POST STAND AND RELATED METHOD OF INSTALLATION

Abstract

A post stand includes a base plate having generally aligned first and second side supports extending upwardly therefrom. A plurality of anchors extend downwardly from the base plate. The post stand is installed in a hardened concrete slab or masonry by creating marks corresponding to the desired location of the anchors, drilling holes into the hardened concrete slab or masonry, partially filling the holes with an epoxy or quick setting cement mixture, and inserting the anchors of the post stand into the holes.

Description

BACKGROUND OF THE INVENTION

The present invention generally relates to post stands. More particularly, the present invention relates to a post stand having improved characteristics, and enabling a construction worker to install the post stand into existing concrete or masonry.

The use of post stands has been common for quite some time. Post stands are used when constructing gates, fences, patios and the like. Post stands typically comprise a bracket, such as in a U-shaped bracket at an upper portion thereof which is configured to receive the post therein. A lower portion comprises an anchor or fastener which is fastened into the masonry to hold the post stand in place, and secure the typically wooden post to the cement or masonry.

However, existing post stands present several drawbacks. The first drawback is that many of these post stands are comprised of relatively flimsy material, such as thin gauged steel or aluminum. If the post is quite large or tall, and the structure supported by the post relatively heavy, the upper bracket portion of the post stand can bend when subjected to excessive force, causing the post to become off alignment and the structure also to become misaligned, such as when a fence leans to a side. Another problem with existing post stands is that the brackets are typically relatively short, such as six inches or less in height. This exacerbates the problem of the excessive force and the propensity of the post stand to bend or the post to become broken or snapped off at the base when excessive force is applied to the post.

Another disadvantage of existing post stands is that the fastener or anchor must be inserted into wet cement, which is then cured to secure the post stand in its proper position and orientation. When constructing the patio, fence, etc. while also doing the masonry work, this does not present a large problem as the post stand anchors can be inserted into the appropriate depth within the wet cement as the cement is poured before actually building the fence, patio, or other structure. However, a significant problem arises when an existing slab or cement, masonry, etc., is already present and the patio, fence, or other such structure is to be built later. Typically, this requires cutting out segments of the cement or masonry, and pouring new cement in place such that the post stand anchors could be set. Of course, it will be appreciated that this presents a significant amount of labor and additional cost. Also, in some instances, the construction worker who is skilled in making the fence, patio, etc., is not skilled in cutting masonry or pouring masonry. Thus, the job requires additional labor from at least two construction workers skilled in different fields.

Accordingly, there is a continuing need for a post stand which is very rigid so as to withstand forces exerted upon the structure or post that the post stand is supporting. Moreover, there is a continuing need for a post stand which enables the fastening of the post stand to existing masonry, concrete, etc. The present invention fulfills these needs, and provides other related advantages.

SUMMARY OF THE INVENTION

The present invention resides in a unique post stand, as well as a unique method of installing the post stand. A particularly unique aspect of the present invention is that the post stand is able to be installed into existing hardened concrete, masonry and the like.

The post stand generally comprises a base plate. A first side support extends upwardly from an upper surface of the base plate. A second side support extends upwardly from the upper surface of the base plate, being spaced apart and generally aligned with the first side support. Typically, the first and second side supports are spaced inwardly from a peripheral edge of the base plate. The first and second side supports include at least one generally aligned aperture for receiving a bolt therethrough so as to support a wooden post between the first and second side supports.

In a particularly preferred embodiment, the base plate, first side support, and second side support are comprised of between one-eighth and one-quarter inch thick metal plate. Preferably, the first and second side supports are between six and twelve inches in height.

A plurality, typically at least three or more, anchors in spaced relation extend downwardly from a lower surface of the base plate. In a particularly preferred embodiment, the plurality of anchors comprise four anchors, each anchor being disposed adjacent to a corner of the base plate. Typically, the anchors are between three and five inches in length.

The anchors are generally cylindrical in configuration. The outer surface of each of the anchors includes ridges extending outwardly therefrom. In one embodiment, the anchors comprise rebar. In another, the anchors have external threads and a free end of the anchors tapers to a point.

In order to install the post stand, holes are drilled in a hardened concrete slab or masonry corresponding to a desired installation location of the plurality of anchors. If the post stand anchors have a free end tapering to a point, a downward force can be applied to the tapered and pointed ends of the anchors to create marks on the hardened concrete slab or masonry corresponding to the desired installation location of the plurality of anchors. This can be done by hitting the post stand with a hammer.

