Rough-in Box for Creating Penetrations in Poured Concrete Flooring and Method of Use

Abstract

A rough-in box kit (100) for creating a rough-in box (200) to create a penetration in poured concrete flooring during the construction of concrete buildings. The rough-in box kit (100) includes a single unitary piece (1) having a flat section (5) with: a top end; a bottom end opposite to the top end; an inside surface (5a) located between the top end and the bottom end, and configured to form an inside surface of the rough in box (200); and an outside surface (5b) opposite to the inside surface (5a), and configured to form an outside surface of the rough in box (200). The single unitary piece (1) also has a top flange (3) connected to and extending away from the top end of the flat section (5), and perforations, through-holes, or slots (2) that are formed in the flat section (5). The single unitary piece (1) is configured to be bent at locations corresponding to and lining up with the perforations, through-holes, or slots (2) so as to form the rough-in box (200).

Claims

1. A rough-in box kit (100) for creating a rough-in box (200) to create a penetration in poured concrete flooring during the construction of concrete buildings, comprising: a single unitary piece (1) having: a flat section (5) that has: a top end; a bottom end opposite to the top end; an inside surface (5a) located between the top end and the bottom end, and configured to form an inside surface of the rough-in box (200); and an outside surface (5b) opposite to the inside surface (5a), and configured to form an outside surface of the rough-in box (200); and a top flange (3) connected to and extending away from the top end of the flat section (5); perforations, through-holes, or slots (2) that are formed in the flat section (5); wherein the single unitary piece (1) is configured to be bent at locations corresponding to and lining up with the perforations, through-holes, or slots (2) so as to form the rough-in box (200).

2. The rough-in box kit (100) of claim 1; wherein the top flange has: a first extension (3a) that extends from the flat section (5) at approximately a 90 angle; and a second extension (3b) that extends from the first extension (3a) at approximately a 90 angle.

3. The rough-in box kit (100) of claim 2; wherein the perforations, through-holes, or slots (2) are formed in the first extension (3a).

4. The rough-in box kit (100) of claim 2 or 3; wherein the perforations, through-holes, or slots (2) are not formed in a distal end of the second extension (3b) opposite to and distal from the first extension (3a).

5. The rough-in box kit (100) of one of claims 2-4; wherein the perforations, through-holes, or slots (2) are formed in a proximal end of the second extension (3b) adjacent and proximal to the first extension (3a).

6. The rough-in box kit (100) of claim 2 or 3; wherein the perforations, through-holes, or slots (2) are not formed in any portion of the second extension (3b).

7. The rough-in box kit (100) of one of claims 1-5; wherein the single unitary piece (1) additionally has: a bottom flange (4) connected to and extending away from the bottom end of the flat section (5) opposite to the top end of the flat section (5).

8. The rough-in box kit (100) of claim 7; wherein the bottom flange extends from the flat section (5) at approximately a 90 angle.

9. The rough-in box kit (100) of claim 2; wherein the single unitary piece (1) additionally has: a bottom flange (4) connected to and extending away from a bottom end of the flat section (5) opposite to the top end of the flat section (5); and wherein the bottom flange (4) extends approximately parallel to the a first extension (3a) of the top flange (3).

10. The rough-in box kit (100) of claim 7-9; wherein the perforations, through-holes, or slots (2) are not formed in a distal end of the bottom flange (4) opposite to and distal from the flat section (5).

11. The rough-in box kit (100) of one of claims 7-9; wherein the perforations, through-holes, or slots (2) are formed in a proximal end of the bottom flange (4) adjacent and proximal to the flat section (5).

12. The rough-in box kit (100) of claim 7-9; wherein the perforations, through-holes, or slots (2) are not formed in any portion of the bottom flange (4).

13. The rough-in box kit (100) of one of claims 1-12; wherein the perforations, through-holes, or slots (2) form vertical arrays (2a) in the flat section (5), each vertical array (2a) extending in a vertical direction from the top end to the bottom end of the flat section (5).

14. The rough-in box kit (100) of claim 13; wherein the vertical arrays (2a) of perforations, through-holes, or slots (2) are spaced apart from each other in a horizontal direction perpendicular to the vertical direction so that the perforations, through-holes, or slots (2) additionally form horizontal arrays (2b) in the flat section (5) extending in the horizontal direction.

