Window buck system for concrete walls and method of installing a window

A system and associated method for forming a window opening in a poured concrete wall and installing a window therein includes a two-piece reusable window buck having a retainer temporarily coupled thereto. The retainer becomes partially embedded in the poured concrete wall and after the window buck is removed from the window opening formed in the wall, the window is easily and conveniently installed in the window opening and secured therein by the window retainer and cooperating spring clip on the window frame without the need for additional mechanical fasteners or tools.

BACKGROUND OF THE INVENTION
 This invention relates to poured concrete walls, and more particularly, to
 a pouring window buck system and associated method for installing a window
 in a poured concrete wall.
 In pouring walls of concrete such as residential basement walls, window
 openings are commonly formed in the concrete wall as it is being poured.
 In the past, it has been common to construct wood frames for window
 openings as a part of the wood wall forms for the concrete walls. After
 the poured concrete had set, the wood forms, including the wood window
 frames, were removed and at least the wood window frames had to be
 discarded. The cost of the wood window frames which are not reusable, and
 the labor required in building the frames were distinct disadvantages of
 this type of construction.
 Another general method which has been used is a metal buck frame or
 surround which is positioned between the wall forms and cast in place in
 the concrete wall. When the wall forms are removed, the buck frame or
 surround is in place to form the periphery of the window opening.
 Unfortunately, these types of systems have been found to be subject to
 deformation during the pouring of the concrete. Additionally, cast in
 place buck frames or surrounds significantly increase the cost of a window
 installation because they are not reusable.
 To avoid these disadvantages, various methods and systems have been
 proposed. For example, a reusable metal pouring window buck, which is
 positioned between the spaced wall forms, is one alternative. The bucks
 may be made in two parts or a single piece and when the concrete which has
 been poured around the buck has set, the buck is removed from the window
 opening formed in the resulting concrete wall. Typically, a window frame
 is detachably secured within the buck such that the window frame is cast
 in and remains in the window opening when the concrete sets and the buck
 is removed. Unfortunately, due to the heavy forces delivered by the
 concrete being poured around the buck, this method has proven, in many
 instances, to be unreliable to protect the window contained within the
 buck. In many instances, the window is damaged or broken during the
 pouring of the concrete requiring additional time, effort and expense in
 repairing or replacing the window cast in place in the poured concrete
 wall. Furthermore, vinyl window frames, while providing many advantages
 acknowledged in the industry are highly susceptible to being damaged
 during the pouring of the concrete wall in such systems. Therefore, many
 contractors avoid the use of vinyl window frames in poured concrete wall
 installations and pouring bucks of this type.
 Another alternative to the removable pouring buck and window frame
 combination is a removable pouring buck which allows a window to be
 installed into the window opening in the concrete wall after the buck has
 been removed. In the past, One disadvantage to such systems is the need
 for additional and often complicated or cumbersome fasteners to secure the
 window frame into the window opening. Typically, the window frame must be
 screwed, nailed, anchored or otherwise secured into the window opening
 with an additional fastener thereby requiring additional installation
 work, materials, tools and labor. Moreover, in many such systems, the
 window cannot be easily removed for cleaning, repair and/or replacement
 once installed in the window opening.
 An additional shortcoming of many known systems for installing windows in
 poured concrete walls is the inability to provide an accurate and stable
 positioning for the pouring buck, frame or the like between the spaced
 wall forms. This is very important because the position and orientation of
 the pouring buck is the resulting position and orientation of the window
 in the poured concrete wall. In the past, one method to maintain the
 position of the pouring buck between the wall forms has been to sandwich
 the buck between the spaced wall forms and rely upon the compressive force
 between the wall forms to hold the buck in position. However, the heavy
 forces of the concrete being poured around the buck has proven to be
 unsettling to the buck and this method is therefore unreliable for
 accurately and consistently maintaining the proper position and
 orientation of the buck between the wall forms.
 Nails may be driven through wood wall forms and into wood portions of the
 pouring buck or wood window frames to position them relative to the wall
 forms. However, the nails must be pulled out prior to disassembling the
 wall forms which is time consuming and potentially damaging to the wall
 forms. Furthermore, this technique is only practical for use with wood
 wall forms and window frames.
