Abstract:
Apparatus/systems and methods are disclosed for facilitating installation of conduit systems through construction openings. Exemplary embodiments enable one to form, maintain, and controllably block the openings and incorporate the apparatus/systems into the finished construction. Exemplary apparatus/systems disclosed include (i) a structural member that includes one or more side walls defining an opening, one or more base flaps, and one or more top flaps, and (ii) at least one cover to controllably block said opening. Exemplary methods disclosed include (i) installing said apparatus/system that includes (1) securing the structural member relative to a deck, and (2) introducing cement/concrete relative to structural member covering the base flaps and fixing the structural member with respect to the deck, and (ii) installing a conduit system through an apparatus/system-defined opening that includes encasing the cover(s) together with the installed conduit system.

Description:
BACKGROUND 
       [0001]    1. Technical Field 
         [0002]    The present disclosure is directed toward apparatus, systems and methods for facilitating installation of a conduit system within a structure e.g., a building. More specifically, the present disclosure is directed toward apparatus, systems and methods that facilitate installation of a conduit systems, e.g. HVAC conduit systems, that extend, inter alia, between levels of a building or other structure, wherein the apparatus, systems or methods include a structural unit configured and dimensioned to define and maintain an opening during the construction process and a cover to controllably block or substantially block the opening, e.g., for safety purposes. 
         [0003]    2. Background Art 
         [0004]    During the construction of a building or other structure, it is common to leave openings through the floors of the structure through and within which a third party, e.g. an HVAC sub-contractor(s), will, at a later date, install a conduit system for the air conditioning and heating units. These openings are often times also used to facilitate the transfer of material from floor to floor and thus, if safely and correctly maintained, can be beneficial to the overall construction process. 
         [0005]    Currently, the formation and maintenance of floor opening carries with it many inherent disadvantages and problems as well. Conduit systems often times will traverse the full height of the structure, making such openings potentially hazardous to workers above and below alike. The current extent of safety measures employed in this particular art is generally limited to covering the opening with a plywood board or its equivalent. 
         [0006]    The conventional approach to the situation carries with it many clear risks and disadvantages. For example, a board may be improperly fixed (if at all) to the floor during the installation process. Indeed, a periodic need to work through the opening may require that the board be movable relative to the opening, thereby increasing the potential risk of inadvertent and/or undesired displacement thereof. Such displacement increases the risk that individuals and/or objects will fall through the opening. Furthermore, union policies could encumber the process of replacing a displaced board; e.g. by limiting the body of qualified parties who may do so. 
         [0007]    Beyond the potential unreliability of conventional boards in preventing workers and/or objects from falling through such openings, conventional approaches to forming/defining an opening in a floor, e.g. to facilitate subsequent HVAC installation, generally involve construction of an upstanding wooden frame mounted on top of a wooden sub-floor/deck. The height of the frame generally constructed so as to permit the pouring of cement/concrete to a desired depth/thickness onto the wooden sub-floor/deck and around the frame. After the cement/concrete hardens the wooden sub-floor/deck and frame are removed, e.g. chipped away, leaving behind the finished cement/concrete layer and defining an opening there-through. This process carries with it many clear disadvantages. I.e. the construction and removal of the wooden frame can be costly, time-consuming. and generally, inefficient. With respect to HVAC conduit systems, it is important to note that fire code regulations often necessitate a careful and thorough removal of the wooden frame. 
         [0008]    In view of the clear limitations of conventional approaches to forming and maintaining an opening in a floor during construction activities, a need clearly exists for improved apparatus, systems and methods that enhance safety. In addition, apparatus, systems and methods are needed that are easily, efficiently, and reliably used to form and maintain an opening in a floor, e.g., an opening configured and dimensioned for receipt of an HVAC or other conduit system. Apparatus, systems and methods that satisfy the above-noted parameters and simultaneously comply with all applicable building code requirements are also needed. 
         [0009]    The foregoing needs are satisfied by the disclosed apparatus, systems and methods disclosed herein, as will be apparent to persons skilled in the art based on the narrative description, particularly when read in conjunction with the appended figures. 
       SUMMARY OF THE DISCLOSURE 
       [0010]    Advantageous apparatus, systems and methods for facilitating installation of conduit systems in the construction of buildings are provided according to the present disclosure. The disclosed apparatus, systems and methods provide simple, cost-effective means for managing potentially hazardous openings such as those formed and maintained during a construction process for later installation of conduit systems and the like. To this end, in an exemplary embodiment of the present disclosure, advantageous apparatus and systems enable one to efficiently form/define such opening(s), to substantially block or unblock such opening(s) as needed without implicating union policies or OSHA regulations, and to generally incorporate the apparatus into the greater construction process. 