15. The rough-in box kit (100) of one of claims 1-14; wherein the singe unitary piece (1) made of an aluminum alloy.

16. The rough-in box kit (100) of one of claims 1-15, further comprising: a lid (6) formed configured to supporting a weight of at least approximately 2,000 pounds when placed on top of the formed rough-in box (200).

17. The rough-in box kit (100) of claim 16; wherein the lid (6) is formed of resin-impregnated fiberglass.

18. The rough-in box kit (100) of claim 17; wherein the resin-impregnated fiberglass is impregnated with an epoxy resin.

19. The rough-in box kit (100) of claim 17; wherein the lid (6) comprises 18 to 40 fiberglass layer strands of fiber.

20. A rough-in box (200) comprising: the rough-in box kit (100) of one of claims 16-19; wherein the single unitary piece (1) is bent at locations corresponding to and lining up with the perforations, through-holes, or slots (2) so as to form the rough-in box (200) with the lid (6) being flush with a poured concrete floor.

21. The rough-in box (200) of claim 20, further comprising: a seal arranged between the lid (6) and the top flange (3) to create a waterproof or water-resistant seal when the lid (6) is arranged on the top flange (3).

22. A method of constructing a penetration in a concrete floor (300), comprising: bending the single unitary piece (1) of the rough-in box kit (100) of one of claims 1-19 at locations corresponding to and lining up with the perforations, through-holes, or slots (2) so as to form a rough-in box (200); placing the rough-in box (200) in a location on a formed deck corresponding to a predetermined location for the penetration in the concrete floor (300); pouring concrete around the rough-in box (200) to form the concrete floor (300).

23. A method of constructing a penetration in a concrete floor (300), comprising: bending a single unitary piece (1) so as to form a rough-in box (200); placing the rough-in box (200) in a location on a formed deck corresponding to a predetermined location for the penetration in the concrete floor (300); placing a lid (6) on top of the rough-in box (200); pouring concrete around the rough-in box (200) to form the concrete floor (300).

24. The method according to claim 23; wherein one end (8a) of the single unitary piece (1) is secured and affixed to an opposite end (8b) of the single unitary piece (1) to form the rough-in box (200).

25. The method according to claim 23 or 24, further comprising: cutting a top flange (3) of the single unitary piece (1) at multiple first locations; and cutting a bottom flange (4) of the single unitary piece at multiple second locations; wherein the single unitary piece (1) is bent along multiple bending lines (18) so as to form a rough-in box (200), each bending line (18) extending from one of the first locations to one of the second locations.

26. The method according to claim 25, further comprising: wherein each bending line (18) corresponds to an array of perforations, through-holes, or slots (2) single unitary piece (1) so that the single unitary piece (1) is bent along the arrays of perforations, through-holes, or slots (2).

27. The method according to one of claim 23-26; wherein the concrete is poured around the rough-in box (200) to form the concrete floor (300) so that the lid (6) is flush with the poured concrete floor.

28. A kit for a platform to securely hold a lid (6) over a penetration in a concrete floor (300), comprising: multiple single unitary pieces (12) having: a first extension (12a) extending along a first plane; a second extension (12b) extending from an end of the first extension (12a) along a second plane intersecting with the first plane; and a third extension (12c) extending from an end of the second extension (12b) opposite to the first extension (12a) along a third plane approximately parallel to the first plane.

29. The kit according to claim 28: wherein a height of the second extension (12b) extending between the first and third extensions (12a, 12c) in a direction perpendicular to the first plane corresponds to a thickness dimension of a lid (6).

30. The kit according to claim 28 or 29: wherein at least one of the first and third extensions (12a, 12c) includes through holes (19), each through hole (19) being configured to accept a screw or bolt (13) so that the multiple single unitary pieces (12) can be screwed or bolted to the concrete floor (300).

31. A platform for securely holding a lid (6) over a penetration in a concrete floor (300), comprising: the multiple single unitary pieces (12) of the kit according to one of claims 28-30; wherein each single unitary piece (12) is arranged around an edge of the penetration so that at least a portion of an end (12d) of each single unitary piece (12) overlaps with at least a portion of an end (12d) of an adjacent single unitary piece (12).

Description

BRIEF DESCRPTION OF THE DRAWINGS

[0079] FIG. 1 shows an embodiment of the rough-in box 200 along with basic components of the box (single unitary pieces 1 and lids 6) as they will be provided to a job.

[0080] FIG. 2 shows a perspective view of the side profile of a single unitary piece 1 of kit 100 for a rough-in box 200 in an unassembled state. This single unitary piece 1 can be provided in various lengths to suit the application.

