Patent Grant
9745760
None.
This invention was not federally sponsored.
Field of the invention: This invention relates to the general field of tools used in the concrete trades, and more specifically toward a bull float with one or more modified edges that can be used to level, smooth and finish concrete. To this end, a bull float with a main body made of wood with at least one additional material used as an insert or an edge is disclosed.
Concrete tools have remained relatively unchanged for decades. The average concrete worker pours concrete into a retained area then initially levels it out with a wooden bull float that is removably attached to the end of a pole. The worker pushes and pulls the bull float across the surface in a back-and-forth motion. After the cement has been leveled, the worker normally removes the wooden bull float from the handle and replaces it with a fiberglass bull float, which is used to further smooth out the concrete and begin to bring the water from the concrete column to the surface, forming a ¼″ to ½″ layer of “cream” or “paste” on top of the rock. After using the fiberglass bull float, the worker then replaces it with a metal bull float. With each successive bull float, the goal is less to level the concrete surface (which is done very well with a wooden bull float), and more toward bringing more of the buttery paste, or “cream” to the surface. The overall goal of the “floating” process is to first, push down the rock and smooth the concrete so that it is level, and second, create a workable paste that brings air bubbles to the surface of the concrete and allows it to be smoothed.
While this tried-and-true method has been used to create literally millions of concrete slabs throughout the world, the time spent removing one bull float from the pole and replacing it with another is undesirable. Concrete sets up quickly, leaving only a limited amount of time to “work” the concrete before it dries beyond the point where it can be modified further. Indeed, because of the chemical reactions that occur in freshly poured concrete, if it is not properly “worked” while wet and fresh, it is sometimes impossible to fix the problems during the next stage of work. And although in theory a competent concrete worker can swap one bull float or another, the “used” bull float needs to be cleaned and stored, and the worker may have to clean his/her hands or do something else that requires time. The current method also requires a concrete worker to bring a minimum of two—and usually three—bull floats, which requires extra storage space, and takes extra cleaning time. There is also the danger that a worker will bring bull floats with different types of head, and will forget to bring the proper adaptor for each bull float.
A second major problem with having to exchange bull floats occurs when a worker is trying to float a large area or is “locked out” by geographical barriers. For large bodies of concrete that are more than two times as wide as the pole, the worker normally walks in the concrete to float the center, then gradually retreats back toward the edges, working the section that he/she stood in from outside the forms. Obviously, once the worker has floated an entire slab with a wooden bull float, it makes no sense to walk all over the floated surface just to get to the center portion again with a fiberglass and/or metal bull float. “Lock out” occurs when the slab to be poured has physical barriers, such as walls, fences, or other obstacles that prevent the workers from getting access to a section of concrete once they have floated it with a wooden bull float. In both the “large slab” and “lock out” scenarios, the main problem is not the time it takes to exchange bull floats of different materials, but rather the fact that the workers cannot physically access portions of the concrete after the first stage using a wooden bull float. The result is that the air bubbles in the concrete are not brought to the surface, but rather remain in the concrete and weaken it considerably over time.
Thus there has existed a long-felt need for a single bull float that is adaptable to any type of pole, and can effectively perform the functions of wooden, metal, and fiberglass bull floats.
The current invention provides a solution to this problem by creating a bull float made from more than one material, such that the user need only use a different part of the bull float to effectively float a concrete slab without having to worry about “lock out” or large slab size. The worker can retreat across a concrete job, leaving behind a flattened and finished concrete surface that otherwise would require at least two separate bull floats.
The invention saves time, as no longer does the worker have to exchange bull floats. It also provides a superior finished product as the worker can both level and finish a portion of a concrete slab before moving on to another; never having to return to that section to “finish” it further before the floating stage is completed.
A preferred embodiment of the invention has an inserted trailing edge made of fiberglass, but other possible embodiments include two inserts of different materials and having the insert or inserts be thin strips placed into routed indentations in the bottom of the bull float, or entire side pieces adhered to the edge of the bull float, where the side piece extends from the bottom to the top of the bull float. A number of different possible materials are contemplated for the edge or insert, including but not limited to aluminum, magnesium or other metals, fiberglass, plastic, composite material, or even wood of a different density. Possible combinations in the embodiment of the invention that have the base unit of wood combined with inserts or side pieces where the insert or side piece is on only one side of the base, and where there are two inserts or side pieces—one on either edge of the base. Various combinations of material from which the inserts and side edges are made include wood fiberglass, wood/metal, fiberglass/wood/metal, wood/plastic, plastic/wood/metal and others. It should also be noted that while the main metals contemplated are aluminum and magnesium, other suitable metals are contemplated.