         [0011]    Exemplary apparatus and systems disclosed herein include a structural member and a cover. More particularly, the structural member generally includes one or more side walls defining an opening therethrough, one or more base flaps extending outwardly relative to the side wall(s), and one or more top flaps extending outwardly relative to the side wall(s). The cover is pivotally connected with respect to the structural member so as to controllably obstruct or block the opening. In an exemplary embodiment, the cover is hingedly connected with respect to the structural member so as to controllably obstruct or block the opening. However, alternative pivotal connections are expressly contemplated according to the present disclosure. In an exemplary embodiment, the cover is pivotally connected with respect to one or more of the top flaps so as to provide means for substantially blocking or unblocking the opening, as needed. However, the present disclosure is not limited by or to such exemplary configuration. Indeed, the cover may, alternatively, be pivotally connected relative to any one or combination of localities on the structural member, including one or more side walls. 
         [0012]    The bottom flap(s) are configured and dimensioned to facilitate mounting of the structural member with respect to a sub-floor/deck. The structural member may define openings of various geometry, e.g., square openings, rectangular openings, circular openings, elliptical openings and the like. The height of the side wall(s) may vary from installation-to-installation. In exemplary embodiments of the present disclosure, the side wall(s) define a height of between about 6″ to 12″, although alternative heights may be employed without departing from the spirit or scope of the present disclosure. The pivotally connected cover is typically configured and dimensioned to fully (or substantially fully) obstruct the opening defined by the side wall(s). However, multiple covers may be pivotally connected with respect to the structural member, e.g., on opposite sides of the opening, such that, in combination, the opening is fully (or substantially fully) obstructed, e.g., akin to a “barn door” arrangement. Multiple covers supported by the structural member may also overlap, in whole or in part, in obstructing the opening. 
         [0013]    Methods disclosed herein include, but are not limited to, (i) methods for installation of the disclosed apparatus/system, and/or (ii) methods for installation of a conduit system through the opening defined by such apparatus/system. Thus, in an exemplary implementation hereof, an apparatus/system is first mounted relative to a sub-floor/deck by securing one or more of the base flaps of the structural member with respect to the sub-floor/deck. Cement/concrete is then introduced onto the sub-floor/deck and around the apparatus/system such that the base flaps are covered and fixed thereby. After the cement/concrete layer substantially sets/hardens, the sub-floor/deck is removed resulting in a cement/concrete barrier with the apparatus/system defining an opening there-through. 
         [0014]    In an exemplary embodiment, one or more of the base flaps is secured to the sub-floor/deck e.g. with nails, screws, bolts, adhesive, and/or combinations thereof. However, other means of securing the base may likewise be employed including but not limited to the use of clamps, vices, ropes, straps, spikes, tacks, weights, notches or carvings in the sub-floor/deck itself, textured surfaces of one or more base flaps, and/or combinations thereof. It is also contemplated that one or more base flaps may be temporarily secured relative to the deck by hand. 
         [0015]    As secured, the side wall(s) of the structural member are in an upstanding orientation relative to the sub-floor/deck. Generally, the structural element performs the function of and thus eliminates the need for the construction of a wooden frame. In an exemplary embodiment the cover is typically pivoted into an obstructing orientation, i.e., extending across the opening and supported by the side wall(s) of the structural member. However, the cover may also be removed or obtained separately from the structural element and remain so until after the structural element is fixed within the cement/concrete layer. 
         [0016]    To form a cement/concrete layer relative to the sub-floor/deck, cement/concrete is introduced to the building site, i.e., atop the sub-floor/deck. The upstanding side wall(s) of the structural member form a barrier, such that the cement/concrete cannot enter or reach the opening to be defined. As the cement/concrete is introduced atop the sub-floor/deck, the base flaps of the structural member are typically covered thereby, thereby fixedly securing the structural member relative to the cement/concrete layer. Cement/concrete is generally introduced to a height that substantially corresponds to the height of the side wall(s) of the structural member. In an exemplary embodiment, the top flaps are encompassed by such cement/concrete, thereby further fixing and stabilizing the structural member relative to the cement/concrete layer. The sub-floor/deck is then removed once the cement/concrete layer has substantially hardened/set. 