[0081] FIGS. 3a and 3b show the method by which the single unitary piece 1 is cut in specific locations so that it can be bent into the box shape required for the application.

[0082] FIG. 4 shows the side profile of the single unitary piece 1 with a single 90 degree bend.

[0083] FIG. 5 shows an embodiment of a the side profile of the single unitary piece 1 with a 90 degree bend.

[0084] FIG. 6 shows the side profile of the single unitary piece 1 with a second 90 degree bend.

[0085] FIG. 7 shows the single unitary piece 1 side profile with the top and bottom flanges 3, 4 partially trimmed at one of the two ends 8a, 8b (e.g., left end 8a in FIGS. 7-9) and the resulting tab 11 bent at 90 degrees ready to overlap and attach to the other opposite end 8a, 8b of the single unitary piece 1 to form a closed box.

[0086] FIG. 8 shows the tab 11 referenced in FIG. 7 overlapping the opposite end of the single unitary piece 1 so that the opposite ends of the single unitary piece 1 (in this case the tab end and the opposite end) are ready to be attached to each other by screws 13 or other means.

[0087] FIG. 9 is a perspective view of the single unitary piece 1 bent into a completed rectangular rough-in box 200.

[0088] FIG. 10 shows the completed box 200 with a lid 6 attached, with an enlarged a detail showing an optional corner piece 10 that may be applied to protect the corner of the lid.

[0089] FIG. 11 shows a completed rough-in box 200 with optional corner pieces 10 and a lid 6 with a handle 9.

[0090] FIG. 12 shows a lid 6 being installed onto the top of the completed rectangular rough-in box 200.

[0091] FIG. 13 shows a plan view of the rough-in box 200 completed without the lid 6.

[0092] FIG. 14 shows a side view of the completed rectangular rough-in box 200.

[0093] FIG. 15 shows a side view of the rough-in box kit 100 in FIG. 2 along an end of the kit.

[0094] FIG. 16 shows cross sectional view of part of the rough-in box 200 after concrete has been poured.

[0095] FIG. 17 shows cross sectional view of one of the steel sections 12 of FIG. 18.

[0096] FIG. 18 shows a plan view of a version of the invention designed to cover a hole in an existing slab. This is comprised of steel sections 12 surrounding the perimeter of the hole fastened to the surrounding slab that support a cover.

[0097] FIG. 19 a perspective view of one of the steel sections 12 of FIG. 18.

[0098] FIG. 20 shows examples of fire rated rubber seals 14.

[0099] FIG. 21 shows a non-slip or slip resistant surface 15.

[0100] FIG. 22 shows a lid 6 with hydraulic hinges 16.

[0101] FIG. 23 shows an example of a handle 9 for the lid 6.

[0102] FIG. 24 shows examples of the different types of screw heads that can be used to effectively lock the lid 6 to the rough-in box 200.

[0103] FIGS. 25 and 26 show an optional deployable safety rail system 17.

[0104] FIG. 27 is a plan view of the metal rough-in box 200 in place.

[0105] FIG. 28 shows a cross-section through the metal rough-in box 200 with the concrete deck poured.

[0106] FIG. 29 shows a cross-section through the metal rough-in box 200 prior to concrete placement.

[0107] FIG. 30 is a plan view of a configuration 400 of multiple single unitary pieces 1 attached together to form a frame for a single depression of penetration.

[0108] FIG. 31 is a cross sectional view through line A-A of the configuration 400 of FIG. 30.

[0109] FIG. 32 is a side view of the configuration 400 in FIG. 30.

[0110] FIG. 33 shows an embodiment with a slot 46 in the side walls of the rough-in box 200 to receive expandable foam fireproofing.

DETAILED DESCRIPTION OF THE INVENTION

[0111] The present invention is directed to a mechanical rough-in and plumbing box 200 for creating penetrations in concrete flooring and a method of use.

[0112] FIG. 1 shows that these componentssingle unitary pieces 1 and lids 6are capable of being flat packed such that they fit together when stacked on top of one another. This saves space when transporting and storing the components. Thus, the components can be delivered with fewer trucks, and take up less storage space at the jobsite.

