Patent Application
20100043321
The present disclosure relates to building materials and systems and, more specifically, to systems and methods associated with finishing a penetration during construction such as for forming a window, door, or utility access opening in concrete or masonry structures such as walls and floors.
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
As is known in the construction art, modem building construction often includes construction of concrete structure with insulated concrete forms (ICF's) that are composed either from a foam insulating material that form permanent concrete form walls or from concrete masonry construction (CMU). ICF construction sandwiches a heavy, high-strength reinforced concrete between two layers of a light, high-insulation foam. This combination creates a wall with an unusually good combination of desirable properties: air tightness, strength, sound attenuation, insulation, and mass. CMU typically utilizes concrete block or concrete brick in the formation of walls.
Concrete structures such as ICF walls and floors are constructed by placing separate ICF building blocks on each other. Rebar is placed within a cavity formed by the ICF blocks. Concrete is then poured and the walls are formed with the ICF blocks being left in place, even after the concrete hardens. The concrete wall so formed can include foundation walls and other building walls. For ICF construction, further insulation is generally not necessary. Additionally, floors and roofs can be poured using ICF construction techniques. CMU walls are formed by laying concrete blocks or bricks as masonry products. CMU and ICF walls can be externally finished such as with veneers, stucco, gypsum boards, and brick on the interior and exterior of the wall as required.
ICF blocks are typically made with two opposing expanded polystyrene side panels that are arranged in spaced parallel relationship with their inner surfaces facing each other to form a cavity therein. Plastic or metal bridging members can be molded into the side panels to hold them together to form the blocks and to hold them against the forces applied by the poured concrete within the cavity. Typically, an end plate is molded within each side panel as an internal “stud” for attachment of finishing materials. The bridges are typically attached to these end plates for structural support during the pouring of the concrete and for anchoring the endplate into the cured concrete. Rebar is often placed horizontally and vertically within the cavities of the ICF blocks before the concrete is poured. The purpose of using rebar is to hold the concrete in compression to provide added strength. CMU blocks or bricks are typically constructed similar to brick walls and typically include mortar between each adjacent CMU unit.
As these ICF and CMU blocks are stacked to form a wall, it is often necessary to form penetrations such as openings for doors, windows, utilities, HVAC ducts and other mechanical systems. These penetrations are often formed with block-out systems known as “bucks” that provide the openings as required by the ICF or CMU construction techniques, such as with an ICF wall before and after the concrete is poured, or before or during stacking of the CMU blocks. As with traditional construction, bucks have been utilized to provide such a block-out opening in the wall. Many of these conventional bucks are removable once the concrete has hardened, similar to the wood forms. These are often referred to as “reusable bucks”.
These bucks are typically built as wooden framed bucks that provide the opening in the wall. These can be removable or can be left in place similar to the ICF or CMU blocks. If left in place after the wall or floor is constructed and cured, this wooden frame of the buck provides a fastening surface for the window or door and its finishing trim. The buck typically retains the concrete and also provides a point of attachment for interior and exterior finishes around the edge of the openings. In order to keep the wood frame properly aligned in the opening within the stacked wall forms, one or more temporary braces can also be used. These typically help to provide alignment of the wall forms with the wood frame. The buck typically requires supplemental bracing inside its frame to prevent deflection of the wood members under pressure from the poured concrete. This is usually accomplished by temporarily placing a brace between one or more sides of the buck opening.
When the buck frame is to be left in the wall, it is typically secured to the concrete by one or more fasteners, such as nails or anchor bolts. These are positioned prior to the pouring of the concrete and are secured to the frame and left hanging between the sides of the penetration during construction. The subsequent construction such as pouring of wet concrete into the cavity of an ICF wall can cause the concrete to flow around the fasteners and partially secure the buck frame in place once the concrete has hardened. Similarly, during CMU construction the mortar typically partially secures the frame to the CMU blocks about the penetration.
Such bucks have been traditionally constructed of wood and plastic. However, these bucks have demonstrated a variety of problems. For instance, wood bucks are known to change dimensions over time as a result of variations in humidity, temperature, and pressure, such as during the actual construction process. Plastic bucks have been shown to deform similarly, especially over time. Additionally, these plastic and wood bucks are not configured to endure substantial stress and do not offer strong bonds to the wall and as such can become easily dislodged from the wall.
As a result of the foregoing problems and disadvantages, there is a need in building construction for a more efficient, cost-effective and reliable systems and methods for finishing doors and windows in concrete walls and ceiling made with insulated concrete forms or concrete blocks.
The inventors hereof have succeeded at designing edge finishing assemblies and methods that are capable of utilization during the construction of concrete structures such as ICF and CMU walls, floors, and roofs. These assemblies and methods can, in some embodiments, provide for improved construction practices and structures that include integrated structural support for roofing and windows and doors, improved edge finishes, and reduced construction costs, among other benefits and improvements.
