BRACKET STAND SYSTEM AND METHOD FOR POURING CONCRETE DECKING

Abstract

An improved system and method for pouring elevated concrete decking within a frame and backing surface area, wherein deck straps help hold the frame in position relative to the backing surface. The invention involves a bracket stand configured to elevate lower ends of deck straps above the backing surface such that wet concrete can enter the space between the lower end of the deck strap and the backing surface. The bracket stand has a platform elevated by a stable plurality of legs, the tips of which rest on the backing surface. The lower end of the deck strap and bracket stand are secured to the backing surface by one or more fasteners. When the backing surface is removed, a minimal portion of the bracket stand and fasteners is all that might protrude from the underside of the concrete decking. Depending upon the materials, these protruding portions are easily removed.

Description

BACKGROUND OF THE INVENTION

The present invention is directed to a stand for a support bracket for use in pouring and forming concrete decking in construction. The inventive stand has particular application in the pouring and forming of elevated platforms consisting of concrete decking.

Prior art methods for the pouring and forming of concrete decking typically involve constructing a perimeter frame and, particularly in the case of elevated platforms, a backing or bottom surface. A series of support braces or deck straps are typically disposed around the perimeter frame to help maintain its vertical position relative to the backing as the weight of the concrete bears on the frame. Each deck strap is typically fixed to the backing or bottom surface through one or more bolts or braces that extend completely through the backing or bottom surface.

Once the poured concrete is completely set, the backing or bottom surface is removed. When the support brackets are fixed directly to the backing surface, the concrete is unable to get between the deck strap and the backing surface. Once the backing surface is removed, it is often found that the lower end of the deck strap protrudes from the underside of the concrete decking. To finish the concrete decking, any protruding deck straps must be cut away, whether by grinding or other machining. This removal of protruding deck straps adds extra steps to the construction process and add extra time to finishing an elevated concrete decking—requiring lifts or scaffolding and movement of the same to each protruding deck strap. In multi-story buildings, such as high-rise structures, these extra steps can greatly increase the time and expense involved.

Accordingly, there is a need for an improved apparatus or method that addresses these drawbacks. The present invention fulfills these needs and provides other related advantages.

SUMMARY OF THE INVENTION

The present invention is directed to a bracket stand that provides an elevated and simple connection between the deck strap and the backing or bottom surface of a border frame for receiving wet concrete to harden into concrete decking. A deck strap typically secures at an upper end to a top edge of the border frame and at a lower end to the backing surface so as to maintain the position and orientation of the border frame relative to the backing surface.

In general, the inventive bracket stand includes a base or platform configured to receive an end of the decks trap in a fixed manner. The end of the deck strap may be attached to the stand using a by a strap, channel, or similar boundary enclosure, One or more legs or posts are provided to elevate the base or platform above the backing or bottom surface. Preferably, there are a plurality of legs to provide stability. In setting up the concrete frame, the stand and decks trap should be fastened to the backing or bottom surface, but the fastener need not pass completely through the backing or bottom surface. The fastener may be a nail, a screw, a bolt, a strap, or similarly known fastener.

After the concrete is poured and it has hardened sufficiently, the frame can be removed, as well as the backing or bottom surface. Because the fasteners connecting the stand to the backing or bottom surface do not pass all the way therethrough, the backing or bottom surface can be removed with little additional work, i.e., lifting, cutting, and removing. The deck strap and inventive stand are formed within the hardened concrete decking and remains there. No portion of the deck strap should protrude through the bottom of the concrete decking. At most, one or more of the fasteners and legs may protrude through the bottom of the concrete decking. The same may be left in place or simply cut-away at a later step of the overall construction process.

The bracket stand system includes a platform elevated by a plurality of legs with each of the legs configured to rest on the backing surface. The configuration of the platform and legs forms an open space therebetween, as well as between the platform and the backing surface. The platform is configured to receive and secure the lower end of the deck strap. At least two fastener holes are provided through the platform and are configured to align with at least two complementary holes in the lower end of the deck strap when the same is received and secured on the platform. At least two fasteners are configured to pass through the fastener holes and the complementary holes, so as to connect to the backing surface through the open space.

The platform may include raised side edges and a bracket stop at one end configured so as to surround the lower end of the deck strap on three sides when the same is received upon the platform. The platform may further include a bracket band spanning from one side to another side configured so as to secure the lower end of the deck strap when the same is received on the platform.

Alternative, the platform may include a channel bounded by two side walls oppositely disposed, each side wall terminating in an elevated shoulder that extends toward the other side wall, and an end wall connected to each side wall. The channel is configured to surround and secure the lower end of the deck strap when the same is received on the platform.

