Method and Device for Pre-Casting Conduit Holes in Building Foundations

Abstract

A method of constructing multiple conduits in building foundations that eliminates the process of core drilling after the foundation has been poured and set. This method creates optional openings for possible future connections. The process uses removable conduit molds installed before the foundation is poured. Once the foundation has set, conduit molds are removed to explose conduits in the foundation as needed.

Claims

1. A construction system for pre-casting conduit holes in a building foundation, the system comprising: a plurality of concrete molds installed around the building foundation, wherein the plurality of concrete molds are configured to support a poured foundation concrete mix; a plurality of lightweight conduit molds installed within the plurality of concrete molds at locations designated for conduits within the building foundation; wherein each conduit mold comprises a unitary cylindrical bar, a cylindrical central ring surrounding the cylindrical bar, and a rubber surface on each end of the cylindrical bar; wherein the foundation concrete mix is poured in the plurality of concrete forms around the plurality of conduit molds and sets; wherein the plurality of concrete forms are removed, and the rubber surfaces on each end of each cylindrical bar are substantially flush with an interior and exterior wall of the building foundation; and removing the conduit mold from the building foundation to open a conduit hole, and installing a conduit within the conduit hole in the foundation wall.

2. The system of claim 1, wherein the conduit mold is removed from the foundation wall through drilling.

3. The system of claim 1, wherein the conduit mold is removed from the foundation wall through melting with an acetone based solution.

4. The system of claim 1, wherein the conduit mold remains in the foundation wall indefinitely without substantially destabilizing the foundation wall.

5. The system of claim 1, wherein the conduit hole is a conduit for the group of lines consisting of power lines, low voltage lines, cable lines, telephone lines, water supply, sewage, line sets condensers, heat pumps, or any other utility line.

6. The system of claim 1, wherein the rubber ends of the conduit mold provide a substantially water tight seal on the the foundation until the conduit mold is removed.

7. The system of claim 1, wherein the conduit mold is composed of a material selected from the group of consisting of high density Styrofoam, Polystyrene Foam (both EPS and XPS), Polystyrene Plastic, Polystyrene Film, Polyisocyanurate ISO, Polyvinyl Chloride(PVC), Chlorinated Polyvinyl Chloride (CPVC), Unplasticide Polyvinyl Chloride(UPVC), Natural Isoprene, Ethylene Propylene Diene (EPDM), Nitrile Rubber (NBR), Styrene Butadiene Rubber (SBR), Silicone Rubber, Butyl Rubber, Polybutadiene, Aflas, Hypalon Rubber, Epichlorohydrin Rubber, Polyurethane, Polyethylene, lightweight solid wood, plywood, and fire retardant foams.

8. The system of claim 1, wherein the cylindrical bar of the conduit mold comprises diameters of 1.5 to 58 inches.

9. The system of claim 1, wherein the cylindrical bar of the conduit mold comprises lengths of 4 to 48 inches.

10. A method for pre-casting conduit holes in a building foundation, the method comprising: a) installing a plurality of concrete molds around the building foundation, wherein the plurality of concrete molds are configured to support a poured foundation concrete mix; b) installing a plurality of lightweight conduit molds within the plurality of concrete molds at locations designated for conduits within the building foundation, wherein each conduit mold comprises a unitary cylindrical bar, a cylindrical central ring surrounding the cylindrical bar, and a rubber surface on each end of the cylindrical bar; c) pouring the foundation concrete mix in the plurality of concrete forms around the plurality of conduit molds; d) setting the foundation concrete mix; e) removing the plurality of concrete forms, wherein the rubber surfaces of each cylindrical bar are substantially flush with an interior and exterior wall of the building foundation; f) removing the conduit mold from the building foundation to open a conduit hole; and g) installing a conduit within the conduit hole in the building foundation.

11. The method of claim 10, wherein the conduit mold is removed from the foundation wall through drilling.

12. The method of claim 10, wherein the conduit mold is removed from the foundation wall through melting with an acetone based solution.

13. The method of claim 10, wherein the conduit mold remains in the foundation wall indefinitely without substantially destabilizing the foundation wall.

14. The method of claim 10, wherein the conduit hole is a conduit for the group of lines consisting of power lines, low voltage lines, cable lines, telephone lines, water supply, sewage, line sets condensers, heat pumps, or any other utility line.

15. The method of claim 10, wherein the rubber ends of the conduit mold provide a substantially water tight seal on the the foundation until the conduit mold is removed.

