Non-Corrosive Form Setting Stake and Permanent Leak-Proof Vapor Barrier Plugging Method

Abstract

A non-corrosive form setting stake and a permanent leak-proof plugging method of using the stake in cases where soil conditions are such that a vapor barrier is required to prevent potentially harmful elements in the soil from escaping and harming anything or anyone above the barrier. The stake comprises a slender elongated body, a wedge-shaped leading end for piercing the earth, a plurality of holes through which nails are driven to attach the form board to the stake, and a trailing end that serves as a striking surface for driving the stake into the ground. In the forming of a slab on grade foundation, a plurality of stakes is driven through the vapor barrier and into the earth in order to hold the form boards in place. Next, a seal is created around the stakes to the vapor barrier. Once the stakes are sealed, each stake acts as a permanent leak-proof plug in the vapor barrier that prevents elements in the soil from escaping through or around the stake. After governing agencies have inspected the vapor barrier and the forms are removed, a top section of the stake is cut off above the stake's sealed portion and below the slab's finished surface. The concrete is then finished with the lower portion of each stake left permanently embedded in the earth and beneath the finished concrete.

Description

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application is a continuation of U.S. Ser. No. 16 / 173,591, filed Oct. 29, 2018, which is a continuation of U.S. Ser. No. 11 / 182,971, filed Jul. 16, 2005, each of which are herein incorporated by reference in their entirety.FIELD OF THE INVENTION

[0002] The invention generally concerns improvements in the practice of slab on grade form setting. In particular, the present invention is a non-corrosive stake used for securing forms and a method of using the stake in cases where soil conditions are such that a permanent leak-proof vapor barrier is required to prevent potentially harmful elements in the soil from escaping and injuring anything or anyone above the barrier.BACKGROUND OF THE INVENTION

[0003] In slab on grade foundations, forms are necessary to hold the concrete in place while it dries and hardens. The forms themselves are held in place by strategically locating wooden or steel stakes. When the form setting stakes are removed, they create holes in the vapor barrier. Normally these holes are not of great concern. However, there are a growing number of soil conditions in which holes in the vapor barrier can cause problems. For instance, in cases where the soils below the foundation contain elements that corrode concrete (e.g. acid, sulfites, chlorides, nitrates, nitrites) or contain potentially harmful gases (e.g. radon or methane), or contain excessive amounts of water vapor that can cause mold or ruin things inside the structure such as wooden floors. In addition, homes today are now being built on land previously considered unsuitable for housing, such as old landfills, abandoned oil fields, and old industrial sites. In these types of situations the vapor barrier cannot have holes because these elements can leak through the holes and cause not only financial loss but physical ailments that can even potentially be life threatening.

[0004] In view of the foregoing, therefore, a need exists for a form setting stake that permanently prevents leaks through the vapor barrier. Ideally this stake must also be light weight, durable, easy to manufacture, capable of conforming to various form sizes, simple to use, and comprised of few parts.

[0005] A wide variety of stakes and methods of securing stakes to form boards exist. Examples of such stakes and methods are shown in U.S. Pat. No. 6,705,582 B2 (Osborn, 2004), U.S. Pat. No. 6,021,994 (Shartzer, Jr., 2000), U.S. Pat. No. 5,830,378 (Butler, 1998), U.S. Pat. No. 5,230,187 (Reimann, 1993), U.S. Pat. No. 5,076,536 (Fitzgerald, 1991), U.S. Pat. No. 4,776,555 (Maynard, 1988), U.S. Pat. No. 4,723,752 (Thomas, 1988), U.S. Pat. No. 4,635,895 (Johnson, Jr. et. al., 1987), U.S. Pat. No. 4,533,112 (Santos, 1985), U.S. Pat. No. 3,785,606 (Green, 1974), U.S. Pat. No. 3,378,968 (Shoemaker, 1968), U.S. Pat. No. 3,300,920 (Skaare, 1967), U.S. Pat. No. 2,846,749 (Yates et. al, 1958), U.S. Pat. No. 2,741,821 (Findley, 1956), U.S. Pat. No. 1,897,530 (Pandolfi, 1933), U.S. Pat. No. 1,741,829 (Cucolo, 1929), U.S. Pat. No. 1,607,690 (Rue, 1926), U.S. Pat. No. 1,512,165 (Funkhouser, 1924), U.S. Pat. No. 1,382,082 (Heltzel, 1921). While much prior art can be found in the field of slab foundations and related concrete work, the commercial success of the stakes and methods is limited. The primary reasons for this are that these ideas tend cither to be expensive, complicated, and / or inflexible. In addition, and most important, all of the above mentioned inventions create holes in the vapor barrier, and none even address the issue of leakage, let alone putting an end to leakage through the vapor barrier.

