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

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 inFIG. 1 taken along line2-2.
• FIG. 3 is a bottom view of the bracket assembly shown inFIG. 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 inFIG. 4 taken along line5-5.
• FIG. 6 is a bottom view of the bracket assembly shown inFIG. 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 inFIG. 8 taken along line9-9.
• 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 toFIGS. 1-3, abracket assembly10 is shown for facilitating installation of a concrete wall on a concrete footing. Thebracket assembly10 includes abracket12 having abase member14 with anupper surface16 and alower surface18. Each of the upper and lower surfaces,14 and16 respectively, can be planar and/or smooth in appearance or either can have an irregular appearance. Thebracket12 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, thebracket12 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, thebracket12 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, thebracket12 is constructed of a waterproof and rust-proof plastic.
• Referring toFIGS. 1 and 2, thebracket12 has a length l, a width w and a thickness t. The length l, width w and the thickness t of thebracket12 can vary depending upon the material from which it is constructed and the process used to form thebracket12. 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 thebracket assembly10 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 thebracket12 can range from between about 0.25 inches to about 12 inches. Desirably, the width w of thebracket12 can range from between about 0.5 inches to about 6 inches. More desirably, the width w of thebracket12 can range from between about 0.75 inches to about 3 inches. Even more desirably, the width w of thebracket12 can range from between about 1 inch to about 2 inches. A width w for thebracket12 of about 1 inch is sufficient for most residential construction of concrete foundation walls.
• Referring toFIG. 2, the thickness t of thebracket12 can be very dependent upon the process used to form thebracket12 especially when thebracket12 is formed from a thermoplastic material, such as polyethylene. The thickness t of thebracket12 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 thebracket12 will range from about 0.1 inches to about 0.3 inches. Even more desirably, the thickness t of thebracket12 will range from about 0.12 inches to about 0.2 inches. A thickness t for thebracket12 of about 0.125 inches is sufficient for most residential construction of concrete foundation walls.
• Still referring toFIGS. 1 and 2, thebracket12 also includes afirst end20 and an oppositesecond end22. Thebracket12 further has afirst flange24 and asecond flange26. The first and second flanges,24 and26 respectively, are spaced apart from one another with thefirst flange24 being located adjacent to or abutting thefirst end20 and thesecond flange26 being located adjacent to or abutting thesecond end22. The first and second flanges,24 and26 respectively, are aligned approximately at a right angle or 90 degrees to thebase member12. Desirably, the first and second flanges,24 and26 respectively, are aligned at a right angle to thebase member12. In other words, the first and second flanges,24 and26 respectively, are aligned perpendicular to thebase member12. Desirably, the first and second flanges,24 and26 respectively, are integrally formed with thebase member14 and extend upwardly therefrom. By “integral” it is meant a unitary or complete unit, essential or necessary for completeness. By forming thebracket12 as an integral unit, one can decrease the cost of manufacturing thebracket12 since the first and second flanges,24 and26 respectively, do not have to be adhered, glued, joined, screwed, bolted or somehow mechanically or chemically joined to thebase member14.
• Referring toFIG. 2, one can clearly see that thebracket assembly10 has a C-shaped or U-shaped configuration. However, thebracket assembly10 can have any desired configuration. Desirably, the first and second flanges,24 and26 respectively, will square off the first and second ends,20 and22 of thebase member14 and give thebracket12 the appearance of half of a rectangle. InFIG. 2, one will also see that each of the first and second flanges,24 and26 respectively, has a height h. The height h is measured from theupper surface16 of thebase member14 to a free or terminal end,28 and30 respectively, of the first and second flanges,24 and26 respectively. The height h of the first and second flanges,24 and26 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 and26 respectively, should range from between about 0.5 inches to about 3 inches. Desirably, the height h of the first and second flanges,24 and26 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 and26 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 and26 respectively, is to adjust the height h of the first and second flanges,24 and26 respectively, relative to the length l of thebracket12. Typically, the height h of each of the first and second flanges,24 and26 respectively, should range from between at least about 5% to at least about 50% of the length l of thebracket12. Desirably, the height h of each of the first and second flanges,24 and26 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 thebracket12. By using a height h dimension for the first and second flanges,24 and26 respectively, within the above ranges, one can be assured that thebracket assembly10 will work well for its intended purpose.
