Title:
Anchor bolt placement protection assembly and method for aligning structural elements in a form when pouring concrete
Kind Code:
A1


Abstract:
An anchor bolt placement and protection assembly for positioning or setting a threaded anchor bolt in a concrete stem foundation or concrete slab in relation to spaced form boards for controlling the depth of the anchor bolt in the concrete and the protected length of the anchor bolt projecting above the concrete foundation or slab. The assembly includes a base plate carrying a fixed, elongated tubular member having a lumen with an inner diameter dimensioned to receive the selected anchor bolt. The tubular member is sized to abut a detached tubular having an inside diameter that is substantially equal to the fixed tubular member's inside diameter. The assembly also includes a fastener with an anchor bolt thread engaging lumen with an inside diameter that is substantially equal to said fixed tubular member's inside diameter.



Inventors:
Smith, James R. (Redding, CA, US)
Application Number:
11/232866
Publication Date:
01/26/2006
Filing Date:
09/23/2005
Primary Class:
International Classes:
E02D27/00; E02D27/32
View Patent Images:



Primary Examiner:
LE, TAN
Attorney, Agent or Firm:
WILLIAM A BLAKE LLC (Laytonsville, MD, US)
Claims:
What is claimed is:

1. An anchor bolt placement and protection assembly for positioning or setting a threaded anchor bolt in a concrete stem foundation or concrete slab in relation to at least one of two spaced form boards defining at least one surface of said concrete stem foundation or concrete slab and for controlling the depth of the anchor bolt in the concrete and the protected length of the anchor bolt projecting above the concrete foundation or slab, comprising: a) a fixed, elongated tubular member having a central axis and a distal end, an open proximal end symmetrical about said central axis, a lumen with a predetermined inner diameter dimensioned to encompass the outer diameter of a selected anchor bolt and a depth between said distal end and said open proximal end correlated to the protected length of said anchor bolt's shaft that is to project above said concrete stem foundation or concrete slab; b) a base plate having an aperture defining the open proximal end of said elongated tubular member and at least one integral elongated reinforcing rib extending laterally from said tubular member, said base plate having a top surface opposing a bottom surface and a first end edge spaced a predetermined distance from said tubular member's central axis; c) a detached tubular member having a cylindrical side wall of selected axial length defining a lumen with an open distal end opposite an open proximal end, said lumen having an inside diameter that is substantially equal to said fixed tubular member's inside diameter; and d) a fastener having a cylindrical side wall of selected axial length defining a thread engaging lumen with an open proximal end, said lumen having an inside diameter that is substantially equal to said fixed tubular member's inside diameter.

2. The anchor bolt placement and protection assembly according to claim 1, wherein said base plate and said fixed tubular member are integrally formed as a one-piece unit.

3. The anchor bolt placement and protection device according to claim 1, wherein said base plate and fixed tubular member are integrally formed as a unitary body fabricated from synthetic resinous material.

4. The anchor bolt placement and protection assembly of claim 1, wherein said base plate circumscribes said tubular member's central axis, and at least one integral elongated plate portion extends perpendicularly from said elongated tubular member.

5. An anchor bolt placement and protection assembly for positioning a threaded anchor bolt in a concrete foundation or concrete slab in relation to at least one of two spaced form boards that define at least one surface of said foundation or slab and for controlling the length of the anchor bolt projecting above the foundation or slab or controlling the depth of the bolt in the foundation or slab, comprising: a) a substantially planar base plate having a bottom surface opposing an upper surface bearing alignment indicia; wherein said base plate includes a plurality of apertures each dimensioned to receive and support a nail; b) said base plate carrying a fixed elongated tubular member having a central axis and an upper terminal end, an open lower end symmetrical about said central axis, a predetermined inner peripheral diameter dimensioned to encompass the diameter of a selected anchor bolt and a depth between said terminal end and said open lower end correlated to the length of said anchor bolt that is to project above said concrete stem foundation or concrete slab; and c) a detached tubular member adapted to be coaxially aligned with said fixed tubular member and dimensioned to receive the anchor bolt when the bolt is inserted within said fixed tubular member and said coaxially aligned detached tubular member to allow a selected length of the anchor bolt to project above the plane of the base plate's upper surface.

6. The anchor bolt placement and protection assembly of claim 5, wherein said base plate has at least one integral elongated plate portion extending laterally from said tubular member and including an end edge spaced a predetermined distance from said central axis.

7. The anchor bolt placement and protection assembly of claim 6, wherein integral reinforcement ribs are spaced about the outer periphery of said fixed elongated tubular member at 90 intervals and extend from said base plate upper surface to adjacent said upper terminal end of said fixed elongated tubular member.