At least one of the plurality of legs on the bracket stand has a protruding tip on an end distal from the platform. The protruding tip preferably has a narrower width than the leg on which is provided. The protruding tip is configured to rest on the backing surface. In this way, when the wet concrete is poured, such may flow between the bottom of the leg and backing surface. Preferably, each of the plurality of legs has a protruding tip on an end distal from the platform, with each protruding tip having a narrower width than the leg on which it is provided, with each protruding tip configured to rest on the backing surface. In this way, the wet concrete can flow under each of the legs.

The present invention is further directed to a method for pouring a concrete decking, where wet concrete is poured within a volume bounded by a frame on top of a backing surface. The method includes providing a bracket stand having a platform and a plurality of legs extending in parallel from the platform so as to create an open space beneath the platform. The legs of the bracket stand are placed on the backing surface within the frame, such that the open space is between the platform and the backing surface. An upper end of a deck strap is attached to a top edge of the frame. A lower end of the deck strap is positioned on the platform of the bracket stand. The lower end of the deck strap and the bracket stand are secured to the backing surface with one or more fasteners. Wet concrete is poured within the volume bounded by the frame and the backing surface such that the wet concrete surrounds the bracket stand and lower end of the deck strap, including in the space between the backing surface and the lower end of the deck strap. The method for pouring concrete decking is completed by removing the frame and the backing surface after the wet concrete has hardened into the concrete decking.

At least one of the legs of the bracket stand has a protruding tip on an end distal from the platform. Such protruding tip has a narrower width than the leg on which it is provided and the protruding tip is configured to rest on the backing surface. Preferably, each of the plurality of legs has a protruding tip on an end distal from the platform, with each protruding tip having a narrower width than the leg on which it is provided. Each protruding tip is configured to rest on the backing surface.

The providing step involves providing a plurality of bracket stands depending upon the size of the volume bounded by the frame and the backing surface. In the case of a plurality of bracket stands, the placing, attaching, positioning, and securing steps are repeated a plurality of times corresponding to the plurality of bracket stands.

Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate the invention. In such drawings:

FIG. 1 is a perspective view of a prior art frame and deck strap used in pouring concrete decking;

FIG. 2 is a cross-sectional view of the prior art deck strap secured to backing for concrete decking;

FIG. 3 is an illustration of the underside of a concrete decking showing prior art deck straps protruding therethrough;

FIG. 4 is an elevated perspective view of a first embodiment of an inventive stand for use in securing a deck strap in pouring concrete decking;

FIG. 5 is a lowered perspective view of a first embodiment of an inventive stand for use in securing a deck strap in pouring concrete decking;

FIG. 6 is a top view of the first embodiment of the inventive stand;

FIG. 7 is a bottom view of the first embodiment of the inventive stand;

FIG. 8 is a front view of the first embodiment of the inventive stand;

FIG. 9 is a side view of the first embodiment of the inventive stand;

FIG. 10 is a perspective environmental view of the inventive stand connected to a deck strap in a frame used in pouring concrete decking;

FIG. 11 is a perspective view of the inventive stand with a deck strap inserted and fasteners positioned to insert into fastener holes;

FIG. 12 is a perspective view of the inventive stand with a deck strap inserted and fasteners inserted into fastener holes;

FIG. 13 is a cross-sectional view of the inventive stand with a deck strap inserted and fasteners inserted into fastener holes and backing;

FIG. 14 is a perspective view of a second embodiment of the inventive stand;

FIG. 15 is a cross-sectional view of the second embodiment of the inventive stand taken along line 15-15 of FIG. 14;

FIG. 16 is a perspective view of the second embodiment of the inventive stand with a deck strap being inserted;

FIG. 17 is a perspective view of the second embodiment of the inventive stand with a deck strap fully inserted; and

FIG. 18 is a cross-section view of the second embodiment of the inventive stand with a deck strap inserted and fasteners inserted through to the backing.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In the following detailed description, the bracket stand of the present invention is generally referred to by reference numeral 30 in FIGS. 4-18. The individual components of the bracket stand 30 include the center platform 32, the legs 34, the bracket band 36, the bracket stop 36a, and the fastener holes 38.

Prior Art System

FIGS. 1-3 illustrate a prior art configuration of a system for forming a frame in pouring concrete decking. This prior art system includes a border frame 20 with a plurality of fastener bolts 22 securing the frame 20 in place. A deck strap or support bracket 24 is secured to an upper edge of the frame 20. A lower end 28 of the deck strap 24 is secured to a backing surface 26 contained within the frame 20. The deck strap 24 is secured directly to the backing surface 26 by fasteners that protrude through. This prior art system does not include a bracket stand 30 of the present invention.

