Abstract:
A floor joist hanger for use with poured concrete walls that allows floor joists to be easily suspended from wall to wall to thereby support a floor, ceiling, or roof of a structure. The floor joist hanger has two parallel and opposing side members that are inserted into vertical slits that have been cut into an insulated form. The floor joist hanger is provided with at least one elongated slit for receiving a strap for securing a floor joist to the floor joist hanger. The floor joist hanger is further provided with a cross-support member extending between the side members. The cross-support member has an upper surface for engaging a bottom surface of a floor joist. The floor joist hanger is anchored to the wall by concrete poured into the insulated form and allowed to cure.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    Not Applicable. 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable. 
       BACKGROUND 
       [0003]    1. The Field of the Invention. 
         [0004]    The present disclosure relates generally to devices for hanging floor joists from walls and beams and more particularly, but not necessarily entirely, to floor joist hangers for use with concrete walls constructed using single and double insulated concrete forms. 
         [0005]    2. Description of Related Art 
         [0006]    Various types of insulated concrete forms (“ICFs”) have been used for over 30 years to build concrete walls for structures. One type of ICF comprises a plurality of stacked foam blocks. Each of the foam blocks includes a pair of spaced apart foam walls separated by spacers made of plastic or other materials. The foam blocks are then stacked to form a wall. Once stacked, concrete is then poured into the space between the foam walls. When the concrete cures, the foam walls are left in place on either side of a concrete core. 
         [0007]    ICFs have several advantages over traditional frame built structures. Structures built using ICFs are far less drafty than frame built structures. In addition, structures built using ICFs have far fewer cold spots, and maintain a noticeably more even temperature. Another advantage to structures built using ICFs is that they are quieter than frame built structures. Further, structures built using ICFs flex less than frame built structures and dampen vibrations. The biggest benefit to structures built using ICFs is the energy savings. Structures built using ICFs cut an estimated 30-40% off the energy used to heat and cool when compared to similarly sized frame built structures due to the high R-value of ICFs. 
         [0008]    One drawback to the use of ICFs has been their use in multilevel structures. In particular, multilevel structures may require the use of floor joist hangers attached to ledger boards to hang floor joists for upper levels and ceilings. (A floor joist hanger is a device that allows a floor joist to be suspended between two walls.) Floor joists are parallel framing members installed horizontally to support a floor and/or ceiling loads. Conventional floor joist hangers are designed to be secured with fasteners to a wood wall. This is not generally possible with ICFs, since ICFs are made from foam and filled with concrete and do not readily accept fasteners capable of supporting the load of floor joists. Thus, conventional floor joist hangers typically cannot be secured to concrete walls constructed using ICFs. The most common method of attaching conventional floor joist hangers was to install a ledger board to the wall and then attach the hangers to the ledger board. 
         [0009]    Some attempts have been made to develop floor joist hangers for use with ICFs. One such attempt is found in U.S. Pat. No. 7,024,833. 
         [0010]    The features and advantages of the disclosure will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by the practice of the disclosure without undue experimentation. The features and advantages of the disclosure may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The features and advantages of the disclosure will become apparent from a consideration of the subsequent detailed description presented in connection with the accompanying drawings in which: 
           [0012]      FIG. 1  is a perspective view of an exemplary floor joist hanger according to the present invention; 
           [0013]      FIG. 2  is top view of the exemplary floor joist hanger illustrated in  FIG. 1 ; 
           [0014]      FIG. 3  is a partially exploded perspective view of the exemplary floor joist hanger illustrated in  FIG. 1  shown mounted in an ICF; 
           [0015]      FIG. 4  is an unexploded side view of the illustration of  FIG. 3 ; and 
           [0016]      FIG. 5  is another unexploded side view of the illustration of  FIG. 3 . 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    For the purposes of promoting an understanding of the principles in accordance with the disclosure, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the disclosure as illustrated herein, which would normally occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the disclosure claimed. 
         [0018]    It must be noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. In describing and claiming the present disclosure, the following terminology will be used in accordance with the definitions set out below. As used herein, the terms “comprising,” “including,” “containing,” “characterized by,” and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, unrecited elements or method steps. 
         [0019]    Applicant has discovered a floor joist hanger for use in walls constructed using ICFs. Referring now to  FIG. 1 , there is shown a perspective view of a floor joist hanger  10  pursuant to the present invention. The hanger  10  comprises two opposing sidewalls  12  and  14 . The sidewalls  12  and  14  are substantially parallel and define a space between them for receiving a floor joist. Each of the sidewalls  12  and  14  is substantially planar and has a relatively thin construction. The sidewall  12  comprises a top edge  16 , a rear edge  18 , a bottom edge  20 , and a front edge  22 . Likewise, the sidewall  14  comprises a top edge  24 , a rear edge  26 , a bottom edge  28 , and a front edge  30 . 
