US20080315065A1

US20080315065A1 - Bracket assembly for facilitating the installation of a concrete wall on a concrete footing and a method of forming the wall

Info

Publication number: US20080315065A1
Application number: US11/821,304
Authority: US
Inventors: Troy A. Hanson
Original assignee: Individual
Current assignee: Individual
Priority date: 2007-06-22
Filing date: 2007-06-22
Publication date: 2008-12-25

Abstract

A bracket assembly is disclosed for facilitating the installation of a concrete wall on a concrete footing. The bracket assembly includes a bracket having a base member with an upper surface and a lower surface. First and second spaced apart flanges extend upwardly from the base member. The bracket assembly also includes a cavity formed in the base member having an opening aligned with the lower surface. An aperture is formed through the base member and is aligned with the cavity. A sealant is positioned in the cavity. The bracket assembly further includes a movable fastener positioned in the aperture which is capable of being driven through the sealant and into the concrete footing to secure the bracket assembly thereto.

Description

FIELD OF THE INVENTION

This invention relates to a bracket assembly for facilitating the installation of a concrete wall on a concrete footing and a method of forming the wall. More specifically, this invention relates to a bracket assembly that can be used to position forms on a concrete footing for forming a concrete wall and the bracket assembly has a seal which will prevent moisture and/or water from seeping between the concrete wall and the concrete footing.

BACKGROUND OF THE INVENTION

In constructing a building, many foundation walls are formed by pouring concrete between interior and exterior wall forms. Typically, the first order of construction is to dig beneath the nominal surface of the ground, to a depth from which the building will be supported. In a mild climate, e.g. in a southern climate, where no basement is being included in the building, a typical digging depth is about 3 to 4 feet. In a colder climate, e.g. in a northern climate, the minimum depth is typically about 4 feet. Where a basement is being included, the digging depth is approximately 8 to 10 feet.
Once the excavation has been completed, the next order of activity is to form a concrete footing which generally extends about the perimeter of the building. The concrete footing is intended to underlie all other load-bearing portions of the building and can transmit the load of the building to the underlying soil. The dimensions of the concrete footing is about 12 to about 24 inches for a typical single-family home. The width of the footing is typically greater than the width of the upstanding foundation wall which extends upward therefrom. The concrete footing is wider so as to be able to spread the load of the building over a wider foot-print of soil than that which directly underlies the foundation wall. Another advantage of forming a wide concrete footing is that the footings are typically laid out in a more casual fashion than the foundation walls. This means that the footings do not have to exactly conform to the dimensions, angles, widths, etc. shown on the construction drawings.
Typically, after the concrete footing has set or cured for at least two days, one or more workers will have to spend several hours laying out and marking the precise locations where the building foundation walls are to be build on the footing. These locations are typically marked on an upper surface of the concrete footing with chalk, such as a powdered, colored chalked line, known in the trade as a “chalk line”. Powdered colored chalk is applied to a chalk line by a special tool. The line is then stretched taut directly over and adjacent to a length of the footing being marked by two construction workers. The taut line is then drawn or stretched slightly away from the footing and is allowed to snap back. The stretch in the chalk line causes the chalk line to “snap” against the footing, applying a line of colored chalk to the cured concrete footing. This process is repeated, as necessary, until the entirety of the perimeter of the concrete footing is marked or chalked, indicating exactly where the foundation walls are to be constructed.
A foundation wall is normally constructed between an interior foundation wall form and an exterior foundation wall form. The interior and exterior foundation wall forms can consist of one or more panels attached together to provide the required length. The interior and exterior foundation wall forms can be united or secured together at regularly spaced intervals by metal ties which maintain the spacing of the interior and exterior foundation wall forms from each other when the foundation wall forms are erected in place on the concrete footing.
The interior and exterior foundation wall forms can be erected separately and be held in place by temporary supports while the metal ties are being inserted and fixed in place. Alternatively, the metal ties can be attached before the interior and exterior foundation wall forms are placed on the concrete footing, whereby the interior and exterior wall forms are placed on the concrete footing as a single pre-assembled unit. Finally, it is known to attach ties between the interior and exterior foundation wall forms at the tops of the foundation wall forms.
One problem with such conventional foundation wall construction is that the only thing holding a foundation wall forms on the concrete footing is gravity. Accordingly, any substantial lateral force applied at the base of the interior and/or exterior foundation wall forms can move the wall forms laterally relative the concrete footing. On a typical 10 to 40 foot length of wall form, the force of a worker accidentally kicking the wall form adjacent to the concrete footing can move the wall form by one or more inches, sometimes up to 3 to 4 inches. If concrete is then poured between the interior and exterior wall forms with the wall forms being misaligned, the resulting concrete foundation wall will not straight. In addition, misalignments at the base of the foundation wall can typically be magnified, and in opposing direction, at the top of the foundation wall. The overall result is that the upright wall of the building is formed crooked, typically crooked longitudinally and off-specification with respect to its, typically vertical, upright angle. Such a crooked foundation wall can result in all variety of compromises having to be made in that portion of the building which is supported by the misaligned foundation wall.
A second problem encountered when the chalking system is used to mark the locations for the interior and exterior foundation wall forms is that rain or inclement weather can readily erase the chalk lines. The chalk lines are usually made the day before the interior and exterior foundation wall forms are set into place. If a rain shower occurs in the meantime, it will be necessary for the construction people to again rechalk the positioning lines, thus doubling the work.
Now a bracket assembly and method of using such bracket assemblies has been invented to solve the above-identified problems.