The current invention provides a solution to the prior art problems of both time waste through exchanging multiple bull floats and those caused by large slabs and lock-out by having a wooden bull float made from more than one material. One embodiment of the invention calls for a wooden base with a fiberglass insert inserted into a similarly size slot on the trailing edge. As the bull float is being pushed away from the worker, the wooden portion of the bull float levels and smooths out the concrete. As the worker pulls the bull float back, the fiberglass insert finishes the concrete. Another embodiment calls for a strip of a second material to be attached to the edge of a bull float, where the strip is of the same height as the main body of the bull float.
A particularly preferred embodiment of this version of the invention has a wooden bull float with a fiberglass edge. The edge is generally created in two possible forms. First, a slot can be routed into the wood base, and a fiberglass insert the same height, length and width as the slot can be inserted into the slot and secured in place. Second, an entire strip of fiberglass can be attached to one edge of the wooden base. The advantage of the first version is that it will take less of the expensive fiberglass material. The advantage of the second version is that from time to time bull floats are sanded to make sure the bottom is perfectly flat, thus there is no danger that repeated sandings will eventually wear away the thin fiberglass strip.
It is a principal object of the invention to provide a single bull float that can perform the functions of wooden, metal, and fiberglass bull floats.
Another object of this invention is to provide a single bull float with two or more different materials for working concrete during the floating stage such that the concrete worker does not have to exchange bull floats made from a single material with another bull float of a single material, or have to re-enter a locked-out location or a slab that is so wide worker cannot float the center of slab without walking back over the concrete he/she has just been working on.
It is a further object of the invention to provide a means by which a concrete worker can avoid the problems of “lock out” on a job site.
Another object of the invention is to prevent the problem a concrete worker faces when trying to float a large area of concrete where after floating the entire slab with a wooden float, he/she has to either not work the center portion that is not reachable with a pole, or walk all over the previously floated section to access the central portion.
It is another object of the invention to provide a means for finishing a slab or other working unit of concrete using a single bull float, thereby avoiding the need to switch different types of bull floats in the middle of a job.
Another object of the invention is to avoid the necessity of cleaning multiple bull floats in the middle of a concrete job.
A further object of the invention is to avoid having to haul more than one bull float along on a job.
Another object of the invention is to provide a superior concrete slab that avoids the problem of Plastic Shrinkage Cracking, which is cracking that occurs in the surface of freshly poured concrete that has not been properly worked, as can happen when a worker using the prior art method of two or three separate bull floats cannot work a section of the slab with a second bull float because he/she is either “locked out” or does not have pole long enough to effectively work the center of a large slab.
It is a final object of this invention to provide a bull float that creates a concrete slab or other unit of concrete that is superior to that created utilizing the prior art as the work can devote 100% of his/her time to working the concrete without have to spend time swapping out different types of bull floats and cleaning each when it has performed its step of the process.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. The features listed herein and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims.
The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of this invention.
Many aspects of the invention can be better understood with the references made to the drawings below. The components in the drawings are not necessarily drawn to scale. Instead, emphasis is placed upon clearly illustrating the components of the present invention. Moreover, like reference numerals designate corresponding parts through the several views in the drawings.
The insert 3 is attached to the base 2 by screws or other known means of attachment (not shown in this figure). To attach the bull float to a pole, there are several means contemplated. First, the bull float could attach directly to the end of the pole through screws, bolts or other known means. Second, a bracket 4 could be used to not only provide structure to the base, but also to provide the connection to the pole. The bracket 4 serves to mount the pole attachment point 5 in a location where a pole (not shown in this figure) can be conveniently attached, and to support the base 2. The bracket 4 is attached to the base 2 by means of attachment 6 such as screws, bolts, or pop rivets. It is contemplated that a number of different bracket designs could be used with this invention, including the “H” shaped one shown in the figures, various meshes, a rectangular one that covers the edges of the bull float, and a straight one that is merely a single member extending horizontally down the bull float.
The method of use of this invention will be detailed in
With most concrete jobs, the bull float will be positioned with the insert 3 facing away from the worker. For some conditions, however, particularly with steeply sloped concrete slabs, the work will reverse the bull float as a “pulling” stroke is not desirable as it tends to pull the concrete down the slope.
These figures also illustrate an embodiment of the bull float in which there are two separate inserts, one on each edge of the bull float. In this embodiment of the invention, the wooden base can still perform its normal job of leveling the concrete, while there are two separate edges to perform different functions. For example, one edge could be fiberglass and the other metal.