Generally, this disclosure addresses various assemblies for finishing a penetration in a concrete structure during construction of the concrete structure. The assemblies are improvements on a winding edge system having a plurality of jambs forming the penetration configured with at least one elongated body having two surface portions coupled together with an intermediate portion positioned between the two surface portions in a substantially parallel position. The intermediate portion is dimensioned for enclosing an end of a side panel of a concrete block and a portion of the concrete within the structure. One of the two parallel surface portions is dimensioned for covering a portion of the side panel proximate to the end. A plurality of retention members are positioned along the at least one elongated body, each being adapted for receiving and securing a coupling device for coupling to an internal structural support member within the concrete of the structure.
One aspect is an assembly for finishing a penetration in a concrete structure during construction having at least one elongated body with two surface portions or surfaces coupled together with an intermediate portion positioned between the two surface portions in a substantially parallel position. The intermediate portion is dimensioned for enclosing an end of a side panel of a construction block and a portion of the concrete or mortar of the structure and one of the two parallel surface portions is dimensioned for covering a portion of the side panel proximate to the end. A plurality of retention members is positioned along the at least one elongated body, with each retention member being adapted for receiving and securing a coupling device for coupling to an internal structural support member within the concrete or mortar of the structure. The assembly includes a jamb connector configured for coupling a first jamb with a second jamb that is adjacent to the first jamb. The jamb connector having a first portion with two segments lying substantially in a same plane and positioned at a predetermined angle from each other. Each first portion segment is configured for coupling with an associated surface portion of an associated one of the first and second jambs. A second portion having two segments that are each coupled to corresponding segments of the first portion. Each second portion lies at an angle equal to the predetermined angle from the other second portion. The second portion is configured for positioning about the intermediate portions of one of the first and second jambs.
According to another aspect, an assembly for finishing a penetration in a concrete structure during construction, with one of a plurality of jambs having an inspection port having two ends defining a predetermined length formed along one of the two surface portions and at least a portion of the intermediate portion. An inspection plate has a mating surface portion and a mating intermediate portion with each mating with the corresponding portion of the jamb having the inspection port. The inspection plate has a length greater than the predetermined length of the inspection port such that a portion of the inspection plate overlaps at each end of the inspection portion. Fasteners are configured for coupling the inspection plate to the jamb having the inspection port and for covering the inspection port.
According to yet another aspect, at least two jambs are vertical jambs forming vertical uprights of a penetration in a concrete structure during construction of the concrete structure. An anchor bracket is fixedly attached to the intermediate portion of a bottom end of each vertical jamb. The anchor bracket has a foot portion adapted for securing to a mounting fixture for at least temporarily affixing the position of the vertical jamb relative to another vertical jamb.
In yet other aspects, the current disclosure includes the methods of manufacturing and using the assemblies as described above and herein. Further aspects of the present disclosure will be in part apparent and in part pointed out below. It should be understood that various aspects of the disclosure may be implemented individually or in combination with one another. It should also be understood that the detailed description and drawings, while indicating certain exemplary embodiments, are intended for purposes of illustration only and should not be construed as limiting the scope of the disclosure.
It should be understood that throughout the drawings and the specification, corresponding reference numerals and/or text labels indicate like or corresponding parts and features.
The following description is merely exemplary in nature and is not intended to limit the present disclosure or the disclosure's applications or uses.
Generally, this disclosure addresses various assemblies for finishing a penetration in a concrete structure during construction of the concrete structure. The assemblies are improvements on a penetration edging system having a plurality of jambs forming the window or door configured with at least one elongated body having two surface portions coupled together with an intermediate portion positioned between the two surface portions in a substantially parallel position. The intermediate portion is dimensioned for enclosing an end of a side panel of a concrete block (such as an ICF or CMU block) and a portion of the concrete structure being built by the concrete blocks. One of the two parallel surface portions is dimensioned for covering a portion of the side panel proximate to the end. A plurality of retention members are positioned along the at least one elongated body, each being adapted for receiving and securing a coupling device for coupling to an internal structural member within the concrete structure.
In some embodiments, an assembly for finishing a penetration such a window and door or utility opening for an ICF or CMU wall includes a jamb connector configured for coupling a first jamb with a second jamb that is adjacent to the first jamb. The jamb connector has a first portion with two segments lying substantially in a same plane and positioned at a predetermined angle from each other. Each first portion segment being configured for coupling with an associated surface portion of the adjacent first or second jamb. A second portion has two segments that are each coupled to corresponding segments of the first portion. The second portion segments lie at an angle equal to the predetermined angle from each other. Each second portion is configured for positioning about the intermediate portions of one of the first and second adjacent jambs.
Of course, it should be understood that more than one jamb connector can be used to connect two adjacent jambs, for example one on either side, such as front and back, of the jamb. Additionally, an opening in a concrete structure, whether a wall, floor or otherwise, typically has multiple jambs forming the opening and therefore multiple jamb connectors and/or sets of jamb connectors can be used to complete and finish the assembly.