The holes are of a greater diameter than an outer diameter of the anchors. The holes are partially filed with an epoxy or quick setting cement mixture. The anchors of the post stand are then inserted into the holes. An aperture is drilled through a wooden post, and a bolt is inserted through the aligned apertures of the first and second side supports and the wooden post.

Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate the invention. In such drawings:

FIG. 1 is a perspective view of a post stand embodying the present invention;

FIG. 2 is a perspective diagrammatic view illustrating the post stand if FIG. 1 positioned over an aperture formed in concrete;

FIG. 3 is a diagrammatic view illustrating addition of wet concrete to the aperture;

FIG. 4 is a perspective view illustrating the post stand of FIG. 1 placed within the wet concrete, in accordance with the present invention;

FIG. 5 is a cross-sectional view taken generally along line 5-5, illustrating the post stand set within the concrete, after the concrete has cured, and supporting a wooden post, in accordance with the present invention;

FIG. 6 is a perspective view of another post stand embodying the present invention;

FIG. 7 is a diagrammatic perspective view illustrating marking of a hardened concrete slab or masonry;

FIG. 8 is a diagrammatic view illustrating the creation of holes in the concrete slab aligned with anchors of the post stand;

FIG. 9 is a cross-sectional view taken generally along line 9-9 of FIG. 8, illustrating the placement of epoxy or quick setting cement into the holes prior to the post stand insertion;

FIG. 10 is a perspective view, illustrating the post stand disposed within the drilled hole; and

FIG. 11 is a cross-sectional view taken generally along line 11-11, illustrating the post stand cured within the slab of concrete, and supporting a wooden post, in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As shown in the accompanying drawings, for purposes of illustration, the present invention resides in a unique post stand, and a method of installing the same. As will be more fully described herein, the post stand is very rigid so as to withstand forces exerted upon the structure or post that the post stand is supporting. In one form of the invention, as will be more fully described herein, an installation method of the post stand enables the fastening and installation of the post stand to existing masonry, concrete, etc.

With reference now to FIG. 1, a post stand 10 embodying the present invention is illustrated. The post stand 10 includes a base plate 12. Typically, the base plate 12 will have a square configuration, although it is not limited to such. Preferably, the base plate 12 is comprised of a durable material, such as a metal plate having a thickness between one-eighth and one-quarter inch thick. Although the size of the base plate 12 can vary, in a particularly preferred embodiment, it is approximately six inches square.

A first side support 14 extends upwardly from an upper surface of the base plate 12. A second side support 16 extends upwardly from the upper surface of the base plate 12 so as to be generally spaced apart, aligned and run parallel to the first side support 14. Although the base plate 12 and first and second side supports 14 and 16 could be formed as a unitary structure, more typically the first and second side supports 14 and 16 are attached to the base plate 12 such as by welds 18 or the like. Similar to the base plate 12, the first and second side supports 14 and 16 are preferably comprised of a sturdy metal, such as one-eighth to one-quarter inch thick steel. In a particularly preferred embodiment, the base plate 12 is six inches square and comprised of one-quarter inch hot roll steel flat ASTM-A-36 plate steel. The side supports 14 and 16 are one-quarter inch in thickness, two inches in width, and twelve inches in length, and comprised of hot roll steel ASTM-A-36 steel plate.

The first side support 14 includes at least one aperture 20 formed therethrough. The second side support 16 includes corresponding apertures 22 formed therethrough so as to be generally aligned with the aperture 20 of the first side support 14. In a particularly preferred embodiment, the apertures 20 and 22 are of a sufficient width so as to accommodate a bolt 24 extending therethrough. The bolt 24 includes a threaded end 26 which receives a nut 28 thereon so as to secure the bolt 24 in place, as shown in FIG. 6. As will be more fully described below, the bolts 24 extend through a wooden post structure so as to secure the post structure to the post stand 10. Preferably, the first and second side supports 14 and 16 are between six and twelve inches in height so as to securely and rigidly hold the wooden post in place. The thickness or gauge of the metal used in the first and second side supports 14 and 16 as well as their extended height make the post stand 10 very durable, and not likely to be susceptible to forces which would bend the post stand 10 and cause the structure, such as a fence or patio, to be misaligned or bent off of the true intended alignment of the structure.