 Therefore, there exists a need for an improved system and method for
 forming a window opening in a poured concrete wall and installing the
 window in that opening. The system and method should be economical,
 efficient and robust to withstand the forces of the poured concrete while
 allowing for the accurate and reliable positioning of the window in the
 poured concrete wall. Furthermore, the system and method must be
 applicable for a wide variety of window styles and materials.
 SUMMARY OF THE INVENTION
 These and other objectives of the invention have been attained by a system
 and associated method for forming a window opening in a poured concrete
 wall and installing the window and associated frame into the opening. The
 components of the system include a reusable window buck which is adapted
 for placement between spaced wall forms to divert poured concrete around
 the window buck to form the window opening in the concrete wall.
 Advantageously, the window buck is reusable after being removed from the
 concrete wall.
 In a presently preferred embodiment, the window buck is a two-piece
 component including a generally rectangular mold nested within a generally
 rectangular frame. The mold is preferably roto-molded and includes an
 extension which telescopically fits within the preferably aluminum frame.
 The frame and mold are removable in opposite directions from the poured
 concrete wall. The window buck advantageously forms a raised ledge along a
 sill of the window opening proximate an interior side of the poured
 concrete wall to inhibit water from flowing through the window opening
 toward the interior side of the poured concrete wall. The raised ledge is
 positioned against an inner face of the window frame or window. Moreover,
 the window buck forms a protruding rim along a jamb at each side of the
 window opening against which an outer face of the window or window frame
 is positioned when installed in the window opening.
 A component of the system according to a presently preferred embodiment of
 this invention is a retainer coupled to the window buck while the concrete
 is being poured so that the retainer is preferably partially embedded in
 the concrete wall proximate the window opening. The retainer preferably
 includes two frangible members which couple the retainer to the window
 buck so that upon removal of the window buck from the window opening the
 frangible members are broken leaving the remainder of the retainer
 embedded in the concrete wall. The frangible members are seated within
 holes preferably in the mold of the window buck for coupling the retainer
 to the window buck during installation thereof and subsequent pouring of
 the concrete.
 The retainer in a presently preferred form includes a socket which is
 exposed when the retainer is embedded in the concrete wall and is located
 along a side edge of the window opening. A window or window frame is
 easily snapped into the window opening and retained therein by a spring
 clip or other device mounted on a side edge of the window frame or window.
 The spring clip temporarily deflects inwardly while the window or frame is
 being installed until the clip is seated within the socket of the embedded
 retainer. Accordingly, the installation of the window or window frame is
 easily accomplished without tools or additional fasteners such as nails,
 screws or the like.
 The window buck and retainer are accurately and robustly mounted between
 the wall forms by a suspension member which in a first presently preferred
 embodiment is a pair of elongate bars inserted through associated sleeves
 in the frame of the window buck. When inserted in the sleeves, the bars
 project outwardly from the window buck to rest along a top edge of the
 wall forms. Preferably the window bucks include a plurality of sleeves at
 different positions so that a user may select the appropriate sleeve for
 the position of the window buck and resulting window opening in the poured
 concrete wall.
 If a lintel is formed in the poured concrete wall, a second presently
 preferred embodiment of the suspension member is used and includes a
 lintel drop projecting downwardly from the bar. A terminal end of the
 lintel drop includes a key which mates with a keyhole slot in the mold to
 selectively couple the window buck to the suspension member bar.
 With the system and associated method according to this invention, a window
 opening is reliably formed in the desired location in a poured concrete
 wall without damaging a reusable and robust window buck. Moreover, a
 window is efficiently and conveniently installed in the window opening
 without the need for tools or additional fasteners in an easy, efficient
 and economical manner.

DETAILED DESCRIPTION OF THE INVENTION
 Referring to FIGS. 1 and 2, a presently preferred embodiment of a window
 buck 10 according to this invention is shown. The window buck 10 includes
 a generally rectangular and preferably aluminum frame 12 which is sized
 and configured to nest with a generally rectangular mold 14. The mold 14
 according to a presently preferred embodiment is roto-molded with a foam
 filled shell of medium density polyethylene. The shell thickness is
 preferably within a range from about one-sixteenth inch up to about
 one-eighth inch. The mold 14 includes a generally rectangular telescopic
 extension 16 which snugly fits within the interior of the frame 12 as
 shown in FIG. 2. The telescopic extension 16 is generally rectangular with
 reinforcing triangular shaped webs 18 in each corner of the extension for
 added support and rigidity. Upper and lower members of the telescopic
 extension 16 each include a pair of spaced notches 20 for receipt of
 reinforcing generally vertical ribs 22 on the frame 12 when nested
 therewith. The ribs 22 on the frame extend between upper and lower frame
 members. Similarly, notches 24 are provided in the end walls of the
 telescopic extension 16 for receipt therein of an optional cross brace
 (not shown) extending laterally within the frame 12.
