Patent Grant
12116780
The embodiments of the present disclosure are related in general to the field of installation of supports for uprights of fences, traffic signs, real estate signage, etc., and in particular to post supports that can be permanently installed, and from which one post can be removed and another emplaced.
A post is a substantially straight, elongated columnar structure that is anchored at one end so as to stand upright, and that supports thereon another structure. A post can be made of any appropriate material, including wood, metal, or plastic. Posts of various lengths and compositions are used in a wide range of applications, including supporting fences, traffic control signs, temporary structures, etc. Where a post is intended to be substantially permanent, it is often placed in a hole and anchored in a concrete footing to increase its cross section and hold it firmly in place. One problem that is commonly encountered in such situations is that posts, especially wooden posts, are subject to breakage, warpage, and decomposition. Replacing a post that has been anchored in concrete is difficult, wasteful, and unfriendly to the environment for reasons that include excessive use of natural resources and the generation of landfill material. The concrete footing must be removed from the ground in order to make room for the new post. This requires that a much larger hole must be dug around the concrete footing. In turn, this requires a much larger volume of concrete or re-compaction of the surrounding soil, to fill the hole around the new post and create the new footing in proper contact with undisturbed or adequately compacted soil.
One of the most common causes of deterioration in wooden posts is water trapped around the end of the post inside the concrete. For example, when the post is damp or wet for an extended period of time, the wood absorbs water and draws it by capillary action downward into the concrete footing. Water becomes trapped between the wood and the inside wall of the concrete, so that the end of the post remains wet even while the upper portion is dry. This is especially true in cases where the end of the post is completely encapsulated in concrete, preventing water from escaping through the bottom of the footing, in which case the majority of the water escapes only through the wicking action of the end grain of the post.
To reduce this problem, installers often pour several inches of gravel into the bottom of a post hole and place the post directly on the gravel before they pour concrete around it. This prevents the concrete from completely sealing up the bottom of the post by flowing under it, and thus provides a channel for water to escape into the gravel. However, this is only a partial solution. Often the drainage gravel is not fully compacted and settles, causing more need for repair and replacement. Furthermore, with this common method, it takes substantial time for water, once having entered the footing, to work its way all the way through the footing and out the bottom. If the post is subjected to frequent or extended wet periods, the end of the post inside the footing may remain constantly wet even though water continues to drain out the bottom. Additionally, because of the direct contact with the ground on the end of the post, water can move upward into the footing when the ground is wet, due to the capillary or wicking effect of the end grain. This constant dampness encourages the growth of organisms that digest the wood fiber and eventually destroy the post, or in the case of steel, rusts the post away. Additionally, the bottom of the footing is substantially open to insects, which can enter unobstructed from the gravel below to attack and eat the post.
Furthermore, direct contact between concrete and some species of wood generates a reaction that promotes deterioration of the wood. This limits the species of wood that can be used for fence or sign posts where concrete footings will be used in direct contact with the post.
Another approach that is used to protect wood posts and other lumber in direct contact with the ground or with concrete is commonly referred to as pressure treating. In this process, protective chemicals are forced into an outer surface of the post under high pressure. The chemicals provide the post with protection from common funguses and other organisms that cause deterioration. Pressure treatment generally extends the useful life of a post by a factor of five to ten. However, the chemicals used in pressure treatment are often toxic to humans and non-target organisms, and can leach into the water supply. In other cases, the chemicals are highly corrosive, tending to cause corrosion in fasteners and structures that are attached thereto. An additional problem with pressure treatment is that the wood cannot generally be recycled when it is replaced, and should not be composted, because of the chemicals still present. This means that it must be deposited in a landfill which in turn is a result of the need to install a post in direct contact with the ground and or concrete.
A third approach to this problem is the use of prefabricated anchors or sleeves, i.e., pockets that are placed in the ground or anchored in a concrete footing. These anchors permit a post to be removed and replaced without requiring that the pocket itself be replaced. Some examples of such anchors are disclosed in the following U.S. patents, all of which are incorporated herein by reference in their entireties: U.S. Pat. Nos. 5,632,464; 6,098,353; and 7,325,790.
According to an embodiment, a post sleeve includes a concrete body that is poured on site, using a sleeve core that is prepositioned in the post hole, and around which wet concrete is poured. After the concrete is cured, the core is removed, leaving a post sleeve cavity configured to receive a post. The sleeve core includes features for forming selected features of the post sleeve. According to an embodiment, a drainage chamber is attached to the bottom of the sleeve core, and remains in the concrete when the core is removed. the chamber can be configured to drain by percolation, or can be placed in fluid communication with the soil surrounding the post hole.
According to one embodiment, the sleeve core comprises a flexible shell, made of an elastomeric material, for example, and a stiffener configured to hold the shell to its proper shape while the concrete cures.
According to another embodiment, the sleeve core is rigid. It can be provided with a pattern draft, or a release agent is applied to a thickness sufficient to permit removal of the core, without a pattern draft.
According to an embodiment, a preformed sleeve top is provided, and configured to be coupled to the sleeve core prior to placement in the post hole. The wet concrete firmly engages the sleeve top, which remains as part of the finished post sleeve once the sleeve core is removed.
According to an embodiment, half sleeves are provided, which are configured to be bonded together in a face-to-face position, to form a complete post sleeve.
The rim 104 is shown as having a smooth regular surface. According to other embodiments, the rim 104 can have any of a variety of shapes and configurations. For example, it can be embossed or debossed with text or symbols, textured to resemble stone or brick, or provided with architectural detail to coordinate with other nearby elements. The material of the body can be colored to add architectural detail, to promote functionality, or provide decorative appeal. The identification plate 108 is provided with a unique identifier that may be applied during fabrication, and serves to separately identify each post sleeve assembly 100.