With continuing reference to FIG. 1, a plurality of anchors 30 extend downwardly from a lower surface of the base platel 2. In a particularly preferred embodiment, the anchors, 30 are of a generally cylindrical configuration. Typically, there are a total of four anchors 30, each anchor being disposed adjacent to a corner of the base plate 12. The anchors 30 are typically three-eights of an inch to one-half of an inch in width, and approximately three to five inches in length. So as to securely anchor the post stand 10 in the concrete, the anchors 30 do not have a smooth outer surface, but instead have ridges 32, or other projections, so as to form a tight bond within the concrete, as will be described more fully herein. The anchors 30 may comprise segments of steel rebar, which meets these requirements.

With reference now to FIGS. 2-5, a method for installing the post stand 10 is illustrated. In FIG. 2, a slab of existing and hardened concrete 50, masonry or the like is shown. In such a case, the concrete 50 may be cut so as to create an aperture 52 having a diameter which is less than the diameter of the base plate 12, but larger than the distance between the anchors 30. New cement 54 is then poured into the cut-out aperture 52 so as to substantially fill the hole or aperture 52, as illustrated in FIG. 3. The anchors 30 are then set into the wet concrete 54 until the base plate 12 is approximately level with, or slightly raised with respect to the existing hardened concrete slab or masonry 50. The wet concrete 54 is then allowed to cure.

This particular post stand 10 is particularly well-suited for use in applications wherein the entire concrete slab 50 comprises wet cement, alleviating the need to create the cut-out section 52. In that case, the post stand 10 will be installed, as shown in FIG. 4, in the wet cement at the desired location.

With reference now to FIG. 5, once the concrete 50 has cured and hardened, securely and permanently setting the anchors 30 therein, a wooden beam or the like 56, (shown in phantom) is inserted between the first and second side supports 14 and 16. A hole is drilled through the wooden beam 56 so as to be aligned with the apertures 20 and 22 of the first and second side supports 14 and 16. Bolt 24 is then inserted through these aligned apertures, and nut 28 secured thereto to hold the bolt 24, and thus the post 56, in place.

With reference now to FIG. 6, another post stand 100 embodying the present invention is illustrated. Similar to post stand 10 described above, this post stand includes a base plate 112, a first side support 114 and a second side support 116. These are preferably comprised of a durable and strong material, such as one-eighth-one-quarter of an inch steel plate or the like.

The first and second side supports 114 and 116 also include one or more apertures 120 and 122, which are generally aligned with one another so as to receive a bolt 124 therethrough, as illustrated in FIG. 6. As described above, a nut 128 is threadably received at the end of the bolt 124 to hold it in place.

The post stand 100 also includes a plurality of anchors 130 extending downwardly therefrom. Preferably, there are three or more anchors 130 extending downwardly from the bottom surface of the base plate 112. Typically, there are four anchors 130, each extending from an area adjacent to a corner of the base plate 112.

Once again, the anchors 130 do not have a smooth outer surface, but instead have ridges 132 or other projections which would facilitate the bonding of the anchor 130 to the cement or other bonding material. In a particularly preferred embodiment, the ridges 132 comprise external threads, each anchor being configured similar to a threaded screw. In fact, the anchors 130 can comprise threaded steel screws or bolts welded or otherwise attached to the bottom surface of the base plate 112. A particularly unique aspect of the anchors 130 is that their free ends are tapered to a sharp point 134.

With reference now to FIGS. 7-10, a particularly unique method of installation will be described. Typically, as described above, when installing a post stand, a cut-out must be formed in the existing hardened concrete or masonry, which is subsequently filled with new wet concrete or the like such that the post stand can be inserted therein and become fixed in place as the wet cement cures and hardens. This may also be done, for example, when pouring an entirely new slab of concrete, the post stand being placed in the wet cement at the desired location. However, when there exists a hardened and cured slab of concrete, or other masonry such as tiles, brick, etc., it is a time-consuming and sometimes expensive task to create a cut-out within the hardened slab or masonry. In fact, in some cases, the individual or company which is installing the post stand and fence needs to hire and subcontract with one skilled in cutting out the concrete or masonry to accommodate the post stand. The present invention overcomes this with a combination of the design of the post stand 10 and 100, described above, and the methodology for installing it.

With reference now to FIG. 7, marks 58 are created in the hardened concrete slab or masonry corresponding to the desired location of installation of the anchors 130. In the case of post stand 100, this can be easily done by applying a downward force (shown by the arrow) to the pointed ends 134 of the anchors 130, which will create a divot or small crack in the concrete slab 50. This can be done, for example, by hitting the post stand 100 with a hammer or the like. As the anchors 30 of post stand 10 have generally flat ends, this step typically does not work, thus one would need to trace around the outside diameter of each anchor 30.