SUMMARY OF THE INVENTION

Briefly, this invention relates to a bracket assembly for facilitating the installation of a concrete wall on a concrete footing. The bracket assembly includes a bracket having a base member with an upper surface and a lower surface. First and second spaced apart flanges extend upwardly from the base member. The bracket assembly also includes a cavity formed in the base member having an opening aligned with the lower surface. An aperture is formed through the base member and is aligned with the cavity. A sealant is positioned in the cavity. The bracket assembly further includes a movable fastener positioned in the aperture which is capable of being driven through the sealant and into the concrete footing to secure the bracket assembly thereto.
In another embodiment, the bracket assembly includes a bracket having a base member with an upper surface and a lower surface. First and second spaced apart flanges, each integral with the base member, extend upwardly from the base member. The bracket assembly also includes a pair of channels formed in the base member. Each of the pair of channels has an opening aligned with the lower surface of the base member. A pair of apertures is formed through the base member and each of the pair of apertures is aligned with one of the pair of channels. A sealant is positioned in each of the pair of channels and extends across the width of the lower surface of the bracket. The bracket assembly further includes a pair of movable fasteners each positioned in one of the pair of apertures. The pair of fasteners is capable of being driven into the concrete footing to secure the bracket assembly thereto. As the bracket assembly is secure to the concrete footing, the sealant forms a watertight seal under the bracket and adjacent to the concrete footing.
This invention also relates to a method of facilitating the installation of a concrete wall on a concrete footing. The method includes the steps of marking a pair of spaced apart lines on an upper surface of a concrete footing. Two or more bracket assemblies are then positioned between the pair of spaced apart lines at predetermined distances. Each of the bracket assemblies includes a bracket having a base member with an upper surface and a lower surface. First and second spaced apart flanges, each integral with the base member, extend upwardly from the base member. A pair of channels is formed in the base member. Each of the pair of channels has an opening aligned with the lower surface of the base member. A pair of apertures is formed through the base member and each of the pair of apertures is aligned with one of the pair of channels. A sealant is position in each of the pair of channels and extends across the width of the lower surface of the bracket. A pair of movable fasteners is present with each being positioned in one of the pair of apertures. The pair of fasteners is driven into the concrete footing to secure each of the bracket assemblies thereto. As the bracket assembly is secure to the concrete footing, the sealant forms a watertight seal under the bracket and adjacent to the concrete footing. An interior and an exterior foundation wall form are positioned on either side of the bracket assemblies and concrete is then poured therebetween to create a concrete foundation wall.
The general object of this invention is to provide a bracket assembly for facilitating installation of a concrete wall on a concrete footing. A more specific object of this invention is to provide a method of facilitating installation of a concrete wall on a concrete footing.
Another object of this invention is to provide inexpensive bracket assemblies that can be easily and quickly secured to an upper surface of a concrete footing so as to align interior and exterior foundation wall forms into which concrete can be poured to form a concrete foundation wall on top of a concrete footing.
A further object of this invention is to provide bracket assemblies that are permanently secured between a concrete footing and an upstanding concrete foundation wall and which form a watertight seal between a lower surface of the bracket and the upper surface of the concrete footing.
Still another object of this invention is to provide bracket assemblies that are inexpensive to manufacture and are easy to use to ensure that a concrete foundation wall which is to be poured onto a concrete footing is correctly positioned.
Still further, an object of this invention is to provide a unitary bracket assembly that will reduce the time it takes to correctly position interior and exterior wall forms on a concrete footing.
Other objects and advantageous of the present invention will become more apparent to those skilled in the art in view of the following description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a bracket assembly.

FIG. 2 is a cross-sectional view of the bracket assembly shown in FIG. 1 taken along line 2-2.

FIG. 3 is a bottom view of the bracket assembly shown in FIG. 1 depicting the sealant positioned across the width of the bracket.

FIG. 4 is a top view of an alternative embodiment of a bracket assembly.

FIG. 5 is a side view of the bracket assembly shown in FIG. 4 taken along line 5-5.

FIG. 6 is a bottom view of the bracket assembly shown in FIG. 4 depicting the sealant positioned in a pair of channels and extending across the width of the bracket.

FIG. 7 is a plan view of interior and exterior foundation wall forms positioned on a concrete footing and spaced a set distance apart by a plurality of bracket assemblies.

FIG. 8 is a top view of a concrete foundation wall set between an interior foundation wall form and an exterior foundation wall form which are separated by a bracket assembly and the foundation wall is formed on the upper surface of a concrete footing.

FIG. 9 is an elevation cross-sectional view of the various elements shown in FIG. 8 taken along line 9-9.

