Flush Plug and Collar Kit for Level Drain Installation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Drains and cleanouts installed during construction are prone to damage from construction activities and weather exposure, leading to uneven concrete finishes and costly repairs, as they sit higher than the concrete surface, causing tripping hazards and aesthetic issues.
Innovation Solution
A kit comprising a flush plug and collar that allows concrete to be poured flush with the plug's surface, ensuring a smooth finish, and later adjusts to the correct height for tile installation, with a removable design and sealant for a water-tight installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the drain sits higher than the concrete surface to accommodate tile thickness, then the tile can be installed level with the drain, but the concrete finish becomes rougher and requires additional manual smoothing
Solution Approach 1:
The drain assembly is segmented into multiple components: a base drain unit, an adjustable elevation ring, and a top cover. This segmentation allows the elevation to be adjusted independently after concrete pouring, enabling precise tile level alignment without compromising concrete finish quality. The elevation ring can be positioned at different heights to match various tile thickness requirements.
Solution Approach 2:
The drain assembly incorporates dynamic adjustability through the elevation ring, which can be raised or lowered to accommodate different tile thicknesses. This dynamic adjustment capability allows the drain to adapt to varying installation requirements while maintaining a flush finish with the surrounding tile surface, eliminating the need for rough concrete finishes around fixed-height drains.
2Ease of operation
If the drain cover is exposed during construction, then it can be accessed for installation, but it becomes vulnerable to damage from construction activities and weather exposure
Solution Approach 1:
The drain base and elevation ring are installed and positioned before concrete pouring, allowing them to be set at the correct location and elevation in advance. The concrete is then poured around these pre-positioned components, protecting them during the curing process. This preliminary positioning ensures the drain is accessible for installation while protecting it from construction damage and weather exposure during the critical curing period.
3Adaptability or versatility
If the drain sits higher above the concrete, then tile thickness is accommodated, but the area around the drain requires more manual concrete removal or addition to achieve proper leveling
Solution Approach 1:
The adjustable elevation ring provides dynamic height adjustment capability, allowing the drain to be positioned at the exact height needed for different tile thicknesses. This adjustability eliminates the need for time-consuming manual concrete removal or addition, as the drain can simply be raised or lowered to match the tile thickness, significantly reducing finishing time while maintaining versatility across different tile specifications.
4Productivity
If the drain is not perfectly level during installation, then installation is faster, but the finished floor creates tripping hazards and aesthetic issues
Solution Approach 1:
The adjustable elevation ring enables dynamic level adjustment after the drain base is installed. Installers can quickly set the drain base in position and then use the elevation ring to fine-tune the height and levelness to match the surrounding floor. This two-stage process maintains installation speed while achieving precise level accuracy, eliminating tripping hazards and aesthetic issues that would result from improper leveling.
Data Source
AI summary
A flush plug and a collar are used in installing a drain or cleanout. A flush plug is temporarily attached to the nipple of a cleanout or to a drain base and leveled. Concrete is then poured flush with the top of the flush plug. After the flush plug is removed from the cured concrete, a collar is installed in the hole in the concrete left by the flush plug. The outside of the lower portion of the collar is beveled like the flush plug. The upper portion of the collar includes a sleeve rising above the top surface of the surrounding concrete by an amount equal to the thickness of the specific floor finish. Tile or other finish may then be laid to around the collar. The installed drain will be flush and level with the flooring around it.