 The frame 12 includes a plurality of generally tubular rectangular-shaped
 sleeves welded or otherwise secured thereto. A lower pair of sleeves 26
 are mounted on the exterior faces of the ribs 22. An upper pair of sleeves
 28 are mounted on the upper face of the upper frame member. Preferably,
 the exterior face of each member of the frame 12 is tapered or sloped
 downwardly from an outer edge spaced from the mold 14 toward an inner edge
 thereof adjacent to the mold 14. The frame 12 includes a hole 30 on the
 exterior face of each side frame member and a hole 32 in a comparable
 position on the interior face of each side frame member confronting the
 mold 14. The holes 30, 32 are sized and positioned so that a retainer 34
 can be coupled to the window buck 10 prior to installation and use of the
 window buck 10.
 The mold 14 includes a generally rectangular peripheral case 36 which on
 lateral sides thereof includes a tapered section 38 and a transition
 section 40 generally perpendicular to a vertical bulkhead 42 which is
 juxtaposed against the interior face of the frame 12 nested therewith. The
 mold 14 also includes a lower shelf 44 spaced from the telescopic
 extension 16 and extending the length of the mold 14. A pair of spaced
 keyhole slots 46 are formed on the upper edge of the case 36 proximate the
 vertical bulkhead 42 thereof. Each keyhole slot 46 is sized and configured
 to receive therein a key 48. The key 48 is part of a first presently
 preferred embodiment of a suspension member 50 and has a generally
 barrel-shaped cylindrical configuration and is located on a terminal end
 of a cone or lintel drop 52 which projects downwardly from a generally
 rectangular plate or suspension bar 54.
 A presently preferred alternative embodiment of the suspension member 50
 for use with the window buck according to this invention is shown in FIGS.
 2 and 3. The alternative embodiment of the suspension member 50 is a
 generally planar rectangular suspension bar 54 which is sized and
 configured to be inserted through one of the sleeves 26, 28 in the frame
 12. Sleeves 26, 28 are provided in multiple locations to provide for
 different orientations and placement of the window buck 10.
 As shown in FIG. 2, the lateral width of the frame 12 is greater than the
 lateral width of the mold 14 proximate the bulkhead 42 to thereby produce
 an offset 56 when the mold and frame are nested together. Similarly, the
 depth of the shelf 44 of the mold 14 is less than that of the frame 12
 nested with the mold 14 thereby providing an offset 58 extending the
 length of the window buck 10 along a lower edge thereof.
 Specifically referring to FIG. 3, the suspension bars 54 when inserted
 through the upper sleeves 28 position the window buck 10 in an
 intermediate position with each suspension bar 54 extending across the top
 edges of spaced wall forms 60 sandwiching therebetween the window buck 10.
 Concrete 62 is poured between the wall forms 60 and allowed to cure
 thereby forming a poured concrete wall. A presently preferred embodiment
 of the wall form 60 is disclosed in U.S. Pat. No. 60/071,758 filed Jan.
 16, 1998, offered for sale by the assignee of this invention and hereby
 incorporated by reference. The window buck 10 diverts the poured concrete
 62 thereby forming a window opening 64 in the concrete wall, as shown
 particularly in FIG. 4. Anchor bolts 66 are commonly provided along the
 top edge of the poured concrete wall 62 for the construction of a house
 and attachment of a cap member (not shown) or the like as is readily known
 by those skilled in the art. The lower sleeves 26 in the frame 12 are
 utilized to position the window buck 10 in an alternative and higher
 position than the upper sleeves 28. The sleeves 26, 28 are utilized with
 the suspension members 50 to produce the window opening 64 in the poured
 concrete wall 62 which does not include a lintel 68. The suspension member
 50 with lintel drop 52 and key 48, as shown in FIGS. 1 and 5, is utilized
 with the window buck 10 of this invention to suspend the window buck 10
 between the spaced wall forms 60 when the lintel 68 is to be formed along
 the top edge of the window opening 64, as is readily understood by one of
 ordinary skill in the art. The poured concrete 62 surrounds the window
 buck 10 and lintel drop 52 thereby forming the lintel 68.
