Abstract:
The present invention relates to construction forms and more specifically to a device for making concrete forms for making stairs.

Description:
SUMMARY OF THE INVENTION  
         [0001]    The present invention relates to construction forms and more specifically to a device for making concrete forms for making stairs. Pouring concrete requires a form to hold the liquid concrete until it can dry to its solid form. The top surface of the wet concrete is left open to allow excess material removal. Creating a form to pour stairs involves securing a set of risers to a set of stringers. The risers contain the wet concrete and when removed correspond to the rise of each step. The top surface of the wet concrete hardens to form the tread of each step. Currently, a stair form is created by cutting portions out of a piece of wood (see FIGS.  8 - 9 ). Removing the outline of the stairs, including the thickness of the risers and a finishing space, forms a stringer. The stringer is then hung in place by anchoring at a floor elevation and securing at a landing elevation. Additional stringers are added at regular intervals between the right and left sides of the desired stairs. A portion of each riser is removed to allow a finish tool access to the portion of the tread adjacent the next rise. The risers are then secured at a right angle to the stringer using an additional block of wood attached to both the stringer and the riser. After the concrete dries, the risers and stringers are removed and the stringers must be discarded because of the unlikelihood of needing that exact configuration. This method of creating stair forms is time consuming and wasteful. There is a need for a system that is quicker and allows reuse of the stringers.  
           [0002]    U.S. Pat. No. 4,916,796 discloses a method for assembly of stair forms. The apparatus allows the risers to be positioned without having to cut the stringer. This apparatus requires attachment at a pivot point  22  to a line marked on the stringer. The apparatus is then positioned using scales  56  located on an arcuate edge of the scales and the line on the stringer. Kneeboard  72  is added to allow a worker to kneel on the kneeboard to finish the concrete tread. There are a couple of drawbacks to this system. The kneeboard must be removed in order to finish the portion of the tread previously covered by the kneeboard. Concrete work is notoriously messy and the back surface of the apparatus does not pivot well when dirty. In addition, access to the previous apparatus is necessary to install a subsequent apparatus. There is a need for a system that does not require a separate kneeboard. There is also a need for a system that is easy to use and allows repeated use of the apparatus. The present invention meets those needs.  
           [0003]    One aspect of the present invention is an apparatus having a bracket having a first end opposite a second end. The bracket further includes a stringer mount face and a riser mount face including first and second riser mounting regions. The stringer mount face and the riser mount face extending longitudinally between the first end and the second end. At least a portion of the stringer mount face defines a stringer mount plane and at least a portion of the riser mount face defines a riser mount plane. The bracket is configured such that the stringer mount plane is generally perpendicular to the riser mount plane. A riser mounting structure is located on the riser mount face. A stringer mounting structure is located on the stringer mounting face. A longitudinally extending stringer stop extends away from and perpendicular to the stringer mount plane. The stringer stop has first and second abutting surfaces. One of the first and second abutting surfaces can abut a bottom of a stringer such that the stringer mounting face can be positioned adjacent a side of the stringer. The apparatus further includes a laterally extending first riser stop having a first riser abutting surface. The first riser stop extends away from the riser mount face and is longitudinally spaced a first distance from the stringer stop. The first riser mounting region is located between the first riser stop and the second end. The first riser abutting surface is adapted to abut a top of a riser such that the first riser mounting region of the riser mounting face is positioned adjacent a side of the riser.  
           [0004]    Another aspect of the present invention is an assembly comprising an apparatus, a stringer and a riser. The apparatus has a bracket having a first end opposite a second end. The bracket further includes a stringer mount face and a riser mount face including first and second riser mounting regions. The stringer mount face and the riser mount face extend longitudinally between the first end and the second end. At least a portion of the stringer mount face defines a stringer mount plane and at least a portion of the riser mount face defines a riser mount plane. The bracket is configured such that the stringer mount plane is generally perpendicular to the riser mount plane. The apparatus further comprises a riser mounting structure located on the riser mount face and a stringer mounting structure located on the stringer mounting face. A longitudinally extending stringer stop extends away from and perpendicular to the stringer mount plane. The stringer stop has first and second abutting surfaces. A laterally extending first riser stop has a first riser abutting surface. The first riser stop extends away from the riser mount face and is longitudinally spaced a first distance from the stringer stop. A laterally extending second riser stop has a second riser abutting surface. The second riser stop extends away from the riser mount face and is longitudinally spaced a second distance from the stringer stop. The first distance is equal to the second distance. The first riser mounting region is located between the first riser stop and the second end and the second riser mounting region is located between the second riser stop and the first end. The assembly further comprising a stringer having a stringer bottom, a first stringer side and a second stringer side. The stringer is attached to the apparatus such that one of the first and second stringer sides is adjacent the stringer mounting face and the stringer bottom is abutted by one of the first and second abutting surfaces of the stringer stop. The assembly further comprising a riser having a riser top and a riser side. The riser is attached to the apparatus such that the riser side is adjacent one of the first and second riser mounting regions and the riser top is abutted by one of the first and second riser stops.  