[0113] In the embodiment of the present invention in FIG. 2, the rough-in box 200 is formed from a single unitary piece 1, which can be supplied in a single stock length to form rough-in boxes 200 of differing sizes and dimensions. The single unitary piece 1 is supplied with perforations, through-holes, or slots 2 in increments across their width. By snipping the top and bottom flanges 3, 4 of the single unitary piece 1 at locations corresponding to and lining with the perforations, through-holes, or slots 2, the profile may be bent or cut at any of the incremental lengths that correspond to the spacing of the perforations, through-holes, or slots 2, as shown in FIG. 3 and further shown in FIGS. 4, 5, 6, and 7. This feature allows the single unitary piece 1 to be formed into virtually any shape by varying the lengths between the bends and the angle of bends. The profile is fastened into a closed shape by trimming a short length of the flanges 3, 4 of one end 8a, 8b (e.g., left end 8a in FIGS. 7-11) of the single unitary piece 1 to form a tab 11, and then bending the resulting tab 11 (FIG. 7) to match the opposite end 8a, 8b (e.g., right end 8b in FIGS. 7-11) of the single unitary piece 1 and securing the two ends 8a, 8b by screws 13 or some other means. Should the shape of the desired rough-in box 200 exceed the longest length of the single unitary piece 1 supplied, a second single unitary piece 1 can be spliced to the first in a manner similar to that described above wherein a tab 11 is created by trimming the flanges 3, 4 of the piece 1 allowing the end 8a, 8b of one piece 1 to lie flat on the corresponding opposite end 8a, 8b of the second piece 1. The pieces 1 can then be spliced or affixed together with screws 13 or other appropriate means.

[0114] Preferably, the perforations, through-holes, or slots 2 are formed along vertical arrays 2a from the top of the single unitary piece 1 to the bottom of the bottom of the single unitary piece 1. This allows the single unitary piece 1 to be bent along straight lines to form the corners of the rough-in box 200. The vertical arrays 2a are spaced apart from each other at fixed increments along the width of the single unitary piece 1. Preferably the distance between adjacent vertical arrays 2a is constant. In one embodiment, the constant distance between the vertical arrays 2a is from 0.5 inches to 6.0 inches. Preferably, the constant distance between the vertical arrays 2a is from 0.5 inches to 3.0 inches. More preferably, the constant distance between the vertical arrays 2a is from 0.5 inches to 2.0 inches. Most preferably, the constant distance between the vertical arrays 2a is from 0.5 inches to 1.5 inches. In a particularly preferred embodiment, the constant distance between vertical arrays 2a is approximately 1.0 inches.

[0115] In another embodiment, the vertical arrays 2a of perforations 2 are spaced so that the perforations 2 also line up with each other horizontally to form horizontal arrays 2b that are perpendicular to the vertical arrays 2a.

[0116] Preferably, each perforation, through-hole, or slot 2 is formed in an oval or rectangular shape with its longest dimension extending along the same direction of the vertical array 2a in which it is arranged. This further facilitates bending the single unitary piece 1 to form the rough-in box 200.

[0117] The single unitary piece 1 consists of a flat section (web) 5, a top flange 3 which is shaped to support the box lid 6 flush with the surface of the concrete 300 (see FIG. 16), and a lower flange 4 that enhances the strength of the single unitary piece 1 and allows the finished box 200 to be securely fastened to the deck form. The flat section (web) 5 has an inside surface 5a and an outside surface 5b, with the inside surface 5a forming an inside surface of the final rough-in box 200 and the outside surface 5b forming an outside surface of the final rough-in box 200.

[0118] The rough-in box 200 is formed by snipping the flanges 3, 4 at locations corresponding to the perforations, through-holes, or slots 2, and bending the single unitary piece 1 along the perforations, through-holes, or slots 2 as required to attain the finished shape desired. Once the shape is attained the box 200 is fastened by securing the web tab 11 from one end 8a, 8b of the profile to the opposite end 8a, 8b.

[0119] In one embodiment, the profile of the rough-in box may be snipped and bent at very small intervals thereby creating a chorded circular shape.

[0120] There is no need to have a bottom surface on the rough-in box 200 as that would hinder the installation of plumbing, ducts, or other mechanical systems between floors. Thus, only a lid 6 needs to be opened so that these systems can be passed up from the floors below.

[0121] Once the side walls 7 of the rough-in box 200 are formed and the ends 8a, 8b joined together, the lid 6 is attached to the rough-in box 200. Each side wall 7 of the rough-in box has a top flange 3 to provide support for the lid 6 so that the lid 6 can is supported by each of the side walls 7 of the rough-in box 200.