In the prior art system, concrete is poured into the space bounded by the frame 20 and backing surface 26. The deck strap 24 secured at one end to the top edge of the frame 20 and at the other lower end 28 directly to the backing surface 26 maintains the border frame 20 in the desired orientation relative to the backing surface 26 against the weight of the poured concrete. While it is being poured, the concrete is unable to flow between the backing surface 26 and the lower end 28 of the deck strap 24. In some instances, the lower end 28 of the deck strap 24 may be completely beneath the concrete decking.

Once the concrete is hardened, the border frame 20 and backing surface 26 are removed. Because the concrete is generally unable to flow between the backing surface 26 and the deck strap 24, the lower end 28 of the deck strap 24 almost always protrudes from the underside of the concrete decking and must be grinded or otherwise machined to remove the same. Depending on how much of the lower end 28 of the deck strap 24 is protruding, this grinding or machining can be time consuming.

In the pouring of elevated concrete decking, the backing surface 26 is typically elevated at least ten feet or more above decking below. This elevated distance makes removing the protruding lower ends 28 of the deck straps 24 a time-consuming process because of the need for ladders or other raising means and moving that raising means across the wide surface area of typical concrete decking in an elevated structure. The finishing of the concrete decking cannot be completed until all protruding lower ends 28 of the deck straps 24 are removed. Thus, the process of removing the frame 20 and backing surface 26, and finishing the concrete decking is delayed until these additional steps can be completed.

Inventive System

As described above, the inventive bracket stand 30, shown in detail in FIGS. 4-9, includes a center platform 32, a plurality of legs 34, a bracket band 36, a bracket stop 36a, and one or more fastener holes 38. The center platform 32 has a generally planar surface upon which the lower end of the deck strap 24 is designed to rest, as described below. The plurality of legs 34, preferably in sufficient number to provide a stable base for the stand 30, raise the center platform 32 above the backing surface 26. By raising the center platform 32 above the backing surface 26, a space 32a is provided under the lower end 28 of the deck strap 24 for poured concrete to completely surround the same during the pouring process described below.

Raised side edges 32b are positioned on either side of the platform 32 to more securely hold the deck strap 24. The bracket band 36 passes over the platform 32 and side edges 32b to further securely hold the deck strap 24. The fastener holes 38 preferably number at least two and pass through the platform 32. The fastener holes 38 also align with complementary holes 24a in the deck strap 24 when the same is fully positioned on the platform 32. The bracket stop 26a is positioned at one end of the center platform 32 so as to prevent over insertion of the deck strap 24 into the bracket band 26. When properly positioned, the complementary holes 24a are fully aligned with the fastener holes 38.

The preferred configuration of the bracket stand 30, support brace 24, and border frame 20 is shown in FIG. 10. As described, the stand 30 elevates the lower end of the deck strap 24 above the backing surface 26. Each of the legs 34 may include a protruding tip 34a to further elevate the legs 34 above the backing surface 26 so that the poured concrete may further fill in beneath the legs 34 prior to hardening. FIGS. 11-13 illustrate fasteners 40 being inserted into the complementary holes 24a and the fastener holes 38. The fasteners 40 are preferably nails, screws or similar types of fasteners. Once fully inserted into the deck strap 24 and stand 30, the fasteners 40 are partially inserted into the backing surface 26 as shown in FIG. 13. While not illustrated, the fasteners 40 may extend completely through the backing surface 26.

The fasteners 40 help secure the stand 30 in place while the wet concrete is poured into the frame 20. Because of the space 32a beneath the stand 30 the wet concrete is able to fill under and surround the stand 30 to help hold it in place as the concrete presses outward against the frame 20. In addition, by elevating the platform 32 and the lower end of the deck strap 24, the likelihood of the lower end 28 of the deck strap 24 protruding from the underside of the concrete decking is minimized. At most, a portion of the legs 34 may protrude from the underside of the concrete decking. If the legs 24 include protruding tips 34a, even less of the legs 34 is likely to protrude through the concrete decking. Depending on the material from which the stand 30 is made, preferably plastic, the process of grinding or machining any protruding portion is greatly simplified and shortened. Without the protruding lower end 28 of the deck strap 24, the concrete decking can be completed faster and with less manual labor required.

FIGS. 14-18 illustrate a second embodiment of the inventive bracket stand 32. In this second embodiment, as opposed to the raised edges 32b, bracket band 36, and bracket stop 36a, the center platform 32 is bounded by platform walls 42 on three sides forming a channel 44 configured to receive the lower end of the deck strap 24. Specifically, the platform 32 includes two side walls 42a that each end in an elevated shoulder 42b that extend slightly over the platform 32. One end of the platform 32 includes an end wall 42c that may or may not include an elevated shoulder.