FIG. 10 is a flow diagram of a method of facilitating the installation of a concrete wall on a concrete footing.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1-3, a bracket assembly 10 is shown for facilitating installation of a concrete wall on a concrete footing. The bracket assembly 10 includes a bracket 12 having a base member 14 with an upper surface 16 and a lower surface 18. Each of the upper and lower surfaces, 14 and 16 respectively, can be planar and/or smooth in appearance or either can have an irregular appearance. The bracket 12 can be formed from almost any material, including but not limited to: aluminum, tin, zinc, plastic, a thermoplastic such as polyethylene or polypropylene, a composite material formed from two or more different materials, an alloy, a metal alloy, or from any other material known to those skilled in the art. Desirably, the bracket 12 is formed from a non-ferrous material or a non-metallic material so that it will not rust. By “nonferrous” it is meant a material that is not composed of or contains iron. By “nonmetallic” it is meant a material that is not metallic or being a nonmetal. More desirably, the bracket 12 will be constructed from a thermoplastic material since it is inexpensive compared to an alloy or composite material. A thermoplastic material can be formed by any known process, including but not limited to: injection molding, extrusion, etc. Even more desirably, the bracket 12 is constructed of a waterproof and rust-proof plastic.
Referring to FIGS. 1 and 2, the bracket 12 has a length l, a width w and a thickness t. The length l, width w and the thickness t of the bracket 12 can vary depending upon the material from which it is constructed and the process used to form the bracket 12. The length l can be any desired length but normally will correspond to the standard width at which concrete foundation walls are poured so as to meet city, town, county, state and/or federal building codes. For a residential house, the concrete foundation walls are normally 6 or 8 inches in thickness. For commercial buildings, the concrete foundation walls are typically 8, 10 or 12 inches in thickness. However, depending upon the load of the building, the concrete mix and the presence of any reinforcement members or chemicals used in the concrete, the width of the concrete foundation wall can vary from 4 inches up to about 2 feet. Some government installations can actually use concrete foundation walls that are greater than 2 feet in width.
It should also be recognized that new materials, such as sheets of insulation formed from Styrofoam and other materials, are being used in place of the conventional aluminum, steel, metal or wood concrete foundation wall forms. When such insulation sheets are used, they normally stay in place after the concrete cures and therefore the finished width of the concrete foundation wall located between these sheets can result in some odd dimensions. Because of this, the length l of the bracket assembly 10 may have to be constructed at 8.25 inches, 8.5 inches or 8.75 inches versus the standard 8 inches.
The width w of the bracket 12 can range from between about 0.25 inches to about 12 inches. Desirably, the width w of the bracket 12 can range from between about 0.5 inches to about 6 inches. More desirably, the width w of the bracket 12 can range from between about 0.75 inches to about 3 inches. Even more desirably, the width w of the bracket 12 can range from between about 1 inch to about 2 inches. A width w for the bracket 12 of about 1 inch is sufficient for most residential construction of concrete foundation walls.
Referring to FIG. 2, the thickness t of the bracket 12 can be very dependent upon the process used to form the bracket 12 especially when the bracket 12 is formed from a thermoplastic material, such as polyethylene. The thickness t of the bracket 12 can range from about 0.05 inches to about 0.5 inches. Desirably, the thickness t will range from about 0.08 inches to about 0.4 inches. More desirably, the thickness t of the bracket 12 will range from about 0.1 inches to about 0.3 inches. Even more desirably, the thickness t of the bracket 12 will range from about 0.12 inches to about 0.2 inches. A thickness t for the bracket 12 of about 0.125 inches is sufficient for most residential construction of concrete foundation walls.
Still referring to FIGS. 1 and 2, the bracket 12 also includes a first end 20 and an opposite second end 22. The bracket 12 further has a first flange 24 and a second flange 26. The first and second flanges, 24 and 26 respectively, are spaced apart from one another with the first flange 24 being located adjacent to or abutting the first end 20 and the second flange 26 being located adjacent to or abutting the second end 22. The first and second flanges, 24 and 26 respectively, are aligned approximately at a right angle or 90 degrees to the base member 12. Desirably, the first and second flanges, 24 and 26 respectively, are aligned at a right angle to the base member 12. In other words, the first and second flanges, 24 and 26 respectively, are aligned perpendicular to the base member 12. Desirably, the first and second flanges, 24 and 26 respectively, are integrally formed with the base member 14 and extend upwardly therefrom. By “integral” it is meant a unitary or complete unit, essential or necessary for completeness. By forming the bracket 12 as an integral unit, one can decrease the cost of manufacturing the bracket 12 since the first and second flanges, 24 and 26 respectively, do not have to be adhered, glued, joined, screwed, bolted or somehow mechanically or chemically joined to the base member 14.
Referring to FIG. 2, one can clearly see that the bracket assembly 10 has a C-shaped or U-shaped configuration. However, the bracket assembly 10 can have any desired configuration. Desirably, the first and second flanges, 24 and 26 respectively, will square off the first and second ends, 20 and 22 of the base member 14 and give the bracket 12 the appearance of half of a rectangle. In FIG. 2, one will also see that each of the first and second flanges, 24 and 26 respectively, has a height h. The height h is measured from the upper surface 16 of the base member 14 to a free or terminal end, 28 and 30 respectively, of the first and second flanges, 24 and 26 respectively. The height h of the first and second flanges, 24 and 26 respectively, can vary to suit one's particular needs and requirements. However, it has been found that the height h of the first and second flanges, 24 and 26 respectively, should range from between about 0.5 inches to about 3 inches. Desirably, the height h of the first and second flanges, 24 and 26 respectively, should be at least about 0.6 inches, and more desirably at least about 0.75 inches. A height h for the first and second flanges, 24 and 26 respectively, of between about 0.75 inches to about 2 inches works well for most residential construction of concrete foundation walls.
Another way of calculating a sufficient height h for the first and second flanges, 24 and 26 respectively, is to adjust the height h of the first and second flanges, 24 and 26 respectively, relative to the length l of the bracket 12. Typically, the height h of each of the first and second flanges, 24 and 26 respectively, should range from between at least about 5% to at least about 50% of the length l of the bracket 12. Desirably, the height h of each of the first and second flanges, 24 and 26 respectively, should be at least about 7%, more desirably, at least about 8%, and even more desirably, at least about 10% of the length l of the bracket 12. By using a height h dimension for the first and second flanges, 24 and 26 respectively, within the above ranges, one can be assured that the bracket assembly 10 will work well for its intended purpose.
Referring now to FIGS. 2 and 3, the bracket assembly 10 also has at least one cavity 32 formed in the base member 14. The cavity 32 has an opening 34 aligned with the lower surface 18. The cavity 32 can be almost any desired geometrical shape or configuration. In FIG. 3, the cavity 32 is shown as having a round or circular opening similar to what can be produced by a counter bore or a counter sink. By “counter bore or counter sink” it is meant a hole with the exposed part enlarged adjacent to the lower surface 18. The opening 34 can be sized to be smaller than, equal to or be larger than the dimensions of the cavity 32. Depending upon the configuration of the cavity 32, in most cases the opening 34 should be larger than the dimensions of the cavity 32.
In FIG. 3, the cavity 32 is shown having a width w₁. The width w₁should extend across at least about 75% of the width w of the bracket 12. Desirably, the width w₁should extend across at least about 85% of the width w of the bracket 12. More desirably, the width w₁should extend across at least about 95% of the width w of the bracket 12. Even more desirably, the width w₁should extend completely across the width w of the bracket 12. The reason for this size dimension will be explained shortly.