[0122] The lid 6 is load bearing to permit workmen, equipment, vehicles, and materials to move over the lid 6 without risk of the lid 6 collapsing and caving in. Therefore, the lid 6 needs to be made from a strong enough material to provide a working surface on the floor while construction is being carried out. In one embodiment, the lid 6 is designed to support a weight of at least approximately 2,000 pounds concentrated load and approximately 200 pounds per square foot uniform load. The lid 6 can be made from fiberglass or from heavy duty plastics such as polyethylene, polyvinyl, and polypropylene. Additionally, in some embodiments, the lid 6 can be made from engineered wood. It is also possible that the lid 6 is made from a combination of fiberglass, heavy duty plastic, and/or engineered wood.

[0123] In one embodiment, the lid 6 can be made from resin impregnated fiberglass with the density of fibers being determined by the weight that the lid 6 has to bear. The resins used to make the lid 6 can include epoxy resins as well as other types of thermosetting plastics such as polyester or vinyl-ester resins and thermoplastics.

[0124] A fire rated rubber seal 14, such as the one shown in FIG. 20, can be added to the lid 6 for water resistance. The shape of the seal 14 should correspond to the shape of the lid 6 so that the seal 14 added to the under surface of the lid 6 of the rough-in box 200 to create a tight seal with the top flange 3 of the side walls 7 when the rough-in box 200 is closed. Waterproofing the rough-in box 200 allows sheetrock and other water-sensitive materials to be stored on floors below without worry of damage.

[0125] Optionally, compressed fireproofing can be embedded into the side walls 7 of the rough-in box 200. As shown in FIG. 33, a slot 46 can be left into the side walls of the rough-in box 200 to receive expandable foam fireproofing. Alternatively, an expandable fireproofing materialfor example, expandable foam fireproofing materialcan be affixed to the inside surface 5a of the single unitary piece 1 which will form an inside surface of rough-in box 200. After the rough-in box 200 is assembled and put into place, a worker can pull off a tape that will expose the expandable fireproofing material (e.g., expandable foam fireproofing). When the tape is removed, the fireproofing material will expand until it meets a solid barrierfor example, air conditioner ductssuch that when a duct is passed through the rough-in box 200, the fireproofing material is adhered to the surface of the duct. The fireproofing material can be an intumescent tape or any equivalent thereof. Intumescent materials that can be included in the tape include, for example, polyphosphates (such as ammonium polyphosphate) and materials that react with such phosphates such as pentaerythritol and melamine, or silicate-containing materials

[0126] If desired, the lid 6 can be supported by a strut (not shown) stretching across the box from an opening or vertical slot in one wall to an opening or vertical slot in an opposite wall to provide additional load bearing strength.

[0127] As shown in FIG. 22, the lid 6 may be equipped with hydraulic hinges 16 to control the speed at which the lid 6 opens and also to keep the lid 6 in a vertical open position when the lid 6 is opened by a worker working on the hole.

[0128] The lid can also be equipped with a lanyard or tether 20. The lanyard or tether 20 will provide positive attachment between the lid and the side walls of the box. The lanyard or tether 20 will allow lids to be removed but will insure that the lid is not removed from the immediate area of the opening.

[0129] The lid 6 can feature a grip and/or handle 9 for easy opening of the lid 6. An example of a handle is shown in FIG. 23.

[0130] Different locks/screw heads can be utilized to secure the lid 6 to the rough-in box 200 so that only certain personnel from a particular trade can open the rough-in box 200. For example, some designated rough-in boxes 200 can be equipped with a special screw head that can only be opened by plumbers, whereas other designated rough-in boxes 200 can be equipped with a different screw head that can only be opened by electricians. Examples of the different types of screw heads that can be used to effectively lock the lid 6 to the rough-in box 200 are shown in FIG. 24.

[0131] As a safety measure, the top side of the lid 6 can have a non-slip surface 15 so that workers and equipment moving over the lid 6 do not slip when crossing the rough-in box 200. A slip resistant surface that can be applied to the lid 6 is shown in FIG. 21.