8. The anchor bolt placement and protection assembly of claim 7, wherein said base plate and fixed tubular member are integrally formed as a unitary body fabricated from synthetic resinous material.

9. The anchor bolt placement and protection assembly of claim 8, wherein said base plate comprises a substantially rectangular member having a length of at least four and one half inches.

10. The anchor bolt placement and protection assembly of claim 8, wherein said base plate comprises a substantially rectangular member having a length of approximately twelve half inches.

11. The anchor bolt placement and protection assembly of claim 8, wherein said base plate includes an integral elongated reinforcement rib is provided medianly of an elongated plate portion extending from adjacent said edge thereof to said elongated tubular member.

12. The anchor bolt placement and protection assembly of claim 8, wherein said base plate includes a plurality of integral elongated reinforcement ribs spaced at 90 intervals about said tubular member.

13. The anchor bolt placement and protection assembly of claim 8, wherein a plurality of transversely extending form board position indicating integral ribs are provided on the top surface of said base plate, said form board position indicating ribs being spaced about one inch apart.

14. The anchor bolt placement and protection assembly of claim 8, wherein a plurality of transversely extending form board position indicating integral ribs are provided on the top surface of said base plate, said indicating ribs being evenly spaced and said nail receiving apertures being spaced about one inch apart.

15. An anchor bolt placement assembly comprising: a) an elongated anchor bolt having an elongated main body portion symmetrical about a longitudinal axis, said anchor bolt having threads at said bolt's distal end portion and a transversely extending abutment portion at said bolt's proximal end portion; b) an anchor bolt placement and protection device including a fixed elongated tubular member symmetrical about a central longitudinal axis and having an open distal end and an open proximal end integral with a base plate including at least two integral laterally extending elongated plate portions each having top and bottom surfaces and an end edge spaced a predetermined distance from and extending in opposite directions from said central axis; c) at least one detached tubular member adapted to abut the distal end of said fixed tubular member; d) elongated form boards spaced apart to define a space to be filled with concrete and including parallel top edges coincident with the top surface of concrete filling said space; and e) wherein said distal end portion of said anchor bolt is surrounded by said tubular extension sleeve and said fixed elongated tubular member of said anchor bolt placement and protection device and said proximal end portion of said anchor bolt is thrust into said body of concrete filling said space between said form boards until the bottom surface of said elongated plate portion of said base plate rests on the surface of said concrete until the concrete hardens whereupon said anchor bolt placement and protection device is removed from said anchor bolt.

16. The anchor bolt placement assembly of claim 15, wherein said detached tubular member comprises an extension sleeve.

17. The anchor bolt placement assembly of claim 15, wherein said detached tubular member comprises a threaded nut fastener adapted to threadably engage said anchor bolt's distal threads.

18. The anchor bolt placement assembly of claim 15, wherein the edge of at least one laterally extending elongated plate portion overlaps said top edge of one of said form boards.

19. The anchor bolt placement assembly of claim 18, wherein the end portion of said elongated plate portion that overlaps the top edge of said form board is detachably secured to the top edge of said form board.

20. The anchor bolt placement assembly of claim 18, wherein each said integral elongated plate portion overlaps and extends past said top edge of an associated form board, and further including means detachably securing the distal end portions of each of said two elongated plate portions to an underlying form board.

Description:

This application is a continuation in part of and claims priority to the filing date of U.S. patent application Ser. No. 10/335,656 entitled “Anchor Bolt Placement and Protection Device”, filed Dec. 31, 2002. The entire disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to concrete foundations and the foundation forms made of boards into which concrete is poured and more particularly relates to mud sill anchor bolts and structural hardware bolts imbedded in the concrete. The present invention also relates to an anchor bolt placement and protection device adapted to be detachably mounted to the threaded end of an anchor bolt to shield the threads and vertical shaft exposed after pouring, protecting the threads and shaft from being coated with concrete during the pour. This invention also relates to properly positioning the anchor bolt in relation to the form boards between which the concrete is poured.