16. The method of claim 10, wherein the conduit mold is composed of a material selected from the group of consisting of high density Styrofoam, Polystyrene Foam (both EPS and XPS), Polystyrene Plastic, Polystyrene Film, Polyisocyanurate ISO, Polyvinyl Chloride(PVC), Chlorinated Polyvinyl Chloride (CPVC), Unplasticide Polyvinyl Chloride(UPVC), Natural Isoprene, Ethylene Propylene Diene (EPDM), Nitrile Rubber (NBR), Styrene Butadiene Rubber (SBR), Silicone Rubber, Butyl Rubber, Polybutadiene, Aflas, Hypalon Rubber, Epichlorohydrin Rubber, Polyurethane, Polyethylene, lightweight solid wood, plywood, and fire retardant foams.

17. The method of claim 10, wherein the cylindrical bar of the conduit mold comprises diameters of 1.5 to 58 inches.

18. The method of claim 10, wherein the cylindrical bar of the conduit mold comprises lengths of 4 to 48 inches.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Advantages of the present invention will be apparent from the following detailed description of embodiments thereof, which description should be considered in conjunction with the accompanying drawings, in which:

[0036] FIG. 1 illustrates a perspective view of a lightweight conduit mold for creating pre-cast holes in a building foundation.

[0037] FIG. 2 illustrates another perspective view of the lightweight conduit mold for creating pre-cast holes in a building foundation.

[0038] FIG. 3 illustrates a top view of the lightweight conduit mold for creating pre-cast holes in a building foundation.

[0039] FIG. 4 illustrates marked positions in the foundation for placing lightweight conduit molds in advance of pouring the concrete over the concrete forms.

[0040] FIG. 5 illustrates marked positions in the foundation for placing lightweight conduit molds in advance of pouring the concrete over the concrete forms.

[0041] FIG. 6 illustrates lightweight conduit molds attached to the concrete forms in pre-determined positions in advance of pouring the concrete over the conduit molds and the concrete forms.

[0042] FIG. 7 illustrates lightweight conduit molds attached to the concrete forms in pre-determined positions in advance of pouring the concrete over the conduit molds and the concrete forms.

[0043] FIG. 8 illustrates lightweight conduit molds attached to the concrete forms in pre-determined positions in advance of pouring the concrete over the conduit molds and the concrete forms.

[0044] FIG. 9 illustrates lightweight conduit molds attached to the concrete forms in pre-determined positions in advance of pouring the concrete over the conduit molds and the concrete forms.

[0045] FIG. 10 illustrates lightweight conduit molds attached to the concrete forms in pre-determined positions in advance of pouring the concrete over the conduit molds and the concrete forms.

[0046] FIG. 11 illustrates lightweight conduit molds attached to the concrete forms in pre-determined positions in advance of pouring the concrete over the conduit molds and the concrete forms.

[0047] FIG. 12 illustrates lightweight conduit molds attached to the concrete forms in pre-determined positions in advance of pouring the concrete over the conduit molds and the concrete forms.

[0048] FIG. 13 illustrates lightweight conduit molds attached to the concrete forms in pre-determined positions in advance of pouring the concrete over the conduit molds and the concrete forms.

[0049] FIG. 14 illustrates lightweight conduit molds attached to the concrete forms in pre-determined positions in advance of pouring the concrete over the conduit molds and the concrete forms.

[0050] FIG. 15 illustrates a perspective view of a cast building foundation with installed lightweight conduit molds.

[0051] FIG. 16 illustrates a perspective view of a cast building foundation with installed lightweight conduit molds.

[0052] FIG. 17 illustrates a perspective view of an installed lightweight conduit mold being drilled out of a cast building foundation.

[0053] FIG. 18 illustrates a perspective view of an installed lightweight conduit mold and a hole from a removed lightweight conduit mold in a building foundation.

[0054] FIG. 19 illustrates a perspective view of installed lightweight conduit molds and holes from a removed lightweight conduit molds in a building foundation.

[0055] FIG. 20 illustrates a perspective view of installed lightweight conduit molds and holes from a removed lightweight conduit molds in a building foundation.

[0056] FIG. 21 illustrates a perspective view of installed lightweight conduit molds and holes from a removed lightweight conduit molds in a building foundation.

[0057] FIG. 22 illustrates a perspective view of multiple conduits inserted into a building foundation through holes from removed lightweight conduit molds and a lightweight conduit mold remaining installed in the foundation until later use.