Turning now to
According to the embodiment pictured, the post sleeve 102 is sized to receive a 4×4 post, of the kind that is widely used for fences and signs. When a 4×4 post is positioned in the post sleeve 102 (as shown in
The sleeve liner 120 is produced by injection molding, blow molding, or some other appropriate method of manufacture, and can be assembled from two or more pieces, or can be made as a single piece. The sleeve liner 120 is placed within a mold, and the body 116 of the post sleeve 102 is cast around the sleeve liner 120. The body 116 extends above the upper portion of the sleeve liner 120, which shields the plastic sleeve from long term exposure to UV rays, which can cause many plastics to deteriorate. The standoff ribs 122 contact and support the post 110 and prevent contact between the wood post and the concrete body 116, while the drain channels 124 allow water to drain away from the post and permit air ventilation to promote moisture evaporation.
In one embodiment, the body 116 is cast from a high strength concrete mix that includes glass fiber reinforcement and is formulated to have compression strength of 5,000 to 9,000 psi, or more. It is formed to be highly resistant to most environmental and incidental wear and tear that such a structure is likely to be subjected to. Accordingly, it is anticipated that the post sleeve 102 will have a serviceable life span many times that of a typical wood post footing that is poured on site, and may exceed 50 years, perhaps reaching 100 years or more.
According to alternate embodiments, the body 116 and the sleeve liner 120 can be formed from any suitable material, including recycled plastic, metal, fiberglass, composite resin etc. Alternatively, the sleeve liner can be a thin concrete shell into which the interior features of the sleeve are cast, which is then encapsulated in a concrete post sleeve or footing, as described herein
The identification plate 108 is shown as a metal (e.g., brass) plate that is embedded in the body 116 during the fabrication process. Alternatively, the identification plate 108 can be mounted to the body after fabrication, or the reference number can be formed in the material of the body 116, either on the rim 104 or inside the upper aperture 121, during the casting process. In other embodiments, the post sleeve has no identification markings.
The post collar 112 includes a plurality of spacing ribs 198 distributed around a bottom surface thereof, which are shaped such that a portion of each of the spacing ribs 198 rests on an upper slightly outward sloped surface of the rim 104 of the post sleeve 102, with another portion extending into the upper aperture 121 of the post sleeve 102 between an inner surface of the post sleeve 102 and the post 110. In this way, the spacing ribs 198 serve to maintain a gap between the upper surface of the rim 104 and the lower surface of the post collar 112, providing ventilation while still allowing lateral support to the post by the post collar 112. The gaps between the spacing ribs 198 permit air to enter the post sleeve to assist in evaporation of moisture within the sleeve, but the post collar 112 is shaped to generally prevent water from entering the sleeve via the gaps between the spacing ribs 198. The spacing of the spacing ribs 198 is selected to prevent most insects from entering the post sleeve, including bees, hornets, and larger termites. An upper surface of the post collar 112 is sloped to promote run-off of moisture, and the bottom edge of the outer rim includes a break edge to prevent water from traveling back into the underside of the collar by capillary action as it drips off the edge.
The heating affect of the sun on the exposed concrete rim 104 creates a heat differential within the post sleeve 102 that generates convection within the cavity 111 to increase the airflow. Water that does enter the post sleeve 102 readily drains into the drainage gravel 130 via the flexible drain hose 114. Furthermore, as noted with reference to
According to an embodiment, the dimensions defined by the ribs 122 are slightly greater than the dimensions of a standard 4×4 post in order to accommodate a swollen or slightly bowed post. Alternatively or additionally, the material and thickness or shape of the innermost surfaces of the standoff ribs 122 of the sleeve liner 120 are selected to permit some resiliency to accommodate slight variations in size while adequately supporting the post.
The post sleeve assembly 100 helps to limit moisture damage to posts positioned therein in a number of ways. For example, water that strikes the post 110 runs down until it encounters the post collar 112, which diverts most of the water away from the post 110 and onto the upper surface of the rim 104 of the post sleeve 102. The water then flows down the sloped surface of the rim 104 and away from the post entirely. The limited amount of water that does enter the post sleeve 102 is generally channeled away from the post 110 by the drain channels 124 of the post sleeve liner 120 and runs to the bottom of the post sleeve 102, whence it exits via the flexible drain hose 114. Additionally, air circulation enabled by the gap under the post collar 112, and enhanced by convection and the normal flow of air around the post, further reduce the amount of moisture in the post sleeve 102.
The soffit 144 extends from an outer surface of the rim 104 to the lower portion of the body 116 of the post sleeve 102 at a substantial downward angle. When the post sleeve 102 is encapsulated in the concrete footing 132, as shown in
A poured-in-place concrete footing will typically have a psi rating in the range of 2,500 to 3,500 lbs. In contrast, concrete that is handled in a controlled manufacturing environment, with proper temperature control, vibration, mixing, and admixtures, such as the high strength material used to form the post sleeve 102, can easily reach a 5,000 to 9,000 psi rating, or more, resulting in a hardened casing of extreme durability and life expectancy. The life expectancy of the relatively weaker poured-in-place concrete footing 132 is significantly increased by the post sleeve 102 because the substantially larger cross-sectional area of the post sleeve distributes and decreases the point load exerted under lateral loads by the narrower effective section of the post 110 itself.
Turning now to
According to an alternate embodiment, one or more apertures are provided from the exterior of the post sleeve 102, similar to the combined apertures 126, 128, and common fasteners, such as, for example, long deck screws, are driven into the post via the apertures, thereby securely anchoring the post to the post sleeve.