[0006] The area of form setting is extremely resistant to change, and despite the inventions proposed above, the vast majority of slabs continue to be set with standard wooden boards and stakes. Similarly the concern for vapor barrier leakage has been handled through the use of common construction materials, and nothing is currently in use that has been specifically designed to address this issue.

[0007] In the field of slab foundations there are several methods currently in use to help prevent leakage through the vapor barrier. However each method has its own set of problems. One of the oldest methods uses common steel dowels to hold the forms. The vapor barrier is then sealed to the dowels. Before the concrete is cured, the dowels are cut off just below the concrete's surface. The concrete is then finished, completely covering the remaining portion of the dowels. Because the dowels are permanently left in place, the holes made in the vapor barrier are temporarily plugged. However, the reality is that, over time, the steel dowels will eventually corrode, thus again leaving holes in the vapor barrier that leak. Because this is only a temporary solution to the problem of vapor barrier leakage, many inspecting agencies today are no longer allowing construction companies to use this method.

[0008] A second method involves suspending the forms from above, using beams supported by stakes that are driven into the ground outside the vapor barrier, thus avoiding all types of penetration through the vapor barrier. This method is not widely used, however, because it is time consuming and has only proven to be barely effective in the creation of small foundations that can be easily spanned. In the case of large foundations, the distance that must be spanned in order to support the forms from above, is too great. Or conversely, systems that are engineered to span great distances are too costly and unmanageable. Even in cases where this method is used, the finished product is often below building industry standards.

[0009] A third method involves taking a two to three foot section of polyvinyl chloride (PVC) pipe with a PVC cap glued to one end. A hole is dug and the PVC pipe is placed with the capped end facing down into the hole. The pipe is plumbed and secured in place by compressing the earth around it. Several inches of the pipe are left exposed above the earth and the vapor barrier is scaled around the exposed pipe, similar to a plumber's pipe penetration. A wooden dowel is wedged into the pipe and protrudes above the pipe high enough to accommodate the forms. This process is repeated approximately every two feet on center at which point forms are held in place by being nailed to the dowels. Before the concrete is cured, the wooden dowels are removed from the PVC pipe. The PVC pipe is left in place below the surface of the concrete and the concrete is finished. Although this method leaves the vapor barrier intact, it is time consuming, labor intensive, and, thus, costly.

[0010] A fourth method involves driving a stake or dowel into the ground. A small section of PVC pipe is then slid over the stake or dowel, and rests on the ground. This process is repeated approximately every two feet on center at which point forms are then nailed in place to the stakes. The vapor barrier is sealed around the pipes, again similar to a plumber's pipe penetration. The concrete is poured. Before the concrete is cured, the stakes or dowels are removed from the PVC pipes. A cap is glued in place over each exposed PVC pipe, but below the finished concrete surface. The concrete is then finished and completely covers the PVC pipes and caps. One of the main problems with this method, however, has to do with the timing of inspections. Before pouring the concrete and gluing the caps in place, each job must pass inspection. Inspections typically occur several days before the concrete pour, thus allowing enough time to schedule the arrival of the concrete. After giving their approval to pour the concrete, inspectors are assuming and hoping that the caps are glued in place after the stakes or dowels have been removed and before the concrete is finished. However, other than breaking through the concrete to check, there is no real way to confirm that the caps have been properly installed, if installed at all. And, without the caps properly in place, the vapor barrier has been breached.

[0011] The difficulties encountered in the prior art are substantially eliminated by the present invention.

[0012] Accordingly, besides the objects and advantages of the non-corrosive stake for form setting described above, several objects and advantages of the present invention are:

[0013] a) to provide a stake for form setting that is permanently leak-proof;

[0014] b) to provide a stake for form setting that is inexpensive to manufacture;

[0015] c) to provide a stake for form setting that is simple to use;

[0016] d) to provide a stake for form setting that will not corrode;

[0017] e) to provide a stake for form setting that uses less labor than current methods;

[0018] f) to provide a stake for form setting that may be used in the creation of foundations of any size or shape;

[0019] g) to provide a stake for form setting that creates a finished foundation which meets or exceeds industry standards;

[0020] h) to provide a stake for form setting that is timed to meet industry standard inspection requirements.

[0021] Further objects and advantages are to provide a stake for form setting which is strong enough to hold the forms yet lightweight enough to easily handle and carry, which is similar enough to what is already used in the field so that crews will not have to be extensively trained or have to learn any new techniques, which is made of a single piece of non-corrosive material that does not require any additional pieces and can be used with all other materials currently in use, which is less time consuming to use, and which can accommodate forms of different sizes.