Still referring to FIGS. 2 and 3, the bracket assembly 10 further includes an aperture 36 formed through the base member 14 and which is aligned with the cavity 32. The aperture 36 is shown extending from the upper surface 16 of the bracket 12 down into the cavity 32. Desirably, the aperture 36 is coaxially aligned with the circular opening 34. The length of the aperture 36 will partly depend upon the thickness of the base member 14.
A sealant 38 is positioned in the cavity 32. Desirably, some of the sealant 38 will extend downward a slight amount below the lower surface 18 of the bracket 12. More desirably, some of the sealant 38 will extend across the width w of the bracket 12. It is important to have the sealant 38 extend across the width w of the bracket 12 so as to form a moisture and/or watertight seal under the bracket 12. The sealant 38 can initially extend below the lower surface 18 of the bracket 12 by from between about 0.01 to about 0.25 inches. Since the upper surface of a cured concrete footing can be rather rough or coarse, the extra sealant 38 present below the lower surface 18 of the bracket 12 will assure that a good seal is formed when the bracket assembly 10 is secured to the concrete footing.
The sealant 38 can be any material that can be used to form a moisture and/or water barrier on the lower surface 18 of the bracket 12 to prevent moisture and/or water from passing from the outside of the foundation wall to the inside of the foundation wall. The sealant 38 should be capable of forming a moisture proof, watertight, waterproof or water repellant seal between the lower surface 18 of the base member 14 and an upper surface of a concrete footing. Various materials known to those skilled in the art can be used for the sealant 38. A number of polymers are readily available that can perform this intended function. One material that works well as the sealant 38 is silicone. Silicone is any of a group of semi-inorganic polymers of siloxane, characterized by high lubricity and therefore stability, extremely water repellence, and physiological inert. Silicone is a water repellant, pliable material that remains receptive to change in physical dimensions during its useful life. Silicone is commercially available from a number of vendors. The sealant 38 can also be a foam, an insulating foam, an expandable foam, a polyurethane or any other material known to those skilled in the art which has moisture and/or water resistance and/or water repellant properties.
The sealant 38 should be pliable so that it can be inserted into the cavity 32 and can extrude outward from the perimeter of the cavity 32 a predetermined amount so as to form a moisture and/or watertight seal across the width w of the lower surface 18 of the bracket 12. By “pliable” it is meant that the sealant 38 can be easily shaped and is receptive to change and adaptable. As pressure is exerted on the upper surface 16 of the bracket 12, the sealant 38 will form a tight seal against the upper surface of the concrete footing.
It should be noted that the sealant 38 does not have to set or acquire a final configuration but instead can be fluid such that it can change shape over its useful life. Silicone has this unique characteristic.
Referring again to FIGS. 1 and 2, the bracket assembly 10 further includes a movable fastener 40 sized and configured to be positioned in and at least partially pass through the aperture 36. The fastener 40 can be almost any kind of mechanical device known to those skilled in the art. For example, the fastener 40 can be a nail, a nail having a plurality of slits, grooves, or threads to facilitate its ability to enter into cured concrete, a screw, a bolt, a rivet, a stud, etc. The fastener 40, as shown in FIG. 2, has an enlarged head 42 at its upper end and a sharp point 44 at its opposite end. The fastener 40 can be movably retained in the aperture 36 by an interference fit and can also be retained by the sealant 38. Desirably, the diameter or cross-section of the aperture 36 will be slightly less than the diameter or cross-section of the fastener 40, so that an interference fit is present. However, the fastener 40 should still be capable of being hammered or driven down through the aperture 36 and the sealant 38 into the concrete footing. The interference fit will also assist in retaining the fastener 40 to the bracket assembly 10. The enlarged head 42 on the fastener 40 allow a construction worker to strike the fastener 40 with a hammer and drive or move it down through the aperture 36, through the sealant 38 and into a concrete footing. However, fasteners 40 without enlarged heads 42 can also be utilized. As the fastener 40 passes through the sealant 38, it will displace some of the sealant 38 and force it to extend downward and/or outward across the entire width w of the bracket 12. This action, along with the excess sealant 38 that is present below the lower surface 18 of the bracket 12, will create a moisture proof, watertight, waterproof or water repellant seal between the lower surface 18 of the bracket 12 and the upper surface of the concrete footing. By “moisture proof” it is meant that the bracket assembly 10 is secured to the concrete footing such that moisture cannot enter or escape under the lower surface 18 of the bracket 12. By “watertight” it is meant that the bracket assembly 10 is secured to the concrete footing such that water cannot enter or escape under the lower surface 18 of the bracket 12. By “waterproof” it is meant that the bracket assembly 10 is secured to the concrete footing such that water cannot penetrate under the lower surface 18 of the bracket 12.
The sealant 38 is made of or treated with rubber, plastic, a polymer or a sealing agent to resist water penetration. By “water repellant” it is meant that the bracket assembly 10 is secured to the concrete footing such that it is resistant to water but not entirely waterproof. The fastener 40 will also permanently secure the bracket assembly 10 to the concrete footing. The bracket assembly 10 is not designed to be removed once it is attached to the concrete footing unless it is incorrectly positioned.
Still referring to FIGS. 1 and 2, the bracket assembly 10 is also depicted as having a shock absorber 46. The shock absorber 46 can be formed from various materials. The shock absorber 46 can be constructed of almost any flexible, malleable, ductile, plastic, pliable, pliant, supple and/or adaptable material which has the ability to readily undergo change or modification without breaking. One material that works well as the shock absorber 46 is rubber. Rubber is an amorphous, elastic, solid polymer of isoprene. Rubber is generally prepared by coagulation and drying of the milky sap or latex of various tropical plants, especially the rubber tree, and subsequently vulcanized, pigmented, and otherwise modified. However, other numerous synthetic elastic materials, synthetic rubber, polymers, etc. of varying chemical composition, with properties similar to those of natural rubber, can also be used. The shock absorber 46 is shown having an aperture 48, see FIG. 2, sized to permit a portion of the fastener 40 to pass there through. A slight interference fit between the shock absorber 46 and the fastener 40 is beneficial in keeping the shock absorber 46 attached to the fastener 40. The shock absorber 46 can also be constructed such that it only partially surrounds a portion of the fastener 40. In FIG. 2, the shock absorber 46 is depicted as a disc or thick washer situated above the upper surface 16 of the base member 14. The shock absorber 46 can also be formed in a variety of other geometrical shapes.
Optionally, an adhesive 50 can be positioned between a lower surface of the shock absorber 46 and the upper surface 16 of the base member 14 to hold the shock absorber 46 secure to the bracket 12. When the adhesive 50 is present and an interference fit is present between the fastener 40 and the aperture 48, one can feel secure in the fact that the fastener 40 will be joined to the bracket 12. This will ensure that the fastener 40 is not separated from the bracket assembly 10. One of the clear benefits of the bracket assembly 10 is that it is a unitary device that does not require additional elements or items to be attached or to be joined to it. At the construction site, the construction worker simply has to place or position the bracket assembly 10 onto the upper surface of the cured concrete footing and secure it in its proper alignment by hammering the fastener 40 into the concrete footing. Each of the bracket assemblies 10 will remain in place and it is not necessary to remove any of the bracket assemblies 10 after the concrete foundation wall is poured and cured.