The combination of the side walls 42a, elevated shoulders 42b and end wall 42c form the channel 44 configured for receiving the lower end 28 of the deck strap 24, as shown in FIGS. 16-17. The end wall 42c preferably does not include an elevated shoulder so that one can see when the deck strap 24 is fully inserted into the channel 44. The end wall 42c functions as a stop to prevent over insertion of the deck strap 24, at which point the fastener holes 38 are preferably aligned with the complementary holes 24a in the deck strap 24. The elevated shoulders 42b on the side walls 42 preferably extend only so far as to securely hold the lower end 28 of the deck strap 24 without interfering with the complementary holes 24a, fastener holes 38, or the insertion of fasteners 40 into the same (FIG. 18).

This second embodiment of the stand 30 functions in a similar manner as the first embodiment when pouring concrete. The platform walls 42 provide a sturdier structure for holding the deck strap 24 secure on the stand 30. In the first embodiment, the bracket band 36 may be subject to breakage or other failure. In addition, in certain instances, the deck strap 24 may raise up relative to the bracket stop 36a and pass over the same such that adjustment is necessary to properly align the complementary holes 24a with the fastener holes 38. The channel 44 eliminates this risk and provides a sturdier structure for holding the deck strap 24 in place against the platform 32. The second embodiment of the stand is also easier to manufacture in reliable, repeatable manufacturing methods.

The inventive stand 30 is preferably made from plastic or similar durable, rigid materials that is easily producible such as by injection molding or similar processes. The stand 30 may also be made from metal or other materials that are durable enough to support the deck strap 24 and frame 20, while withstanding the forces of pouring concrete decking.

Although several embodiments have been described in detail for purposes of illustration, various modifications may be made without departing from the scope and spirit of the invention. Accordingly, the invention is not to be limited, except as by the appended claims.

Claims

1. A bracket stand system for use in pouring concrete decking, wherein the concrete decking is poured in a border frame surrounding a backing surface with a deck strap is affixed at an upper end to the border frame and at a lower end to the backing surface, characterized in that, the bracket stand system comprises: a platform elevated by a plurality of legs, each of the legs configured to rest on the backing surface such that an open space is formed between the platform and the backing surface, the platform configured to receive and secure the lower end of the deck strap;at least two fastener holes through the platform and configured to align with at least two complementary holes in the lower end of the deck strap when the same is received and secured on the platform; andat least two fasteners configured to pass through the fastener holes and the complementary holes, and to connect to the backing surface through the open space.

2. The bracket stand system of claim 1, wherein the platform includes raised side edges and a bracket stop at one end configured so as to surround the lower end of the deck strap on three sides when the same is received upon the platform.

3. The bracket stand system of claim 2, wherein the platform further includes a bracket band spanning from one side to another side configured so as to secure the lower end of the deck strap when the same is received on the platform.

4. The bracket stand system of claim 1, wherein the platform includes a channel bounded by two side walls oppositely disposed, each side wall terminating in an elevated shoulder that extends toward the other side wall, and an end wall connected to each side wall, the channel configured to surround and secure the lower end of the deck strap when the same is received on the platform.

5. The bracket stand system of claim 1, wherein at least one of the plurality of legs has a protruding tip on an end distal from the platform, the protruding tip having a narrower width than the leg, wherein the protruding tip is configured to rest on the backing surface.

6. The bracket stand system of claim 5, wherein each of the plurality of legs has a protruding tip on an end distal from the platform, each protruding tip having a narrower width than the leg, wherein each protruding tip is configured to rest on the backing surface.

7. A method for pouring a concrete decking, wherein wet concrete is poured within a volume bounded a frame on top of a backing surface, characterized in that the method for pouring concrete decking comprises: providing a bracket stand having a platform and a plurality of legs extending in parallel from the platform so as to create an open space beneath the platform;placing the legs of the bracket stand on the backing surface within the frame, such that the open space is between the platform and the backing surface;attaching an upper end of a deck strap to a top edge of the frame;positioning a lower end of the deck strap on the platform of the bracket stand;securing the lower end of the deck strap and the bracket stand to the backing surface with one or more fasteners; andpouring wet concrete within the volume bounded by the frame and the backing surface such that the wet concrete surrounds the bracket stand and lower end of the deck strap.

8. The method of claim 7, wherein at least one of the legs of the bracket stand has a protruding tip on an end distal from the platform, the protruding tip having a narrower width than the leg, wherein the protruding tip is configured to rest on the backing surface.

9. The method of claim 8, wherein each of the plurality of legs has a protruding tip on an end distal from the platform, each protruding tip having a narrower width than the leg, wherein each protruding tip is configured to rest on the backing surface.

10. The method of claim 7, wherein the providing step involves providing a plurality of bracket stands depending upon the size of the volume bounded by the frame and the backing surface.

11. The method of claim 10, wherein the placing, attaching, positioning, and securing steps are repeated a plurality of times corresponding to the plurality of bracket stands.

12. The method of claim 7, further comprising the step of removing the frame and the backing surface after the wet concrete has hardened into the concrete decking.