2. Discussion of the Prior Art

In conventional construction of homes and other buildings, it is well known to pour concrete between form boards for foundations set into trenches accommodating the wooden forms which retain the concrete while it hardens or cures. Conventional industry practice has been to place a wooden spacer bar between the form boards at the bottom of the trench and to nail a cleat across the top of the form boards to retain the proper spacing of the form boards while concrete is being poured into the form. While it is expected that the bottom spacer bars will be of appropriate length to retain the bottom edges of the form boards at the appropriate spacing in the trench bottom where they can be held in place by the pressure of the dirt filled into the trench against the outside surfaces of the form, it has been discovered that the wooden cleats nailed across the top edges of the form board provided unsatisfactory results. Often, the top edges of the form boards spread apart as the form is filled with concrete, and the spacing of the form boards is ruined. This is caused by improper nailing of the top cleat. Often, one end portion of the cleat must be nailed to the top edges of the form board after which the workman needs to manipulate a measuring rule between the inner surfaces of the top edge portions of the form boards while placing a second nail through the cleat and into the remaining form board while attempting to retain the two form boards at the appropriate spacing. This procedure is expensive in terms of materials and time since it often takes the workman a significant amount of time to achieve proper spacing at the top edges of the form boards. Another disadvantage of this method of spacing and retaining the upper edges of the form boards is that frequently workmen are paid for the number of linear feed of forms they erect. Workmen paid in this manner are motivated to work quickly rather than carefully and so contribute to the improper spacing of the top edges of the form boards or improper nailing of the cleats. Another disadvantage is that during the concrete pour, as the form is filled, the cleats are an obstruction to the agitation of the concrete. Concrete is agitated at this time to remove bubbles from the concrete. And the cleats obstruct the trowels used to “float” or smooth the top of the concrete to provide a relatively smooth surface for the placement of the mud sill which must be anchored to the top of the foundation or concrete slab by the anchor bolts when set into the concrete.

When anchoring the mud sill using anchor bolts, various systems have been utilized to support or align anchor bolts supported in relation to the top edges of the form boards while concrete is being poured. Placement of these anchor bolts is critical but the position of the anchor bolt is often misjudged, thus increasing the difficulty of boring holes in the mud sill to receive the anchor bolts. In addition to misplacement or irregular spacing between successive anchor bolts, another problem in the prior art system of setting anchor bolts is that the depth to which the anchor bolts are set is very often not uniform. Sometimes the anchor bolts are set so deeply that the threaded end of the anchor bolt does not project through the thickness of the mud sill, thereby providing no way to fix the position of the mud sill. Another problem is that the threaded end of the anchor bolt may project too far above the mud sill, requiring numerous washers to provide a surface properly engaging the threaded portion of the anchor bolts so that a nut may be threaded on to the anchor bolt to retain the mud sill, after it is placed over the anchor bolt.

Another problem is that during the pour, concrete may adhere to the anchor bolt and accumulate at the base of that portion of the anchor bolt shaft outer surface where the anchor bolt projects upwardly from the horizontal surface of the concrete. Once the concrete is cured, it is very difficult to remove this now hardened unwanted cement material and if the mud sill is simply placed over an anchor bolt which includes that accumulated material, the mud sill will not make uniform contact with the surface of the foundation, thereby providing an uneven, non-level surface upon which carpenters must build the wall. Very often this misaligned mud sill will cause misalignments in the wall and in the structures which rest on the wall, and such misalignments can even be seen where walls meet roof members, and so problems associated with unwanted material adhering to the upwardly projected portion of the anchor bolt shaft can propagate through and create significant defects in all of the structure that rests upon the mud sill.

There is a need, therefore, for an improved anchor bolt placement and protection device and a method for installing anchor bolts and aligning form boards.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide an anchor bolt protection and support assembly that cooperates with the threaded end of the anchor bolt to properly position the anchor bolt and protect the anchor bolt during the pour. Proper position provides a precise spacing in relation to the inner surface of a form board and also provides an appropriate depth for the length of the bolt and the thickness of the mud sill so that the mud sill (when placed over the anchor bolt) is properly oriented. It is another object of the present invention to protect the anchor bolt threads and the anchor bolt shaft from contamination by concrete during the pour, thereby avoiding an accumulation of cement material at the intersection of the anchor bolt where it projects above the surface of the pour concrete foundation.

Depending on the structure being constructed, foundation walls are frequently dimensioned to receive two by four (1.5 inch by 3.5 inch) or two by six (1.5 inch by 5.5 inch) mud sills. Usually, the mud sill is a red wood beam or other structural lumber member that must be drilled or bored at appropriate intervals to receive the threaded ends of the anchor bolts projecting vertically from the top surface of the foundation or concrete slab.

In accordance with the present invention, a protective placement device detachably envelopes and engages the exposed threaded end of the anchor bolt and includes at least one lateral projecting flange to index and accurately space the anchor bolt from a selected (e.g., inside) surface of the form board, so that all the anchor bolts are uniformly spaced from a reference form board surface. Proper spacing of the anchor bolts facilitates boring of the mud sill so that the holes in the mud sill are appropriately spaced to match the spacing between the anchor bolts and any structural hardware bolts.