[0022] Still further objects and advantages will become apparent from a consideration of the ensuing description and drawings.SUMMARY OF THE INVENTION

[0023] In accordance with the present invention, a non-corrosive stake for form setting a slab on grade foundation when a vapor barrier is required comprising an elongated body, a leading end adapted for piercing the earth, a trailing end that serves as a striking surface for driving the stake into the earth, a way of securing a form board to the stake, and a permanent leak-proof plugging method that prevents elements in the soil from escaping through the vapor barrier.

[0024] In the drawings, closely related figures have the same number but different alphabetic suffixes.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1 is an overall perspective view of the non-corrosive stake.

[0026] FIG. 2A shows a form in accordance with the present invention set up for forming a depression in concrete slab on grade.

[0027] FIG. 2B shows the present invention in its final state with a lower portion of the stake left permanently embedded in the earth and finished concrete.DRAWINGS--REFERENCE NUMERALS10 non-corrosive stake12 wedge-shaped leading end14 nail holes16 stake head (trailing end)20 temporary form22 duplex nails24 vapor barrier26 protective sand layers28 Earth30 permanent seal32 finished surface of foundation34 concrete foundationDETAILED DESCRIPTION OF THE INVENTION

[0028] Reference is now made to FIG. 1 (overall perspective), wherein the stake 10 is in the shape of a cylinder. The cylindrical form is preferred because it is smooth and has rounded edges, thus facilitating the stake's ability to adhere to the vapor barrier and minimizing the possibility of leaks. The cylindrical form also takes advantage of existing sealing methods already proven to be effective in plumbing penetrations. Thus, the cylindrical form is easier to work with and more cost effective.

[0029] In the preferred embodiment the stake 10 is made of a sturdy solid plastic. The stake is solid so as to reduce the possibility of leaks through the stake itself and in order to increase the stake's strength and rigidity. And, in the preferred embodiment, the stake will be made of plastic, because it is currently the most cost effective non-corrosive material available.

[0030] In the preferred embodiment the overall length of the stake is one meter with a diameter of 2 centimeters. In essence, the stake is long enough to accommodate the majority of building conditions and thick enough to endure the force of concrete. However, to accommodate less common building conditions, the stake may vary in length and diameter. It is very possible, for instance, that a viable secondary market may exist for another stake that is approximately 125 cm in length and 2.5 cm in diameter.

[0031] At the leading end of the stake, and as best viewed in FIG. 1, is a point 12 adapted to penetrate the ground. In the preferred embodiment, the point is wedge-shaped thus helping to prevent the stake from twisting into the earth and keeping the holes in the stake 14 perpendicular to the form board. Holes that are perpendicular to the form board, in turn, will increase the case of driving nails through the stake and into the form board.

[0032] In the preferred embodiment, and as best viewed in FIG. 1, six holes 14 run through the width of the stake 10. In the preferred embodiment, the first hole is located 2.5 cm from the trailing end of the stake and consecutive holes are located every 3.5 cm on center for the remaining five holes. If needed, additional holes, or differently located holes, may be provided to accommodate various forming conditions.

[0033] In the preferred embodiment, the holes 14 will have a diameter large enough to accommodate a 16d duplex nail. Although the present invention may be held securely in place in a variety of ways, in the preferred embodiment the temporary form is secured with duplex nails, because duplex nails are current industry standard and are easy to remove.

[0034] On the trailing end of the stake, and as best viewed in FIG. 1, is the stake head 16. In the preferred embodiment, the stake head is cut perpendicular to the shaft of the stake 10. The trailing end serves as a striking surface for driving the stake into the ground.Operation—FIGS. 1, 2A and 2B.

[0035] FIGS. 2A and 2B are perspectives of the non-corrosive stake as it is to be used in the construction of a slab on grade foundation when a leak proof vapor barrier is required to prevent potentially harmful elements in the soil from escaping and injuring anything or anyone above the barrier.

[0036] FIG. 2A shows the present invention as it is being used to support a form board during the forming of a depression in the slab on grade foundation. In this figure, two stakes 10 hold the temporary form 20 securely in place. One stake is perpendicular to the form board and the other rests at approximately a 45 degree angle. The stakes 10 penetrate the vapor barrier 24, its protective sand layers 26, and are driven into the earth 28. In the preferred embodiment, the temporary form is secured with duplex nails 22. As seen in FIG. 1, the duplex nails run through the holes 14 in the stake 10. This process is repeated with a plurality of stakes until all form boards required for a particular project are supported.