Uppermost is the 4×4 socket 150, configured to receive a standard 3½×3½ inch fence post (nominally 4×4). The four sides of the 4×4 post are supported laterally by the standoff ribs 122 to hold the post snugly in place. The bottom end of the post rests on the ledge, or step, indicated by the reference number 150. A 3½ inch round post will also be accommodated in the 4×4 socket 150. Next is the 3 inch socket 152, configured to receive a standard 3 inch square post. The base of the post rests on the step indicated at reference number 152, and the four sides are supported by the side walls that extend upward from that step toward the 4×4 socket 150. The 2½ inch socket 154 is configured to receive a 2½ inch square post or a nominal 3 inch round post. The base of the post rests on the step indicated at reference number 154, and the four sides are supported by the side walls that extend upward from the step toward the 3 inch socket 152. Similarly, the (nominal) 2½ inch round socket 156, (nominal) 2 inch round socket 158, and 1% inch round socket 160 are positioned one beneath the next as shown in
The socket sizes shown are merely exemplary, and do not limit the scope of the invention. For example, according to an embodiment, the post sleeve is provided with common metric-sized sockets for use where metric-sized posts are standard. Furthermore, the post sleeve is not limited to square and round sockets, or even to the most common sizes. It may be beneficial in some applications to provide rectangular or polygonal sockets for particular applications.
In the embodiment of
The flexible drain hose 114 shown in
According to an embodiment, the lower aperture 115 sits directly on the gravel 130. Alternatively, a straight, rigid fitting is provided that extends directly down into the drainage gravel 130 below, which is advantageous where the footing is significantly longer than the post sleeve 102 to extend below a frost line. According to another embodiment, an elbow fitting 168, shown in
It should also be noted that it is not required that the drain hose be coupled directly to the lower aperture 115. Thus, according to further embodiments, in place of a drain hose, a large diameter—e.g., 6 inch or 8 inch—rigid or corrugated plastic or cardboard tube drain tube can be employed. The lowermost outer surface of the sleeve can be shaped to be engaged by the drain tube, and may be round and may have annular ridges to engage corrugated pipe or smooth-walled tubing. Alternatively, a section of large diameter pipe can be placed at the bottom of the post hole, and the post sleeve placed so that its lower end engages the pipe. It is only necessary that the joint between the post sleeve and drainage means be sufficiently tight to prevent quantities of wet concrete from flowing in. According to another embodiment, the drain hose comprises a thin permeable membrane of plastic or fabric, for example, which is filled with drainage sand or gravel to allow drainage, but also to prevent uplift of the drain hose by displacement as the concrete is poured. The lower end of the weighted drain hose rests on the soil at the base of the hole to allow a permanent connection for water to infiltrate out of the hose. The lower end can be provided with an enlarged water-permeable or degradable pad placed in contact to the ground.
A notch 149 is provided in the sleeve liner 120 above the lower aperture 115 to receive a replaceable corrosion resistant mesh screen 146 to prevent debris from accumulating in the flexible drain hose 114 over the life of the post sleeve 102. While the spacing ribs 198 of the post collar 112 will prevent most debris from entering, some will inevitably enter. Additionally, as the post ages and eventually deteriorates, wood fragments may also drop to the bottom of the sleeve. The mesh screen 146 prevents most debris from entering the flexible drain hose 114 and blocking the drainage of the post sleeve 102. While it is true that such debris may also block the lower aperture 115 from above the mesh screen 146, it is anticipated that prior to installing a new post, the installer will vacuum out the bottom of the post sleeve 102 as necessary, to remove any such blockage. This is a much simpler operation than cleaning the area below the lower aperture, which would otherwise be necessary. In the embodiment of
Referring now to
Provided the post is adequately supported laterally, it is not required that the post extend the full depth of the sleeve. Accordingly, stops are provided at various depths within the post sleeve 102 to permit the post to be supported at less than the full depth of the sleeve. Stops are most clearly shown in the embodiment of
The first stops above the 4×4 socket 150 are the 13 inch stops 164, which are 13 inches below the upper surface of the rim 104. 13 inch stop plate 172 is provided, including a plurality of tabs 176 extending from the edges of the plate. When the 13 inch stop plate 172 is positioned in the post sleeve 102, the tabs extend into the drain channels 124, and engage the 13 inch stops as shown in
9 inch stops 166 are provided 9 inches below the upper surface of the rim 104. 9 inch stop plate is provided with tabs 176 arranged to engage the 9 inch stops 166, as shown in
Referring to
Assuming that a fence of six feet in height is desired, eight-foot posts would normally be used, and set at a depth of about 18 to 24 inches, depending on how much of the post is to extend above the fence. Accordingly, the eight-foot post 110a, which is supported 19 inches below the rim 104 of the post sleeve assembly 100a, extends about 79 inches above ground level G, which is sufficient to accommodate most fence heights by trimming any excess from the post. However, by positioning a post as shown with reference to post sleeve assembly 100b, using a 13 inch stop plate 172 at the 13 inch stop, the post 110b extends six inches further above ground level G. Bearing in mind that the post sleeve 102 is to be installed with the upper surface of the rim 104 at about two inches above ground level for proper drainage, the top of the seven-foot post 110b is about 73 inches above ground level G, which will support a six-foot fence with one inch of clearance below. Accordingly, where an eight-foot post is normally required for a six-foot fence, a seven-foot post will serve if installed with a post sleeve and a 13 inch stop plate 172. Furthermore, by using the 9 inch stop plate 174 at the 9 inch stops 166, as shown with reference to post sleeve assembly 100c, the seven-foot post 110c extends an additional four inches above the post 110b. Thus, a six-foot fence can be built using post sleeves configured as shown with reference to post sleeve assembly 100b to support most of the posts, and the corner posts can be supported by post sleeves configured as shown with reference to post sleeve assembly 100c to provide additional height for the post cap to be properly placed, all without cutting any of the posts.