         [0020]    Extending between the bottom edge  20  of sidewall  12  and the bottom edge  28  of sidewall  14  is a cross-support member  32 . A front edge  34  of the cross-support member  32  is co-planar with the front edges  22  and  30  of the sidewalls  12  and  14 , respectively. The cross-support member  32  comprises a top surface  36  for engaging a bottom surface of a floor joist. 
         [0021]    Each of the sidewalls  12  and  14  comprises a set of small apertures  38  for receiving a fastener, such as nail. The apertures  38  are vertically staggered along the front edges  22  and  30  of the sidewalls  12  and  14 , respectively. Each of the sidewalls  12  and  14  comprises a single larger aperture  40 . The apertures  40  are configured to receive a larger fastener such as a bolt. The apertures  40  are located near the front edges  22  and  30  of the sidewalls  12  and  14 , respectively. 
         [0022]    Each of the sidewalls  12  and  14  comprises an elongated slit  42  (only one visible in  FIG. 1 ). The elongated slits  42  are vertically oriented. The slits  42  are positioned the same distance from the front edges  22  and  30  as a rear edge  50  of the cross-support member  32 . The elongated slits  42  are configured and dimensioned for receiving a strap, such as a nailing strap. The elongated slits  42  are disposed in a front portion of the sidewalls  12  and  14 . 
         [0023]    Located in a rear portion of each of the sidewalls  12  and  14  are apertures  44 . The apertures  44  allow a poured material, such as concrete, to evenly flow between the sidewalls  12  and  14 . Further, when the poured material, e.g., concrete, cures, the apertures  44  secure the hanger  10  in the poured material. 
         [0024]    The top edges  16  and  24  of the sidewalls  12  and  14  each comprises recesses  46 . The recesses  46  are disposed in the rear portion of the top edges  16  and  24 . The recesses  46  are each configured and dimensioned for engaging a support structure, such as rebar. 
         [0025]    Referring now to  FIG. 2 , where the same reference numerals indicate the same components, there is shown a top view of the floor joist hanger  10  illustrated in  FIG. 1 . It will be noted that other than the cross-support member  32 , there is no connection between the sidewalls  12  and  14 . The sidewalls  12  and  14  are separated by a distance indicated by the double arrows marked with the reference numeral  48 . The distance  48  is just wide enough to accommodate the width of a floor joist. The distance  48  can thus be varied to allow the floor joist hanger  10  to receive different sizes of floor joists as needed. 
         [0026]    The cross-support member  32  comprises a rear edge  50  and an aperture  52  for receiving a fastener. The distance of the rear edge  50  from the front edge  34  of the cross-support member  32  may be approximately one to four inches, or alternatively about one third the overall length of the hanger  10 . It will be appreciated, however, that there is no restriction on this distance. 
         [0027]    Referring now to  FIG. 3 , there is illustrated a partially exploded view of the floor joist hanger  10 , an ICF  54 , and a floor joist  56 . The ICF  54  comprises a front wall  58  and a rear wall  60 . The front wall  58  and the rear wall  60  are formed from an insulating material, such as foam. The front wall  58  and the rear wall  60  define a space between each other. The framework  68  holds the front wall  58  and the rear wall  60  in place with respect to each other. A support  66 , such as rebar, may be placed in the space between the front wall  58  and the rear wall  60  to strengthen the poured material when it cures. The support  66  may be placed in the recesses  46  to hold the support  66  in place. A poured material, such as concrete, is poured into this space at the appropriate time. 
         [0028]    The front wall  58  comprises a front surface  62  having a pair of vertical slits  64  extending completely through the front wall  58 . The vertical slits  64  are adapted to receive the rear portion of the sidewalls  12  and  14  of the floor joist hanger  10 . The vertical slits  64  may be cut into the front wall  58  by hand or an electric tool. The hanger  10  is inserted by hand or other means into the slits  64  until the rear edge  50  of the cross-support member  32  abuts against the front surface  62  of the front wall  58 . 
         [0029]    A nailing strap  70  is insertable into the elongated slits  42  in the sidewalls  12  and  14 . The nailing strap  70  may include apertures  72 . The apertures  72  receive fasteners, such as nails, that are driven into the floor joist  56  as will be described in more detail hereinafter. 
         [0030]    A fastener, such a bolt  74  and a nut  76 , may be used to attach a strap  78  to the hanger  10 . The bolt  74  is inserted into the apertures  40  on the sidewalls  12  and  14 . The strap  78  may include apertures  80  and  82 . Apertures  80  are large enough to receive bolt  74 , while apertures  82  may be used to received fasteners, such as nails. 