In accordance with the present invention, a pre-manufactured or pre-molded device having a tubular extension projecting at a substantially perpendicular angle upward from an indexing flange is slipped over the threaded end of an anchor bolt to a predetermined depth and provides a surface upon which one can rest one or more optional tubular extension members dimensioned in selected lengths to provide a desired length of protected anchor bolt surface. Optionally, the device of the present invention can include a molded threaded nut member including an interior lumen having a side wall defined with thread receiving structural features so that the nut member, having an open or closed distal end can be threaded over the anchor bolt after the selected number of protective tubular segments are placed over the upwardly projecting anchor bolt's distal threaded end.

In the preferred embodiment, the laterally projecting flange members include printed indicia and through holes or bores adapted to receive nails at selected, marked intervals so that a workman can easily see where to place the flange member on the form board's selected reference surface and simply insert the nails in the through holes where they are conveniently held in a vertical orientation so that they can be hammered home, thereby at least temporarily fixing the position of the flange on the form.

Another embodiment includes an elongated flange having an upper surface with indicia used to measure form spread. The elongated flange is useful when installing forms and selecting the spread or transverse spacing or width between interior form board surfaces, since the distances are, in the preferred embodiment, included on the flange's upper surface.

The above and still further features and advantages of the present invention will become apparent upon consideration of the following detailed description of a specific embodiment thereof, particularly when taken in conjunction with the accompanying drawings, wherein like reference numerals in the various figures are utilized to designate like components.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective exploded view of an anchor bolt placement and protection assembly, in accordance with the present invention.

FIG. 2 is a perspective view of assembled elements of the anchor bolt placement and protection assembly of FIG. 1.

FIG. 3 is a plan view, in elevation, of the base plate of the anchor bolt placement and protection assembly of FIGS. 1 and 2, in accordance with the present invention.

FIG. 4 shows a plan view of an alternative embodiment of the anchor bolt placement and protection assembly base plate.

FIG. 5 shows a side view, in partial cross-section, of the base plate of FIG. 4.

FIG. 6 shows, in partial cross-section, the anchor bolt placement and protection assembly of the present invention including an anchor bolt placed in concrete, illustrating how the base plate can be nailed to form boards, in accordance with the present invention.

FIG. 7 is another alternative embodiment of the base plate of the present invention.

FIG. 8 is a side view of the base plate of FIG. 7, in partial cross-section, in accordance with the present invention.

FIG. 9 is an exploded view, in perspective, showing an alternative embodiment of the anchor bolt placement and protection assembly of the present invention.

FIG. 10 is a perspective view of the anchor bolt placement and protection assembly of FIG. 9.

FIG. 11 is a top view of the base plate for the anchor bolt placement and protection assembly of FIGS. 9 and 10.

FIG. 12 is a top or plan view of an alternative embodiment of the base plate.

FIG. 13 is a side view, in partial section, of the base plate of FIG. 12.

FIG. 14 is another alternative embodiment of the base plate, as seen from the top.

FIG. 15 is a side view, in partial section, of the base plate of FIG. 14.

FIG. 16 is a side elevation view, in partial section, showing the anchor bolt placement and protection assembly installed upon an anchor bolt and nailed to a form board in a concrete foundation, in accordance with the present invention.

FIG. 17 is an exploded view of an alternative embodiment of the anchor bolt placement and protection assembly of the present invention.

FIG. 18 is a plan view of the base plate of the anchor bolt placement and protection assembly of FIG. 17.

FIG. 19 is a perspective view of the assembled anchor bolt placement and protection assembly of FIG. 17.

FIG. 20 is a side view, in partial section, of the anchor bolt placement and protection assembly of FIGS. 17-19 installed in a concrete or cement structure bounded by form boards, in accordance with the present invention.

FIG. 21 is perspective view of a form spreading base, in accordance with the present invention.

FIG. 22 is a plan or top view of the form spreading base of FIG. 21.

FIG. 23 is a side view, in elevation, showing in partial cross-section the form spreading base of FIGS. 21 and 22 used in connection with alternate placements of form boards for pouring a concrete foundation or the like, in accordance with the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

A first embodiment of the anchor bolt placement and protection assembly 10 of the present invention is illustrated in FIGS. 1-5. Referring now to FIGS. 1 and 2, anchor bolt placement and protection assembly 10 includes a substantially planar base plate or flange 12 having an upper surface 14 opposite a lower surface 16. In the illustrated embodiment, a base plate bolt aperture 18 is provided in the shape of a circle. Base plate 12 also includes a plurality of nail-receiving apertures 20 each including a raised collar portion dimensioned to receive and hold a nail placed within the collar in preparation for having that nail driven into a foundation form board or the like. The nail apertures 20 are preferably spaced at even increments selected to appropriately position base plate 12 in relation to form boards during a pour (e.g., as seen in FIG. 6).