• Referring now toFIGS. 2 and 3, thebracket assembly10 also has at least onecavity32 formed in thebase member14. Thecavity32 has anopening34 aligned with thelower surface18. Thecavity32 can be almost any desired geometrical shape or configuration. InFIG. 3, thecavity32 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 thelower surface18. Theopening34 can be sized to be smaller than, equal to or be larger than the dimensions of thecavity32. Depending upon the configuration of thecavity32, in most cases theopening34 should be larger than the dimensions of thecavity32.
• InFIG. 3, thecavity32 is shown having a width w₁. The width w₁should extend across at least about 75% of the width w of thebracket12. Desirably, the width w₁should extend across at least about 85% of the width w of thebracket12. More desirably, the width w₁should extend across at least about 95% of the width w of thebracket12. Even more desirably, the width w₁should extend completely across the width w of thebracket12. The reason for this size dimension will be explained shortly.
• Still referring toFIGS. 2 and 3, thebracket assembly10 further includes anaperture36 formed through thebase member14 and which is aligned with thecavity32. Theaperture36 is shown extending from theupper surface16 of thebracket12 down into thecavity32. Desirably, theaperture36 is coaxially aligned with thecircular opening34. The length of theaperture36 will partly depend upon the thickness of thebase member14.
• Asealant38 is positioned in thecavity32. Desirably, some of thesealant38 will extend downward a slight amount below thelower surface18 of thebracket12. More desirably, some of thesealant38 will extend across the width w of thebracket12. It is important to have thesealant38 extend across the width w of thebracket12 so as to form a moisture and/or watertight seal under thebracket12. Thesealant38 can initially extend below thelower surface18 of thebracket12 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, theextra sealant38 present below thelower surface18 of thebracket12 will assure that a good seal is formed when thebracket assembly10 is secured to the concrete footing.
• Thesealant38 can be any material that can be used to form a moisture and/or water barrier on thelower surface18 of thebracket12 to prevent moisture and/or water from passing from the outside of the foundation wall to the inside of the foundation wall. Thesealant38 should be capable of forming a moisture proof, watertight, waterproof or water repellant seal between thelower surface18 of thebase member14 and an upper surface of a concrete footing. Various materials known to those skilled in the art can be used for thesealant38. A number of polymers are readily available that can perform this intended function. One material that works well as thesealant38 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. Thesealant38 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.
• Thesealant38 should be pliable so that it can be inserted into thecavity32 and can extrude outward from the perimeter of the cavity32 a predetermined amount so as to form a moisture and/or watertight seal across the width w of thelower surface18 of thebracket12. By “pliable” it is meant that thesealant38 can be easily shaped and is receptive to change and adaptable. As pressure is exerted on theupper surface16 of thebracket12, thesealant38 will form a tight seal against the upper surface of the concrete footing.
• It should be noted that thesealant38 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 toFIGS. 1 and 2, thebracket assembly10 further includes amovable fastener40 sized and configured to be positioned in and at least partially pass through theaperture36. Thefastener40 can be almost any kind of mechanical device known to those skilled in the art. For example, thefastener40 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. Thefastener40, as shown inFIG. 2, has anenlarged head42 at its upper end and asharp point44 at its opposite end. Thefastener40 can be movably retained in theaperture36 by an interference fit and can also be retained by thesealant38. Desirably, the diameter or cross-section of theaperture36 will be slightly less than the diameter or cross-section of thefastener40, so that an interference fit is present. However, thefastener40 should still be capable of being hammered or driven down through theaperture36 and thesealant38 into the concrete footing. The interference fit will also assist in retaining thefastener40 to thebracket assembly10. Theenlarged head42 on thefastener40 allow a construction worker to strike thefastener40 with a hammer and drive or move it down through theaperture36, through thesealant38 and into a concrete footing. However,fasteners40 withoutenlarged heads42 can also be utilized. As thefastener40 passes through thesealant38, it will displace some of thesealant38 and force it to extend downward and/or outward across the entire width w of thebracket12. This action, along with theexcess sealant38 that is present below thelower surface18 of thebracket12, will create a moisture proof, watertight, waterproof or water repellant seal between thelower surface18 of thebracket12 and the upper surface of the concrete footing. By “moisture proof” it is meant that thebracket assembly10 is secured to the concrete footing such that moisture cannot enter or escape under thelower surface18 of thebracket12. By “watertight” it is meant that thebracket assembly10 is secured to the concrete footing such that water cannot enter or escape under thelower surface18 of thebracket12. By “waterproof” it is meant that thebracket assembly10 is secured to the concrete footing such that water cannot penetrate under thelower surface18 of thebracket12.
