Abstract:
A self-checking anchor bolt suspension assembly includes an array of suspension segments color coded in accordance with the size of the bolt suspending openings formed therein. The threaded shaft of the appropriate anchor bolt is inserted into the properly spaced opening and then grasped in the interior of a resilient split-tube retainer that then rests on the edges around the opening to suspend the bolt therefrom. The segments are then nailed to the concrete form and their correct color code assures the correct bolt selection.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to concrete form framing and positioning structures, and more particularly to a method and apparatus for securing concrete forms and suspending anchor bolts therein prior to pouring concrete. 
         [0003]    2. Description of the Prior Art 
         [0004]    Pouring wet concrete into temporary forms that determine its eventual shape is a process that occurs with substantial frequency in the course of virtually all construction. In each instance, form integrity against distortion by the weight of the wet concrete and the correct placement retention of various anchors that are to be captured in the hardened concrete are matters of constant concern as cured concrete is absolutely unforgiving of all oversights and mistakes. These concerns over the shape and placement dimensional fidelity are therefore a subject of repeated attention from various governmental and private supervisors and inspectors. 
         [0005]    In the past various mechanisms have been devised which in one manner or another suspend anchoring bolts between the walls of a concrete form to be thereafter immersed to the desired depths and at the desired location once the concrete is poured into the form. Examples of such suspending structures can be found in the teachings of U.S. Pat. No. 7,103,984 to Kastberg; U.S. Pat. No. 5,060,436 to Delgado, Jr.; U.S. Pat. No. 4,736,554 to Tyler; and others. While suitable for the purposes intended each of the foregoing describes what is essentially a positioning template for an anchor bolt devoting only a limited focus to concerns over selection and form integrity and inspection convenience. 
         [0006]    Those prior art references that appear to attend, at least in part, to form integrity concerns, as exemplified in U.S. Pat. No. 5,240,224 to Adams; U.S. Pat. No. 7,225,589 to Smith; and also the published continuation in part thereof US 2006/0016140 fail to address the inspection convenience of the anchor bolt selections and placements before the concrete is poured. In large building projects that predominate the industry now this inattention to inspection convenience tends to raise labor costs as employees and equipment stand by to allow the inspectors to finish their job. 
         [0007]    Those in the art will appreciate that proper attention to the inspection process has its own inherent benefits. Anticipating the arrival of an inspector will direct the focus of the construction workers to the details that are a part of the inspection check list and these same details are, of course, also the significant aspects of the quality of their work product. Anchor bolt locating mechanisms that are not only useful for their primary function but also useful in enhancing selection and form integrity while assisting the inspection process will, by these combined features, assure proper attention to this detail. A mechanism that accommodates this combination of features is therefore extensively desired and it is one such device that is disclosed herein. 
       SUMMARY OF THE INVENTION 
       [0008]    Accordingly, it is the general purpose and object of the present invention to provide an anchor bolt suspending structure that is also useful to brace the concrete form, that is sized and visually identifiable in coordinated association with several anchor bolt sizes, and that is easily affixed to and removed from the concrete form. 
         [0009]    Other objects of the invention are to provide an anchor bolt suspending combination that protects the exposed threads thereof from inadvertent coating by wet cement. 
         [0010]    Further objects of the invention are to provide a deployment method for anchor bolts in concrete forms that by the dimensional selection of components used therein determines the appropriate anchor bolt choice and the appropriate spacing thereof from the form edges. 
         [0011]    Yet additional objects of the invention are to provide a process for mounting anchor bolts for immersed capture in poured concrete that includes visual indications of the bolt size and its deployed spacing relative the concrete form walls while also providing bracing therefor. 