         [0031]    Referring now to  FIG. 4 , there is illustrated a side view of the hanger  10  inserted into the ICF  54 . Once the concrete has been poured and cured, the floor joist  56  is inserted into the hanger  10  between the sidewalls  12  and  14 . The ends of the strap  70  are positioned to lie against the floor joist  56 . Fasteners, not shown, such as nails, are inserted into apertures  72  in the strap  70  and are driven into the floor joist  56  either by handheld tool or using an electric tool. 
         [0032]    In addition, fasteners may be inserted into apertures  38  and driven into the floor joist  56 . It will be noted that the floor joist  56  abuts against the front wall  58  of the ICF  54 . It will further be noted that the floor joist  56  is generally not inserted into the hanger  10 , until after concrete as been poured into the space between the front wall  58  and the rear wall  60  of the ICF  54 . It should also be noted that if the floor joist is of an engineered wood I-beam type, such as BCI or TJI, then along with the installation of the floor joist, a filler board may need to be installed on either side of the web as a web stiffener to provide the proper density for the fastener to be installed in the straps  70  and  78 . The stiffener is not required if standard lumber is used for the floor joists, such as a 2×10. 
         [0033]    The rebar support  66  is placed into the recess  46  on the hanger  10 . The recess  46  holds the support  66  in place while the concrete is being poured into the ICF  54 . The embodiment in  FIG. 4  may accommodate up to two rebar supports  66  using recesses  46 . It will be appreciated that the present invention may accommodate several more supports  66 . 
         [0034]    It will be further appreciated that the apertures  44  allow concrete poured into the ICF  54  to flow freely around the joist hanger  10 . Further, when the concrete cures, the apertures  44  further secure the hanger in the ICF  54 . 
         [0035]    Referring now to  FIG. 5 , where the same reference numerals indicate the same components, there is illustrated a side view of the hanger  10  inserted into the ICF  54 . The floor joist  56  is inserted into the hanger  10 . In lieu of the strap  70 , the strap  78  is used to hold the floor joist  56  in place. In particular, the bolt  74  is inserted into one of the apertures  80  in the strap  78 . The bolt  74  is then inserted through both apertures  40  in the sidewalls  12  and  14 . This may require that a hole of adequate size be drilled into the floor joist  56  at the appropriate location. The nut  76  is then used to secure the bolt  74  in place. Fasteners, such as nails, may then be inserted into apertures  38  and  82  and driven into the floor joist  56  to thereby further secure the floor joist  56  to the hanger  10 . 
         [0036]    One method for installing floor joist hangers according to the present disclosure comprises the steps of (a) establishing a level line at which the floor joist hangers will be installed; (b) installing a temporary 2×4 ledger board onto the ICFs such that the top surface of the 2×4 is even with the level line; (c) cutting vertical slits from the top surface of the 2×4 to the height of the floor joist hangers; (d) installing the floor joist hangers into the slits in the ICFs such that the bottom of the floor joist hanger sits on the top surface of the 2×4 ledger board; (e) installing screws through apertures, such as aperture  52 , in the cross-support members of the floor joist hangers  52  and into the 2×4 ledger board; (f) pouring concrete into the ICFs and allowing it to cure; (g) removing the ledger board; and (h) installing the floor joists into the floor joist hangers. In the above described manner the floor joist hangers will maintain proper alignment while the concrete is being poured into the ICFs and while any concrete vibrator is being used to settle the concrete. 
         [0037]    It will be appreciated that the structure and apparatus disclosed herein is merely one example of a means for hanging a floor joist from a concrete wall, and it should be appreciated that any structure, apparatus or system for hanging a floor joist from a concrete wall which performs functions the same as, or equivalent to, those disclosed herein are intended to fall within the scope of a means for hanging a floor joist from a concrete wall, including those structures, apparatus or systems for hanging a floor joist from a concrete wall which are presently known, or which may become available in the future. Anything which functions the same as, or equivalently to, a means for hanging a floor joist from a concrete wall falls within the scope of this element. 
         [0038]    Those having ordinary skill in the relevant art will appreciate the advantages provide by the features of the present disclosure. For example, it is a feature of the present disclosure to provide a floor joist hanger improving the securement of a floor joist to a concrete wall structure. 
         [0039]    In the foregoing Detailed Description, various features of the present disclosure are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed disclosure requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description of the Disclosure by this reference, with each claim standing on its own as a separate embodiment of the present disclosure. 
         [0040]    It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present disclosure. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the present disclosure and the appended claims are intended to cover such modifications and arrangements. Thus, while the present disclosure has been shown in the drawings and described above with particularity and detail, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly and use may be made without departing from the principles and concepts set forth herein.