[0037] As shown in FIG. 2A, a permanent seal 30 is created around each stake 10 to the vapor barrier 24. The seal 30 is the same seal currently being used around plumber's pipe penetrations, thus does not require additional training, equipment, or engineering; it has been proven to resist leaks and is cost effective. Once the stakes 10 are sealed, each stake acts as a plug in the vapor barrier that prevents elements in the earth from escaping through or around the stakes. After the stakes 10 have been sealed, the vapor barrier 24 is inspected by the appropriate governing agencies for leaks. Once approved by the inspector, concrete can be ordered and a labor force can be scheduled to place the concrete. At this point, no further inspections are required to ensure the consumer that a leak proof vapor barrier has been provided.

[0038] FIG. 2B shows the present invention in its final state with a portion of the stake left permanently embedded in the earth and finished concrete. In this figure, a portion of each stake 10 has been cut roughly 2.5 cm above the stake's sealed portion 30. After the project passes inspection, the forms (see FIG. 2A) are no longer needed because they have performed their job. The forms are then removed and the top section of each stake 10 is cut off above the stake's sealed portion 30 but below the slab's finished surface 32. The concrete foundation 34 is then finished. As shown in FIG. 2B the lower portion of each stake 10 is left permanently embedded in the earth 28 and finished concrete 32, thus the lower portion of each stake 10 acts as a permanently plug in the vapor barrier 24, ensuring a long term solution to leaking.

[0039] This process creates a foundation that is aesthetically acceptable to the consumer while providing a permanent leak-proof plug in a cost effective manner. The process is also timed to meet industry standard inspection requirements, so that, the consumer is assured of a long term, non-corrosive, solution to leakage. In addition, the process is simple, and is less time consuming than other methods currently in use. And most important, this method keeps potentially harmful elements in the soil below the vapor barrier and away from objects and individuals residing above the vapor barrier.

[0040] Although the description above contains many specifications, these should not be construed as limiting the scope of the invention but merely providing illustrations of some of the presently preferred embodiments of this invention. For example, the stake can be made in a variety of other shapes, such as oval, square, triangular, etc., or even made of a combination of shapes, such as square at the trailing end and cylindrical at the leading end.

[0041] The stake can be made of a variety of non-corrosive materials other than plastic, such as stainless steel or even titanium. The stake can be made in a variety of lengths and in other diameters to accommodate a variety of construction demands. In addition, the stake could have a variety of leading ends differently adapted to penetrate the earth (e.g. a pointed end, or tapered wedge-shape, etc.), or be made with a variety of trailing ends differently adapted to act as a striking surface (e.g. a trailing end with a wider or rounded striking surface, etc.). The stake might be made with a different number of holes, differently sized holes, or holes that are differently located on the stake. Moreover, the stake can be secured to the temporary forms with a variety of other fasteners (e.g. screws, or u-nails) or in a completely different manner than the one described in the preferred embodiment. And finally, a wide variety of sealants and methods of sealing may be used to seal the stake to the vapor barrier.

[0042] Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.

Examples

Embodiment Construction

[0028]Reference is now made to FIG. 1 (overall perspective), wherein the stake 10 is in the shape of a cylinder. The cylindrical form is preferred because it is smooth and has rounded edges, thus facilitating the stake's ability to adhere to the vapor barrier and minimizing the possibility of leaks. The cylindrical form also takes advantage of existing sealing methods already proven to be effective in plumbing penetrations. Thus, the cylindrical form is easier to work with and more cost effective.

[0029]In the preferred embodiment the stake 10 is made of a sturdy solid plastic. The stake is solid so as to reduce the possibility of leaks through the stake itself and in order to increase the stake's strength and rigidity. And, in the preferred embodiment, the stake will be made of plastic, because it is currently the most cost effective non-corrosive material available.

[0030]In the preferred embodiment the overall length of the stake is one meter with a diameter of 2 centimeters. In es...

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application is a continuation of U.S. Ser. No. 16 / 173,591, filed Oct. 29, 2018, which is a continuation of U.S. Ser. No. 11 / 182,971, filed Jul. 16, 2005, each of which are herein incorporated by reference in their entirety.FIELD OF THE INVENTION

[0002] The invention generally concerns improvements in the practice of slab on grade form setting. In particular, the present invention is a non-corrosive stake used for securing forms and a method of using the stake in cases where soil conditions are such that a permanent leak-proof vapor barrier is required to prevent potentially harmful elements in the soil from escaping and injuring anything or anyone above the barrier.BACKGROUND OF THE INVENTION

[0003] In slab on grade foundations, forms are necessary to hold the concrete in place while it dries and hardens. The forms themselves are held in place by strategically locating wooden or steel stakes. When the form setting stakes are removed, they create holes in the vapor barrier. Normally these holes are not of great concern. However, there are a growing number of soil conditions in which holes in the vapor barrier can cause problems. For instance, in cases where the soils below the foundation contain elements that corrode concrete (e.g. acid, sulfites, chlorides, nitrates, nitrites) or contain potentially harmful gases (e.g. radon or methane), or contain excessive amounts of water vapor that can cause mold or ruin things inside the structure such as wooden floors. In addition, homes today are now being built on land previously considered unsuitable for housing, such as old landfills, abandoned oil fields, and old industrial sites. In these types of situations the vapor barrier cannot have holes because these elements can leak through the holes and cause not only financial loss but physical ailments that can even potentially be life threatening.

