lid and the side walls of the box. The lanyard or tether 20
will allow lids to be removed but will insure that the lid is not
removed from the immediate area of the opening.
[0129] The lid 6 can feature a grip and/or handle 9 for easy
opening of the lid 6. An example of a handle is shown in FIG.
23.
[0130] Different locks/screw heads can be utilized to secure the
lid 6 to the rough-in box 200 so that only certain personnel from a
particular trade can open the rough-in box 200. For example, some
designated rough-in boxes 200 can be equipped with a special screw
head that can only be opened by plumbers, whereas other designated
rough-in boxes 200 can be equipped with a different screw head that
can only be opened by electricians. Examples of the different types
of screw heads that can be used to effectively lock the lid 6 to
the rough-in box 200 are shown in FIG. 24.
[0131] As a safety measure, the top side of the lid 6 can have a
non-slip surface 15 so that workers and equipment moving over the
lid 6 do not slip when crossing the rough-in box 200. A slip
resistant surface that can be applied to the lid 6 is shown in FIG.
21.
[0132] As shown in FIGS. 25 and 26, the lid 6 can also be equipped
with a deployable safety rail system 17 as an additional safety
measure. The deployable safety rail 17 is a series of tubular
members that are connected together and fastened to the rough-in
box 200 and the lid 6 when the lid 6 is open to prevent accidental
trips and falls due to the hole being open. The deployable safety
rail 17 can be collapsed/de-constructed and stored in pieces within
the rough-in box 200 on the underside 6a of the lid 6 for storage
as shown in FIG. 25. When deployed, the tubular pieces of the
safety rail 17 are removed from the underside of the lid 6, and are
then assembled together atop the rough-in box 200 to form a
rectangular prism that would prevent a worker from falling inside
the hole of the rough-in box 200 when the lid 6 is open as shown in
FIG. 26. The presence of the deployed safety rail 17 also acts as a
warning to workers walking on the construction site that the lid 6
of the rough-in box 200 is open.
[0133] A sensing system that would alert workers and staff on the
jobsite as to when a particular rough-in box has been left open can
be included in the rough-in box 200. For example, a pressure sensor
can be integrated into the lid 6, side walls 7, or both the lid 6
and side walls 7 of the rough-in box 200. When the lid 6 is closed,
the sensor will register the applied pressure. When the lid 6 is
open, no pressure will be detected by the sensor, and the sensor
will then wirelessly relay to a visual display that the rough-in
box 200 is open.
[0134] When installing the rough-in box 200, a numbering system can
be used such that each box is numbered to match a corresponding
hole at the jobsite. This ensures that the right rough-in box 200
goes over the correct hole. Also, if lids 6 are removed or placed
over the wrong hole, this can be easily inspected and
corrected.
[0135] The rough-in box 200 with the lid 6 attached allows holes to
be covered prior to the pouring of concrete and stops leaks of
concrete from entering the holes. When the concrete is poured to
form the floor of a building, the lid 6 prevents over-pour from the
concrete and creates a perfect edge that is level with the concrete
when the concrete solidifies. Thus, there are no obstructions on
the floor because the lid 6 will be flush with the concrete floor,
allowing for the use of dollies, manlifts, modular scaffolding, and
designated walkways because the lid 6 is load bearing and capable
of handling loads from heavy machines and equipment. As a result,
fewer safety personnel are needed and work shutdowns are minimized
and reduced.
[0136] The rough-in box 200 of the present invention is embedded in
the concrete floor, and only the lid 6 needs to be removed to
complete mechanical work. When the lids 6 are removed, the lids 6
can be easily stacked and removed all together.
[0137] While the present invention has been described above in
terms of specific embodiments, it is to be understood that the
invention is not limited to these disclosed embodiments. Many
modifications and other embodiments of the invention will come to
the mind of those skilled in the art to which this invention
pertains, and which are intended to be and are covered by both this
disclosure and the appended claims. It is indeed intended that the
scope of the invention should be determined by proper
interpretation and construction of the appended claims and their
legal equivalents, as understood by those of skill in the art
relying upon the disclosure in this specification and the attached
drawings.
[0138] The single unitary piece 1 may be formed of any strong,
tough material. For example, the side walls can be made from an
aluminum sheet, steel sheet, high strength plastic, or any other
material that can be formed into the required shapes that has
adequate strength.
[0139] The box or boxes 200 can be and fastened together by
welding, rivets, screws 13, or any appropriate fastening method.
The top will be left open. A flange 3 will be formed at the top of
the boxes in a configuration as shown in FIG. 9. This flange 3 will
serve to support a box lid 6 which will be installed in the box
prior to placing concrete. The lid 6 will be flush with the surface
of concrete after it is placed.
[0140] Different configurations 400 of boxes 200 may be made by
joining individual boxes 200 of the required sizes, for example as
shown in FIGS. 30-32. Typical configurations 400 can be a simple
rectangular configuration 400 to form a straight trough or several
boxes 200 may be connected in a configuration 400 to form
penetrations having shapes resembling the letter "L", "T", or a
cruciform shape in plan view.