         [0017]    In an exemplary embodiment the cover remains free to pivot relative to the side wall(s) of the structural member throughout the fixation process. Alternatively, the cover is pivotally connected relative to the structural member only after the cement/concrete has hardened/set. To the extent the cement/concrete impinges upon the location and/or desired path of the cover or (in the case of a detached embodiment) the cover&#39;s would be location and/or path, it is generally desired to remove such material from the structural member, cover and/or surrounding location, e.g., by conventional chiseling or the like. At this juncture, the structural member defines an opening through the cement/concrete layer and is configured/dimensioned to facilitate introduction of conduit member(s) or other building materials (e.g., wires, pipes, cables and the like) therethrough at such time as is convenient for the building trades. 
         [0018]    In exemplary implementations of the present disclosure (post-installation of the apparatus), the cover remains pivotally secured to the structural member during and after installation of a conduit system. More particularly, the cover is pivoted or otherwise positioned so as to unblock the opening and allow for installation of the conduit system. Generally, a framed enclosure is built around installed conduit systems encasing the system in, for example, a wall or pillar. In an exemplary embodiment, when building such framed enclosure, the cover is generally pivoted or otherwise positioned within the framed enclosure so as to engage the inner face of the framed enclosure or the outer face of the conduit system, e.g., ductwork. In either case, the disclosed method for implementation of the disclosed apparatus/system eliminates any potential labor, costs or inefficiencies that would result from a need to remove the disclosed cover. Of note, the structural member and cover are typically fabricated from a material that complies with applicable building/fire codes such that their positioning within the framed enclosure raises no potential issues. 
         [0019]    The apparatus, systems and methods of the present disclosure thus provide, inter alia, a cost-effective, efficient and reliable means for promoting and ensuring safety of construction workers. The disclosed apparatus, systems and methods thus offer numerous benefits to construction workers, contractors and building owners alike. The disclosed apparatus/system is relatively straightforward and inexpensive to manufacture and use. Indeed, a less hazardous work environment should lead to fewer accidents, greater efficiency and a reduced potential for liability. 
         [0020]    Additional advantageous features, functions and applications of the disclosed apparatus, systems and methods will be apparent from the descriptions which follow, particularly when read in conjunction with the appended figures. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]    To assist those of ordinary skill in the art in making and using the disclosed apparatus and methods, reference is made to the accompanying figures, wherein: 
           [0022]      FIG. 1  is a perspective view of an exemplary embodiment of a structural member and cover (in the open position). 
           [0023]      FIG. 2  is a top view of an exemplary embodiment of a structural member. 
           [0024]      FIG. 3  is a bottom view of the exemplary structural member of  FIG. 2 . 
           [0025]      FIG. 4  is a perspective view of an exemplary embodiment of a structural member with side walls exploded apart. 
           [0026]      FIG. 5  is an top view of an exemplary embodiment of a cover  FIG. 6  is a bottom view of the exemplary cover of  FIG. 5 . 
           [0027]      FIG. 7  is a perspective view of an exemplary apparatus according to the present disclosure that includes a structural member and cover (in the closed position). 
           [0028]      FIG. 8  is an exploded perspective view of an exemplary embodiment of a structural member and cover (in the open position) installed within or positioned with respect to an exemplary barrier before the removal of the sub-floor/deck 
           [0029]      FIG. 9  is a top view of an exemplary apparatus according to the present disclosure that includes a structural member and cover (with cover open for ease of viewing) installed with respect to a barrier. 
           [0030]      FIG. 10  is a cross-section of a perspective view of a structural member and cover subsequent to installation of a conduit system. 
       
    
    
     DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       [0031]    The disclosed apparatus, systems and methods facilitate installation of conduit systems in building construction in a simple and cost-effective manner. Indeed, the present disclosure permits contractors and other building trades to manage potentially hazardous openings that are formed and maintained during the construction process for later installation of conduit systems and the like. In an exemplary embodiment the disclosed apparatus/systems generally take the form of self-contained, modular units that are easily installed and that comply with all applicable building codes. Alternatively, the disclosed apparatus/systems may take the form of a kit where the cover and structural member may be obtained separately for on-site assembly prior to or during the installation process. 
         [0032]    With initial reference to  FIG. 1 , a top perspective view of exemplary apparatus  10  is schematically depicted. Apparatus  10  includes a structural member  11  and cover  12  that is depicted in an open position. The structural member  11  includes four side walls  16  that define an opening  18 , four base flaps  20 , and four top flaps  22 . In this exemplary embodiment, the cover  12  is pivotally connected with respect to structural member  11  by hinge  14 . Hinge  14  is mounted to a top flap  22  and cover  12 , thereby facilitating pivotal motion of cover  12  relative to structural member  11 . The precise design and configuration of hinge  14  is not critical to the design and/or operation of the disclosed apparatus  10 . Thus, for example, hinge  14  may include a single elongated hinge unit or a plurality of hinge units that are in a spaced relationship. Similarly, alternative pivotal connections other than the hinge are expressly contemplated according to the present disclosure e.g. material elasticity at and/or around the point of connection, wire lacing, slot and lock mechanisms and the like. 