[0004] In view of the foregoing, therefore, a need exists for a form setting stake that permanently prevents leaks through the vapor barrier. Ideally this stake must also be light weight, durable, easy to manufacture, capable of conforming to various form sizes, simple to use, and comprised of few parts.

[0005] A wide variety of stakes and methods of securing stakes to form boards exist. Examples of such stakes and methods are shown in U.S. Pat. No. 6,705,582 B2 (Osborn, 2004), U.S. Pat. No. 6,021,994 (Shartzer, Jr., 2000), U.S. Pat. No. 5,830,378 (Butler, 1998), U.S. Pat. No. 5,230,187 (Reimann, 1993), U.S. Pat. No. 5,076,536 (Fitzgerald, 1991), U.S. Pat. No. 4,776,555 (Maynard, 1988), U.S. Pat. No. 4,723,752 (Thomas, 1988), U.S. Pat. No. 4,635,895 (Johnson, Jr. et. al., 1987), U.S. Pat. No. 4,533,112 (Santos, 1985), U.S. Pat. No. 3,785,606 (Green, 1974), U.S. Pat. No. 3,378,968 (Shoemaker, 1968), U.S. Pat. No. 3,300,920 (Skaare, 1967), U.S. Pat. No. 2,846,749 (Yates et. al, 1958), U.S. Pat. No. 2,741,821 (Findley, 1956), U.S. Pat. No. 1,897,530 (Pandolfi, 1933), U.S. Pat. No. 1,741,829 (Cucolo, 1929), U.S. Pat. No. 1,607,690 (Rue, 1926), U.S. Pat. No. 1,512,165 (Funkhouser, 1924), U.S. Pat. No. 1,382,082 (Heltzel, 1921). While much prior art can be found in the field of slab foundations and related concrete work, the commercial success of the stakes and methods is limited. The primary reasons for this are that these ideas tend cither to be expensive, complicated, and / or inflexible. In addition, and most important, all of the above mentioned inventions create holes in the vapor barrier, and none even address the issue of leakage, let alone putting an end to leakage through the vapor barrier.

[0006] The area of form setting is extremely resistant to change, and despite the inventions proposed above, the vast majority of slabs continue to be set with standard wooden boards and stakes. Similarly the concern for vapor barrier leakage has been handled through the use of common construction materials, and nothing is currently in use that has been specifically designed to address this issue.

[0007] In the field of slab foundations there are several methods currently in use to help prevent leakage through the vapor barrier. However each method has its own set of problems. One of the oldest methods uses common steel dowels to hold the forms. The vapor barrier is then sealed to the dowels. Before the concrete is cured, the dowels are cut off just below the concrete's surface. The concrete is then finished, completely covering the remaining portion of the dowels. Because the dowels are permanently left in place, the holes made in the vapor barrier are temporarily plugged. However, the reality is that, over time, the steel dowels will eventually corrode, thus again leaving holes in the vapor barrier that leak. Because this is only a temporary solution to the problem of vapor barrier leakage, many inspecting agencies today are no longer allowing construction companies to use this method.

[0008] A second method involves suspending the forms from above, using beams supported by stakes that are driven into the ground outside the vapor barrier, thus avoiding all types of penetration through the vapor barrier. This method is not widely used, however, because it is time consuming and has only proven to be barely effective in the creation of small foundations that can be easily spanned. In the case of large foundations, the distance that must be spanned in order to support the forms from above, is too great. Or conversely, systems that are engineered to span great distances are too costly and unmanageable. Even in cases where this method is used, the finished product is often below building industry standards.

[0009] A third method involves taking a two to three foot section of polyvinyl chloride (PVC) pipe with a PVC cap glued to one end. A hole is dug and the PVC pipe is placed with the capped end facing down into the hole. The pipe is plumbed and secured in place by compressing the earth around it. Several inches of the pipe are left exposed above the earth and the vapor barrier is scaled around the exposed pipe, similar to a plumber's pipe penetration. A wooden dowel is wedged into the pipe and protrudes above the pipe high enough to accommodate the forms. This process is repeated approximately every two feet on center at which point forms are held in place by being nailed to the dowels. Before the concrete is cured, the wooden dowels are removed from the PVC pipe. The PVC pipe is left in place below the surface of the concrete and the concrete is finished. Although this method leaves the vapor barrier intact, it is time consuming, labor intensive, and, thus, costly.