[0141] This embodiment of the present invention solves many of the
labor inefficiencies and costs incurred when creating void spaces
in slabs for connecting plumbing fixtures. When the kits 100 for
new boxes 200 or configurations 400 arrive on site, the boxes 200
are assembled prior to installation in the slab. They are delivered
to the floor to be poured, and from there they are installed in a
prearranged spot on the deck. To fasten the boxes 200 or
configurations 400 in place, they are simply nailed to the wooden
deck and are then ready for the pouring process. Unlike previous
methods, the boxes 200 in the present invention stay in the
concrete permanently this eliminates the need to grease or
otherwise prepare the box 20 or configuration 400 to be stripped
out of the floor as is required with current methods. The boxes 200
or configurations 400 are fitted with one or more covers 6 prior to
placing the concrete so work around the boxes 200 or configurations
400 can proceed faster because workers do not have to worry about
accidentally filling the boxes 200 or configurations 400 with
concrete. The flush surface provided by the lid(s) 6 of the box 200
or configuration 400 also facilitates screeding and finishing the
concrete around the boxes. The present invention eliminates the
need to strip out rough-in boxes after the concrete is placed.
[0142] Current methods require the boxes to be pried out of the
concrete to leave the appropriate void. Typically this removal of
the boxes is done after the concrete fully sets, which is labor
intensive, wastes time on the construction site, and can be
hazardous to the workers removing the box. Additionally, concrete
may overflow during placement and get inside the boxes and this
must be cleaned out by workers.
[0143] Another benefit of the present invention is the top flange
3, which allows the lid 6 to sit flush with the surface of the
concrete. Current methods require that plumbing boxes be covered
with plywood hole covers that are proud of the concrete surface.
These plywood covers are a tripping hazard and they interfere with
the use of any wheeled devices for moving material around the
floor.
[0144] According to conventional processes, the covers must be
inspected daily for each floor. The present invention would
drastically reduce this requirement, if not eliminate it
completely, as the structural capabilities of the lid 6 would mean
that the boxes 200 and configurations 400 would be able to
withstand the loads and forces present on the site without failure.
The reduction in inspection frequency would save on labor costs for
the duration of the construction phase.
[0145] When the general contractor takes control of the floor, they
do not need to add the additional covers for the holes. The plumber
and mechanical services can immediately take responsibility for the
boxes and run the pipework or shafts needed.
[0146] The proposed method greatly improves existing methods by the
fact that it increases productivity and reduces labor costs, while
also reducing the potential trip or fall hazards present with
existing methods, which in turn reduces job stoppages from falls
and injuries.
[0147] Another embodiment of the present invention will serve as a
hole cover for penetrations that have been conventionally formed in
a concrete slab or any hole in any floor that needs to be covered
securely. In this embodiment, as shown in FIGS. 17-19, a frame of
bent steel sections 12 is fastened in the opening and provided with
a top lid 6 with sufficient strength to allow construction
activities to safely proceed.
[0148] Each bent steel section 12 has a first extension 12a, a
second extension 12b, and a third extension 12c. The first and
third extensions 12a, 12c are approximately parallel to each other
and extend in the same direction. The second extension 12b extends
approximately perpendicular to the first and third extensions 12a,
12c to connect the first and third extensions 12a, 12c with each
other.
[0149] The height of the second extension 12b (i.e., the up-down
direction in FIG. 16) is preferably selected to correspond to a
thickness of the top lid 6 that will be used so that a top of the
lid 6 is flush with the top of the concrete floor 300--for example,
approximately 0.5 inches. This reduces the chance of trips
occurring while people work on the concrete floor 300.
[0150] Optionally, the first and third extensions 12a, 12c can
include through holes 19, which allow the steel section 12 to
easily be affixed to the concrete floor 300 by screws or bolts 13.
The through holes 19 can also be used to secure the lid 6 to the
steel section 12 by screws or bolts 13.
[0151] Preferably the steel sections 12 are placed around a hole in
the concrete floor 300 so that ends 12d of two adjacent steel
sections 12 overlap. This increases the strength of the platform
formed by the first extensions 12a on which the lid 6 rests.
LIST OF REFERENCE NUMBERS
[0152] 1 single unitary piece [0153] 2 perforations, through-holes,
or slots [0154] 2a vertical arrays of perforations, through-holes,
or slots 2 [0155] 2b horizontal arrays of perforations,
through-holes, or slots 2 [0156] 3 top flange [0157] 3a first
extension of top flange 3 [0158] 3b second extension of top flange
3 [0159] 4 bottom flange [0160] 5 flat section (web) [0161] 5a
inside surface [0162] 5b outside surface [0163] 6 lid [0164] 7 side
walls [0165] 8a, 8b ends of the single unitary piece 1 [0166] 9 lid
handle [0167] 10 corner piece [0168] 11 end tab [0169] 12 steel
sections [0170] 12a first extension of steel sections 12 [0171] 12b
second extension of steel sections 12 [0172] 12c third extension of
steel sections 12 [0173] 12d ends of steel sections 12 [0174] 13
screws [0175] 14 fire rated rubber seal [0176] 15 non-slip surface
[0177] 16 hydraulic hinges [0178] 17 safety rail system [0179] 18
bending lines [0180] 19 through holes [0181] 20 lanyard or tether
[0182] 46 slot for fireproofing [0183] 100 rough-in box kit [0184]
200 rough-in box [0185] 300 concrete [0186] 400 configuration
* * * * *