Furthermore, any portion of the interior of a post sleeve that lies below the bottom of the post serves as a reservoir to hold water until it can percolate into the gravel or soil below the post sleeve assembly. Thus, another desirable benefit of using plates like stop plates 172 or 174 and the stops 164,166 is that they create a larger drainage reservoir within the post sleeve 102 below the post and reduce the likelihood that standing water will contact the wicking end of the post. This is especially beneficial in climates with seasonal periods of high rain fall.
According to another embodiment, the drain channels 124 are tapered or stepped so that they are widest at the top of the post sleeve 102, and become narrower toward the bottom. Tabs on stop plates and other fittings have widths selected to engage the drain channels 124 at different heights. Thus, the position of a post within the sleeve is infinitely variable, according to the selected widths of the tabs of the stop plate employed.
Returning to
Plates 170, 172, 174, 180, 182, 184, 186, and 189 are provided as examples only, to show a variety of plates configured to support fence posts of different sizes and shapes at various levels within the post sleeve 102, and to properly orient and support the posts in the x, y, and z axes. It will be recognized that many different configurations of stop plates and support plates can be employed for use at the 19, 13, or 9 inch levels, or any other desired levels, depending on the particular application.
The various plates described above can be inexpensively manufactured in large quantities through a wide variety of processes, including, for example, stamping or blanking. Alternatively, where a small number of non-standard plates is required, and the limited quantity of a given configuration does not justify the expense of preparing stamping dies, the plates can be made from an efficiently machineable material such as UHMW polyethylene. For example, plates with the appropriate apertures, tabs, sockets, etc., for many applications can be machined from sheets of UHMW polyethylene. One such plate is described later with reference to
As shown in
Returning again to
Post collars are generally provided with spacing ribs 198 that hold the collars up off the angled top surface of the rim 104 and penetrate into the upper aperture 121 of the post sleeve 102, providing insect and debris resistant ventilation channels while also transmitting lateral load from the post to the internal face of the post sleeve 102. The spacing, thickness, and length of the spacing ribs 198 can be chosen to provide more or less lateral resistance to accommodate, for example, a resilient or breakable model intended to protect a post from damage due to minor impacts. Alternatively, a hardened post collar can be provided, that includes a sharp edge to focus lateral force, so that under a selected lateral force, the post will tend to shear off cleanly at or below grade, to reduce the likelihood of injury when the post is struck by a moving vehicle, and to reduce or eliminate the resulting hazard of a splintered post stub that might otherwise stand in that location until the post can be replaced. In such embodiments, it may be beneficial to provide one or two holes through the post in each direction, in a position that corresponds to the sharp edge of the sleeve, to further encourage a clean break at that position. As a further alternative, the sharp edge can be pre-formed or installed into the sleeve itself, and used in combination with a resilient collar so that a post is protected from impacts up to a threshold, but will breakaway under impacts that exceed the threshold. Where a post sleeve is
Pressure tabs 199 are positioned so as to be engaged by the fastener 142 and transmit pressure from the fastener to the post to lock the post in position. Where the post collar is configured to support a post that is smaller than the 4×4 post size, an inner pressure tab 195 is provided, with extension ribs 197 or similar structures extending onto the inner pressure tab 195 to provide the necessary transition to be engaged by the fastener and to transmit the pressure to the post.
According to an alternate embodiment, the fastener is configured to engage the post directly. Where a smaller post is to be installed and direct contact with the post is desired, the standard fastener is removed, and a longer fastener is positioned in its place. The post is then installed in the post sleeve and the longer fastener is driven in to engage the post.
Sleeve cap 206 is configured to be positioned in the upper aperture 121 of the post sleeve 102 to close the upper aperture 121 during periods of non-use or between the time the post sleeve 102 is installed in the ground and a post is inserted. The sleeve cap 206 serves to prevent the introduction of rocks and debris into the post sleeve 102, and also to prevent injury to pedestrians or animals when not in use. Like the post collars, the sleeve cap can be constructed of any suitable material including, for example, steel, aluminum, and plastic.
In the embodiment of
It can be seen that the rim cover 190 provides a number of surfaces that can be used, for example, by the installation contractor to place a logo or contact information, or to identify the function of the post, as in the example pictured, or to provide a backup sign or an indication of the necessary replacement in the instance where the post becomes snapped off. Other examples of uses for the rim cover 190 are reflective address markings at the bases of posts supporting mail boxes for fire and rescue, reflective “Stop” with red plastic body color for “Stop Signs” and added visibility, “No Trespassing” warnings for property lines etc. Spacing ribs 191 provide clearance between the rim 104 and the rim cover 190 for the fasteners 196. The spacing ribs 198 extend to the aperture and line up with the spacing ribs 198 in the post collars to provide continuous air ventilation as described above.
The rim cover 190 comprises an aperture 192 in a position that corresponds to the position of the identification plate 108, such that when the rim cover 190 is coupled to the rim 104 of the post sleeve 102, the identification plate 108 is visible through the aperture 192. In those embodiments where the identification plate 108 is not employed, or where it is not required to be visible, an additional plate or cover can be snapped into the aperture 192. The rim cover 190 can also be equipped with motion sensors, solar cells, luminosity cells, lighting and audible effects, etc., as described above with reference to the post collars.
The stops, stop plates, support plates, post collars, sleeve caps, and other elements described above with reference to
The inventor has recognized that a particular problem in the fencing industry is that fences are often built from scratch on site, meaning adjoining segments of a fence may not be identical, and that, even where prefabricated fence panels are employed, many will be modified or customized to fit specific spans and angles between posts. When a portion of a fence is damaged or knocked down, it is generally necessary for a fence contractor to bring to the site all the materials necessary to re-fabricate the damaged portions of the fence, and often to reproduce a complex pattern using materials and equipment on hand, or, alternatively, to come to the site a first time to take measurements and patterns, then fabricate replacement panels and return to the site to install them.