The shock absorber 46 functions to permit the fastener 40, i.e. a nail, screw, etc. to be driven through both the aperture 36 and the sealant 38 and into the concrete footing by a hammer, nail gun, etc. to secure the bracket assembly 10 thereto. As the fastener 40 is driven down into the concrete footing, the enlarged head 42 on the fastener 40 will contact the shock absorber 46. The shock absorber 46 can flex and contract while providing resistant which prevents the fastener 40 from being driven further downward by an appreciable amount. In short, the shock absorber 46 will prevent the bracket 12 from breaking or cracking as the fastener 40 is inserted into the concrete footing. As the fastener 40 passes through the sealant 38, it will displace some of the sealant 38 and cause it to move downward and/or outward. This helps assure that a good water tight seal is created between the lower surface 18 of the bracket 12 and the upper surface of the cured concrete footing.
Referring now to FIGS. 4-6, another embodiment of a bracket assembly 10′ is shown for facilitating the installation of a concrete wall on a concrete footing. The bracket assembly 10′ includes a bracket 12′ having a base member 14′ with an upper surface 16′ and a lower surface 18′. The upper surface 16′ is not planar but instead is irregular while the lower surface 18′ is planar. The bracket 12′ has a length l′, a width w′ and a thickness t′. The length l′, the width w′ and the thickness t′ of the bracket 12′ can vary depending upon the material from which it is constructed and the process used to form the bracket 12′. The bracket 12′ also includes a first end 20′ and an opposite second end 22′. The bracket 12′ further has a first flange 24′ and a second flange 26′. The first and second flanges, 24′ and 26′ respectively, are spaced apart from one another with the first flange 24′ being located adjacent to or abutting the first end 20′ and the second flange 26′ being located adjacent to or abutting the second end 22′. The first and second flanges, 24′ and 26′ respectively, are aligned approximately at a right angle or 90 degrees to the base member 12′. In other words, the first and second flanges, 24′ and 26′ respectively, are aligned approximately perpendicular to the base member 12′. Desirably, the first and second flanges, 24′ and 26′ respectively, are integrally formed with the base member 14′ and extend upwardly therefrom. By forming the bracket 12′ as an integral unit, one can decrease the cost of manufacturing the bracket 12′ since the first and second flanges, 24′ and 26′ respectively, do not have to be adhered, glued, joined, screwed, bolted or somehow mechanically or chemically joined to the base member 14′.
Referring to FIG. 5, one can clearly see that the bracket assembly 10′ has a C-shaped or U-shaped configuration. However, other configurations can also be utilized. Desirably, the first and second flanges, 24′ and 26′ respectively, will square off the first and second ends, 20′ and 22′ of the base member 14′ and give the bracket 12′ the appearance of half of a rectangle. In FIG. 5, one will also see that each of the first and second flanges, 24′ and 26′ respectively, has a height h′. The height h′ is measured from the upper surface 16′ of the base member 14′, adjacent each flange 24′ or 26′, to a free or terminal end, 28′ and 30′ respectively, of the first and second flanges, 24′ and 26′ respectively. The height h′ of the first and second flanges, 24′ and 26′ respectively, can vary to suit one's particular needs and requirements. However, it has been found that the height h′ of the first and second flanges, 24′ and 26′ respectively, should be at least about 0.5 inches, desirably, at least about 0.6 inches, and more desirably at least about 0.75 inches. A height h′ for the first and second flanges, 24′ and 26′ respectively, of between about 0.75 inches to about 2 inches works well for most residential construction of concrete foundation walls.
Referring now to FIGS. 5 and 6, the bracket assembly 10′ differs from the embodiment shown in FIGS. 1-3, in that it has a pair of cavities 32′, 32′ formed in the base member 14′. The pair of cavities 32′, 32′ is spaced apart from one another. Each of the pair of cavities 32′, 32′ is formed or configured as a channel 50 having a central axis z—z, see FIG. 6. Each of the channels 52, 52 can be a long, narrow cavity of various cross-sectional configurations. In FIG. 5, each of the channels 52, 52 has a trapezoidal configuration. By “trapezoidal” it is meant a quadrilateral having two parallel sides. However, it is to be understood that each of the channels 52, 52 can have any desired cross-sectional configuration including, but not limited to: square, rectangular, triangular, circular, round, oval, elliptical, or any other geometrical shape known to those skilled in the art. Each of the channels 52, 52 has a first end 54 and a second end 56. Each of the channels 52, 52 spans or bridges across the entire width w′ of the bracket 12′ such that the first end 54 is located on one side of the bracket 12′ and the second end 56 is located on the opposite side of the bracket 12′. The central axis z-z of each of the channels 52, 52 is aligned approximately parallel or 180 degrees to the first and second flanges, 24′ and 26′ respectively. Desirably, each of the channels 52, 52 is aligned parallel to the first and second flanges, 24′ and 26′ respectively.
Each of the pair of cavities 32′, 32′ or channels 52, 52 is located adjacent to and inward of one of the first and second flanges, 24′ and 26′ respectively. The central axis z—z of each of the channels 52, 52 should be spaced at least about 0.5 inches away from the adjacent flange 24′ or 26′. This clearance is needed to provide sufficient room for a construction worker to drive a fastener 40′ down through the respective channels 52, 52 when the bracket assembly 10′ is being secured to an upper surface of a concrete footing. It is also desirable to have at least 3 inches of clearance, measure along the length l′ of the bracket 12′, between each of the channels 52, 52. Furthermore, each of the pair of cavities 32′, 32′ has an opening 34′ aligned with the lower surface 18′ of the bracket 12′. In FIG. 5, each of the openings 34′ is narrower than the remainder of the cavity 32′. This is another difference from the embodiment shown in FIGS. 1-3. Desirably, each of the opening 34′ have a minimum dimension, measured parallel to the length l′ of the bracket 12′, of at least 0.1 inches, and more desirably, of at least 0.2 inches. This size dimension will help ensure that the sealant 38, positioned in the channels 52, 52, can form an effective seal beneath the lower surface 18′ of the bracket 12′ and an upper surface of the concrete footing.
Still referring to FIGS. 5 and 6, the bracket assembly 10′ further includes a pair of apertures 36′, 36′ each aligned with one of the cavities 32′, 32′ or one of the channels 52, 52. Each of the pair of apertures 36′, 36′ extends from the upper surface 16′ of the bracket 12′ down into the cavities 32′, 32′. Desirably, each of the apertures 36′, 36′ is equally spaced across the width w′ of the bracket 12′ between the first and second ends, 54 and 56 respectively, of each of the channels 52, 52. The length of each of the apertures 36′, 36′ will partly depend upon the thickness of the base member 14′.
A sealant 38′, as described above, is position in each of the pair of cavities 32′, 32′ or pair of channels 52, 52. Desirably, some of the sealant 38′ will extend downward a slight amount below the lower surface 18′ of the bracket 12′. Since each of the channels 52, 52 extends completely across the width w′ of the bracket 12′, the sealant 38′ will also extend completely across the width w′ of the bracket 12′. The sealant 38′ can initially extend below the lower surface 18′ of the bracket 12′ by from between about 0.01 to about 0.25 inches. Since the upper surface of a cured concrete footing can be rather rough or coarse, the extra sealant 38′ present below the lower surface 18′ of the bracket 12′ will assure that a good seal is formed when the bracket assembly 10′ is secured to the concrete footing.
Referring again to FIGS. 4 and 5, the bracket assembly 10′ further includes a pair of movable fasteners 40′ each sized and configured to be positioned in and at least partially pass through one of the apertures 36′. Each of the pair of fasteners 40′ can be constructed as described above with reference to the embodiment shown in FIGS. 1-3. Each of the pair of fasteners 40′, as shown in FIG. 5, has an enlarged head 42′ at its upper end and a sharp point 44′ at its opposite end. Each of the pair of fasteners 40′ can be movably retained in one of the apertures 36′ by an interference fit and can also be retained by the sealant 38′. Desirably, the diameter or cross-section of the aperture 36 will be slightly less than the diameter or cross-section of the fastener 40 so that an interference fit is present. However, the fastener 40 should still be capable of being driven or hammered down through the aperture 36. The enlarged head 42′ allows a construction worker to strike each of the pair of fasteners 40′ with a hammer and drive or move it down through the respective aperture 36′, through the sealant 38′ and into a concrete footing. As each of the fasteners 40′ passes through the sealant 38′, it will displace some of the sealant 38′. This action, along with the excess sealant 38′ that is present, will create a moisture proof, watertight, waterproof or water repellant seal between the lower surface 18′ of the bracket 12′ and the upper surface of the concrete footing. The pair of fasteners 40′ will also permanently secure the bracket assembly 10′ to the concrete footing. The bracket assembly 10′ is not designed to be removed once it is attached to the concrete footing unless it is incorrectly positioned.