• Thesealant38 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 thebracket assembly10 is secured to the concrete footing such that it is resistant to water but not entirely waterproof. Thefastener40 will also permanently secure thebracket assembly10 to the concrete footing. Thebracket assembly10 is not designed to be removed once it is attached to the concrete footing unless it is incorrectly positioned.
• Still referring toFIGS. 1 and 2, thebracket assembly10 is also depicted as having ashock absorber46. Theshock absorber46 can be formed from various materials. Theshock absorber46 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 theshock absorber46 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. Theshock absorber46 is shown having anaperture48, seeFIG. 2, sized to permit a portion of thefastener40 to pass there through. A slight interference fit between theshock absorber46 and thefastener40 is beneficial in keeping theshock absorber46 attached to thefastener40. Theshock absorber46 can also be constructed such that it only partially surrounds a portion of thefastener40. InFIG. 2, theshock absorber46 is depicted as a disc or thick washer situated above theupper surface16 of thebase member14. Theshock absorber46 can also be formed in a variety of other geometrical shapes.
• Optionally, an adhesive50 can be positioned between a lower surface of theshock absorber46 and theupper surface16 of thebase member14 to hold theshock absorber46 secure to thebracket12. When the adhesive50 is present and an interference fit is present between thefastener40 and theaperture48, one can feel secure in the fact that thefastener40 will be joined to thebracket12. This will ensure that thefastener40 is not separated from thebracket assembly10. One of the clear benefits of thebracket assembly10 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 thebracket assembly10 onto the upper surface of the cured concrete footing and secure it in its proper alignment by hammering thefastener40 into the concrete footing. Each of thebracket assemblies10 will remain in place and it is not necessary to remove any of thebracket assemblies10 after the concrete foundation wall is poured and cured.
• Theshock absorber46 functions to permit thefastener40, i.e. a nail, screw, etc. to be driven through both theaperture36 and thesealant38 and into the concrete footing by a hammer, nail gun, etc. to secure thebracket assembly10 thereto. As thefastener40 is driven down into the concrete footing, theenlarged head42 on thefastener40 will contact theshock absorber46. Theshock absorber46 can flex and contract while providing resistant which prevents thefastener40 from being driven further downward by an appreciable amount. In short, theshock absorber46 will prevent thebracket12 from breaking or cracking as thefastener40 is inserted into the concrete footing. As thefastener40 passes through thesealant38, it will displace some of thesealant38 and cause it to move downward and/or outward. This helps assure that a good water tight seal is created between thelower surface18 of thebracket12 and the upper surface of the cured concrete footing.
• Referring now toFIGS. 4-6, another embodiment of abracket assembly10′ is shown for facilitating the installation of a concrete wall on a concrete footing. Thebracket assembly10′ includes abracket12′ having abase member14′ with anupper surface16′ and alower surface18′. Theupper surface16′ is not planar but instead is irregular while thelower surface18′ is planar. Thebracket12′ has a length l′, a width w′ and a thickness t′. The length l′, the width w′ and the thickness t′ of thebracket12′ can vary depending upon the material from which it is constructed and the process used to form thebracket12′. Thebracket12′ also includes afirst end20′ and an oppositesecond end22′. Thebracket12′ further has afirst flange24′ and asecond flange26′. The first and second flanges,24′ and26′ respectively, are spaced apart from one another with thefirst flange24′ being located adjacent to or abutting thefirst end20′ and thesecond flange26′ being located adjacent to or abutting thesecond end22′. The first and second flanges,24′ and26′ respectively, are aligned approximately at a right angle or 90 degrees to thebase member12′. In other words, the first and second flanges,24′ and26′ respectively, are aligned approximately perpendicular to thebase member12′. Desirably, the first and second flanges,24′ and26′ respectively, are integrally formed with thebase member14′ and extend upwardly therefrom. By forming thebracket12′ as an integral unit, one can decrease the cost of manufacturing thebracket12′ since the first and second flanges,24′ and26′ respectively, do not have to be adhered, glued, joined, screwed, bolted or somehow mechanically or chemically joined to thebase member14′.