         [0012]    Briefly, these and other objects are accomplished within the present invention by providing a plurality of generally rectangular, flat, polymeric segments each of a longitudinal dimension that is equal or greater than the customary width of a stem wall, concrete footing or other structure formed by pouring wet concrete into a form. Preferably both sides of each segment are scribed with transverse grooves, or visibly indented transverse guide marks, spaced from each other by dimension increments conforming to the customary dimensions of the sill or base piece of a framed wall. In the United States, for example, these customary framing lumber dimensions are 2 by 4 inch, 2 by 6 inch, 2 by 8 or even by 10 inch nominal, selected by the load that is to be carried by the wall, the depth needed for adequate insulation thickness that may be demanded by the local climate, potential local earthquake shear loads, and so on. 
         [0013]    These same loading concerns also demand that the sill or base piece forming the wall be firmly anchored to the footing or slab. For these reasons anchoring bolts, sometimes referred to a J-bolts, are suspended to extend into the form before the wet concrete is poured, the spacing therebetween, their depth of immersion into the concrete and the thickness of their shanks being again determined by the loads that are to be carried therein. Since it has been well appreciated in the construction industry that the load transfer from a framed wall into the footing or foundation effected by an anchor bolt can be greatly enhanced by appropriately sized square washers or sill plates, the lateral spacing from the exterior form wall is also predetermined in coordination with the sill width and the sill plate dimensions. 
         [0014]    To facilitate this suspension of the severally sized anchor bolts each of the polymeric segments includes a plurality of equally sized circular holes or drillings spaced along the length thereof at spacing intervals that correspond to the sill plate dimensions associated with a one or another sill or base framing piece. Preferably these spaced holes on a segment are each of one common size selected to receive with a small clearance the threaded portion of a correspondingly sized anchor bolt, with the segments then color coded in accordance with the anchor bolt size that can be suspended therein. For example, a segment that is drilled to accept anchor bolts of only a 1¼ inch shank can be color coded bright yellow, a 1 inch shank may be color coded orange, a ⅞ inch shank color coded green, and so on. 
         [0015]    A set of polymeric, resiliently deformable split tube retainers are then positioned onto the threaded portions of the anchor bolt shanks that are inserted into the appropriate openings and project above the segment, grasping the bolt shank by resilient compression against the threads formed thereon. The resulting radial dimension increased by the thickness of the mounted retainer results in dimensional interference with the opening, thus effecting a suspending dimensional interference for the received bolt. Of course, once properly positioned the resilient retainers also provide an effective shield for the bolt threads against any splashing by the poured concrete. 
         [0016]    To insure a fool-proof bolt selection and suspension process the wall thickness of the split tube retainers is about equal to the smallest increment in bolt shank diameters. By providing a radial clearance between the appropriate bolt shank and its corresponding hole that is about one half this retainer wall thickness a resulting dimensional hierarchy is obtained where the improper hole-to-bolt shank selection is immediately revealed since a bolt shank that is too large for the hole just can not be inserted and a bolt that is too small will simply fall out even with the retainer mounted thereon. 
         [0017]    Those skilled in the art will appreciate that an appropriate bolt selection is effectively assured by this inventive dimensional hierarchy and once the appropriate color coding of the segments is determined to comply with the local building code the correct anchoring selection is immediately revealed. Similar considerations are also obtained by the spacing of the holes relative the transverse guide marks which can be labeled in coordinated groupings as corresponding to a 2 by 4, a 2 by 6 or 2 by 8, and so on, sill. These guide marks then set the proper transverse deployment of the segment on a form wall which then also properly spaces the suspended anchor bolt from the wall edge to accommodate the correctly sized sill plate. 
         [0018]    In this manner the inspector needs to check only the closest one of the bolt suspensions and thereafter just a generally observe for the proper color coding and similar alignment along the form edge to assure him or herself of the proper complement and position before the concrete is poured. Prior to the inspector&#39;s check this same complement also effects a self-checking process for the construction workers by the coordinated dimensional hierarchy obtained in the inventive combination. Once the coordinated details are observed the worker can then safely affix the complement to the form by driving double-headed nails through corresponding nail holes formed in each segment. 