[0132] As shown in FIGS. 25 and 26, the lid 6 can also be equipped with a deployable safety rail system 17 as an additional safety measure. The deployable safety rail 17 is a series of tubular members that are connected together and fastened to the rough-in box 200 and the lid 6 when the lid 6 is open to prevent accidental trips and falls due to the hole being open. The deployable safety rail 17 can be collapsed/de-constructed and stored in pieces within the rough-in box 200 on the underside 6a of the lid 6 for storage as shown in FIG. 25. When deployed, the tubular pieces of the safety rail 17 are removed from the underside of the lid 6, and are then assembled together atop the rough-in box 200 to form a rectangular prism that would prevent a worker from falling inside the hole of the rough-in box 200 when the lid 6 is open as shown in FIG. 26. The presence of the deployed safety rail 17 also acts as a warning to workers walking on the construction site that the lid 6 of the rough-in box 200 is open.

[0133] A sensing system that would alert workers and staff on the jobsite as to when a particular rough-in box has been left open can be included in the rough-in box 200. For example, a pressure sensor can be integrated into the lid 6, side walls 7, or both the lid 6 and side walls 7 of the rough-in box 200. When the lid 6 is closed, the sensor will register the applied pressure. When the lid 6 is open, no pressure will be detected by the sensor, and the sensor will then wirelessly relay to a visual display that the rough-in box 200 is open.

[0134] When installing the rough-in box 200, a numbering system can be used such that each box is numbered to match a corresponding hole at the jobsite. This ensures that the right rough-in box 200 goes over the correct hole. Also, if lids 6 are removed or placed over the wrong hole, this can be easily inspected and corrected.

[0135] The rough-in box 200 with the lid 6 attached allows holes to be covered prior to the pouring of concrete and stops leaks of concrete from entering the holes. When the concrete is poured to form the floor of a building, the lid 6 prevents over-pour from the concrete and creates a perfect edge that is level with the concrete when the concrete solidifies. Thus, there are no obstructions on the floor because the lid 6 will be flush with the concrete floor, allowing for the use of dollies, manlifts, modular scaffolding, and designated walkways because the lid 6 is load bearing and capable of handling loads from heavy machines and equipment. As a result, fewer safety personnel are needed and work shutdowns are minimized and reduced.

[0136] The rough-in box 200 of the present invention is embedded in the concrete floor, and only the lid 6 needs to be removed to complete mechanical work. When the lids 6 are removed, the lids 6 can be easily stacked and removed all together.

[0137] While the present invention has been described above in terms of specific embodiments, it is to be understood that the invention is not limited to these disclosed embodiments. Many modifications and other embodiments of the invention will come to the mind of those skilled in the art to which this invention pertains, and which are intended to be and are covered by both this disclosure and the appended claims. It is indeed intended that the scope of the invention should be determined by proper interpretation and construction of the appended claims and their legal equivalents, as understood by those of skill in the art relying upon the disclosure in this specification and the attached drawings.

[0138] The single unitary piece 1 may be formed of any strong, tough material. For example, the side walls can be made from an aluminum sheet, steel sheet, high strength plastic, or any other material that can be formed into the required shapes that has adequate strength.

[0139] The box or boxes 200 can be and fastened together by welding, rivets, screws 13, or any appropriate fastening method. The top will be left open. A flange 3 will be formed at the top of the boxes in a configuration as shown in FIG. 9. This flange 3 will serve to support a box lid 6 which will be installed in the box prior to placing concrete. The lid 6 will be flush with the surface of concrete after it is placed.

[0140] Different configurations 400 of boxes 200 may be made by joining individual boxes 200 of the required sizes, for example as shown in FIGS. 30-32. Typical configurations 400 can be a simple rectangular configuration 400 to form a straight trough or several boxes 200 may be connected in a configuration 400 to form penetrations having shapes resembling the letter L, T, or a cruciform shape in plan view.

[0141] This embodiment of the present invention solves many of the labor inefficiencies and costs incurred when creating void spaces in slabs for connecting plumbing fixtures. When the kits 100 for new boxes 200 or configurations 400 arrive on site, the boxes 200 are assembled prior to installation in the slab. They are delivered to the floor to be poured, and from there they are installed in a prearranged spot on the deck. To fasten the boxes 200 or configurations 400 in place, they are simply nailed to the wooden deck and are then ready for the pouring process. Unlike previous methods, the boxes 200 in the present invention stay in the concrete permanently this eliminates the need to grease or otherwise prepare the box 20 or configuration 400 to be stripped out of the floor as is required with current methods. The boxes 200 or configurations 400 are fitted with one or more covers 6 prior to placing the concrete so work around the boxes 200 or configurations 400 can proceed faster because workers do not have to worry about accidentally filling the boxes 200 or configurations 400 with concrete. The flush surface provided by the lid(s) 6 of the box 200 or configuration 400 also facilitates screeding and finishing the concrete around the boxes. The present invention eliminates the need to strip out rough-in boxes after the concrete is placed.