• Referring toFIG. 5, one can clearly see that thebracket assembly10′ has a C-shaped or U-shaped configuration. However, other configurations can also be utilized. Desirably, the first and second flanges,24′ and26′ respectively, will square off the first and second ends,20′ and22′ of thebase member14′ and give thebracket12′ the appearance of half of a rectangle. InFIG. 5, one will also see that each of the first and second flanges,24′ and26′ respectively, has a height h′. The height h′ is measured from theupper surface16′ of thebase member14′, adjacent eachflange24′ or26′, to a free or terminal end,28′ and30′ respectively, of the first and second flanges,24′ and26′ respectively. The height h′ of the first and second flanges,24′ and26′ 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′ and26′ 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′ and26′ respectively, of between about 0.75 inches to about 2 inches works well for most residential construction of concrete foundation walls.
• Referring now toFIGS. 5 and 6, thebracket assembly10′ differs from the embodiment shown inFIGS. 1-3, in that it has a pair ofcavities32′,32′ formed in thebase member14′. The pair ofcavities32′,32′ is spaced apart from one another. Each of the pair ofcavities32′,32′ is formed or configured as achannel50 having a central axis z—z, seeFIG. 6. Each of thechannels52,52 can be a long, narrow cavity of various cross-sectional configurations. InFIG. 5, each of thechannels52,52 has a trapezoidal configuration. By “trapezoidal” it is meant a quadrilateral having two parallel sides. However, it is to be understood that each of thechannels52,52 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 thechannels52,52 has afirst end54 and asecond end56. Each of thechannels52,52 spans or bridges across the entire width w′ of thebracket12′ such that thefirst end54 is located on one side of thebracket12′ and thesecond end56 is located on the opposite side of thebracket12′. The central axis z-z of each of thechannels52,52 is aligned approximately parallel or 180 degrees to the first and second flanges,24′ and26′ respectively. Desirably, each of thechannels52,52 is aligned parallel to the first and second flanges,24′ and26′ respectively.
• Each of the pair ofcavities32′,32′ orchannels52,52 is located adjacent to and inward of one of the first and second flanges,24′ and26′ respectively. The central axis z—z of each of thechannels52,52 should be spaced at least about 0.5 inches away from theadjacent flange24′ or26′. This clearance is needed to provide sufficient room for a construction worker to drive afastener40′ down through therespective channels52,52 when thebracket assembly10′ 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 thebracket12′, between each of thechannels52,52. Furthermore, each of the pair ofcavities32′,32′ has anopening34′ aligned with thelower surface18′ of thebracket12′. InFIG. 5, each of theopenings34′ is narrower than the remainder of thecavity32′. This is another difference from the embodiment shown inFIGS. 1-3. Desirably, each of theopening34′ have a minimum dimension, measured parallel to the length l′ of thebracket12′, of at least 0.1 inches, and more desirably, of at least 0.2 inches. This size dimension will help ensure that thesealant38, positioned in thechannels52,52, can form an effective seal beneath thelower surface18′ of thebracket12′ and an upper surface of the concrete footing.
• Still referring toFIGS. 5 and 6, thebracket assembly10′ further includes a pair ofapertures36′,36′ each aligned with one of thecavities32′,32′ or one of thechannels52,52. Each of the pair ofapertures36′,36′ extends from theupper surface16′ of thebracket12′ down into thecavities32′,32′. Desirably, each of theapertures36′,36′ is equally spaced across the width w′ of thebracket12′ between the first and second ends,54 and56 respectively, of each of thechannels52,52. The length of each of theapertures36′,36′ will partly depend upon the thickness of thebase member14′.