 Referring to FIGS. 8 and 9, a presently preferred embodiment of the
 retainer 34 according to this invention is shown. The retainer 34 is
 secured between the bulkhead 42 of the mold 14 and the interior face of
 the frame 12 when the frame 12 and mold 14 are nested together. The
 retainer 34 is preferably molded from any one of a number of suitable
 plastics such as polyethylene or the like. The retainer includes a
 generally L-shaped body having a first longer leg 70 and a second shorter
 leg 72 extending perpendicularly thereto. A T-shaped anchor tab 74
 projects rearwardly from the longer leg 70 of the retainer 34 in an
 opposite direction from the second leg 72. The anchor tab 74 is buttressed
 by a pair of generally triangular-shaped gussets 76 on opposite faces of
 the anchor tab 74.
 The retainer 34 includes a generally rectangular socket 78 formed in a face
 of the first leg 70 opposite from the anchor tab 74. The retainer 34 also
 includes a pair of frangible members projecting from terminal ends of each
 of the legs 70, 72. The first frangible member is in the form of a boss 80
 projecting perpendicularly from the short leg 72 proximate a terminal end
 thereof. The boss 80 is reinforced by a number of spaced webs 82 located
 along the barrel thereof.
 The second frangible member is in the form of a pin 84 which is received
 within a hole 86 in a tab 88 projecting from the terminal end of the
 longer leg 70 of the retainer 34. The pin 84 is oriented generally
 perpendicularly to the long leg 70 and can be selectively positioned to
 and between a retracted position as shown in FIG. 8 and an extended
 position as shown in FIG. 9. The pin 84 includes a generally cylindrical
 head 90 joined to a neck 92 region thereof. The neck 92 snugly fits within
 the hole 86 in the tab 88 of the retainer 34 when the pin 84 is in the
 extended position. The pin 84 also includes a shaft 94 having a helical
 thread 96 formed on an exterior surface thereof. The pin 84 is retained in
 the hole 86 in the tab 88 by a thin web 98 covering the hole 86 until the
 pin 84 is pushed into the extended position thereby rupturing the web 98
 and seating the neck 92 within the hole 86.
 With the pin 84 in the retracted position, the retainer 34 is easily
 coupled to the frame 12 of the window buck 10 by sliding the long leg 70
 in face to face contact with the exterior surface of the side frame member
 until the boss 80 is seated within the hole 32 on the interior face of the
 side frame member. In this position, the pin 84 in the retracted position
 is aligned with the hole 30 in the face of the side frame member and can
 be then manually or otherwise inserted therein to securely couple the
 retainer 34 to the frame 12. The helical threads 96 increase the
 frictional interaction between the pin 84 and the hole 30.
 After the concrete 62 has been poured and allowed to cure and the wall
 forms 60 removed from the poured concrete wall, the shaft 94 of the pin 84
 and the boss 80 are easily broken or severed from the frame 12 as the
 frame 12 is removed from the window opening 64. The anchoring tab 74 and
 adjacent surfaces of the retainer 34 are embedded in the poured concrete
 wall 62 with the socket 78 and adjacent faces of the legs 70, 72 exposed
 along a side of the window opening 64, as shown in FIG. 4. The
 configuration of the anchor tab 74 increases the holding power of the
 concrete 62 to securely hold the retainer 34.