A common method of leveling and finishing concrete is to “push” the bull float out, in direction 30, where the pole in a “lowered” position 10A, such that the back edge of the base 2 forms a straight barrier and helps to even out the concrete. Once the bull float has been pushed out as far as the pole can go, the worker raises (or twists, in the case of 9A) the pole 10B to flatten the bull float so the entire bottom sits on the concrete, then raise it further 10C to create a significantly greater angle between the surface of the concrete and the pole, then “pulls” back on the pole. Because of the greater angle between the surface of the concrete and the pole, the front edge of the bull float with the insert 3 is now in contact with the surface of the concrete and smooths out the surface as it is pulled back. While the wooden portion generally is used to level out the concrete slab, the fiberglass or in some cases metal, is used the create a thin level of “butter”, “cream”, or “paste”, which is a layer in the upper ¼″ to ½″ of the concrete slab, which can be further worked to remove the air bubbles and leave a clean, smooth surface.
With the prior art, the worker has to stop working at least once to swap bull floats, as the fully wooden bull float that is used as the first working tool in the currently used method of working a concrete slab is good mainly for leveling out the surface of the concrete, but the final finishing is done with one or more separate bull floats made of different materials. With most concrete work, the worker has to break from work twice, first to remove the wooden bull float and install a metal one; second, to remove the metal one and install a fiberglass one. With the current invention though, there is no need to swap out (and clean) different bull floats, as this invention performs all the tasks that currently require three bull floats.
Two other major problems presented to concrete workers are the Lock Out and access problems. With a large slab, the worker who has floated the slab with a wooden bull float may not have a long enough pole to reach the center of the slab with the second bull float. Thus, the alternatives are to either leave the center unfinished, which creates problems with the quality of the slab, or to tromp through the already worked concrete along the edges of the slab to reach to the center to work that section with the proper bull float, then re-float the edges that were trodden. This is obvious unsatisfactory as it will take additional time to re-do the area where the worker had to walk, and concrete has a limited amount of time during which it can be worked.
The lock out problem is equally challenging, and occurs when the slab to be poured has physical barriers such as walls that prevent the worker from finishing a section that was already worked with a wooden bull float. Concrete workers often work by backing up and working successive patches of concrete as they back toward the edge of the slab. If there is a barrier to prevent them from getting back to the area in which they started, they cannot work the area with another bull float of a different material, leaving them with the same equally undesirable choices as in the access situation above.
With either scenario, the worker who doesn't finish the floating with more than one bull float leaves a weak area, full of air bubbles, while the worker who steps back into already floated concrete wastes valuable time re-finishing the section in which he/she walked. In either case, by the time the worker is ready for the next phase of finishing the concrete, the Kneeboard or sliders 2nd stage, it may be too late in the concrete hardening process to effectively start working the concrete, resulting in air bubbles, which will eventually become shrink cracks.
With the current invention, a worker needs only push and pull a few times and the concrete surface is finished for this stage, and the worker can move to the next section immediately. During the push, the wooden back edge flattens and levels the concrete. On the pull back, the fiberglass front edge butters the surface, pulling water and air to the surface, creating a cream or paste above the rock, and leaving a smooth, attractive finish to the concrete.
Thus, a considerable amount of time is saved, which is extremely valuable in the concrete trade, as concrete has a limited amount of time during which it can be manipulated before it sets. Once concrete sets, or hardens, it becomes unworkable and even the most skilled concrete worker cannot level out any bumps or provide a smooth finish to the slab. Should concrete harden before it is properly worked, one of two things usually happens. The professional concrete worker will have to tear out the entire slab and start all over. The less professional concrete worker will put a thin coat of “finish” cement over the improperly worked slab, which will mask the air pockets and other defects in the slab for a month or two, before the cracks start appearing through the finish (and the hack concrete worker is long gone).
As such, saving time in the concrete trade equates to saving money and providing a superior product, benefitting the concrete workers, the customers, and the general reputation of the concrete trade.
It should be understood that while the preferred embodiments of the invention are described in some detail herein, the present disclosure is made by way of example only and that variations and changes thereto are possible without departing from the subject matter coming within the scope of the following claims, and a reasonable equivalency thereof, which claims I regard as my invention.
All of the material in this patent document is subject to copyright protection under the copyright laws of the United States and other countries. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in official governmental records but, otherwise, all other copyright rights whatsoever are reserved.
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| Number | Date | Country |
|---|---|---|
| 699114 | Jan 2010 | CH |
| 2636818 | Sep 2013 | EP |
| Entry |
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| Partial machine translation of CH 699,114, Jan. 15, 2010. |
| Number | Date | Country | |
|---|---|---|---|
| 20160138282 A1 | May 2016 | US |