According to one embodiment, the identification plate 108, described above with reference to
In the event a repair is required, the property owner makes note of the identifiers of the post sleeves that are involved and contacts a contractor—either the original contractor, whose contact information may be provided on the rim or rim cap of at least one of the post sleeves, as described above, or another qualified contractor—and provides the identifiers and a description of the damage. The contractor then accesses the database, via a secure website, for example, and obtains the details and dimensions of the fence design, and, more importantly, the specific details of the fence panels associated with the identifiers provided by the property owner. The contractor can then fabricate the replacement fence sections in a shop to replace the damaged sections, to the precise dimensions and pattern of the original, then transport the completed sections and install them at the site. The property owner may, alternatively, choose to order the replacement sections and install them herself, without the assistance of a contractor. Even though the fence dimensions will vary from one span to the next, the identifying numbers on the post sleeves will provide the exact location with the exact dimensions. This saves considerable time and expense, as well as reducing waste, because material optimization is much easier in a controlled shop environment than in the field. Because the information is maintained at a central database, it can be accessed by the contractor or property owner, even if the original contractor is no longer in business.
Similar systems are provided, according to other embodiments, to track the location and details of commercial signs, traffic signs, guard rails, etc. If, for example, a traffic sign is damaged or deteriorated, an inspector need only take note of the identifying number on the identification plate of the post sleeve in which the supporting post is mounted, and relay the number to the appropriate authority. The database will provide such details as the text and size of the sign, the height of the post, the materials of the sign and post, and even the replacement history of that particular sign. The replacement sign can be assembled according to the specifications, and installed.
According to an embodiment, the identification plate 108 includes a bar code number, which simplifies the capture of the identifier, and prevents transcription errors. The operator, when recording the pertinent information, scans the bar code with a portable scanner, and then enters the associated data.
According to another embodiment, a radio-frequency identification (RFID) tag is provided, either as part of the identification plate 108, embedded in the body 116 of the post sleeve 102, or otherwise attached thereto. When an interrogation signal is transmitted from a nearby RFID reader, an antenna of the RFID tag collects power from the signal and activates a transmitter circuit that transmits the unique identifier of the respective post sleeve, which is received by the reader. As is well known in the RFID art, RFID tags can be extremely simple, providing only basic identification information, or can be more complex, comprising a non-volatile memory to store a significant amount of data, either in a read-only format or in a read-write format. Accordingly, in some embodiments, additional information that may be relevant to a particular application can be saved in the RFID tag of a post sleeve for later retrieval. The RFID tag can also be detected by properly equipped emergency or delivery vehicles to assist them in locating a specific location or address.
The term unique identifier is used broadly to refer to an identifying element that is unique to a single post sleeve and that distinguishes one post sleeve from other post sleeves. The unique identifier can be a string of letters, numbers, symbols, or a combination of elements. It can, for example, comprise a serial number applied to a post sleeve during fabrication, or a string of characters that includes additional information relative to the make or model of the post sleeve, or its date or place of manufacture.
According to an embodiment, a unique identifier associated with particular post sleeves is maintained in a database, and includes data necessary to locate each post sleeve, such as, for example, one or more of: GPS coordinates, street address, and positioning data with respect to nearby post sleeves or other reference features. It is therefore not necessary to physically mark or label each sleeve, because each is identifiable from the database, on the basis of its unique location.
Referring now to
As described above with reference to
Detents 169 are provided to assist in installation of the post sleeve 102. According to an embodiment, the detents 169 are engaged by an installation mechanism configured to support the post sleeve from an overhead structure, so as to permit the sleeve to hang plumb at the desired height in the hole 138 while an installer pours the concrete footing. In this way, the post sleeve can, if required, be provided with a concrete footing that extends some distance below the sleeve without requiring support from below while the concrete footing cures, and can be properly oriented and plumbed.
While the sleeve liner 120 has been described in combination with a prefabricated concrete sleeve body, the sleeve liner 120 can itself serve as a preformed post sleeve, fixed in a concrete footing in the field, without the prefabricated concrete body. For example, where the extreme longevity and other advantages afforded by the high-strength prefabricated body are not primary considerations, it may be advantageous to omit the concrete body, and instead to use the sleeve liner 120 as a preformed sleeve and pour the footing around it. In another example, where a large surface is to be paved, with a number of sleeves provided to support posts, e.g., to support a guardrail along a concrete walkway, the sleeve liners can be set directly in the concrete, as sleeves, during the pour of the walkway to provide a clean and unified appearance.
Also shown in
In many cases, it is not desirable to permit a wood post to directly contact the concrete of the post sleeve. Accordingly, where the post sleeve is cast without a separate sleeve liner, such as the embodiment of
Also shown in the embodiment of
According to a related embodiment, a reservoir is provided that is covered with gravel or sand before the footing is pouring, and a slow-flow membrane is provided to regulate the flow of water into the reservoir from outside the post sleeve 102. The slow-flow membrane 326 can be formed by providing a plurality of openings of a selected size in the reservoir, or can be a material with a selected porosity positioned over an open bottom of the reservoir.