         [0019]    It will be appreciated that these conveniences that the invention provides are not just useful in large construction projects, but are also useful to guide a novice along the rigorous path of proper construction practice. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]      FIG. 1  is a perspective illustration of the inventive anchor bolt positioning assembly affixed to the form defining structures that confine poured concrete; 
           [0021]      FIG. 2  is yet another perspective illustration, separated by parts, illustrating the cooperative parts and components of the inventive anchor bolt positioning assembly that when combined in accordance with the invention cooperate in a manner shown in  FIG. 1 ; 
           [0022]      FIG. 3  is a sectional view taken along line  3 - 3  of  FIG. 1 , illustrating the inventive dimensional interrelationships that assure correct selection and positioning of anchor bolts; 
           [0023]      FIG. 4  is a perspective illustration of an array of the inventive positioning assemblies deployed along one linear portion of a concrete form illustrating the inspection convenience thereof; 
           [0024]      FIG. 5  is a plan view of exemplary sets of suspension segments and their associated anchor bolts in accordance with the present invention; and 
           [0025]      FIG. 6  is a flow chart illustrating the sequence of steps effected in the course of use of the inventive anchor bolt positioning assembly. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0026]    As shown in  FIGS. 1-3 , the inventive anchor bolt positioning assembly, generally designated by the numeral  10 , comprises a generally rectangular, elongate segment  11  marked on both sides with transversely aligned grooves or guide marks  12  and including spaced along the length thereof a set of equally sized circular openings  14 . The threaded portion  15   t  of the shank or shaft of an appropriately sized anchor bolt  15 , sometimes referred to as a J-bolt, is then inserted from below into a selected one of the openings  14  to extend through the plate or segment  11  a projecting portion of the shaft for capture in the interior  21   i  of a resilient, longitudinally split tube section or retainer  21 . 
         [0027]    Preferably, the clearance between the opening  14  and the threaded portion  15   t  of the bolt shaft is less than the wall thickness of retainer  21  and once the threaded shaft portion is resiliently captured therein a retaining engagement of the bolt in the segment  11  is effected by the resulting dimensional interference and the lower bolt end  16 . Thus once the proper opening  14  for receiving an appropriately sized bolt shank  15   t  is selected an effective dimensional interlock is obtained by the engaged tube retainer  21 . 
         [0028]    Those skilled in the art will appreciate that this dimensional interlock is effective only in those instances where the bolt shaft can pass through the opening and also where the combined diameter of the bolt shaft  15   t  with the tube section  21  positioned thereon results in a dimensional interference with the periphery of opening  14 . Simply, smaller diameter bolts will fall out of the opening, even when captured by the split tube section, and the shank of the oversized bolt just won&#39;t fit at all into the any one of the equally sized openings  14  of the segment  11 . In this manner a coordinated interrelationship is inventively established between a particular set of segments  11  and a corresponding set of bolts  15  that is utilized to further advantage in accordance with the description following. 
         [0029]    By particular reference to  FIGS. 4 and 5  variously dimensioned segments  11  may be combined into a set shown as segments  11 - 1 ,  11 - 2 ,  11 - 3  and so on, with the correspondingly sized openings  14 - 1 ,  14 - 2  and  14 - 3  formed to match the shank diameters of the anchor bolts  15 - 1 ,  15 - 2  and  15 - 3  that is to be received therein. Thus, for example, segment  11 - 1  may be provided with openings  14 - 1  sized to receive an anchor bolt  15 - 1  having a 1¼ inch shank diameter, i.e., openings  14 - 1  of about 1 5/16 inch diameter. All the openings  14 - 2  in segment  11 - 2 , in turn, may be of a 1 1/16 inch diameter to receive the 1 inch shank of anchor bolt  15 - 2 , the openings  14 - 3  in segment  11 - 3  may be sized at a 15/16 th  inch diameter to receive the ⅞ inch diameter shanks of bolts  15 - 3 , and so on. 