• Asealant38′, as described above, is position in each of the pair ofcavities32′,32′ or pair ofchannels52,52. Desirably, some of thesealant38′ will extend downward a slight amount below thelower surface18′ of thebracket12′. Since each of thechannels52,52 extends completely across the width w′ of thebracket12′, thesealant38′ will also extend completely across the width w′ of thebracket12′. Thesealant38′ can initially extend below thelower surface18′ of thebracket12′ 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, theextra sealant38′ present below thelower surface18′ of thebracket12′ will assure that a good seal is formed when thebracket assembly10′ is secured to the concrete footing.
• Referring again toFIGS. 4 and 5, thebracket assembly10′ further includes a pair ofmovable fasteners40′ each sized and configured to be positioned in and at least partially pass through one of theapertures36′. Each of the pair offasteners40′ can be constructed as described above with reference to the embodiment shown inFIGS. 1-3. Each of the pair offasteners40′, as shown inFIG. 5, has anenlarged head42′ at its upper end and asharp point44′ at its opposite end. Each of the pair offasteners40′ can be movably retained in one of theapertures36′ by an interference fit and can also be retained by thesealant38′. Desirably, the diameter or cross-section of theaperture36 will be slightly less than the diameter or cross-section of thefastener40 so that an interference fit is present. However, thefastener40 should still be capable of being driven or hammered down through theaperture36. Theenlarged head42′ allows a construction worker to strike each of the pair offasteners40′ with a hammer and drive or move it down through therespective aperture36′, through thesealant38′ and into a concrete footing. As each of thefasteners40′ passes through thesealant38′, it will displace some of thesealant38′. This action, along with theexcess sealant38′ that is present, will create a moisture proof, watertight, waterproof or water repellant seal between thelower surface18′ of thebracket12′ and the upper surface of the concrete footing. The pair offasteners40′ will also permanently secure thebracket assembly10′ to the concrete footing. Thebracket assembly10′ is not designed to be removed once it is attached to the concrete footing unless it is incorrectly positioned.
• Still referring toFIGS. 4 and 5, thebracket assembly10′ is also depicted as having a pair ofshock absorbers46′. Each of the pair ofshock absorbers46′ can be formed as described above. Each of the pair ofshock absorbers46′ is shown having anaperture48′, seeFIG. 5, sized to permit a portion of one of thefasteners40′ to pass there through. A slight interference fit between each of theshock absorbers46′ and therespective fastener40′ is beneficial in keeping each of theshock absorbers46′ attached to itsrespective fastener40′. Each of theshock absorbers46′ can also be constructed such that it only partially surrounds a portion of one of thefasteners40′. InFIG. 5, each of theshock absorbers46′ is depicted as a disc or thick washer situated above theupper surface16′ of thebase member14′. As explained above, each of theshock absorbers46′ can also be formed in a variety of other geometrical shapes, if desired.
• Optionally, an adhesive50′ can be positioned between a lower surface of each of theshock absorbers46′ and theupper surface16′ of thebase member14′ to hold each of theshock absorbers46′ secure to thebracket12′. When the adhesive50′ is present and an interference fit is present between each of thefasteners40′ and itsrespective aperture48′, one can feel secure in the fact that each of thefasteners40′ will be joined to thebracket12′. This will ensure that each of thefasteners40′ is not separated from thebracket assembly10′. One of the clear benefits of thebracket assembly10′ 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 thebracket assembly10′ onto the upper surface of the cured concrete footing and secure it in its proper alignment by hammering each of thefasteners40′ into the concrete footing. Each of thebracket assemblies10′ will remain in place and it is not necessary to remove any of thebracket assemblies10′ after the concrete foundation wall is poured and allowed to cure.