Stops 414 are provided at various depths within the post sleeve 400 for engagement by plates 416. Each plate 416 is provided with tabs 176 positioned on two opposing edges of the plate so as to engage opposing stops 414 and bridge across the interior of the post sleeve 400. In the transverse dimension the plates 416 are narrower so as to fit through the aperture 410 and between the standoff ribs 122 at an angle, as shown in
According to an embodiment, stops 414 on one face of each section 404 are positioned some distance above the stops on the adjacent face. When the sections are assembled together, the stops 414 directly opposite each other are at the same depth, while those on the transverse faces are at a different depth. Thus, the plate 416 can be positioned at any of a number of different depths by selecting the orientation of the plate as it is introduced into the sleeve, then selecting the set of stops to engage on a given pair of opposing faces.
The sections 404 are joined as described with reference to the sleeve sections 118 of
The insert 420 includes an engagement element 424 having outer dimensions that correspond to the size of a 4×4 post, and therefore fits into the lower end of the sleeve 422. The engagement element 424 includes a substantially planar top surface 426 with a plurality of notches 428. The insert 420 is provided with an aperture 115 to permit water to drain via a drain hose, etc., while preventing direct contact of the post with concrete or the underlying soil. Additionally, a universal socket section 151 is provided, similar to that described with reference
A user positions the insert 420 in the lower end of the post sleeve section 422 and fixes the combined assembly in the ground according to the requirements of the particular application. Typically, the engagement element 424 engages the sleeve section 422 with an interference fit that is sufficient to hold the assembly together until it is emplaced, especially if it is to be fixed in a concrete footing. However, if necessary, the insert 420 can be fixed to the sleeve through the use of commercial adhesives, tape, or screws. When a post is positioned in the sleeve section 422, the bottom end of the post rests on the top surface 426, if it is a 4×4 post, or in the appropriate one of the sockets of the universal socket section 151, according to its dimensions. As with the post sleeves of other embodiments, water that enters the sleeve 422 is permitted to drain from the assembly, via the notches 428, gutters 161 of the universal socket section 151, and the aperture 115.
To assemble a post sleeve, a user first positions the joining faces 525 of two half sleeves 520 together so that the pins 522 of each mate with the apertures 524 of the other, thereby correctly aligning the halves. The halves are then bound together by appropriate means, such as, for example, straps or wire around the outside. In some cases gravity is sufficient to hold the halves together during the bonding process. When the two half sleeves 520 are mated together, the lands 538 of both halves contact each other to enclose the adhesive channels 530. The user then injects an appropriate grade of construction adhesive into the inlet ports 532. The adhesive flows into the inlet ports 532 and into the distribution manifold sections 536. From there, the adhesive flows into the remaining regions of the adhesive channels 530 and is distributed throughout the channels. Eventually, the adhesive begins to flow from the outlet ports 534, which is a positive indication that the adhesive channels 530 are completely filled. During injection, the highest pressure occurs in the distribution manifold sections 536. The tongue 526 and groove 528 are positioned opposite the manifold sections 536 to minimize leakage of the adhesive into the internal cavity of the complete post sleeve 521. When the adhesive has hardened, the half sleeves are permanently joined to form the complete sleeve 521. While completely filling the adhesive channels 530 with adhesive is not essential to permanently join the halves, the adhesive also acts as a seal to prevent moisture from entering the sleeve via the joint. The adhesive may be flexible for certain applications while rigid in others.
Although referred to in the specification as, e.g., inlet ports and outlet ports, etc., many of the features of the joining faces 525 are not complete until two half sleeves are placed face-to-face with each other. Thus, a complete inlet port is formed when an inlet port of one half sleeve is joined with an inlet port of another half sleeve. Accordingly, in the claims, such features of a half sleeve are referred to as sections, e.g., inlet port section. This is to distinguish the elements of the half sleeve from the elements formed when two half sleeves are mated.
Blind cavities 531 provide a strong mechanical engagement with a concrete footing when the complete sleeve 521 is installed in the ground. In cases where the installer does not use a poured-concrete footing, the cavities 531 provide a mechanical engagement with sand, crushed rock, or even dirt, to more firmly fix the sleeve into the ground.
The half sleeves 520 also include utility knockouts 533 that can be removed to provide access to the sleeve. For example, a user may employ a post sleeve to support a lamp post, or may wish to provide lights on a fence. In such cases, an electrical cable can be routed into the post sleeve 531 via the knockout 533. The knockouts comprise defined regions of the sleeve wall that are substantially thinner than the surrounding wall. With a mallet and chisel, the user strikes the knockout, breaking away the thinned portion.
According to an embodiment, the complete sleeve 521 is configured to be installed in a post hole by floating the sleeve in freshly poured concrete. Because the density of concrete varies, in part, according to the density of the aggregate used, it may, in some cases, be necessary to adjust the buoyancy of the post sleeve. Accordingly, rigid foam inserts can be placed in some of the cavities 531, which will displace corresponding volumes of concrete without adding appreciably to the weight, thus increasing the buoyancy of the sleeve 521. The half sleeve 520 is shown with a percolation chamber 540 that is defined, in part, by a degradable seal 542. While half of the seal 542 is shown in
In one embodiment, the lowermost part of the sleeve is tapered or otherwise adapted to receive an extension, substantially increasing the effective length and surface area of the sleeve. This can be especially helpful for added infiltration area or lateral stability when using sand, gravel, or native dirt in place of poured concrete to encase the sleeve.
Turning now to
The sleeve core 500 is placed in wet concrete in a location where a post sleeve is required, and the concrete is allowed to set around it. Once the concrete is adequately hardened, the stiffener 504 is removed from the outer shell 502. Without the stiffener, the shell 502 is sufficiently flexible that it can be removed from the concrete, leaving a cast-in-place post sleeve. Similarly, where a sleeve liner lacks sufficient rigidity to withstand the lateral pressure of wet concrete without deforming, a stiffener can be used to support the liner until the concrete sets, whether in a factory or in the field, with the liner being set in concrete on site.