         [0033]    Referring now to  FIGS. 2 and 3 , top and bottom views of exemplary structural member  1  are depicted. The four base flaps  20  and four top flaps  22  are shown extending outwardly relative to side walls  16 . Base flaps  20  and top flaps  22  are generally integrally formed with side walls  16 . Thus, in an exemplary embodiment of the present disclosure, base flaps  20  and top flaps  22  are formed through a bending action relative to adjoining side walls  16  and are oriented in a substantially perpendicular orientation relative thereto. The widths of base flaps  20  are generally selected so as to facilitate mounting of apparatus  10  relative to a sub-floor/deck. Thus, in an exemplary embodiment of the present disclosure, base flaps  20  are about 1 to 3 inches in width. The width of the top flap  22  that interacts with hinge  14  is generally selected so as to provide sufficient surface area to facilitate hinge mounting/interaction. The widths of the remaining top flaps  22  are generally of substantially equal width dimension so to, facilitate interaction/support of the structural member relative to a cement/concrete layer, manufacture of the apparatus, and overall inventory management, e.g. stacking. Exemplary width dimensions for top flaps  22  are between 1 and 3 inches. 
         [0034]    Side walls  16  define opening  18  therewithin. In the exemplary embodiment disclosed herein, opening  18  is substantially rectangular in geometry. However, the present disclosure is not limited by or to such exemplary geometry. Indeed, alternative geometries are expressly contemplated according to the present disclosure, including circular geometries, square geometries, and elliptical geometries. Different geometric openings may be particularly suited to specific construction needs, e.g., a circular and/or elliptical opening may be well suited for trash chutes, pipes and the like. In exemplary embodiments of the present disclosure, opening  18  is sized so as to accommodate conventional HVAC conduit structures/ductwork. Thus, opening  18  may define substantially rectangular dimensions of about 24 by 36 inches, although alternative dimensions may be employed without departing from the spirit or scope of the present disclosure. The height of side walls  16  is generally selected to accommodate conventional cement/concrete flooring depths, e.g., between about 6″ and 12″. 
         [0035]    With reference to  FIG. 4 , an exploded perspective view of exemplary apparatus  10  is provided, wherein structural member  11  includes side walls  16 , base flaps  20  and top flaps  22 . Base flaps  20  and top flaps  22  extend outwardly relative to side walls  16 . 
         [0036]    Referring now to  FIGS. 5-7  respectively, top and bottom views of an exemplary cover  12  and a perspective view of apparatus  10  with cover  12  in a closed orientation are provided. In this exemplary embodiment, cover  12  includes a rectangular plate  24  and a flap  26 . Hinges  14  are mounted with respect to plate  24  and flap  26  to establish a pivotal connection therebetween. Flap  26  is in turn mounted with respect to top flap  22 , thereby pivotally mounting cover  12  with respect to structural member  11 . In an alternative embodiment, flap  26  is omitted and hinge(s)  14  are mounted directly between plate  24  and top flap  22 . Similarly, in a further exemplary embodiment plate  24  is mounted relative to side wall  16 . Cover  12  is configured and dimensioned to fully or substantially block opening  18 , thereby preventing an individual and/or object from falling through opening  18  when cover  12  is in a closed orientation. 
         [0037]    In alternative embodiments, cover  12  may feature alternative geometries, e.g., based on the geometry of opening  18 . Thus, for example, cover  12  may feature a substantially circular geometry for interaction with a structural member that defines a circular opening. In addition, blockage of opening  18  may be achieved through interaction with a plurality of covers  12  that are pivotally mounted with respect to different portions/regions of the periphery of structural member  11 . In such implementation, individual covers may be sized to abut (or substantially abut), but not overlap, when in a closed orientation. Alternatively, individual covers may be sized to overlap, in whole or in part, when in a closed orientation, thereby providing greater structural integrity to the cover region, i.e., the cover elements that span the opening. 
         [0038]    Referring now to  FIG. 8 , a perspective view of an exemplary installation of apparatus  10  is schematically depicted prior to the removal of the sub-floor/deck. As shown therein, structural member  11  with cover  12  attached is installed with respect to a sub-floor/deck  28  and cement/concrete barrier  30 . It is important to note that the cover  12  need not be attached to structural member  11  until the end of the installation process. Thus in an alternative embodiment the cover  12  is not pivotally fixed relative to structural member  11  until after the cement/concrete barrier  30  has been introduced and has sufficiently hardened/set. 
