Abstract:
A flush plug and a collar are used in installing a drain or cleanout. A flush plug is temporarily attached to the nipple of a cleanout or to a drain base and leveled. Concrete is then poured flush with the top of the flush plug. After the flush plug is removed from the cured concrete, a collar is installed in the hole in the concrete left by the flush plug. The outside of the lower portion of the collar is beveled like the flush plug. The upper portion of the collar includes a sleeve rising above the top surface of the surrounding concrete by an amount equal to the thickness of the specific floor finish. Tile or other finish may then be laid to around the collar. The installed drain will be flush and level with the flooring around it.

Description:
PRIORITY CLAIM 
     Priority is claimed to U.S. provisional patent application Ser. No. 61/356,773 filed 21 Jun. 2010, which is incorporated herein in its entirety by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     Drains and cleanouts are installed near the beginning of construction of a residence, business office or industrial facility, typically just before the concrete floors are poured. Construction may continue after that for months or several years. If the floor is finished with concrete, of course, the drain will be set flush with the top of the concrete pour. When the concrete is poured around drains in a floor that is to be finished using tile, the drain must sit above the top surface of the concrete by a sufficient margin to allow for the thickness of the tile and grout, adhesive or other securement so that, when the tile is installed around the drain, the top surface of the tile will be level with the top surface of the drain. The amount the drain sits up above the concrete prior to tile installation varies with the type of tile to be used, such as for example, ⅛″ (3.175 mm) up from the surface of the concrete for VCT (vinyl composite tile); ½″ (6.35 mm) up from the surface of the concrete for porcelain tile (⅛″ grout plus ⅜″ tile); 2″ (51 mm) up from the surface of the concrete for ceramic tile (½″ tile plus 1½″ grout bed). Other floor finish materials may vary in thickness. 
     During construction, the drains and cleanouts are subject to abuse from the on-going construction work taking place around them, such as the impact of heavy objects and lateral forces caused, for example, by forklifts driving over them carrying pallets of blocks, steel, and other loads. Exposure to weather may cause drains to corrode, rust or tarnish. To provide some protection for drain covers, they may be covered with duct tape. Tape may provide protection from weather exposure but is little protection from abuse. After a while, tape tends to peel off, or it may be scraped off. At that point, water may wash concrete, dirt, and rocks into the drain. 
     Construction engineers will visit job sites regularly to inspect and note defects. Drains and cleanouts that are damaged or broken will be noted and their replacement demanded. Replacement requires breaking up the concrete around the drain, providing a new drain, and patching the concrete floor around the replacement drain. A damaged or broken drain can be expensive to fix, and the floor around it will be, and will look like, “a patch job.” 
     Although the drains and cleanouts are installed near the beginning of construction, the area around the drain or cleanout is finished near the end of the process. At this point, all heavy construction has been completed and the building is protected from weather. 
     Concrete finishers use 10′ (30.5 cm) to 15′ (46 cm) screen boards to pull the concrete flat. When a drain sits up higher than the level of the concrete, the board must be picked up and moved over the drain. This requirement results in a rougher finish in the area immediately around the drain. When the concrete sets and becomes firm, a power screed machine is used to obtain a smooth finish. Because the drain sits higher than the concrete, the screed must be maneuvered around the drain. Finishers will then use a hand trowel to smooth the concrete around the drain, visually maintaining the clearance of the drain by a distance above the finished concrete sufficient for the thickness of grout and tile. If they leave too much concrete, the drain will not sit up high enough to match the tile&#39;s top surface, and the excess concrete will need to be removed by chiseling or grinding. If the finisher pulls too much concrete away, then the drain will sit too high and floor fill material will be spread around the drain to bring the concrete surface even with the tile top surface. Drains sitting lower or higher than the tile are a tripping hazard. Drains may not be level and be flush on one side but a little higher or lower on the opposing side. Whenever the drain and surrounding tile are not level, both appearance and safety are adversely affected. 
     SUMMARY OF THE INVENTION 
     The present invention overcomes the problems associated with the prior art by using a kit for installing a drain. The kit includes a flush plug and a collar as well as the drain base. The flush plug is a temporary cover that attaches to the threaded, adjustable nipple of a cleanout or to a threaded, adjustable drain base. The drain cover is stored safely during construction so it is not damaged or exposed to weather or wear. The flush plug is not set at the elevation of the drain but rather at the elevation to which the concrete is to be poured. Concrete is then poured flush with the top surface of the flush plug, making it much easier to obtain a smooth, even finish around the drain. Hand trowels and screeds can be worked over the flush plug and drain as if they were any other part of the concrete surface; they do not have to be avoided as in the case of the prior art drain cover. Moreover, the top surface of the flush plug indicates to the pourer of the concrete when the amount of concrete is sufficient because its top surface is at the right level for the pour. He just needs to stop pouring concrete when the concrete is flush with the top surface of the flush plug. Accordingly, the flush plug&#39;s top surface serves as a guide for that level. 
     When it is time for the finished floor to be installed, the flush plug is removed. The shape and design of the flush plug makes it easily removable. To facilitate removal of the flush plug from the surrounding, cured concrete, it is formed with a threaded hole in the center of the plug&#39;s top surface. The threaded hole is fitted with a plastic insert that sits even with the top surface of the flush plug during construction, and keeps out concrete and dirt. The insert can be popped out with a screwdriver or knife, revealing a ⅜″ (9.5 mm) bolt screwed into the hole for use in lifting the flush plug from the surrounding poured concrete. In addition, the flush plug is tapered slightly (⅛″ (0.32 mm)) from top to bottom so it can be easily removed from the cured concrete, leaving a tapered hole behind. The flush plug may also carry a bulls-eye bubble level to set a level drain. 
     After the flush plug is removed, the collar can be installed in the same, tapered hole in the concrete as was left by the flush plug. The outside of the lower portion of the collar is tapered exactly like the flush plug so it fits perfectly into the tapered hole left in the concrete by the flush plug and on top of the cleanout nipple or drain base below. The upper portion of the collar serves as a sleeve extension to raise the top surface of the collar above the surrounding concrete by the exact amount required for the specific floor finish specified for that floor. 
     The bottom of the collar may be sized to fit on the threaded adjustable nipple of the cleanout body or to fit on the rim of the drain base turning down into the drain base. The top portion of the collar is shaped to hold the drain top cover. The bottom of the collar sits on the drain base. The upper portion of the collar extends vertically above the concrete so that tile, when installed, can butt against the collar level with the collar&#39;s top surface. Screws are used to anchor the collar to the drain base. A small tube of silicone caulk seals the collar to the base. By applying a small bead of the silicone caulk to bottom of collar where it meets the base, and a small bead around the top of the beveled edge of collar where it meets the top surface of the concrete, the drain or cleanout will have a water-tight seal with the floor. 
     Before installing the collar, a user may vacuum dust and dirt from the drain base and concrete hole to ensure a proper fit and seal. 
     The flush plug assures a smooth, even concrete surface around drain for the collar, and the collar assures that the drain and cleanout tops are set level and to the proper height above the concrete so that they will be level with the top surface of the finished floor. Accordingly, the installed drain with its top cover in place will have a smooth, finished and professional appearance that sits level and flush with the surrounding floor. In addition to the better finished appearance, the present method and system saves money and time by reducing the likelihood that the drain will need to be repaired between the time the concrete is poured and the drain surrounds are finished at the conclusion of construction. 
     Flush plugs can be made to fit various drains and cleanouts, and collars can be made to correspond to any floor finish thickness. Cleanout and drain bases may be shipped with a flush plug installed on the base at the factory, ready to be set in concrete. Collars and top covers may be packaged and shipped separately so they can be ordered closer to the time when needed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the figures, 
       FIGS.  1 A and  1 B—side and top views of flush plug for a round floor drain or cleanout, according to an embodiment of the present invention. 
       FIGS.  2 A and  2 B—side and top views of flush plug for square floor drain, according to another embodiment of the present invention. 
       FIGS.  3 A and  3 B—side views of collar made to fit in a void in concrete left by a flush plug as illustrated in  FIGS. 2A and 2B , respectively. 
       FIGS.  4 A and  4 B—side and top views, respectively, of a collar anchor screw, according to an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention is a method and system for installing a drain or cleanout. The word “drain” will be used herein to represent both a drain and a cleanout in order to simplify the description of the present invention that follows and in the claims that follow. The improvement of the present method begins after installation of a drain base for a drain and the installation of the adjustable nipple for a cleanout. The term “drain base” will be used herein for a drain base and for the adjustable nipple of a cleanout. 
     The present drain installation kit includes three major components (and may be provided as part of a larger kit that also contains the components for forming a drain base). The kit includes a tapered flush plug formed to be securable to the drain base. The flush plug has a top surface that is set at a first pre-selected height above the drain base by selecting the size flush plug needed to achieve that pre-selected height in order to match the level of concrete to be poured around the drain. The kit includes a tapered collar also formed to be securable to the drain base in place of the flush plug. The collar has a top edge and is also selected to be securable to the drain base so that its top edge is set above the drain base by a second pre-selected height in order to match the level of the flooring to be laid around the drain cover. Finally, the kit includes a drain top cover formed to be securable to the collar within its top edge. Of course, fasteners and sealant may also be provided to secure the flush plug and collar to the drain base and the top cover to the top collar as part of the present kit. 
     The flush plug may have a threaded hole formed therein for use in temporarily securing a handle, such as a bolt, to the plug. The hole may be fitted with an insert until the hole is needed for attaching the handle. The flush plug may also include a level indicator such as a bull&#39;s-eye level. 
     The present method involves several steps. Initially, a prior art drain base with a factory installed flush plug, is installed on the drain pipe so that the top surface of the flush plug is at a first pre-selected height above the drain base. Then a tapered flush plug is secured to the drain base using provide screws so that the top surface of the flush plug is brought to a first pre-selected height above the drain base. This first pre-selected height is the level to which the concrete floor around the drain should be poured. The top of the flush plug will thus serve as a guide for those pouring the concrete so that they do not pour too little or too much concrete. Furthermore, because the top surface of flush plug is flush with the poured concrete, finishing the concrete is simplified; the usual tools will ride over the top surface and do not have to go around it. 
     The flush plug should be checked with a level indicator to see that it is level after it and the drain base are fastened to the drain pipe. Concrete is then poured around the flush plug until it is level with or flush with the top surface of the tapered flush plug. After the concrete cures, the flush plug can be removed, leaving a tapered hole in the cured concrete. Because the flush plug was level, the vertical axis of the hole is also vertical. 
     Next, after vacuuming any dirt and debris out of the drain, a collar is placed on the drain base. The collar has a top edge and is then secured with, screws, such as collar anchor screws described below, to the drain base so that the top edge of the collar is at a second pre-selected height above the base. The difference between the first and second pre-selected heights is the thickness of the flooring to be installed on the concrete, bringing the surface of the floor with the installed flooring flush with the leveled drain. 
     The flooring is then laid on the concrete and the top cover is secured with screws within the top edge of the collar. 
     Referring now to  FIGS. 1A and 1B , the present system includes a flush plug  10  that is used temporarily during construction to cover a prior art drain base (not shown) and which is inserted onto the drain base. After it is removed toward the end of construction, flush plug  10  may then be disposed of or reused elsewhere. Using flush plug  10  avoids the damage to the permanent drain that often occurs during construction.  FIGS. 1A and 1B  are side and top views of flush plug  10 . Flush plug  10 , as illustrated in  FIGS. 1A and 1B , is circular and tapered from top to bottom so that the bottom  22  has a smaller diameter than top surface  24 . Flush plug  10  is preferably made of plastic or nylon. It may have several holes about the periphery of top surface  24 , such as three counter-sunk holes  26 , for receiving anchoring screws (not shown) to secure flush plug  10  to the drain base (not shown) through corresponding holes in the drain base. It may also have a hole  28 , such as a ⅜ th  inch threaded hole, which may be formed in the center of top surface  24 , with an insert  30  to temporarily cover hole  28 . Flush plug  10  may have a bull&#39;s-eye bubble level  31  incorporated into it. 
     When flush plug  10  is to be removed, insert  30  is first pried off, perhaps with a screw driver or knife, then a ⅜ th  inch bolt (not shown) is threaded into hole  28  to serve as a convenient, temporary handle used to lift flush plug  10  from the surrounding concrete. Flush plug  10  can be removed by pulling on the bolt. 
       FIGS. 2A and 2B  illustrate side and top views, respectively, of a square flush plug  12 . Note the ledge  32  along the bottom edge of flush plug  12  where flush plug  12  will sit securely on a square drain base. Flush plug  12  has a top surface  34  and a bottom surface  36 , with counter-sunk holes  38  for receiving screws to hold it to the drain base. Flush plug  12  has an insert  40  that fits into a threaded central hole  42 . As with flush plug  10 , insert  40  is removed to allow a bolt to be threaded to hole  42  of flush plug  12  to facilitate its removal from surrounding, cured concrete. 
     Different drains may have different shapes and sizes and hole patterns. Flush plugs may be shaped and sized and have hole patterns that correspond to the drain specified by the builder, except that each flush plug will have beveled sides so that, after the concrete is poured even with the top surface of flush plug and the concrete cures, the flush plug can be easily removed from the drain base, leaving behind a beveled and leveled hole in the surrounding concrete. 
     For large drains, that require a large flush plug, a support pipe  37  (see  FIGS. 2A and 2B  may be used to support to the center portion of flush plug  34  against the inside of the drain base. Support pipe may be section of polyvinyl chloride piping preferably set with its top within a circular recess formed in flush plug  37  and having a bottom beveled to engage the sloping part of drain base. Support pipe  37  is removed with flush plug  34  when the concrete poured around it has cured. 
       FIGS. 3A and 3B  are a side view of a collar  50  and cross sectional views of collar  50  in place and when the area surrounding the drain is finished, respectively.  FIG. 3A  shows collar  50  that corresponds to square flush plug  12  illustrated in  FIG. 2A  from the side;  FIG. 3B  illustrates in cross-section collar  50  in place on a drain base  52  and with top drain cover  54  installed and fastened on collar  50  into collar anchor screw  55 . Collar  50  has the same shape and size as the flush plug  12  including ledge  56  to correspond to ledge  32  as shown in  FIG. 2A  except for the addition of an upper, vertical top edge  58 . The lower, beveled portion  60  of collar  50  fits into the hole  62  made in concrete  65  made by flush plug  12  for that drain. The top edge  58  extends above hole  62 . Note that the height of top edge  58  of collar  50  is sized to equal the thickness of the adjacent tile  64  including its grout  66  so that the top surface of the top drain cover  54  and collar  50  are flush with the top surface of tile  64 . So that the top surface of tile  64  is flush with the top surface of drain cover  54 , the height of top surface  34  above drain base  52  is pre-selected to determine the top of concrete and the top edge  58  above drain base  52  is pre-selected to determine the top surface of tile  64 . The difference is the thickness of tile  64  and the grout or adhesive that holds it to the concrete. 
     Referring now to  FIGS. 3B ,  4 A and  4 B, there is illustrated a collar anchor screw  70  that secures collar  62  to drain base  52  and enables top drain cover  54  to be secured to collar anchor screw  70 . Anchor screw has external threads  72  at a lower end  74  and an internal threaded hole  76  at an opposing upper end  78  that is radially wider than lower end  74  so as to be able to receive a screw  80  to hold top cover drain to collar  62  (best seen in  FIG. 3B ). Anchor screw  70  has a transverse slot  82  formed in upper end  78  dimensioned to receive a flathead screw driver that can be used to turn anchor screw  78  and thereby screw lower end  74  into drain base  52 . Holes dimensioned to receive anchor screw are pre-drilled into collar  62  and drain base  52 . 
     With only straight-forward changes, the flush plug and collar can be adapted to accommodate a wide variety of shapes of pre-existing drains and cleanouts. Flush plugs can be made of PVC, ABS, nylon or high density plastic. Fiberglass and coated wood may also be used. Manufacturing cost and durability on materials determine the appropriate choice as well as whether the flush plug is to be re-used. Flush plugs that span larger drains may be supported by a section of pipe, such as polyvinyl chloride (PVC) pipe. The pipe is placed with its axis oriented vertically between the drain base and the bottom of the flush plug. A small annular groove cut in bottom of the flush plug keeps pipe centered and in place. Used flush plugs may be returned to manufacturer to be used again, if so desired. 
     Those skilled in the art of floor drains and cutouts and their installation will appreciate that many changes and modifications can be made in the foregoing embodiments without departing from the spirit and scope of the present invention, which is defined by the appended claims.