 One presently preferred method of installing a window 100 in a poured
 concrete wall 62 according to this invention begins with erecting the pair
 of spaced wall forms 60. The retainer 34 is then coupled to the window
 buck 10 with the frangible members 80, 84 inserted into the corresponding
 holes 30, 32 in the frame 12 as previously described. The retainer 34 and
 window buck 10 are then suspended between the spaced wall forms 60 with
 any one of the suspension members 50, as shown in FIGS. 1-3 and 5,
 depending upon the desired position of the window opening 64 in the poured
 concrete wall 62. Concrete is then poured between the spaced wall forms 60
 and around the window buck 10 thereby partially embedding the retainer 34
 in the poured concrete. After the poured concrete is allowed to cure, the
 wall forms 60 are dismantled and the retainer 34 is uncoupled from the
 window buck 10 by severing, breaking or otherwise fracturing the frangible
 members 80, 84 from the retainer 34. The frame 12 and mold 14 are then
 pulled in opposite directions from the window opening 64 in the poured
 concrete wall 62. The frame 12 is pulled toward the interior of the wall
 62 whereas the mold 14 is pulled toward the exterior of the wall 62 to
 thereby remove the components from the window opening 64. While a
 two-piece window buck 10 is shown and described, other designs are
 contemplated within this invention.
 The offset 58 between the shelf 44 of the mold 14 and the frame 12 forms a
 raised ledge 102 on a sill 104 of the window opening 64. The raised ledge
 102 of the sill 104 advantageously prevents the ingress of water or other
 moisture to the interior of the concrete wall 62 when the window 100 is
 seated on the sill 104 as shown in FIG. 6.
 The offsets 56 between the side frame members and the case 36 form a rim
 106 along each jamb 108 of the window opening 64. Furthermore, the jamb
 108 and rim 106 members in the poured concrete wall 62 inhibit the window
 100 from being pulled from the window opening 64 from the exterior of the
 poured concrete wall 62 as a security measure.
 The window 100 to be installed in the window opening 64 according to a
 presently preferred embodiment of this invention has a generally
 rectangular or other shaped configuration. The window 100 preferably
 includes a perimeter frame 110; although, other window constructions or
 types can be used, such as glass blocks or the like, that may not include
 a perimeter frame. Preferably, the perimeter frame 110 of the window 100
 includes an insulation 112 or weather strip seal extending around the
 periphery thereof. A metal spring clip 114 or other type of preferably
 outwardly biased device or the like is mounted by a bolt, screw or other
 fastener 116 to a side edge of the window frame 110 as shown in FIG. 6 for
 snap-fit engagement with the socket in the embedded retainer 34. While the
 spring clip 114 is a presently preferred embodiment, it should be
 understood that any of a variety of other devices, whether biased or not,
 are encompassed within this invention. The spring clip or other device is
 advantageously mounted on the window 100 or window frame 110 prior to
 installation for easier and simpler installation without the need for
 additional mechanical fasteners or tools during installation.
 The window 100 is installed from the interior of the poured concrete wall
 62 by seating a bottom edge of the window 100 or frame 110 along the sill
 104 of the window opening 64 with the raised ledge 102 juxtaposed to an
 interior face of the window frame 110 or window 100. The window 100 is
 then pivoted upwardly toward the jamb members 108 formed in the window
 opening 64 until an exterior face of the frame 110 seats against the rims
 106 on the jambs 108 at the side edges of the window opening 64. The
 spring clips 114 temporarily deflect inwardly as the window 100 is pivoted
 upwardly and then spring out to extend into the sockets 78 of the
 retainers 34 and thereby secure the window 100 in the window opening 64.
 The window 100 can be selectively removed from the window opening 64 by
 inserting a hook-shaped tool or other device (not shown) between the
 window frame 110 and the jamb 108 to deflect the spring clip 114 on the
 window 100 inwardly and unseat it from the socket 78 and retainer 34 and
 then pivot the window 100 toward the interior of the poured concrete wall
 62 for removal.
 As a result, the window 100 is easily installed in an efficient manner
 without the need for additional tools or fasteners to secure the window
 100 into the formed window opening 64 in the concrete wall 62. Moreover,
 the window buck 10 used in forming the window opening 64 can be cleaned
 and subsequently reused thereby minimizing the cost for the construction
 of the poured concrete wall 62 and window opening 64 therein.
 From the above disclosure of the general principles of the present
 invention and the preceding detailed description of at least one preferred
 embodiment, those skilled in the art will readily comprehend the various
 modifications to which this invention is susceptible. For example,
 numerous other configurations and/or designs for the window buck, retainer
 and spring clip are possible within the scope of this invention.
 Therefore, we desire to be limited only by the scope of the following
 claims and equivalents thereof.