Base plate 12 also includes, on upper surface 14, a plurality of substantially parallel spaced, transverse alignment indicia ribs 22 which can be used as layout guides for foundation walls or the like. Base plate 12 is a substantially rectangular member having radiussed corners, a length of approximately twelve inches, a width of approximately one and three quarters inches and a thickness of approximately three sixteenths of an inch, when made from fiber reinforced resin or polymer. The six transversely extending form board position indicating integral ribs 22 are provided on the top surface 14 of each of two integral elongated base plate portions and are spaced along the long axis of base plate 12 at about one inch apart. The fourteen nail-receiving apertures 20 are formed in transversely aligned pairs in the plate portions and are also spaced along the long axis of base plate 12 at about one inch apart, center to center.

As best seen in FIGS. 1 and 3, base plate 12 carries a substantially perpendicular upwardly projecting fixed tubular member 30 having an open distal end defining a sealing surface with a substantially flat or planar edge adapted to seal against, a butt or receive a similar flange sealing surface on either an optional movable tubular member 64 or a threaded nut 68. Fixed tubular member 30 has an elongate central access 26 and defines an interior lumen 36 terminating proximally in base plate and coaxially with circular base plate aperture 18. Tubular member proximal end 34 is rigidly fixed to or is an integral part of base plate 12 and is supported by a plurality of ribs or web segments, 44, 46 which reinforce and support fixed tubular member 30. Tubular member lumen 36 has a selected inside diameter 37 adapted too closely encircle, protect and support a selected anchor bolt size (e.g., sized to fit one half inch O.D. bolts or five eighth inch O.D. bolts). Tubular member interior wall 38 defines, preferably, a circular lumen 37 and the tubular member exterior wall 40 is adapted to deflect debris, poured cement and other materials, protecting an anchor bolt when the anchor bolt placement and protection assembly 10 is in use.

As noted above, longitudinal reinforcing web or rib 44 extends along at least part of the central axis of base plate 12 and is arrayed at, preferably, a 90° angle to transverse reinforcing webs 46 which are aligned transversely to the central axis of base plate 12, thereby providing optimal reinforcement or support to upwardly projecting fixed tubular member 30.

In accordance with a preferred embodiment of the present invention, the anchor bolt placement and protection assembly 12 preferably is packaged as a kit including one and possibly more extension sleeves 50, 64 defined in selected lengths to permit the installer or user to pre-select the amount of anchor bolt shaft to extend above the concrete foundations upper surface. An extension sleeve (e.g., 50 or 64) can also be used alone or in combination to determine the anchor bolt depth projecting into the concrete material.

Extension sleeve 50 preferably includes a substantially tubular or cylindrical side wall segment having a distal end 52 defining a sealing surface opposite a proximal end 54 carrying a sealing flange dimensioned to closely fit upon and sealably engage the sealing surface (e.g., of tubular member 32 or of another extension sleeve). Extension sleeve 50 defines an interior lumen 56 which is preferably symmetrical around a central axis and constrained by extension sleeve interior wall 58. Extension sleeve exterior wall 60 includes, preferably, radially arrayed reinforcing ribs 62 providing mechanical support and stiffing to the protective extension sleeve. In the embodiment of FIG. 1, second extension sleeve 64 is shown in a second, longer axial length (e.g., three and one half inches) than first extension sleeve 50 (at, e.g., one and three quarter inches) and can be used alone or combination with other extension sleeves (e.g., 50) to provide an anchor bolt placement and protection assembly 10 having a number of different possible configurations.

The components of assembly 10 which come into contact with the anchor bolt, as best seen in FIGS. 6, 16 and 20, each have a proximal flange with a transverse sealing surface bounded by a peripheral barrier wall segment that effectively deflects any material falling from above away from the sealing surface. Each tube-like component also has a distal sealing surface adapted to engage and abut the proximal sealing surface of the mating component, and the distal sealing surface and distal end are sized to fit within and be protected by the mating component's proximal end peripheral barrier wall. Accordingly, as shown in FIG. 6, tubular member distal end has a sealing surface 32 that fits within and is protected by the proximal end and sealing flange 72 of threaded nut 68.