           [0005]    Another aspect of the present invention is a method of creating a form for pouring concrete steps. The method comprising providing an apparatus having a bracket having a first end opposite a second end. The bracket further includes a stringer mount face and a riser mount face including first and second riser mounting regions. The stringer mount face and the riser mount face extend longitudinally between the first end and the second end. At least a portion of the stringer mount face defines a stringer mount plane and at least a portion of the riser mount face defines a riser mount plane. The bracket is configured such that the stringer mount plane is generally perpendicular to the riser mount plane. The apparatus further comprises a riser mounting structure located on the riser mount face and a stringer mounting structure located on the stringer mounting face. A longitudinally extending stringer stop extends away from and perpendicular to the stringer mount plane. The stringer stop has first and second abutting surfaces. A laterally extending first riser stop has a first riser abutting surface. The first riser stop extends away from the riser mount face and is longitudinally spaced a first distance from the stringer stop. A laterally extending second riser stop has a second riser abutting surface. The second riser stop extends away from the riser mount face and is longitudinally spaced a second distance from the stringer stop. The first distance is equal to the second distance. The first riser mounting region is located between the first riser stop and the second end and the second riser mounting region is located between the second riser stop and the first end. The method further comprising providing a stringer having a stringer bottom, a first stringer side and a second stringer side. Providing a riser having a riser top and a riser side. Securing the apparatus to the stringer; and securing the apparatus to the riser.  
           [0006]    Other features and advantages will be in part apparent and in part pointed out hereinafter. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]    [0007]FIG. 1 is a perspective view of an apparatus according to the invention;  
         [0008]    [0008]FIG. 2 is a front plan view of the apparatus of FIG. 1;  
         [0009]    [0009]FIG. 3 is a side plan view of the apparatus of FIG. 1;  
         [0010]    [0010]FIG. 4 is a perspective view of an extension clip according to the invention;  
         [0011]    [0011]FIG. 5 is a front plan view of an extension clip and apparatus according to the present invention;  
         [0012]    [0012]FIG. 6 is a side view of an assembly according to the present invention;  
         [0013]    [0013]FIG. 7 is a perspective view of the assembly of FIG. 6;  
         [0014]    [0014]FIG. 8 is a side view of an example of the prior art; and  
         [0015]    [0015]FIG. 9 is a perspective view of the example shown in FIG. 8. 
     
    
       [0016]    Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0017]    Referring now to the drawings, FIG. 1 shows an apparatus  20  according to the present invention. The apparatus has a first end  22  opposite a second end  24  of a bracket  26 . The apparatus includes the bracket  26 , a stringer stop  28 , and at least a first riser stop  30 . The apparatus may also include a second riser stop  32 .  
         [0018]    The bracket  26  has a stringer mount face  34  and a riser mount face  36 . The riser mount face includes a first mounting region  38  and a second riser mounting region  40 . The stringer mount face and the riser mount face extend longitudinally between the first end  22  and the second end  24 . At least a portion of the stringer mount face defines a stringer mount plane and at least a portion of the riser mount face defines a riser mount plane. The bracket is configured such that the stringer mount plane is generally perpendicular to the riser mount plane.  
         [0019]    Referring now to FIGS.  2 - 3  (a side and front plan view respectively of the apparatus of FIG. 1), the riser mount face  36  and the stringer mount face  38  is shown. A riser mounting structure  42  is located on the riser mount face. A stringer mounting structure  44  is located on the stringer mounting face. The stringer stop  28  extends longitudinally away from and perpendicular to the stringer mount plane. The stringer stop has a first abutting surface  46  and a second abutting surface  48 . If one of the first and second abutting surfaces abuts a stringer bottom the stringer mounting face can be positioned adjacent a stringer side.  
         [0020]    The first riser stop  30  extends laterally from the riser mount face  36 . The first riser stop has a first riser abutting surface  50 . The first riser stop extends away from the riser mount face and is longitudinally spaced a first distance  52  from the stringer stop  28 . The first riser mounting region  38  is located between the first riser stop  30  and the second end  24  and the second riser mounting region  40  is located between the second riser stop  32  and the first end  22 . The first riser abutting surface  50  is adapted to abut a riser top such that the first riser mounting region  38  of the riser mounting face is positioned adjacent a riser side.  
         [0021]    The apparatus can also include the second riser stop  32 . The second riser stop has a second riser abutting surface  54 . The second riser stop extends away from the riser mount face and is spaced longitudinally a second distance  56  from the stringer stop  28 . The second distance  56  is equal to the first distance  52 . The second riser mounting region  40  is located between the second riser stop and the first end  22 . The second riser abutting surface abuts a riser top such that the riser mounting face may be positioned adjacent a side of the riser.  