Still referring to FIGS. 4 and 5, the bracket assembly 10′ is also depicted as having a pair of shock absorbers 46′. Each of the pair of shock absorbers 46′ can be formed as described above. Each of the pair of shock absorbers 46′ is shown having an aperture 48′, see FIG. 5, sized to permit a portion of one of the fasteners 40′ to pass there through. A slight interference fit between each of the shock absorbers 46′ and the respective fastener 40′ is beneficial in keeping each of the shock absorbers 46′ attached to its respective fastener 40′. Each of the shock absorbers 46′ can also be constructed such that it only partially surrounds a portion of one of the fasteners 40′. In FIG. 5, each of the shock absorbers 46′ is depicted as a disc or thick washer situated above the upper surface 16′ of the base member 14′. As explained above, each of the shock absorbers 46′ can also be formed in a variety of other geometrical shapes, if desired.
Optionally, an adhesive 50′ can be positioned between a lower surface of each of the shock absorbers 46′ and the upper surface 16′ of the base member 14′ to hold each of the shock absorbers 46′ secure to the bracket 12′. When the adhesive 50′ is present and an interference fit is present between each of the fasteners 40′ and its respective aperture 48′, one can feel secure in the fact that each of the fasteners 40′ will be joined to the bracket 12′. This will ensure that each of the fasteners 40′ is not separated from the bracket assembly 10′. One of the clear benefits of the bracket assembly 10′ is that it is a unitary device that does not require additional elements or items to be attached or to be joined to it. At the construction site, the construction worker simply has to place or position the bracket assembly 10′ onto the upper surface of the cured concrete footing and secure it in its proper alignment by hammering each of the fasteners 40′ into the concrete footing. Each of the bracket assemblies 10′ will remain in place and it is not necessary to remove any of the bracket assemblies 10′ after the concrete foundation wall is poured and allowed to cure.
The pair of shock absorbers 46′ functions to permit the pair of fasteners 40′, i.e. nails, screws, etc. to be driven through both the respective aperture 36′ and the respective sealant 38′ and into the concrete footing by a hammer, nail gun, etc. to secure the bracket assembly 10′ thereto. As each of the fasteners 40′ is driven down into the concrete footing, the enlarged head 42′ on each of the fasteners 40′ will contact the respective shock absorber 46′. Each of the shock absorbers 46′ can flex and contract while providing resistant which prevents the respective fastener 40′ from being driven further downward by an appreciable amount. In short, each of the shock absorbers 46′ will prevent the bracket 12′ from breaking or cracking as the respective fastener 40′ is inserted into the concrete footing. As each of the fasteners 40′ passes through the respective sealant 38′, it will displace some of the sealant 38′ and cause it to move downward and outward. This helps assure that a good moisture tight and/or water tight seal is created between the lower surface 18′ of the bracket 12′ and the upper surface of the cured concrete footing.
Referring now to FIG. 7, a plan view of a rectangular shaped concrete footing 58 is shown having an upper surface 60. The concrete footing 58 is at least partially cured or hardened so that it can support weight, such as a foundation wall. Secured to the upper surface 60 of the concrete footing 58 is a plurality of the bracket assemblies 10 or 10′. The bracket assemblies 10 or 10′ are spaced a predetermined distance apart over the perimeter of the concrete footing 58. Normally, a bracket assembly 10 or 10′ can be placed about 1.5 feet, 2 feet, 3 feet or any desired distance from an adjacent bracket assembly 10 or 10′. At the corners of the concrete footing 58 or at a bend, at a curved portion, at a shoulder, etc, the bracket assemblies 10 or 10′ can be spaced closer together to provide additional support. At a corner of the concrete footing, for example, adjacent bracket assemblies 10 or 10′ may be spaced only a few inches apart.
Still referring to FIG. 7, an interior foundation wall form 62 and an exterior foundation wall form 64 are shown being positioned on the upper surface 60 of the concrete footing 58 adjacent to the upstanding first and second flanges 24 and 26 or 24′ and 26′ of each bracket 12 or 12′. The interior and exterior foundation wall forms, 62 and 64 respectively, abut against the outside surfaces of the flanges 24 and 26 or 24′ and 26′ and are aligned parallel to one another. The bracket assemblies 10 or 10′ keep and retain the interior and exterior foundation wall forms, 62 and 64 respectively, in a parallel alignment and at a set distance apart. The bracket assemblies 10 or 10′ prevent the interior and exterior foundation wall forms, 62 and 64 respectively, from becoming misaligned, as indicated by the dotted lines in FIG. 7.
The interior foundation wall form 62 has a smooth inner surface 66 and the exterior foundation wall form 64 has a smooth inner surface 68. The two smooth inner surfaces, 66 and 68, face one another when the interior and exterior foundation wall forms, 62 and 64 respectively, are correctly positioned on the upper surface 60 of the concrete footing 58. The interior and exterior foundation wall forms, 62 and 64 respectively, are commonly constructed of aluminum, steel, metal, wood or a combination of two or more different materials. The interior and exterior foundation wall forms, 62 and 64 respectively, can be obtained in a variety of sizes, such as: 1 foot by 8 feet, 2 feet by 8 feet, 4 feet by 8 feet, etc. or in smaller sizes such as 1 foot by 2 feet, 2 feet by 4 feet, 4 feet by 4 feet, etc. The interior and exterior foundation wall forms, 62 and 64 respectively, can also be obtained in various shapes to extend around corners, to form an arc, a semi-circle, a rounded or circular shape, or to form some other geometrical profile. For example, the interior and exterior foundation wall forms, 62 and 64 respectively, can be L-shaped, C-shaped, U-shaped, etc.
Turning now to FIGS. 8 and 9, one can clearly see that the interior and exterior foundation wall forms, 62 and 64 respectively, are not secured, joined or attached to the first and second flanges 24′ and 26′ but instead abut such flanges 24′ and 26′. When properly assembled, the bracket assemblies 10 or 10′ are positioned between the inner surfaces 66 and 68 of the interior and exterior foundation wall forms, 62 and 64 respectively. The bracket assemblies 10 or 10′ are permanently attached or secure to the concrete footing 58 by the fasteners 40′ and are designed to stay in place after the foundation wall is poured. The bracket assemblies 10 or 10′ prevent the interior and exterior foundation wall forms, 64 and 66 respectively, from moving laterally with respect to the concrete footing 58. Concrete is then poured between the smooth inner surfaces 66 and 68 of the interior and exterior foundation wall forms, 62 and 64 respectively. The concrete is allowed to cure or set over a number of days to form a concrete foundation wall 70. The curing time is dependent on: the composition of the concrete mix, the length, width and depth of the concrete, the outside temperature, the relative humidity, the climate, and any chemicals added to the concrete mix, as well as other factors known to those skilled in the art.
Once the concrete foundation wall 70 has at least temporarily cured, the interior and exterior foundation wall forms, 64 and 66 respectively, are removed. The interior and exterior foundation wall forms, 64 and 66 respectively can be reused multiple times on various buildings. With the bracket assemblies 10 or 10′ in place between the upper surface 60 of the concrete footing 58 and a lower surface of the foundation wall 70, a seal will be formed by the sealant 38 or 38′. The sealant 38 or 38′ will prevent moisture and/or water from flowing along the lower surface, 18 or 18′, of the bracket, 12 or 12′ respectively, from outside of the foundation wall 70 to the inside of the foundation wall 70.