[0010] A fourth method involves driving a stake or dowel into the ground. A small section of PVC pipe is then slid over the stake or dowel, and rests on the ground. This process is repeated approximately every two feet on center at which point forms are then nailed in place to the stakes. The vapor barrier is sealed around the pipes, again similar to a plumber's pipe penetration. The concrete is poured. Before the concrete is cured, the stakes or dowels are removed from the PVC pipes. A cap is glued in place over each exposed PVC pipe, but below the finished concrete surface. The concrete is then finished and completely covers the PVC pipes and caps. One of the main problems with this method, however, has to do with the timing of inspections. Before pouring the concrete and gluing the caps in place, each job must pass inspection. Inspections typically occur several days before the concrete pour, thus allowing enough time to schedule the arrival of the concrete. After giving their approval to pour the concrete, inspectors are assuming and hoping that the caps are glued in place after the stakes or dowels have been removed and before the concrete is finished. However, other than breaking through the concrete to check, there is no real way to confirm that the caps have been properly installed, if installed at all. And, without the caps properly in place, the vapor barrier has been breached.

[0011] The difficulties encountered in the prior art are substantially eliminated by the present invention.

[0012] Accordingly, besides the objects and advantages of the non-corrosive stake for form setting described above, several objects and advantages of the present invention are:

[0013] a) to provide a stake for form setting that is permanently leak-proof;

[0014] b) to provide a stake for form setting that is inexpensive to manufacture;

[0015] c) to provide a stake for form setting that is simple to use;

[0016] d) to provide a stake for form setting that will not corrode;

[0017] e) to provide a stake for form setting that uses less labor than current methods;

[0018] f) to provide a stake for form setting that may be used in the creation of foundations of any size or shape;

[0019] g) to provide a stake for form setting that creates a finished foundation which meets or exceeds industry standards;

[0020] h) to provide a stake for form setting that is timed to meet industry standard inspection requirements.

[0021] Further objects and advantages are to provide a stake for form setting which is strong enough to hold the forms yet lightweight enough to easily handle and carry, which is similar enough to what is already used in the field so that crews will not have to be extensively trained or have to learn any new techniques, which is made of a single piece of non-corrosive material that does not require any additional pieces and can be used with all other materials currently in use, which is less time consuming to use, and which can accommodate forms of different sizes.

[0022] Still further objects and advantages will become apparent from a consideration of the ensuing description and drawings.SUMMARY OF THE INVENTION

[0023] In accordance with the present invention, a non-corrosive stake for form setting a slab on grade foundation when a vapor barrier is required comprising an elongated body, a leading end adapted for piercing the earth, a trailing end that serves as a striking surface for driving the stake into the earth, a way of securing a form board to the stake, and a permanent leak-proof plugging method that prevents elements in the soil from escaping through the vapor barrier.

[0024] In the drawings, closely related figures have the same number but different alphabetic suffixes.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1 is an overall perspective view of the non-corrosive stake.

[0026] FIG. 2A shows a form in accordance with the present invention set up for forming a depression in concrete slab on grade.

[0027] FIG. 2B shows the present invention in its final state with a lower portion of the stake left permanently embedded in the earth and finished concrete.DRAWINGS--REFERENCE NUMERALS10 non-corrosive stake12 wedge-shaped leading end14 nail holes16 stake head (trailing end)20 temporary form22 duplex nails24 vapor barrier26 protective sand layers28 Earth30 permanent seal32 finished surface of foundation34 concrete foundationDETAILED DESCRIPTION OF THE INVENTION

[0028] Reference is now made to FIG. 1 (overall perspective), wherein the stake 10 is in the shape of a cylinder. The cylindrical form is preferred because it is smooth and has rounded edges, thus facilitating the stake's ability to adhere to the vapor barrier and minimizing the possibility of leaks. The cylindrical form also takes advantage of existing sealing methods already proven to be effective in plumbing penetrations. Thus, the cylindrical form is easier to work with and more cost effective.

[0029] In the preferred embodiment the stake 10 is made of a sturdy solid plastic. The stake is solid so as to reduce the possibility of leaks through the stake itself and in order to increase the stake's strength and rigidity. And, in the preferred embodiment, the stake will be made of plastic, because it is currently the most cost effective non-corrosive material available.

[0030] In the preferred embodiment the overall length of the stake is one meter with a diameter of 2 centimeters. In essence, the stake is long enough to accommodate the majority of building conditions and thick enough to endure the force of concrete. However, to accommodate less common building conditions, the stake may vary in length and diameter. It is very possible, for instance, that a viable secondary market may exist for another stake that is approximately 125 cm in length and 2.5 cm in diameter.