[0058] FIG. 23 illustrates a perspective view of multiple conduits inserted into a building foundation through holes from removed lightweight conduit molds

[0059] FIG. 24 illustrates a perspective view of multiple conduits inserted into a building foundation through holes from removed lightweight conduit molds.

[0060] FIG. 25 illustrates a perspective view of multiple conduits inserted into a building foundation through holes from removed lightweight conduit molds.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0061] While several variations of the present invention have been illustrated by way of example in particular embodiments, it is apparent that further embodiments could be developed within the spirit and scope of the present invention, or the inventive concept thereof. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present invention, and are inclusive, but not limited to the following appended claims as set forth.

[0062] The subject invention discloses a method of constructing multiple conduits 1 in a residential and commercial building foundations 2 that eliminates the process of core drilling to produce conduits 1 after the foundation 2 has been poured and set. This process also creates optional openings 3 with insulated, water tight, fire retardant locations for possible future connections at a fraction of the cost of core drilling. Multiple watertight uninterrupted openings 3 from the interior of the foundation 2 to the exterior of the foundation 2 can be constructed using the subject method. These openings 3 can be used to install power and fluid conduits 1 for the building.

[0063] In the subject method, as illustrated in FIGS. 4 and 5, the positions 4 of the conduits 1 in the foundation 2 are determined in advance of pouring the concrete. In embodiments of the subject invention, multiple conduits 1 may be at locations at different positions of the foundation 2, as needed by the specific building construction.

[0064] At each selected conduit location 4, as illustrated in FIGS. 6-14, a lightweight conduit mold 5 is installed before the foundation concrete is poured. As illustrated in FIGS. 1-3, each conduit mold 5 is comprised of a unitary cylinder 6, a ring 7 with a larger diameter centered on the mold 5, and two thick rubber ends 8 on each side of the unitary cylinder 6.

[0065] The rubber ends 8 of each conduit mold 5 secure the mold to concrete forms 9 during the concrete pour. The rubber ends 8 also provide a watertight seal on each end of the conduit mold 5 after the foundation 2 has cured.

[0066] As the foundation concrete is poured, it surrounds each pre-installed conduit mold 5. The larger rings 7 of each conduit mold 5 lock it into the foundation 2 concrete at the pre-installed location 4, as the concrete cures and sets.

[0067] As illustrated in FIGS. 15 and 16, once the foundation concrete has set, the concrete forms 9 are removed, and the rubber ends 8 of the conduit mold 5 are flush with the interior and exterior walls of the foundation 2. The rubber ends 8 provide a water tight seal on the conduit mold 5 in the foundation until the hole 3 is exposed for use.

[0068] As illustrated in FIG. 17, when a conduit 1 is ready to be installed, the installed conduit mold 5 is drilled or melted out of the foundation 2 wall with an acetone based solution. The desired conduits 1 can then be installed in the remaining hole 3 and secured with whichever preferred method.

[0069] As illustrated in FIGS. 22-25, once the conduit holes 3 are drilled, and the mold 5 is removed, a cylindrical conduit 1 in placed within the resulting hole 3. A watertight seal is created around the conduit 1 using a link seal which contains a plurality of links and a gasket. As the link seal is tightened, the links compress the gasket to create a tight fitting between the concrete foundation 2 and the conduit 1.

[0070] As illustrated in FIGS. 21 and 22, if a hole 3 is not needed in the foundation 2 at a mold 5 location 4, the conduit mold 5 may be left in the foundation wall indefinitely without any repercussions.

[0071] In embodiments of the subject invention, the lightweight conduit mold 5 may be primarily composed of high density Styrofoam®, or other lightweight material that does not react with concrete, such as: Polystyrene Foam (both EPS and XPS), Polystyrene Plastic, Polystyrene Film, Polyisocyanurate ISO, Polyvinyl Chloride(PVC), Chlorinated Polyvinyl Chloride (CPVC), Unplasticide Polyvinyl Chloride(UPVC), Natural Isoprene, Ethylene Propylene Diene (EPDM), Nitrile Rubber (NBR), Styrene Butadiene Rubber (SBR), Silicone Rubber, Butyl Rubber, Polybutadiene, Aflas, Hypalon Rubber, Epichlorohydrin Rubber, Polyurethane, Polyethylene, lightweight solid wood, or plywood. In another embodiment of the subject invention, the lightweight conduit mold may be composed of fire resistant foam.

[0072] In embodiments of the subject invention the diameters of the lightweight conduit mold 5 range from 1.5″ to 58″. In further embodiments of the subject invention the lengths of the lightweight conduit mold 5 range from 4″ to 48″.