         [0030]    In this manner a complementary relationship is established by this dimensional selection process where only the appropriately sized anchor bolt is retained in a corresponding segment and by distinctly coloring segments  11 - 1 ,  11 - 2 ,  11 - 3  and the others, e.g., yellow, orange, green and so on, a visual indication is provided that immediately informs any inspector or supervisor which anchor bolts are suspended into the form. To refresh recollection and/or assist in the comprehension of this color coding a legend card  35  may be provided to the inspecting or managing personnel with the color coding explained thereon. 
         [0031]    Those skilled in the construction business have long appreciated the convenience of standardized dimensional increments of available building materials. Simply, the needs of regional commerce require that only a limited variety of construction items be stored in inventory to avoid exorbitant storage costs and this variety differs from one part of the world to another. Recognizing these various dimensional conventions practiced throughout the world, no limitation is intended by the choice of the dimensional practices here in the United States in the description herein, the reference to such standardized dimensional increments being solely to effect a cogent explanation of the instant invention. 
         [0032]    The current construction practice in the US utilizes construction lumber in standardized 2 inch dimensional increments with a 12 inch width considered as a practical limit in the width of sawed lumber. Conforming to these practices, each of the segments  11 - 1 ,  11 - 2 ,  11 - 3 , and so on, are preferably of a 16 inch length with the transverse guide marks  12  spaced in equal 2 inch increments on both sides thereof, each interval between the guide marks also including a pair of laterally spaced nail holes  17  through which double-headed nails  18  are passed to attach the segment in a spanning attachment joining the lateral boards B 1  and B 2  of the concrete form. Of course, the 2 inch spaced guide marks  12  are then useful in aligning this generally orthogonal attachment relative the form boards B 1  and B 2  that are also the conventional 2 inch lumber stock. 
         [0033]    To conform with these same dimensional conventions the openings  14  are spaced from the ends of the segment  11  by increment groupings that each include the 2 inch overlap over the form boards B 1  or B 2  and also one half of the true dimension of standard construction lumber. Thus, for example, two of the openings  14  may be spaced from a first end  13   f  of segment  11  by 4.75 and 6.75 inches corresponding to nominal base or sill lumber widths of 6 or 10 inches while a second set of openings  14  may be spaced from the second end  13   s  by 3.75 and 5.75 inches corresponding to 4 and 8 inch sill lumber. Each of the openings thus spaced can then be appropriately marked by markings MM corresponding to these base plate dimensions. 
         [0034]    In this manner all the variables of anchor bolt placement are fully imbedded into the structure itself of the locating piece, i.e., the respective segment  11 . When properly effected visual inspection is greatly simplified by simply examining the locating details of one anchor bolt in a row of anchor bolts and thereafter observing from a distance the relative shank alignments of the rest, the color code of each segment, and the other observables that indelibly ascertain correct structural connections before the concrete is poured. Moreover, by selecting polymeric material structures like Nylon for the respective segments  11  and the split tube retainers  21  any unwanted concrete that may harden thereon is easily removed thus allowing conservation benefits obtained by the repeated use thereof. 
         [0035]    It will be appreciated by those skilled in the art that the foregoing complementing combination is particularly effective in assuring proper construction practices by the working personnel, as illustrated in the sequence shown in  FIG. 6 . Before even reaching for these cooperating parts the worker, in step  101 , must first determine the correct size of the bolt  15  and the correct dimension of the sill or base. Once this is determined the worker, in step  102 , selects the properly spaced opening  14  and thus the lateral spacing of the bolt from the outer form board B 1  or B 2  and suspends the bolt therein by the retaining section  21 . In step  103  the worker then nails the segments across the form boards while observing dimensional similarities. Then right prior to pouring the wet concrete into the form the assembly is inspected in step  104 . 
         [0036]    In this manner a simple, reliable and inexpensive array of cooperative elements assures compliance with the various building codes while also assuring an increased level of care to the several necessary details that must be observed before the unforgiving period during which the poured concrete sets up. 
         [0037]    Obviously many modifications and variations of the instant invention can be effected without departing from the spirit of the teachings herein. It is therefore intended that the scope of the invention be determined solely by the claims appended hereto.