[0031] At the leading end of the stake, and as best viewed in FIG. 1, is a point 12 adapted to penetrate the ground. In the preferred embodiment, the point is wedge-shaped thus helping to prevent the stake from twisting into the earth and keeping the holes in the stake 14 perpendicular to the form board. Holes that are perpendicular to the form board, in turn, will increase the case of driving nails through the stake and into the form board.

[0032] In the preferred embodiment, and as best viewed in FIG. 1, six holes 14 run through the width of the stake 10. In the preferred embodiment, the first hole is located 2.5 cm from the trailing end of the stake and consecutive holes are located every 3.5 cm on center for the remaining five holes. If needed, additional holes, or differently located holes, may be provided to accommodate various forming conditions.

[0033] In the preferred embodiment, the holes 14 will have a diameter large enough to accommodate a 16d duplex nail. Although the present invention may be held securely in place in a variety of ways, in the preferred embodiment the temporary form is secured with duplex nails, because duplex nails are current industry standard and are easy to remove.

[0034] On the trailing end of the stake, and as best viewed in FIG. 1, is the stake head 16. In the preferred embodiment, the stake head is cut perpendicular to the shaft of the stake 10. The trailing end serves as a striking surface for driving the stake into the ground.Operation—FIGS. 1, 2A and 2B.

[0035] FIGS. 2A and 2B are perspectives of the non-corrosive stake as it is to be used in the construction of a slab on grade foundation when a leak proof vapor barrier is required to prevent potentially harmful elements in the soil from escaping and injuring anything or anyone above the barrier.

[0036] FIG. 2A shows the present invention as it is being used to support a form board during the forming of a depression in the slab on grade foundation. In this figure, two stakes 10 hold the temporary form 20 securely in place. One stake is perpendicular to the form board and the other rests at approximately a 45 degree angle. The stakes 10 penetrate the vapor barrier 24, its protective sand layers 26, and are driven into the earth 28. In the preferred embodiment, the temporary form is secured with duplex nails 22. As seen in FIG. 1, the duplex nails run through the holes 14 in the stake 10. This process is repeated with a plurality of stakes until all form boards required for a particular project are supported.

[0037] As shown in FIG. 2A, a permanent seal 30 is created around each stake 10 to the vapor barrier 24. The seal 30 is the same seal currently being used around plumber's pipe penetrations, thus does not require additional training, equipment, or engineering; it has been proven to resist leaks and is cost effective. Once the stakes 10 are sealed, each stake acts as a plug in the vapor barrier that prevents elements in the earth from escaping through or around the stakes. After the stakes 10 have been sealed, the vapor barrier 24 is inspected by the appropriate governing agencies for leaks. Once approved by the inspector, concrete can be ordered and a labor force can be scheduled to place the concrete. At this point, no further inspections are required to ensure the consumer that a leak proof vapor barrier has been provided.

[0038] FIG. 2B shows the present invention in its final state with a portion of the stake left permanently embedded in the earth and finished concrete. In this figure, a portion of each stake 10 has been cut roughly 2.5 cm above the stake's sealed portion 30. After the project passes inspection, the forms (see FIG. 2A) are no longer needed because they have performed their job. The forms are then removed and the top section of each stake 10 is cut off above the stake's sealed portion 30 but below the slab's finished surface 32. The concrete foundation 34 is then finished. As shown in FIG. 2B the lower portion of each stake 10 is left permanently embedded in the earth 28 and finished concrete 32, thus the lower portion of each stake 10 acts as a permanently plug in the vapor barrier 24, ensuring a long term solution to leaking.

[0039] This process creates a foundation that is aesthetically acceptable to the consumer while providing a permanent leak-proof plug in a cost effective manner. The process is also timed to meet industry standard inspection requirements, so that, the consumer is assured of a long term, non-corrosive, solution to leakage. In addition, the process is simple, and is less time consuming than other methods currently in use. And most important, this method keeps potentially harmful elements in the soil below the vapor barrier and away from objects and individuals residing above the vapor barrier.

[0040] Although the description above contains many specifications, these should not be construed as limiting the scope of the invention but merely providing illustrations of some of the presently preferred embodiments of this invention. For example, the stake can be made in a variety of other shapes, such as oval, square, triangular, etc., or even made of a combination of shapes, such as square at the trailing end and cylindrical at the leading end.

[0041] The stake can be made of a variety of non-corrosive materials other than plastic, such as stainless steel or even titanium. The stake can be made in a variety of lengths and in other diameters to accommodate a variety of construction demands. In addition, the stake could have a variety of leading ends differently adapted to penetrate the earth (e.g. a pointed end, or tapered wedge-shape, etc.), or be made with a variety of trailing ends differently adapted to act as a striking surface (e.g. a trailing end with a wider or rounded striking surface, etc.). The stake might be made with a different number of holes, differently sized holes, or holes that are differently located on the stake. Moreover, the stake can be secured to the temporary forms with a variety of other fasteners (e.g. screws, or u-nails) or in a completely different manner than the one described in the preferred embodiment. And finally, a wide variety of sealants and methods of sealing may be used to seal the stake to the vapor barrier.