In the preferred embodiment, a threaded nut 68 includes an open or closed distal end 70 and proximal end with sealing flange 72 is adapted to rest upon and sealably engage a distal end sealing surface of the mating component (e.g., the extension sleeve distal surface 52 or fixed tubular member distal surface 32). Threaded nut 74 includes and interior lumen 74 within an interior wall having thread engaging structural elements, such as threads. Threaded nut 68 also includes a substantially cylindrical exterior wall preferably including a plurality of radially arrayed reinforcing ribs aligned along the axis of threaded nut 68. Threaded nut 68 also preferably includes raised projections 80 adapted to receive and engage tool surfaces such as wrench jaws, pliers of the like for use when installing or removing threaded nut 68 on the anchor bolt distal end.

Referring now to the embodiment shown in FIG. 6, a concrete foundation form 100 includes a first elongate form board 110 aligned, preferably, in parallel with a second elongate form board 112. The form boards are spaced apart to define an interior volume adapted to receive concrete, mud or cement 114 which is poured in and which, once cured, provides, preferably, a relatively level and uniform concrete upper surface 116. Advantageously, the anchor bolt placement and protection assembly of the present invention protects the entire extent of the anchor bolt projecting up from the foundation, and so no splashed cement or other material is accumulated on the anchor bolt shaft above the upper surface of the concrete, and so no time consuming cleaning is required. This will ensure that when the pre-drilled mud sill plate is placed over the anchor bolts upon the foundations, the mud sill plate will lie flat upon and flush with the foundation's upper surface, providing a more level surface to build upon.

In use, the builder or user selects the appropriate indicia to align the base plate and selected nail holes over the form boards. Then a plurality of nails 118 are driven through the base plate nail apertures (e.g., 20) and into the form board, thereby fixing the position of the anchor bolt placement and protection assembly and the anchor bolt 120 secured therein. Anchor bolt 120 has its distal, threaded end 122 securely held within and protected by threaded nut 68 and fixed tubular member 30 so that the mud or concrete material cannot splash upon or adhere to the exterior surface of anchor bolt shaft 126. Use of anchor bolt placement and protection assembly 10 permits the user or form maker to carefully control the depth of the anchor bolts proximal end 124 within the concrete foundation 114.

Optionally, one or more extension sleeves (e.g. 50, 64) could be used to raise the level of anchor bolt 120 so that a greater length of anchor bolt shaft 126 is supported above the upper surface 116 of the concrete.

Referring now to FIGS. 7 and 8, a second embodiment of the anchor bolt placement and protection assembly 140 includes a substantially planar elongated base plate 142 from which projects a perpendicular tubular member 144. Base plate 142 is preferably configured as a rectangular member having a plurality of transverse thru-bores or apertures including a plurality of nail receiving apertures aligned with a plurality of alignment indicia or centering guide indicators. A longitudinal reinforcing web or rib 146 preferably supports fixed tubular member 144 which is also supported by a plurality of reinforcing ribs 148 that extend vertically along the length of tubular member 144. Tubular member 144 preferably has a selected diameter 150 which is slightly larger than and closely fits with a selected size of anchor bolt shaft.

Base plate 142 is a substantially rectangular member having radiussed corners, a length of approximately twelve inches, a width of approximately one and three sixteenth inches and a thickness of approximately three sixteenths of an inch, when made from fiber reinforced resin or polymer. The six transversely extending form board position indicating integral ribs are provided on the top surface of each of two integral elongated base plate portions and are spaced along the long axis of base plate 142 at, preferably, one inch apart. The twelve nail-receiving apertures are formed in transversely aligned pairs in the plate portions and are also spaced along the long axis of base plate 142 at about one inch apart, center to center.

FIGS. 9-11 illustrate a third embodiment of the anchor bolt placement and protection assembly 160 including a substantially planar base plate 162 from which projects a substantially perpendicular cylindrical tubular member adapted to receive and sealably engage with one or more extension sleeves (e.g. 166, 170) or, optionally, a threaded nut 168 all of which have a selected inside diameter adapted to receive and protect an anchor bolt shaft of selected size. When configured as shown in FIG. 10, extension sleeve 166 has a proximal or lower flange area which sealably engages the distal sealing surface 164 of tubular member 164 to seal out debris, cement and other material which may otherwise contaminate the outer surface of the anchor bolt shaft. Similarly, threaded nut 168 includes a proximal flange adapted to bear against and sealably engage the distal end of extension sleeve 166. As shown in FIG. 11, the tubular member inside diameter 172 is dimensioned to accommodate a selected size (e.g., ½″) anchor bolt shaft.

Base plate 162 is a substantially rectangular member having radiussed corners, a length of approximately four and one half inches, a width of approximately one and three quarters inches and a thickness of approximately three sixteenths of an inch, when made from fiber reinforced resin or polymer. The two transversely extending form board position indicating integral ribs are provided on the top surface of the elongated base plate portion and are spaced along the long axis of base plate 162 at one inch apart. The four nail-receiving apertures are formed in transversely aligned pairs in the plate portions and are also spaced along the long axis of base plate 162 at one inch apart, center to center.