Method

Referring now to FIG. 10, a flow chat is depicted of a method for facilitating the installation of a concrete wall on a concrete footing. The method includes the steps of marking a pair of spaced apart, parallel lines on the upper surface 60 of a concrete footing 58. The set of parallel lines can be formed by using a string encased in a powered, colored chalk. The string is stretched to a taut position directly above and in close proximity to the upper surface 60 of the concrete footing 58. The string is then pulled upward and released so that it will snap against the upper surface 60. This action causes the powered, colored chalk to exit the string and form a line on the concrete footing 58. One or two chalked positioning lines can be formed on the upper surface 60 of the concrete footing 58. When one positioning line is used, it should be the exterior positioning line. After the one positioning line is marked, one or more bracket assemblies 10 or 10′ can be aligned perpendicular to the positioning line and be secured in place by the fastener(s) 40 or 40′. Optionally, both an interior positioning line and an exterior positioning line are marked on the upper surface 60 of the concrete footing 58. After the two parallel positioning lines are marked, one or more bracket assemblies 10 or 10′ are secured to the upper surface 60 of the cured concrete footing 58 by driving the fastener(s) 40 or 40′ into the concrete footing 58, such as by the use of a hammer. Desirably, multiple bracket assemblies 10 or 10′ are used for a single building. Each of the bracket assemblies 10 or 10′ are positioned between the pair of spaced apart lines at a predetermined distance from one another. The distance between each bracket assembly 10 or 10′ can vary, especially when one has to contend with corners, bends, jogs, etc. Each of the bracket assemblies 10 or 10′ includes a bracket 12 or 12′ having a base member 14 or 14′ with an upper surface 16 or 16′ and a lower surface 18 or 18′. Each bracket 12 or 12′ also includes first and second spaced apart flanges, 24 and 26 or 24′ and 26′ respectively, which are integrally formed with the base member 12 or 12′. The first and second flanges, 24 and 26 or 24′ and 26 respectively, extend upwardly from the base member 14 or 14′. One or two cavities 32 or 32′ are also formed in the base member 14 or 14′. Each of the cavities 32 or 32′ has an opening, 34 or 34′ respectively, aligned with the lower surface 18 or 18′ of the bracket 12 or 12′. One or more apertures 36 or 36′ are formed through the base member 14 or 14′ and each aperture 36 or 36′ is aligned with one of the cavities 32 or 32′. A sealant 38 or 38′ is positioned in each cavity 32 or 32′ and partially extends outward therefrom below the lower surface 18 or 18′ of the bracket 12 or 12′. Desirably, the sealant 38 or 38′ extends across the entire width w or w′ of the bracket 12 or 12′ in order to form a satisfactory seal. A movable fastener 40 or 40′ is positioned in the aperture 36 or 36′. Each of the bracket assemblies 10 or 10′ is then secured to the upper surface 60 of the concrete footing 58 by driving the fastener(s) 40 or 40′ through the sealant 38 or 38′ and into the concrete footing 58. An interior foundation wall form 62 is then positioned adjacent to and outside of the first flange 24 or 24′. An exterior foundation wall form 64 is simultaneously or sequentially positioned adjacent to and outside of the second flange 26 or 26′. Each of the interior and exterior foundation wall forms, 62 and 64 respectively, has a smooth inner surface, 66 and 68 respectively. The interior and exterior foundation wall forms, 62 and 64 respectively, are spaced an even distance apart and are aligned parallel to one another. Additional brackets or mechanical devices can be attached to the lower, middle and/or upper surfaces of the interior and exterior foundation wall forms, 62 and 64 respectively, to maintain the proper spacing therebetween. Commonly, a mechanical device, such as a tie, is positioned about one foot from the bottom of a foundation wall form, a second mechanical device is positioned about one foot from the top of the foundation wall form, and additional mechanical devices are spaced about every two feet therebetween. Concrete is then poured between the interior and exterior foundation wall forms, 62 and 64 respectively, and the concrete is allowed to cure or set to form an upstanding foundation wall 70.
Once the concrete has cured or set, the interior and exterior foundation wall forms, 62 and 64 respectively, are removed. The bracket assemblies 10 or 10′ are left in place between the upper surface 60 of the concrete footing 58 and a lower surface of the foundation wall 70. The sealant 38 or 38′, located on the lower surface 18 or 18′ of the brackets 12 or 12′, can be a moisture and/or water repellant silicone. The silicone functions to prevent moisture and/or water from seeping under the bracket 12 or 12′ between the concrete foundation wall 70 and the upper surface 60 of the concrete footing 58. It is important to prevent moisture and/or water from seeping from the outside of the foundation wall 70 to the inside of the foundation wall 70.
While the invention has been described in conjunction with several specific embodiments, it is to be understood that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the aforegoing description. Accordingly, this invention is intended to embrace all such alternatives, modifications and variations which fall within the spirit and scope of the appended claims.