A drainage chamber form 610 is also shown, coupled to the sleeve core 600. In the embodiment pictured, the chamber form 610 is configured to slip onto the bottom-most feature of the sleeve core 600. When the sleeve core 600 and chamber form 610 are used to form a post sleeve in the ground, the chamber form remains at the bottom of the post sleeve after the sleeve core is removed. A drainage aperture is formed where the drainage chamber is coupled to the sleeve core. The chamber form 610 can be sized to fit over any of the socket features 606 of the sleeve core 600, although it will be recognized that if the chamber form is coupled to one of the upper features, the features below will be inside the chamber form when concrete is poured around the sleeve core, so corresponding elements of the universal socket will not be formed in the resulting post sleeve.
The chamber form 610 can be made from a material that will degrade or dissolve when exposed to water, or can be of a substantially non-degradable material such as metal or plastic. Additionally, a degradable closure, like the barrier 328 described with reference to
Normally, a commercially available release agent is used to prevent wet concrete from adhering to the core 600, and to act as a lubricant to permit removal of the core once the concrete is cured. Alternatively, a wax coating can be used on the sleeve core 600 as a release agent, and also as a waterproofing agent within the sleeve that is formed thereby.
Depending on the thickness and formulation of the release agent, there may not be a need for any draft to the core. For example, it is known that various petroleum-based waxes can be formulated to have selected thixotropic characteristics, so that, at rest, they will have a given viscosity, but under stress, will undergo shear thinning. The sleeve core 600 can be coated with such a material, which forms a layer of a selected thickness between the sleeve core and the concrete. After the concrete is cured, a pulling force is applied to the sleeve core 600 to draw it from the post sleeve. In response to the force applied, the coating transitions to a liquid or semi-liquid phase, allowing the core to slide easily from the post sleeve, even though the sides of the sleeve core are perfectly parallel. Alternatively, simply by coating the core to a sufficient thickness with a substance that will harden—e.g., wax—to prevent displacement by the wet concrete, a sufficient gap can be established between the concrete and the sleeve core for later removal of the core.
On the other hand, under some circumstances, a draft may be beneficial. For example, given a post sleeve configured to support a 3½ inch square post at a depth of 19 inches, and a draft of 1°, the dimensions of the sleeve will be about % inch smaller at the bottom of the sleeve than at the top. If the spacing between the standoff ribs is 3⅞ inches at the top, to allow for a slightly loose fit as a post is inserted, a true 3½ inch post will make full contact with the ribs a little more than half-way down, and will require some force to drive the post to the bottom of the sleeve. At the bottom, the standoff ribs will press into the sides of the post about ⅛ inch on each side, thereby holding the post firmly in place, while still allowing some flexing of the post at the top.
It is well known that concrete continues to cure and harden for many years after being poured. Thus, the term cure, when used with reference to poured concrete, can be relative. For the purposes of the specification and claims, cure, and related terms, are to be construed as meaning sufficiently cure. Accordingly, where a claim recites, e.g., “removing the post sleeve core from the cured concrete,” the “cured concrete” is concrete that is cured sufficiently for removal of the core.
According to various embodiments, the sleeve top 620 can include any of the elements described with reference to previous embodiments, at least insofar as they relate to the corresponding upper portion of the respective post sleeve. For example, a unique identifier can be provided on an outer surface of the sleeve top 620, or as an encapsulated RFID unit. The sleeve top 620 is intended primarily for use with a post sleeve made from concrete that is poured on site, though there is no reason it cannot also be used as part of a factory-made post sleeve.
Turning now to
To make the post sleeve 640, a user digs a post hole 654, and, if desired, places gravel in the bottom of the hole for drainage. A release agent is applied to the sleeve core 600, which is then positioned in the aperture 626 of the post top 620. A fastener in the aperture 628 of the post top 620 engages the notch 612 of the sleeve core 600, locking them together. The drainage chamber form 610 is coupled to the bottom of the sleeve core 600 by friction fit. The assembly comprising the core 600, the sleeve top 620, and the chamber form 610 is then positioned in the post hole 650. The assembly can be suspended in the hole 654, or can be positioned to rest on the bottom. In the embodiment of
The position, elevation, and orientation of the assembly is confirmed while the concrete in the hole 654 is still loose, to ensure that they are within tolerances, and the assembly is held in position. Preferably, a vibrator is used to settle the concrete and remove entrained air, and the concrete is allowed to cure. The fasteners in the apertures 628 are then loosened or removed, and the sleeve core 600 is drawn out through the aperture 622 of the sleeve top 620, leaving the inner volume 644 of the post sleeve 640 behind, ready to receive a post. After the sleeve core 600 is removed, soil or sod is placed over the main body 642 to the edge of the sleeve top 620, leaving only the decorative upper surface 626 visible. When a post is positioned in the post sleeve 640, the post passes entirely through the sleeve top portion, and is seated in the portion formed by the post sleeve core 600. Elements described with reference to other embodiments, such as, e.g., stop plates, collars, etc., can also be used with the post sleeve 640.
The sleeve core 600 is shown as having notches 612 for engagement by fasteners of the sleeve top 620. Thus, in the embodiment shown, the distance from the top of the post sleeve 640 to the various features within the inner volume are known, as in other embodiments. Alternatively, the sleeve core 600 can be provided with a number of notches 612 spaced vertically for two or three inches along each corner, so that the depth of the post sleeve 640, relative to the sleeve top 620, can be selected when the sleeve is formed, by engaging different ones of the notches according to the desired depth. As a further alternative, the notches can be entirely omitted, and the fastener configured to engage the sleeve core 600 by friction engagement only. This permits a wider range of adjustment for depth selection—it will be recognized that where notches are provided, the maximum depth is limited by the position of the bottom-most notches, which must always be positioned inside the sleeve top so that concrete does not engage the notches and interfere with removal of the core from the sleeve.