[0142] Current methods require the boxes to be pried out of the concrete to leave the appropriate void. Typically this removal of the boxes is done after the concrete fully sets, which is labor intensive, wastes time on the construction site, and can be hazardous to the workers removing the box. Additionally, concrete may overflow during placement and get inside the boxes and this must be cleaned out by workers.

[0143] Another benefit of the present invention is the top flange 3, which allows the lid 6 to sit flush with the surface of the concrete. Current methods require that plumbing boxes be covered with plywood hole covers that are proud of the concrete surface. These plywood covers are a tripping hazard and they interfere with the use of any wheeled devices for moving material around the floor.

[0144] According to conventional processes, the covers must be inspected daily for each floor. The present invention would drastically reduce this requirement, if not eliminate it completely, as the structural capabilities of the lid 6 would mean that the boxes 200 and configurations 400 would be able to withstand the loads and forces present on the site without failure. The reduction in inspection frequency would save on labor costs for the duration of the construction phase.

[0145] When the general contractor takes control of the floor, they do not need to add the additional covers for the holes. The plumber and mechanical services can immediately take responsibility for the boxes and run the pipework or shafts needed.

[0146] The proposed method greatly improves existing methods by the fact that it increases productivity and reduces labor costs, while also reducing the potential trip or fall hazards present with existing methods, which in turn reduces job stoppages from falls and injuries.

[0147] Another embodiment of the present invention will serve as a hole cover for penetrations that have been conventionally formed in a concrete slab or any hole in any floor that needs to be covered securely. In this embodiment, as shown in FIGS. 17-19, a frame of bent steel sections 12 is fastened in the opening and provided with a top lid 6 with sufficient strength to allow construction activities to safely proceed.

[0148] Each bent steel section 12 has a first extension 12a, a second extension 12b, and a third extension 12c. The first and third extensions 12a, 12c are approximately parallel to each other and extend in the same direction. The second extension 12b extends approximately perpendicular to the first and third extensions 12a, 12c to connect the first and third extensions 12a, 12c with each other.

[0149] The height of the second extension 12b (i.e., the up-down direction in FIG. 16) is preferably selected to correspond to a thickness of the top lid 6 that will be used so that a top of the lid 6 is flush with the top of the concrete floor 300for example, approximately 0.5 inches. This reduces the chance of trips occurring while people work on the concrete floor 300.

[0150] Optionally, the first and third extensions 12a, 12c can include through holes 19, which allow the steel section 12 to easily be affixed to the concrete floor 300 by screws or bolts 13. The through holes 19 can also be used to secure the lid 6 to the steel section 12 by screws or bolts 13.

[0151] Preferably the steel sections 12 are placed around a hole in the concrete floor 300 so that ends 12d of two adjacent steel sections 12 overlap. This increases the strength of the platform formed by the first extensions 12a on which the lid 6 rests.

LIST OF REFERENCE NUMBERS

[0152] 1 single unitary piece [0153] 2 perforations, through-holes, or slots [0154] 2a vertical arrays of perforations, through-holes, or slots 2 [0155] 2b horizontal arrays of perforations, through-holes, or slots 2 [0156] 3 top flange [0157] 3a first extension of top flange 3 [0158] 3b second extension of top flange 3 [0159] 4 bottom flange [0160] 5 flat section (web) [0161] 5a inside surface [0162] 5b outside surface [0163] 6 lid [0164] 7 side walls [0165] 8a, 8b ends of the single unitary piece 1 [0166] 9 lid handle [0167] 10 corner piece [0168] 11 end tab [0169] 12 steel sections [0170] 12a first extension of steel sections 12 [0171] 12b second extension of steel sections 12 [0172] 12c third extension of steel sections 12 [0173] 12d ends of steel sections 12 [0174] 13 screws [0175] 14 fire rated rubber seal [0176] 15 non-slip surface [0177] 16 hydraulic hinges [0178] 17 safety rail system [0179] 18 bending lines [0180] 19 through holes [0181] 20 lanyard or tether [0182] 46 slot for fireproofing [0183] 100 rough-in box kit [0184] 200 rough-in box [0185] 300 concrete [0186] 400 configuration