Claims

1. A bracket assembly for facilitating installation of a concrete wall on a concrete footing, comprising:

a) a bracket having a base member with an upper surface and a lower surface, and first and second spaced apart flanges integrally formed with said base member and extending upwardly therefrom;

b) at least one cavity formed in said base member, said cavity having an opening aligned with said lower surface;

c) an aperture formed through said base member and aligned with said cavity;

d) a sealant position in said cavity; and

e) a movable fastener positioned in said aperture, said fastener capable of being driven through said sealant and into said concrete footing to secure said bracket assembly thereto.

2. The bracket assembly of claim 1 wherein said bracket has a width and said cavity extends across at least about 75% of said width.

3. The bracket assembly of claim 2 wherein said cavity extends completely across said width.

4. The bracket assembly of claim 3 wherein said cavity is a channel aligned parallel to said first and second flanges.

5. The bracket assembly of claim 3 wherein said fastener extends into said channel and is movably retained therein by said sealant.

6. The bracket assembly of claim 2 wherein said bracket is a C-shaped member formed from a nonmetallic material.

7. The bracket assembly of claim 6 wherein said bracket is formed from a thermoplastic material.

8. The bracket assembly of claim 1 wherein said bracket has a length and said first and second flanges each having a height which is at least about 8% of said length.

9. The bracket assembly of claim 1 wherein said sealant is water repellant.

10. A bracket assembly for facilitating installation of a concrete wall on a concrete footing, comprising:

a) a bracket having a base member with an upper surface and a lower surface, and first and second spaced apart flanges integrally formed with said base member and extending upwardly therefrom, and said bracket having a length, a width and a thickness;

b) a pair of channels formed in said base member, each of said channels having an opening aligned with said lower surface;

c) a pair of apertures formed through said base member and each of said apertures being aligned with one of said channels;

d) a sealant position in each of said channels;

e) a pair of fasteners, each positioned in one of said apertures; and

f) a pair of shock absorbers each positioned about one of said fasteners and situated above said upper surface of said base member, each of said shock absorbers permitting said respective fastener to be driven through said sealant and into said concrete footing to secure said bracket assembly thereto.

11. The bracket assembly of claim 10 wherein each of said fasteners is a nail having an enlarged head, and said nail can be driven through said sealant and into said concrete footing until said enlarged head contacts said shock absorber.

12. The bracket assembly of claim 10 wherein said base member has a first end and a second end and each of said first and second flanges is located at one of said first and second ends.

13. The bracket assembly of claim 12 wherein each of said pair of flanges is aligned at a right angle to said base member, each of said pair of channels is located adjacent to and inward of one of said first and second flanges, and said sealing material is silicone.

14. The bracket assembly of claim 13 wherein silicone is a water repellant, pliable material that remains receptive to change in physical dimensions.

15. The bracket assembly of claim 10 wherein said sealing material is a foam which extends outward below said lower surface of said bracket and extends across the width of said bracket.

16. A method of facilitating installation of a concrete wall on a concrete footing, said method comprising the steps of:

a) marking a pair of spaced apart lines on an upper surface of said concrete footing;

b) positioning at least two bracket assemblies between said pair of spaced apart lines at a predetermined distance, each of said bracket assemblies including a bracket having a base member with an upper surface and a lower surface, and first and second spaced apart flanges integrally formed with said base member and extending upwardly therefrom, a pair of channels formed in said base member, each of said channels having an opening aligned with said lower surface, a pair of apertures formed through said base member and each of said apertures being aligned with one of said channels, a sealant position in each of said channels, and a pair of movable fasteners each positioned in one of said apertures;

c) securing each of said bracket assemblies to said concrete footing by driving said pair of fasteners through said sealant and into said concrete footing;

d) positioning an interior and an exterior wall form adjacent to said first and second flanges; and

e) pouring concrete between said interior and exterior wall forms to create a concrete wall.

17. The method of claim 16 further comprising the step of removing said interior and exterior wall forms after said concrete wall has at least partially cured.

18. The method of claim 16 wherein multiple brackets assemblies are secured to said upper surface of said concrete footing at predetermined distances.

19. The method of claim 16 wherein said sealant is a water repellant silicone which functions to prevent water from seeping between said concrete wall and said concrete footing.

20. The method of claim 16 wherein said pair of spaced apart lines formed on said upper surface of said concrete footing are formed using powdered, colored chalk.