• The pair ofshock absorbers46′ functions to permit the pair offasteners40′, i.e. nails, screws, etc. to be driven through both therespective aperture36′ and therespective sealant38′ and into the concrete footing by a hammer, nail gun, etc. to secure thebracket assembly10′ thereto. As each of thefasteners40′ is driven down into the concrete footing, theenlarged head42′ on each of thefasteners40′ will contact therespective shock absorber46′. Each of theshock absorbers46′ can flex and contract while providing resistant which prevents therespective fastener40′ from being driven further downward by an appreciable amount. In short, each of theshock absorbers46′ will prevent thebracket12′ from breaking or cracking as therespective fastener40′ is inserted into the concrete footing. As each of thefasteners40′ passes through therespective sealant38′, it will displace some of thesealant38′ and cause it to move downward and outward. This helps assure that a good moisture tight and/or water tight seal is created between thelower surface18′ of thebracket12′ and the upper surface of the cured concrete footing.
• Referring now toFIG. 7, a plan view of a rectangular shapedconcrete footing58 is shown having anupper surface60. Theconcrete footing58 is at least partially cured or hardened so that it can support weight, such as a foundation wall. Secured to theupper surface60 of theconcrete footing58 is a plurality of thebracket assemblies10 or10′. Thebracket assemblies10 or10′ are spaced a predetermined distance apart over the perimeter of theconcrete footing58. Normally, abracket assembly10 or10′ can be placed about 1.5 feet,2 feet,3 feet or any desired distance from anadjacent bracket assembly10 or10′. At the corners of theconcrete footing58 or at a bend, at a curved portion, at a shoulder, etc, thebracket assemblies10 or10′ can be spaced closer together to provide additional support. At a corner of the concrete footing, for example,adjacent bracket assemblies10 or10′ may be spaced only a few inches apart.
• Still referring toFIG. 7, an interiorfoundation wall form62 and an exteriorfoundation wall form64 are shown being positioned on theupper surface60 of theconcrete footing58 adjacent to the upstanding first andsecond flanges24 and26 or24′ and26′ of eachbracket12 or12′. The interior and exterior foundation wall forms,62 and64 respectively, abut against the outside surfaces of theflanges24 and26 or24′ and26′ and are aligned parallel to one another. Thebracket assemblies10 or10′ keep and retain the interior and exterior foundation wall forms,62 and64 respectively, in a parallel alignment and at a set distance apart. Thebracket assemblies10 or10′ prevent the interior and exterior foundation wall forms,62 and64 respectively, from becoming misaligned, as indicated by the dotted lines inFIG. 7.
• The interiorfoundation wall form62 has a smoothinner surface66 and the exteriorfoundation wall form64 has a smoothinner surface68. The two smooth inner surfaces,66 and68, face one another when the interior and exterior foundation wall forms,62 and64 respectively, are correctly positioned on theupper surface60 of theconcrete footing58. The interior and exterior foundation wall forms,62 and64 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 and64 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 and64 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 and64 respectively, can be L-shaped, C-shaped, U-shaped, etc.
• Turning now toFIGS. 8 and 9, one can clearly see that the interior and exterior foundation wall forms,62 and64 respectively, are not secured, joined or attached to the first andsecond flanges24′ and26′ but instead abutsuch flanges24′ and26′. When properly assembled, thebracket assemblies10 or10′ are positioned between theinner surfaces66 and68 of the interior and exterior foundation wall forms,62 and64 respectively. Thebracket assemblies10 or10′ are permanently attached or secure to theconcrete footing58 by thefasteners40′ and are designed to stay in place after the foundation wall is poured. Thebracket assemblies10 or10′ prevent the interior and exterior foundation wall forms,64 and66 respectively, from moving laterally with respect to theconcrete footing58. Concrete is then poured between the smoothinner surfaces66 and68 of the interior and exterior foundation wall forms,62 and64 respectively. The concrete is allowed to cure or set over a number of days to form aconcrete foundation wall70. 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 theconcrete foundation wall70 has at least temporarily cured, the interior and exterior foundation wall forms,64 and66 respectively, are removed. The interior and exterior foundation wall forms,64 and66 respectively can be reused multiple times on various buildings. With thebracket assemblies10 or10′ in place between theupper surface60 of theconcrete footing58 and a lower surface of thefoundation wall70, a seal will be formed by thesealant38 or38′. Thesealant38 or38′ will prevent moisture and/or water from flowing along the lower surface,18 or18′, of the bracket,12 or12′ respectively, from outside of thefoundation wall70 to the inside of thefoundation wall70.