It should be understood to those skilled in the art that while many of the exemplary embodiments described herein are shown for construction of an ICF wall, the same assemblies and methods apply to construction of ICF floors and roofs, as well as CMU walls, e.g., this can include both concrete and masonry wall construction as well as ICF wall construction. Additionally, the exemplary embodiments generally describe, by way of example, outside corners of penetrations/openings. However, the same assemblies and methods can apply to inside corners as well and are still considered to be within the scope of the present disclosure and claims.
In some embodiments, an edge assembly for a penetration in a concrete structure can include a jamb having an inspection port with two ends defining a predetermined length. The jamb can include a bottom jamb such as a kick jamb configured to positioning between two vertical jambs and for establishing and maintaining their distance relative to each other during and after construction. The inspection port can be formed along one of the two surface portions of the jamb and at least a portion of the intermediate portion. An inspection plate has a mating surface portion mating with corresponding surface portions of the jamb having the inspection port. A mating intermediate portion is configured for mating with the corresponding intermediate portion of the jamb having the inspection port. The inspection plate has a length that is greater than the predetermined length of the inspection port and is positioned such that a portion of the inspection plate overlaps at each end of the inspection portion. Fasteners couple the inspection plate to the jamb having the inspection port. When so positioned and fastened, the inspection plate covers the inspection port of the jamb. The inspection port can be left open during construction to aid construction such as for placement of masonry compounds, concrete or insulation in the wall being constructed. This inspection port can also be re-opened for construction inspection at a later time to ensure that the placement of the jamb and or the construction of the wall have been according to requirements or specifications.
In some embodiments, such as when an ICF or CMU wall finishing system is used to finish a door, utility opening, or a floor length window (generally referred to herein as an opening assembly having jambs but is intended to cover each of these arrangements), there are typically at least two jambs that are vertical that form vertical uprights of an opening, each vertical jamb having a top end and a bottom end. An anchor bracket can be attached to the intermediate portion of each bottom end of the two vertical jambs. The anchor bracket can have a foot adapted for securing to a mounting fixture such as a floor. Each foot of each anchor bracket is configured for at least temporarily affixing the position of the vertical jamb relative to the other vertical jamb when the foot portion is secured to the mounting fixture.
Referring now to the figures,
As shown in
In the illustrated embodiments of
In other embodiments, each anchor bracket 120 can have a mounting fixture (not shown), other than the foot 122, that can be specifically adapted for affixing the bottom ends of the two vertical jambs 106V at a predetermined distance from each or to a surface during construction of the concrete structure including the pouring of concrete or placing of mortar about the connected jambs 106 or an mounting fixture that extends into a void filled by concrete or mortar (not shown). Such, mounting fixture can include a kick or bottom jamb, for example, and as will be discussed in more detail below, or an anchor fastener.
Examples of the jamb connectors 102A and 102B, composing the two portions of the jamb connector pair 102, can be formed or manufactured in any manner, but are typically mirror images of each other, thereby providing for their mating on opposing sides of the jambs 106. As shown in
In the example of
This same process is used to form the mating jamb connector 102B by cutting of the second surface 128B instead of the first surface 128A and following the same procedures. The two similarly formed jamb connectors 102A and 102B are then mated on opposing sides of two jambs 106 to be connector together to form a corner of the penetration assembly 100.
In some embodiments, a jamb connector 102 for a penetration assembly 100 can be formed having the angle A of greater than 90 degrees. As shown in
Additionally,
As shown in
The two second surface angled segments 128B-1 and 128B-2 are configured to be parallel to the intermediate portion of the jambs 106 being coupled. In some embodiments, the second surfaces 128B can include a length such that it extends into a void formed by the two surfaces of the coupled jamb 106 and therefore into the concrete that is poured into the void during construction.
As shown in
From the above discussion, one or more benefits of the jamb connectors, inspection port and plate and anchor bracket should be known to those skilled in the art. One or more embodiments of these can provide for improved and less costly construction of a concrete structure having a penetration therein such as for finishing a window, door or utility opening such that the construction process is improved and the finished opening is as planned and expected. Additionally, the methods of using the jamb connector, inspection port and plate, and anchor brackets during the construction and finishing of an opening in a concrete structure during construction of the concrete structure are also included within the scope of the present disclosure.
Further, as should be known to those skilled in the manufacturing and construction arts after reviewing this disclosure and the drawing figures, the methods of manufacturing the jamb connectors, inspection port, inspection plate and anchor bracket are also within the scope of the present disclosure.
When describing elements or features and/or embodiments thereof, the articles “a”, “an”, “the”, and “said” are intended to mean that there are one or more of the elements or features. The terms “comprising”, “including”, and “having” are intended to be inclusive and mean that there may be additional elements or features beyond those specifically described.
Those skilled in the art will recognize that various changes can be made to the exemplary embodiments and implementations described above without departing from the scope of the disclosure. Accordingly, all matter contained in the above description or shown in the accompanying drawings should be interpreted as illustrative and not in a limiting sense. It is further to be understood that the processes or steps described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated. It is also to be understood that additional or alternative processes or steps may be employed.
This application claims the benefit of U.S. Provisional Application No. 61/028,775, filed on Feb. 14, 2008, which is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61028775 | Feb 2008 | US |