         [0022]    In the embodiment shown, the riser mounting structure  42  is a plurality of first riser holes in the riser mounting face  36 . The first riser holes are spaced longitudinally and located between the first riser stop and the second end  24 . The riser mounting structure  42  can also include a plurality of second riser holes space longitudinally and located between the second riser stop and the first end  22 . The riser holes are dimensioned to receive a wood screw. The stringer mounting structure  44  is a plurality of first stringer holes in the stringer mounting face  24 . The first stringer holes are spaced longitudinally and located between the stringer stop and the first end  22 . The stringer mounting structure may also include a plurality of second stringer holes spaced longitudinally and located between the stringer stop and the second  24 . The stringer holes are dimensioned to receive a wood screw.  
         [0023]    Referring now to FIGS.  4 - 5 , the apparatus  20  may also include a riser extension clip  60 . The riser extension clip has an attaching face  62  and an extension face  64 . The extension face includes an extension mounting structure  66 . At least a portion of the attaching face defines an attaching plane and at least a portion of the extension face defines an extension plane. The riser extension clip is configured such that the attaching plane is generally perpendicular to the extension plane. The riser extension clip attaches to the apparatus such that the attaching face  62  is in a face to face orientation with the stringer mount face  34  and the extension face  64  is adjacent the first riser mounting region  38 . In the embodiment shown, the extension clip attaches to the apparatus via an attaching face mounting structure  68 . The attaching face mounting structure  68  is a plurality of holes that align with the plurality of second stringer holes when the extension clip and the apparatus are in a face to face orientation. The extension clip can then be bolted to the apparatus.  
         [0024]    Referring now to FIGS.  6 - 7 , the operation of the apparatus  20  can be demonstrated. The apparatus is shown with a stringer  80  and a riser  82  to create a form for concrete stairs. It should be understood that an existing wall (for enclosed stairs) or a side frame (for freestanding stairs) will be utilized to form the lateral boundaries of each step of the stairs. Using formulas known to those skilled in the art and based upon the total rise and run of the stairs, the dimensions of each step (and the number of steps) can be determined. After ensuring the stringer is straight, each step is drawn on the stringer side from a landing down to a floor. A toe-kick, if included, can be accounted for in this step. An additional line  84  is then drawn parallel to each rise drawn on the stringer at a distance equal to the thickness of the riser  82 . The floor is also drawn where it meets the bottom of the initial step. A floor line is drawn parallel to the floor at a distance x. In the embodiment shown, the distance x is equal to a distance x′ from the first stringer abutting surface  46  to the first riser abutting surface  50 . A surplus  86  below the floor line is then removed. Finally, a notch  88  is added to the stringer. The bottom of each riser  82  is bevelled to allow access to the adjacent tread.  
         [0025]    An apparatus  20  is then attached to the stringer such that the stringer mount face  34  is adjacent the stringer side  90  at a position where the riser mount plane intersects the additional line  84 . With the stringer stop  28  abutting the stringer bottom, the apparatus  20  is screwed to the stringer using wood screws in the stringer mounting structure  44 . The riser  82  is then attached to the apparatus  20  using wood screws in the riser mounting structure  42 . When the initial riser  82  is positioned properly the stringer is anchored to the floor by affixing an anchor board  94  to the floor and then placing the notch  88  over the anchor board. In the embodiment shown the apparatus is used in a left hand positions (on the left side of the stringer). The riser is attached to the apparatus in the first riser mounting region  38 . A right hand position can be achieved by flipping the apparatus over such that the second end  24  is arranged upright and the riser is mounted in the second riser mounting region  40 . This process is then repeated for each riser. Additional stringers are added and the above process is then repeated.  
         [0026]    If a riser is not long enough to cover the step then the riser extension clip  60  is used. Referring to FIG. 4 a riser and an auxiliary are shown in dashed lines abutting one another. The auxiliary is positioned so that the auxiliary top abuts the riser stop and then attaches to the riser extension clip using the extension mounting structure.  
         [0027]    In the preferred embodiment, the stingers are 2″×10″ boards and the risers are 2″×6″ boards. After the risers, stringers and a plurality of apparatus have been utilized to create a form, the tops of the risers are strong enough to withstand the weight of an adult. This allows the workers to finish each tread of each step without the necessity of a kneeboard. The clearance between the bottom of the stringer and the step tread allows the tread to be finished beneath the stringer.  
         [0028]    After the concrete has been poured and the stairs have dried the form can be removed. Because there are no moving parts the apparatus  20  can easily be reused.  
         [0029]    As various changes could be made in the above constructions and methods without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto.