Abstract:
Poured concrete floors and ceilings in buildings contain electrical conduit, air conditioning conduit, plumbing and junction boxes, for example. These conduits must withstand the rigorous activity of a construction floor and the concrete poured on them during the construction phase. Rod support structures made out of steel rod stock are used to hold the conduit and junction boxes in place on a temporary plywood floor in between rebar. The support structures have feet. The poured concrete floor covers the conduit, junction boxes and support structures. The footprint of each of the support structures is designed to be as small as possible by having minimum contact with a temporary plywood floor. When the plywood floor is removed, the support structures are substantially buried in the concrete. The concrete floor is underneath the feet, providing minimum exposure of the feet to the surface of the concrete next to the plywood floor.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of provisional application No. 61/077,849 filed Jul. 2, 2008 for Cast In Place Supports for Cast in Place Riser Pipes and Conduits, the entire subject matter of which is incorporated herein. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to form cast-in-place support structures for conduits, junction boxes and similar structures, and more particularly pertains to cast-in-place support structure for poured floor/ceilings in multiple story buildings or ground level pads. 
         [0004]    2. Description of Related Art 
         [0005]    Poured concrete floors in multiple story buildings contain rebar, electrical and plumbing conduit and other structures, like electrical connection boxes, which are contained with the poured concrete floor. Prior to a concrete pour, the area is a construction site with plumbers and electricians laying their conduits and cables and other workers, causing damage to conduits that are to be contained within the poured concrete. If conduits are dislodged, a subsequent pour will cause the conduit to plug up and become non-functional. This leads to jack hammering the concrete floor to dig up the buried conduit and lay new conduit. To prevent this problem, support structures are utilized to hold the conduit firmly in place before and during a pour, thereby reducing the amount of damage caused to the conduit by the construction activity prior to the pour. Such support structures tend to have large feet. These large feet rest on a temporary plywood floor, for example, which is the base of a form for the concrete pour. The plywood floor is pulled away after the concrete has hardened. The concrete surface next to the plywood floor becomes the ceiling for the story below. When the plywood floor is pulled away, the large feet of the support structures used are seen in the underside of the concrete, i.e., the ceiling. Not only are these feet unsightly, but they tend to cause chipping, cracking and spackling of the concrete around the feet when the floor form is removed. As a result, extensive patching of the ceiling surface may be required. 
       SUMMARY OF THE INVENTION 
       [0006]    The present invention avoids the unsightly show of feet when the temporary pour floor is removed because the feet of the support structure are designed to have minimum contact with the floor. The support structures are formed out of metal or plastic roc stock which may be round, square or rectangular, for example. The feet are formed as part of the support structure. The support structure is designed to have a minimum of three contact points with the temporary floor. Each contact point or foot is minimized in size without compromising the foot&#39;s structural integrity. By causing the foot to contact the floor at an angle, only a small part of each foot actually contacts the floor. The three small contact points are surprisingly strong enough to support the rod support structure and all the conduit attached to it. When the temporary floor is pulled away, only a small part of each foot is seen in the concrete from below. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The exact nature of this invention, as well as the objects and advantages thereof, will become readily apparent upon consideration of the following specification in conjunction with the accompanying drawings in which like reference numerals designate like parts throughout the figures thereof and wherein: 
           [0008]      FIG. 1  is a perspective view of a support structure according to the present invention; 
           [0009]      FIG. 2  is a perspective view of a support structure according to the present invention; 
           [0010]      FIG. 3  is a perspective of a support structure according to the present invention; 
           [0011]      FIG. 4  is a perspective of a support structure according to the present invention; 
           [0012]      FIG. 5  is a perspective of a support structure according to the present invention; 
           [0013]      FIG. 6  is a perspective of a support structure according to the present invention; 
           [0014]      FIG. 7  is a perspective of a support structure according to the present invention; 
           [0015]      FIG. 8  is a perspective of a support structure according to the present invention showing the support of conduit; 
           [0016]      FIG. 9  is a perspective of a support structure according to the present invention; 
           [0017]      FIG. 10  is a perspective from the top indicating the support structure of  FIG. 9  supporting an elbow and conduit; 
           [0018]      FIG. 11  is a perspective from the side of the support structure of  FIG. 9  supporting an elbow and conduit connection; 
           [0019]      FIG. 12  is a perspective of a poured concrete ceiling showing the parts of a support structure that are visible from below; 
           [0020]      FIG. 13  is a perspective of a poured concrete ceiling showing the parts of a support structure that are visible from below; 
           [0021]      FIG. 14  is a perspective of a poured concrete ceiling showing the parts of a support structure that are visible from below; 
           [0022]      FIG. 15  is a perspective of the  FIG. 6  support structure holding conduit; 
           [0023]      FIG. 16  is a perspective of an alternate embodiment of the present invention showing a support structure on a prepared dirt base for slab pour; and 
           [0024]      FIG. 17  is a perspective of an alternate embodiment of the invention showing a support structure for use on a dirt base for a slab floor. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0025]      FIG. 1  illustrates a first preferred embodiment of a support structure for support of a cast-in-place conduit. Support structure  21  is made out of rod stock which may be steel or plastic, for example, formed into the shape shown. Support structure  21  has a vertical riser portion  23  to which a pipe riser, for example, may be fastened by zip-lock ties or some other convenient fastening device. A less than 90° bend  25  at one end of riser  23  forms a first foot for support structure  21 . The rod stock continues to a 180° bend  29  which forms a second foot of support structure  21 . Foot  29  and foot  25  of support  21  contact the same plane, whereas the rest of the rod does not because of the less than 90° downward bends  27  and  31  in the rod. The rod ends in a third foot  33  that has a loop  34  formed at its end. Foot  33  is on the same plane as feet  25  and  29  because of the bend  31  in the rod. 
         [0026]    The rod utilized for the support structure of the present invention may be round, rectangular, square or triangular, for example, even though only a round version is illustrated. The rod may be made out of plastic or metal, such as steel for example, and materials having similar characteristics of strength and formability. 
         [0027]      FIG. 2  illustrates a variation of the support structure of  FIG. 1 . The support structure  35  of  FIG. 2  has a loop  39  formed at the top of the vertical upright  37 . The loop  39  is designed to contain a typical diameter conduit that requires support. Support structure  35  has a less than 90° bend  41  formed in the rod at the other end of the vertical upright, to form the first foot. A 180° bend  45  forms a second foot. Two less than 90° downward bends  43  and  47  cause the second foot to be on the same plane as the first foot  41  without any of the rod touching the temporary floor. A third foot  49 , formed into a loop at its end is on the same plane as the other two feet  41  and  45 . The rod connecting foot  45  and  49  also does not touch the floor because of bend  47 . 
         [0028]      FIG. 3  illustrates a support structure that utilizes more than one rod. Support structure  51  utilizes three separate rods  55 ,  57  and  59  that are connected together in a vertical upstanding portion  53  that acts as an attachment post for conduit. The three rods are bent at like angles  61 ,  63 , greater than 90°, but less than 180° so that the rod ends  65 ,  67  and  69  approach the floor at an angle and the loops formed at the respective ends only contact the floor at an outside edge. 
         [0029]      FIG. 4  illustrates an alternate version of the support structure of  FIG. 3 . The support structure  71  of  FIG. 4  has a loop  75  formed at the top or first end of the vertical support portion  71 . The three rods  76 ,  77  and  79  end in loop feet  81 ,  83  and  123 . The three respective legs approach the floor at an angle, thereby causing the feet to have minimal contact with the temporary floor. 
         [0030]      FIG. 5  illustrates an alternate version of the support structure of  FIG. 3 . The support structure  87  of  FIG. 5  has two loops  91  and  93  formed at the top or first end of vertical support portion  89 . The three rod legs  95 ,  97  and  99  end in looped feet  101 ,  103  and  105 , respectively. 
         [0031]      FIG. 6  illustrates yet another version of the support structure of  FIG. 3 . Support structure  107  has three loops  111 ,  113  and  115  formed at the top or first end of vertical support portion  109 ,  107 . The legs  117 ,  118  and  119  end in feet  121 ,  123  and  125 , having loops that approach the floor at an angle, in the same manner as the other versions of the support structure shown in  FIGS. 3 ,  4  and  5 . 
         [0032]    The function off the support structure  107  is shown in  FIG. 15 . The support structure  107  is shown holding three separate upstanding conduit portions  213 ,  215  and  217  that are to be buried in concrete. 
         [0033]    While the support structures shown in  FIGS. 1-6  are designed to support structures that are vertical, the present invention also contemplates support structures for supporting conduit along a horizontal plane. Such a support structure is shown in  FIG. 7 . Support structure  127  of  FIG. 7  is formed from a single rod to have a trapeze portion  129  which is parallel to the temporary floor. Two 90° bends  131 ,  133  at each end of the trapeze portion  129  lead to a first and second foot  135 ,  141  that contacts a temporary floor. The rod extends from foot  135  to a third foot  139  which may or may not end in the loop. Only a portion of foot  139  contacts the temporary floor because the rod is bent upwardly at the foot  135  and then downwardly at an angle  137 . The rod extends from the second foot  141  in an upward bend to a fourth foot  145  which ends in a loop. A downward bend  143  in the rod between foot  141  and  145  which is less than 90°, prevents the portion of the rod between foot  145  and  141  from contacting the temporary floor. 
         [0034]      FIG. 8  illustrates the support structure of  FIG. 7  holding conduit  148  along its trapeze section  129  with the conduit being held fast to the horizontal rod by wire ties  146 , for example. Zip ties or some other convenient tie mechanism may also be utilized. Support structure  127  is shown as sitting on a temporary floor  147  which may be plywood or some other removable surface that acts as the floor for the form with which the concrete will be poured. 
         [0035]    Another version of the support structure of the present invention which utilizes four feet is shown in  FIG. 9 . Support structure  149  of  FIG. 9  is similar to the support structure of  FIG. 7 . It has a trapeze portion  151 , a pair of 90° bends  153 ,  155  at opposite ends of the trapeze portion that lead to a first foot  157  and a second foot  163 . The rod extends from second foot  163  to third foot  167  which ends in a loop. A bend  165  between foot  163  and foot  167  prevents the rod from contacting the temporary floor. First foot  157  extends to fourth foot  161  which ends in a loop. A bend  159  between the second foot  157  and the fourth foot  161  prevents the rod from contacting the temporary floor. A saddle  169  is attached to the trapeze portion  151  and part of the upright sections that lead to the first foot  157  and second foot  163  of support structure  149 , to form a support surface for conduit and 90° elbows, for example. 
         [0036]      FIG. 10  illustrates how support structure  149  performs its function to hold a 90° elbow  173  for conduit which is attached to flexible conduit  175  that fits within the diameter of the elbow  173 . Pipe tape  176  holds the flexible conduit  175  to the elbow  173 . The joint which connects the flexible conduit  175  to the stiff 90° elbow  173  is sensitive and critical. The support structure  149  shown in  FIGS. 9 ,  10  and  11 , is designed to prevent dislodgement of this joint by providing a flat support surface by way of saddle  169  to which the flexible conduit  175  and the 90° elbow  173  is firmly fastened by zip-locks  179 , for example. 
         [0037]    The two feet  161 ,  167  of the support structure  149  ending in loops facilitate the feet being held fast to the temporary floor  171  by wood screws  177 , for example. The loop feet of all the support structures illustrated in this application are designed to permit the use of screws or some other fastening mechanism to fasten the feet to the floor. Such fastening of the feet is required in those situations where the supported conduits and elbows experience a rough environment resulting from foot traffic and the movement of equipment along the construction floor. 
         [0038]      FIG. 12  illustrates the concrete floor after it has been poured and set, looking at the floor from the underside, effectively the ceiling  181 . What has come through the concrete floor as a result of the footprint of the support structure is shown in  FIG. 12 . The footprint illustrated is for the support structures shown in  FIGS. 3 to 6 . What has come through the concrete floor are three fastening screws  183 ,  187 ,  185  which pass through the loops in the feet of the support structure to fasten the support structure to the temporary wood floor which has now been torn away. These screw ends  183 ,  185  and  187  are simply cut away, leaving a small flat round surface. Also illustrated is the edges of the three feet  191 ,  189  and  193  for the support structure. As can be seen, very little of the feet show through the concrete  181 , requiring no touch up or repair work. The structure of those feet allow the concrete to flow around them and below them. 
         [0039]      FIG. 13  illustrates the concrete poured ceiling  195  housing a trapeze type support structure, as illustrated in  FIGS. 7-11  embedded therein. Only the edges  197 ,  199 ,  201  and  203  of the four feet of the support structure are barely visible in the concrete ceiling  195 . If fastening screws were used they would also be visible. 
         [0040]      FIG. 14  illustrates a ceiling  205  showing the footprint of the support structure illustrated in  FIGS. 1 and 2  embedded there. One wood fastening screw  207  comes through the concrete. Only the edges  209 ,  211  and  213  of the three feet of the support structure are slightly visible in the concrete ceiling  205 . 
         [0041]    The result is that no touch-ups are required. There is no torn away concrete or spackling as is common with prior flat footprint support structures. 
         [0042]    Referring now to  FIGS. 16 and 17  which illustrates the embodiment of a support structure for use in poured concrete foundations at ground level, such as concrete pads. Support structure  219 , shown in  FIG. 16 , has a vertical support rod  221  that is attached to three legs  231 ,  235  and  227 , which are parallel to vertical support rod  221 . These legs are attached to support vertical support rod  221  by angled rods  229 ,  233  and  225 . This support structure is used by pounding the support structure  219  into the ground up to the end of the angled portions  229 ,  233  and  225  of the legs, desired. The angle  223  that these angled portions  225 ,  229 ,  233  make with the vertical support rod  221  is greater than 90° but less than 180°. 
         [0043]      FIG. 17  illustrates a support structure  237  that is used to support a utility box or conduit that may require a flat surface  239 . Flat surface  239  is shown as square but may be any other convenient shape such as rectangular, triangular, round or trapezoidal, for example. Extending from external points, such as the corners of the horizontal flat surface  239 , are a plurality of legs  241 ,  243 ,  245  and  247 . These legs are supported by struts  249  and  251 . Support structure  237  is utilized by pounding the legs which may, for convenience, have pointed ends  253 ,  255  ( FIG. 16 ) into the prepared ground for the slab pour. The legs may be pounded into the ground up to the support struts  249  and  251 , thereby providing quite solid support for any conduit or electrical equipment that is attached to the surface  239 .