         [0039]    In exemplary implementations of the disclosed apparatus  10 , opening  18  is aligned (or substantially aligned) with a the floor/deck  28  where the conduit systems (e.g., HVAC ductwork) or other materials are to be fed. Bottom flaps  20  are then secured to the sub-floor/deck  28  to maintain the desired alignment. Bottom flaps  20  may be provided with one or more apertures to facilitate nailing/bolting with respect to the sub-floor/deck  28 . Alternatively, bottom flaps  20  may be spiked or textured or sub-floor/deck  28  may be notched or carved at the point of juncture so as to facilitate temporarily securing apparatus by hand. When mounted with respect to the sub-floor/deck  28 , structural member  11  of apparatus  10  includes upstanding walls  16  that form a barrier with respect to opening  18 . 
         [0040]    A cement/concrete barrier  30  may be introduced to the sub-floor/deck  28  and around the structural member  11  in a conventional manner. Typically, the cement/concrete barrier  30  is introduced to a desired height based on applicable construction specifications. As introduced, the cement/concrete barrier  30  covers base flaps  20 , thereby fixing such base flaps between the sub-floor/deck  28  and cement/concrete barrier  30 . The upper surface of cement/concrete barrier  30  generally substantially corresponds with the horizontal plane defined by top flaps  22 . In this way, cement/concrete barrier  30  also stabilizes/fixes the top region of structural member  11 . Once the cement/concrete barrier  30  hardens/sets the sub-floor/deck  28  is removed. It may also be necessary/desirable to remove/chip away extraneous cement/concrete that impinge upon the operation of hinges  14  and/or movement of cover  12 . 
         [0041]    Thus, in an exemplary method for installation of the structural member  11  and cover  12  of the present disclosure, the method generally includes the steps of: (1) securing the base flaps  20  to a sub-floor/deck  28  or the like, (2) introducing cement/concrete or comparable material relative to the structural member  11  so as to cover the base flaps  20  and fix structural member  11  with respect to the concrete/cement barrier  30  and (3) removing the sub-floor/deck and cleaning up the extraneous cement/concrete. 
         [0042]      FIG. 9  schematically depicts structural member  11  embedded within a cement/concrete barrier  30 . The cover  12  is free to be pivoted open when and if necessary to complete construction activities. However, the cover  12  will not become detached nor migrate with respect to opening  18 , thereby providing enhanced safety to the worksite. 
         [0043]    Referring now to  FIG. 10 , apparatus  10  is depicted with conduit system  32  installed through opening  18 . To facilitate installation of conduit system  32 , e.g., HVAC ductwork, cover  12  is generally pivoted or otherwise positioned so as to unblock the opening  18  and allow for the insertion/installation of conduit system  32  there-through. A framed enclosure  34  is generally provided around the conduit system  32 , as is known in the construction field, and cover  12  generally rests against either the outer face of conduit system  32  or the inner face of the framed enclosure  34 . In either case, cover  12  remains an integral component of apparatus  10 , thereby eliminating the potential need to remove cover  12  therefrom as the construction process advances. Of note, the positioning of cover  12  within the framed enclosure in either orientation, i.e., resting against conduit system  32  or the framed enclosure  34 , complies with all applicable building codes. Note that the sub-floor/deck has already been removed from the cement/concrete barrier  30  depicted in  FIG. 10 . 
         [0044]    Apparatus  10  is generally fabricated from sheet metal, metal plate, duct metal/composite material, or the like. The side walls may be formed into a desired peripheral geometry through conventional metal working technologies, and opposed edges may be joined through conventional welding and/or bolting techniques. The fabrication materials are generally of a suitable thickness to satisfy applicable fire ratings and to provide the requisite structural integrity. Exemplary embodiments of the present disclosure employ sheet metal/plate material that is approximately  16  gage to ⅛″ thick, although alternative thicknesses may be employed without departing from the spirit or scope of the present disclosure. The thickness of the cover may vary depending on the size of the opening, given the forces to be supported thereby during the construction process. In further exemplary embodiments, support members, e.g. cross-beams, ribs, and brackets may be attached relative to the structural member to increase the structural integrity thereof and support larger covers. 
         [0045]    Although the present disclosure has been described with reference to exemplary embodiments and implementations thereof, the present disclosure is not to be limited by or to such exemplary embodiments and/or implementations. Rather, the apparatus, systems and methods of the present disclosure are susceptible to various modifications, variations and/or enhancements without departing from the spirit or scope of the present disclosure. Accordingly, the present disclosure expressly encompasses all such modifications, variations and enhancements within its scope.