As noted above, anchor bolts of different sizes can be accommodated, and each assembly is preferably color coded by anchor bolt size. In an exemplary embodiment, ½ inch bolts are accommodated using assembly components molded from bright orange polymer or fiber reinforced molded resin material, ⅝ inch bolts are accommodated using assembly components molded from bright blue polymer or fiber reinforced molded resin material, and ⅞ inch bolts are accommodated using assembly components molded from bright green polymer or fiber reinforced molded resin material.

FIGS. 12-23 show additional optional elements included as part of the kit for use with the anchor bolt placement and protection assembly of the present invention. Specifically, FIGS. 12 and 13 show a fourth embodiment of the base plate 176 including an upwardly projecting tubular member having an interior lumen with a selected inside diameter (e.g. ½ inch) adapted for receiving a selected anchor bolt. This tubular member includes a distal sealing surface adapted for engaging the sealing proximal end of an extension tube or threaded nut, as above.

FIGS. 14 and 15 illustrate a fourth embodiment of the base plate 184 including an upwardly projecting reinforced tubular member 186 having a larger lumen with an inside diameter of, for example, ⅞ of an inch, and so is adapted for receiving an anchor bolt of that size. Base plate 184 also includes a distal sealing surface at the upper edge of tubular member 186 adapted to receive and engage a proximal sealing surface and flange for a similarly sized extension or threaded nut.

FIG. 16 shows, in partial cross-section, an anchor bolt placement and protection assembly 160 installed upon and threadably engaged with an anchor bolt 120 of, for example, ⅝ inch diameter. Base plate 162 is first positioned in an appropriate orientation on form board 112 to properly locate anchor bolt 120 within the confines of the form, before concrete is poured. The distal end of the anchor bolt 124 is set at the preselected depth by inclusion of, optionally, one or more extension sleeves (e.g., 50, not shown). In the embodiment illustrated in FIG. 16, no extension sleeves are used. The installer or builder can then proceed to fill the form with cement until the upper surface of the cement 116 rises to the level indicated by the bottom surface of base plate 160, whereupon the cement is allowed to cure, all without staining or splashing upon the anchor bolt shaft 126 or contaminating the anchor bolt threads.

FIGS. 17-20 illustrate a fifth embodiment of the anchor bolt placement and protection assembly of the present invention where a substantially planar L-shaped base plate 210 includes an upper surface carrying raised guide lines or alignment indicia 211. An upwardly projecting tubular member 212 has an open distal end 214 with a sealing distal surface, as above. Optionally, one or more extension sleeves 216, 220 may be used to customize the length of the anchor bolt shaft to be protected and set the depth of the distal end of the anchor bolt in the foundation. Once installed on the anchor bolt, a threaded nut 218 is threadably engaged on the distal end of the anchor bolt. The lumen within tubular member 212 has a selected inside diameter 222 which, in the illustrated embodiment, is one-half inch.

As best seen in FIG. 20, the anchor bolt placement and protection assembly 200 is well suited for use when concrete is poured into a form and then anchor bolts are placed in the yet uncured concrete. The base plate 210 rests upon the upper surface of the concrete 116 thereby setting the depth of the anchor bolt in the concrete. This anchor bolt placement and protection assembly 200 can therefore be used to place anchor bolts anywhere in the foundation, after the concrete has been poured within form 100.

Preferably, the kit including the above-identified components includes one or more optional form spreading bases 230 including a substantially planar base formed as an elongated rectangular body having an upper surface 232 opposite a lower surface and a number of nail receiving apertures or through bores 234 are defined in selected location, preferably next to base alignment indicia 236 which provide transverse raised segments that are easily perceived by the carpenter in the field.

Preferably, base spacing indicia 238 (e.g. six inches or eight inches) are also provided to permit the user to select an appropriate spacing for form boards. Form spreading base 230 is preferably reinforced with a longitudinal reinforcing rib 240 and is fabricated from fiber reinforced resin or a polymer material, optionally provided in selected colors (e.g. orange).