The embodiment of
A number of systems and methods for positioning and supporting post sleeves in post holes are disclosed in the co-pending U.S. patent application Ser. No. 12/403,985, filed Mar. 13, 2009, and incorporated herein by reference, in its entirety.
In addition to the advantages outlined above, a number of advantages are afforded in accordance with various embodiments. For example, post sleeves permit the temporary removal and replacement of posts. It is not uncommon for an individual to find it necessary to remove a section of a fence in order to move a vehicle or temporarily permit access to a normally enclosed area. Under such circumstances, where previously it might have been necessary to dig up two or three posts with their concrete footing, a user can simply pull the posts out of the sleeves and re-install them later.
Because of the protection from water damage provided by the post sleeves, the serviceable lifespan of wood posts is extended. Additionally, lower grades of wood, or more cheaply and environmentally friendly finished wood can be used without sacrificing durability.
Because of the stops and stop plates, shorter posts can be substituted for longer ones with no loss of structural strength. At the lumber mills, the shorter the length of the posts being cut the greater the yield from a given trunk, and the more economical. For example, due to the tapered shape of the trees from which most lumber is produced, there are increased efficiencies obtained if shorter lengths of material are cut therefrom. While eight-foot lengths are the most commonly used, mills inevitably produce shorter lengths, as well, either as leftover sections after a length has been cut into eight-foot pieces, or because, when setting out to produce eight-foot posts, many of the pieces generated will need to be trimmed back due to end defects. Thus, mills generally have a surplus of lumber shorter than eight feet in length, because standard methods of construction require the eight-foot lengths, making the shorter timbers less marketable. By employing post sleeves to anchor the fence posts, seven-foot lengths can be used, which, because of their availability and recovery, are less expensive per linear foot than eight-foot lengths and are more environmentally friendly. Furthermore, even if demand for seven-foot lengths of fence posts increases beyond the surplus currently available, the price will inherently remain lower because of the better yield of shorter posts from a given length of tree, as explained above. Due to the improved economy with respect to both yield and trim backs, mills can sell 7 foot material for substantially less per linear foot, and produce it in a more environmentally friendly way, than the 8 foot material.
Many of the advantages outlined above contribute to a significant reduction in overall environmental impact: the ability to use shorter posts for a given size means a higher yield per trunk and less scrap, which in turn means that fewer trunks need be cut to produce a given number of posts; the increased useful service life of a post means fewer replacement posts need be provided, further reducing consumption; protection of the post from water and most insects means that pressure treatment is no longer necessary, which reduces chemical pollution and also enables composting or recycling of the used posts, and which also potentially reduces the load on solid waste landfills currently necessary to dispose of pressure treated lumber; the permanent, long lasting post sleeve eliminates the need to dig up and dispose of old concrete footings, and the need to replace the concrete footing with new concrete; which means a long-term reduction in high energy consumption required to produce the cement of the replacement concrete; the compatibility of the post sleeve with a wide range of post configurations means that a change in function that requires a change in post height or size does not necessarily require a replacement of the concrete footing; and the tracking of application data associated with the unique identifiers means that large fence sections can be manufactured to order in a shop or factory rather than on site, which results in fewer lifetime site visits, less overall fuel consumption, and less material waste, which further reduces the consumption of raw materials.
Embodiments of the invention are directed to sleeves configured to support posts, e.g., fence posts, sign posts, etc. Accordingly, many of the elements are described and claimed with reference to a post. For example, in describing the standoff ribs 122 of
When used in the specification or claims to refer to a post sleeve assembly or elements thereof, terms that refer to a relative vertical position, such as upper, lower, above, below, top, bottom, etc., are to be construed according to the normal orientation of the referenced element in use, i.e., with an associated post sleeve oriented to support a post vertically—see, for example, the post sleeve assembly 100 of
Ordinal numbers, e.g., first, second, third, etc., are used in the claims merely for the purpose of clearly distinguishing between claimed elements or features thereof. The use of such numbers does not suggest any other relationship, e.g., order of operation or relative position of such elements. Furthermore, ordinal numbers used in the claims have no specific correspondence to such numbers used in the specification to refer to elements of disclosed embodiments on which those claims may read.
As used in the specification and claims, the term post sleeve refers to a structure that is configured to removably receive a post, to hold the post in a substantially fixed and upright position, and, after the post is removed, to removably receive a replacement post.
The term preformed is used to refer to an element that is formed or manufactured at one location, then moved to another location for use.
Where a claim limitation recites a structure as an object of the limitation, that structure itself is not an element of the claim, but is a modifier of the subject. For example, in a limitation that recites “a joining face that, when the half sleeve and a substantially identical half sleeve are mated together, defines a central longitudinal plane of a resulting post sleeve,” the substantially identical half sleeve is not an element of the claim, but instead serves to define the scope of the term joining face. Additionally, subsequent limitations or claims that recite or characterize additional elements relative to the substantially identical half sleeve do not render that structure an element of the respective claim, unless or until the structure is recited as the subject of the limitation.
The abstract of the present disclosure is provided as a brief outline of some of the principles of the invention according to one embodiment, and is not intended as a complete or definitive description of any embodiment thereof, nor should it be relied upon to define terms used in the specification or claims. The abstract does not limit the scope of the claims.
Individual elements of the various embodiments described above can be omitted or combined with elements of other embodiments to provide further embodiments. All of the U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet are incorporated herein by reference, in their entirety. Aspects of the embodiments can be modified, if necessary to employ concepts of the various patents, applications and publications to provide yet further embodiments.
These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.
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