Method
• Referring now toFIG. 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 theupper surface60 of aconcrete footing58. 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 theupper surface60 of theconcrete footing58. The string is then pulled upward and released so that it will snap against theupper surface60. This action causes the powered, colored chalk to exit the string and form a line on theconcrete footing58. One or two chalked positioning lines can be formed on theupper surface60 of theconcrete footing58. When one positioning line is used, it should be the exterior positioning line. After the one positioning line is marked, one ormore bracket assemblies10 or10′ can be aligned perpendicular to the positioning line and be secured in place by the fastener(s)40 or40′. Optionally, both an interior positioning line and an exterior positioning line are marked on theupper surface60 of theconcrete footing58. After the two parallel positioning lines are marked, one ormore bracket assemblies10 or10′ are secured to theupper surface60 of the curedconcrete footing58 by driving the fastener(s)40 or40′ into theconcrete footing58, such as by the use of a hammer. Desirably,multiple bracket assemblies10 or10′ are used for a single building. Each of thebracket assemblies10 or10′ are positioned between the pair of spaced apart lines at a predetermined distance from one another. The distance between eachbracket assembly10 or10′ can vary, especially when one has to contend with corners, bends, jogs, etc. Each of thebracket assemblies10 or10′ includes abracket12 or12′ having abase member14 or14′ with anupper surface16 or16′ and alower surface18 or18′. Eachbracket12 or12′ also includes first and second spaced apart flanges,24 and26 or24′ and26′ respectively, which are integrally formed with thebase member12 or12′. The first and second flanges,24 and26 or24′ and26 respectively, extend upwardly from thebase member14 or14′. One or twocavities32 or32′ are also formed in thebase member14 or14′. Each of thecavities32 or32′ has an opening,34 or34′ respectively, aligned with thelower surface18 or18′ of thebracket12 or12′. One ormore apertures36 or36′ are formed through thebase member14 or14′ and eachaperture36 or36′ is aligned with one of thecavities32 or32′. Asealant38 or38′ is positioned in eachcavity32 or32′ and partially extends outward therefrom below thelower surface18 or18′ of thebracket12 or12′. Desirably, thesealant38 or38′ extends across the entire width w or w′ of thebracket12 or12′ in order to form a satisfactory seal. Amovable fastener40 or40′ is positioned in theaperture36 or36′. Each of thebracket assemblies10 or10′ is then secured to theupper surface60 of theconcrete footing58 by driving the fastener(s)40 or40′ through thesealant38 or38′ and into theconcrete footing58. An interiorfoundation wall form62 is then positioned adjacent to and outside of thefirst flange24 or24′. An exteriorfoundation wall form64 is simultaneously or sequentially positioned adjacent to and outside of thesecond flange26 or26′. Each of the interior and exterior foundation wall forms,62 and64 respectively, has a smooth inner surface,66 and68 respectively. The interior and exterior foundation wall forms,62 and64 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 and64 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 and64 respectively, and the concrete is allowed to cure or set to form anupstanding foundation wall70.
• Once the concrete has cured or set, the interior and exterior foundation wall forms,62 and64 respectively, are removed. Thebracket assemblies10 or10′ are left in place between theupper surface60 of theconcrete footing58 and a lower surface of thefoundation wall70. Thesealant38 or38′, located on thelower surface18 or18′ of thebrackets12 or12′, can be a moisture and/or water repellant silicone. The silicone functions to prevent moisture and/or water from seeping under thebracket12 or12′ between theconcrete foundation wall70 and theupper surface60 of theconcrete footing58. It is important to prevent moisture and/or water from seeping from the outside of thefoundation wall70 to the inside of thefoundation wall70.
• 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 (20)

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 ofclaim 1 wherein said bracket has a width and said cavity extends across at least about 75% of said width.

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

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

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

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

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

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

15. The bracket assembly ofclaim 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 ofclaim 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 ofclaim 16 wherein multiple brackets assemblies are secured to said upper surface of said concrete footing at predetermined distances.

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

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