In use, builders and concrete contractors can employ the foundation bolt installation system 10 in a manner which permits savings of labor, time and money. Advantageously, the components shown in the figures can be provided in kits having a variety of spreaders, guides and nailers to permit a quick and easy selection of the appropriate component in a variety of construction situations. For example, a kit including the a plurality of the components shown in FIGS. 17, 18 and 19, referred to as a Bolt-Rite Stabber™ kit, permits quick and accurate insertion of anchor bolts into wet concrete. The integral or built-in centering guide indicia permit quick setting of anchor bolts to a correct depth and position for either 2×4 or 2×6 sill plates. The protective threaded cover cap 218 completely covers and protects bolt threads from damage and concrete splash. The entire assembly is easily removed when concrete is cured by unthreading the cover cap 218, removing it from the distal end of the anchor bolt 122 and sliding the protective assembly up and off of the bolt. In a preferred embodiment, the guide of FIGS. 17, 18 and 19 are configured for use with ½″ O.D. bolts, but other size bolts can easily be accommodated. The optional use of sleeves of selected length permit the installer to select the desired components from the assembly kit and install the guide, removable sleeve and threaded nut to control both the amount of the anchor bolt to be said into the wet concrete, and the amount of the side-wall or shaft of the bolt to project above the concrete's upper surface, once the concrete is cured.

The kit can also include one or more Bolt-Rite Nailer™ assemblies using base plate 176 as shown in FIGS. 12-16. This allows layout of all anchor bolts, nailed securely in the correct position before pouring concrete. This is especially helpful in that it allows anchor bolts to be in place before or after pouring in fast-curing climates. Use of the assembly shown in FIGS. 12-16 eliminates the need for concrete drilling or epoxy-ing to fix forgotten or mispositioned anchor bolts. Built-in guides or indicia on the upper portion of the flanged base plate allow users or installers to quickly set anchor bolts to the correct depth and then position those bolts in relation to either of the 2×4 or 2×6 sill plates.

The protective assembly of FIG. 16 is easily removed when concrete is cured by unthreading the cover cap or threaded nut 168 from the distal end of the anchor bolt 122, and then removing the nails 118 attaching the flange or base plate 162 to the form board (e.g., 112), whereupon the entire assembly 160 can be slideably removed from the distal end of the bolt 122.

As shown in FIGS. 1-8, the Bolt-Rite w/Spreader™ assembly permits installers to set the anchor bolts and spread forms in one cost effective operation. As above, the protective threaded cap is easily removed after concrete is cured and each of the components is easily removed from the bolt. This also provides protection from concrete splash omitting the need to clean the sidewall or shaft of the bolt after the concrete is cured.

In the preferred embodiment, a spreader 230 as shown in FIGS. 21 and 22 is included as part of a kit with the protective assemblies discussed above. This includes ready to use pre-positioned nail holes 234 and provides a rigid form spreading layout guide for, in the preferred embodiment, 6″ or 8″ wide foundations. When the spreader of FIGS. 21 and 22 is used in conjunction with the other elements in a kit, users can avoid wasting time measuring and cutting expensive stakes to make form spreaders. With predrilled nail holes 234 and layout marks or guide indicia 236, the form spreading or form construction operation is completed more quickly. The narrow profile of the spreader member of FIGS. 21 and 22 eases the trowelling process when finishing the poured foundation's surface. In the preferred embodiment, all of the assembly and kit components discussed above are molded from polymer, possibly reinforced with fibrous material and are finished or molded-in high visibility colors such as orange, blue or green to help installers quickly identify overlooked areas in the form construction process.

The anchor bolt protection and placement assembly and kit elements of the present invention permit users to set perfect anchor bolts 120 in foundations, keeping the anchor bolt surfaces clean, straight and correctly positioned in a repeatable and easily learned method. The apparatus of the present invention permits easy compliance with code (UBC) requirements specifying that all embedments are to be in place prior to pouring the concrete for a foundation. This prevents last-minute hurried efforts to pound bolts into hardening concrete and permits builders to easily recover the invention's purchase cost in relatively few applications, since hours otherwise spent cleaning bolt threads are conserved. The anchor bolt placement and protection assembly components are molded with integral reinforcing ribs, so the components will remain rigid and provide a rugged service to prevent deflection of the bolts when concrete is poured, thereby keeping anchor bolts straight. Each component of each assembly is also reusable, thereby providing more economical use and ease of amortization.

Variations on the foregoing dimensions can be used to conform to standards and practices in other regions. For example, the transversely extending form board position indicating integral ribs 22 provided on the top surface 14 of each of two integral elongated base plate portions can be spaced along the long axis of base plate 12 at another desired spacing, e.g., a selected number of centimeters. The nail-receiving apertures 20 formed in the plate portions can also be spaced at another desired spacing, e.g., two centimeters, center to center.

Having described preferred embodiments of a new and improved method, it is believed that other modifications, variations and changes will be suggested to those skilled in the art in view of the teachings set forth herein. It is therefore to be understood that all such variations, modifications and changes are believed to fall within the scope of the present invention as defined by the appended claims.