[0042] Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.

Examples

Embodiment Construction

[0028]Reference is now made to FIG. 1 (overall perspective), wherein the stake 10 is in the shape of a cylinder. The cylindrical form is preferred because it is smooth and has rounded edges, thus facilitating the stake's ability to adhere to the vapor barrier and minimizing the possibility of leaks. The cylindrical form also takes advantage of existing sealing methods already proven to be effective in plumbing penetrations. Thus, the cylindrical form is easier to work with and more cost effective.

[0029]In the preferred embodiment the stake 10 is made of a sturdy solid plastic. The stake is solid so as to reduce the possibility of leaks through the stake itself and in order to increase the stake's strength and rigidity. And, in the preferred embodiment, the stake will be made of plastic, because it is currently the most cost effective non-corrosive material available.

[0030]In the preferred embodiment the overall length of the stake is one meter with a diameter of 2 centimeters. In es...

Claims

1: A non-corrosive stake, vapor barrier, and sealing material for form setting a slab on grade foundation comprising:a) an elongated body formed from a non-corrosive material, said elongated body having an essentially solid cross-section;b) at least one attachment member positioned along said elongated body;c) a leading end located at a first end of said elongated body, said leading end adapted for penetrating the a vapor barrier, positioned adjacent the earth, and the earth in a plurality of angular directions;d) a trailing end located at a second end of said elongated body, said trailing end adapted to serve as a striking surface for driving said leading end of said stake into said earth at the plurality of angular directions; ande) a surface portion on said elongated body adapted for contact with the sealing material coating located on said surface portion and / or said vapor barrier, said sealing material adapted for permanently sealing at least a portion of the elongated body to the vapor barrier to prevent elements in the soil from escaping through a penetration point caused by penetration of said leading end through the vapor barrier.2: The non-corrosive stake of claim 1, wherein the elongated body, the leading end, and the trailing end are formed from a plastic material.3: The non-corrosive stake of claim 1, having a diameter of approximately 1.5-4 centimeters.4: The non-corrosive stake of claim 1, having an approximately cylindrical shape.5: The non-corrosive stake of claim 1, wherein the leading end has a pointed end.6: The non-corrosive stake of claim 1, wherein the non-corrosive stake is formed from a material adapted to be cut at a predetermined location.7: The non-corrosive stake of claim 1, wherein the attachment member for securing a form board to said non-corrosive stake comprises at least one hole.8: The non-corrosive stake of claim 1, wherein the non-corrosive stake is adapted for acting as a permanent leak-proof plug to prevent elements in the soil from escaping and is formed from a single piece of non-corrosive material.9: The non-corrosive stake of claim 1, wherein the non-corrosive stake is configured to be cut such that the leading end of the non-corrosive stake remains permanently embedded in said earth and within a slab on grade foundation.10: The non-corrosive stake of claim 1, wherein the non-corrosive stake is configured to be driven into the earth at a 45 degree angle.11: A method for supporting forms in the construction of a slab on grade foundation comprising providing a plurality of non-corrosive elongated stakes as defined in claim 1 and securing the plurality of non-corrosive elongated stakes to a plurality of form boards.12: The method of claim 11, comprising providing a vapor barrier adjacent to the earth and driving the plurality of non-corrosive elongated stakes through the vapor barrier and the earth.13: The method of claim 12, comprising providing a sealing material on a surface of the vapor barrier and driving the plurality of non-corrosive elongated stakes through the sealing material to permanently seal at least a portion of the elongated body to the vapor barrier and to prevent elements and vapors in the soil from escaping through a penetration point caused by penetration of the elongated stakes through the vapor barrier.14: The method of claim 12, wherein the driving of the leading ends of the non-corrosive elongated stakes into the earth comprises driving at least one of the non-corrosive elongated stakes at the angular direction not perpendicular with respect to a planar surface of the earth such that the at least one of the non-corrosive elongated stakes is positioned in the earth at an angular direction not perpendicular with respect to a planar surface of the earth.15: The method of claim 12, comprising driving the non-corrosive elongated stakes into the earth such that at least one of the non-corrosive elongated stakes is perpendicular to the form boards and at least a second non-corrosive elongated stake rests at approximately a 45 degree angle to the form boards.16: The method of claim 11, comprising providing a wedge-shape to the leading ends of the non-corrosive elongated stakes to reduce twisting of the non-corrosive elongated stakes while being driven into the earth.

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