Holes 60 are then drilled into the hardened concrete or masonry corresponding to the markings 58 and desired installation location of the anchors 130. The holes 60 are slightly larger in diameter than the outer diameter of the anchors 130. For example, if the anchors are one-half inch in width, the holes 60 will be at least nine-sixteenths inch in diameter. The holes are drilled to a depth at least as long as the anchors 130. Typically, the anchors 130 are between three to five inches in length. A typical slab of concrete 50, such as that used for a walkway, patio, etc. is approximately four to six inches in thickness.

With reference now to FIG. 9, an epoxy, quick setting cement mixture, or the like 62 is poured into the holes 60. Typically, the hole 60 is only partially filled with the bonding material 62. The post stand 100 is then inserted into the holes 60, such as by inserting the anchors 130 into the drilled holes partially filled with bonding agent 62, as illustrated in FIG. 10. Typically, the post stand 100 is pushed into the holes 60 until the base plate 112 rests upon the concrete slab 50. Any wet bonding agent (such as quick setting cement, epoxy, or the like) that is forced from the holes 60 beyond the periphery of the base plate 112 is wiped away. Typically, it will only take thirty minutes to a couple of hours for the epoxy, quick setting cement, or other bonding agent to sufficiently cure.

Holes are drilled through the wooden beam 56 (shown in phantom in FIG. 11) such that the bolt 124 can be inserted through the side support apertures 120 and 122 and the wooden beam 56, such that the nut 128 can secure the bolts 124 in place, and thus the wooden beam 56 to the post stand 100. It will be appreciated that the first and second side supports 114 and 116 are spaced so as to accommodate the wooden post 56. For example, if the wooden post is four inches square, the first and second side supports 114 and 116 will be spaced apart four inches such that the wooden post can be inserted therebetween.

Those skilled in the art will appreciate that the amount of labor and materials used are conserved by the teachings of the present invention. Instead of either tearing up the entire concrete slab and pouring a new slab of wet concrete, or cutting out sufficient sized sections of the concrete to pour new wet concrete to insert post stands therein, one merely need drill holes to accommodate the anchors 130 of the post stand 100 into the existing hardened and cured concrete slab or masonry. The present invention can be used to secure posts of gates, fences, patios, or any other situation where a post stand is required. However, those skilled in the art will appreciate that the post stands of the present invention may not meet building code requirements that specify a footing of at least twelve inches square to two feet below concrete level. Thus, the present invention is particularly suited for concrete or masonry pathways, patios, bases of fences and walls, and the like. Given the rugged materials and construction of the post stand 10 and 100 of the present invention, gates of relatively large size can be supported without fear that the post stand will become dislodged or bend, as is the case with many existing post stands when used in use with large and heavy gates.

Although several embodiments have been described in some detail for purposes of illustration, various modifications may be made without departing from the scope and spirit of the invention. Accordingly, the invention is not to be limited, except as by the appended claims.

Claims

1. A post stand, comprising:

a base plate;

a first side support extending upwardly from an upper surface of the base plate;

and having an aperture therethrough;

a second side support extending upwardly from the upper surface of the base plate, the second side support being spaced apart and generally aligned with the first side support, and having an aperture generally aligned with the aperture of the first side support for receiving a bolt therethrough so as to support a wooden post between the first and second side supports; and

a plurality of at least three anchors in spaced relation extending downwardly from a lower surface of the base plate.

2. The post stand of claim 1, wherein the base plate and first and second side supports are comprised of between one-eighth and one-quarter inch thick metal plate.

3. The post stand of claim 1, wherein the first and second side supports are spaced inwardly from a peripheral edge of the base plate.

4. The post stand of claim 1, wherein the first and second side supports are between six and twelve inches in height.

5. The post stand of claim 1, wherein the plurality of anchors comprise four anchors, each anchor being disposed adjacent to a corner of the base plate.

6. The post stand of claim 1, wherein each of the plurality of anchors are generally cylindrical in configuration.

7. The post stand of claim 6, wherein an outer surface of each of the anchors includes ridges extending outwardly therefrom.

8. The post stand of claim 7, wherein the anchors comprise rebar.

9. The post stand of claim 7, wherein the anchors have external threads.

10. The post stand of claim 9, wherein a free end of the anchors tapers to a point.

11. The post stand of claim 1, wherein each of the plurality of anchors are between three and five inches in length.

12. A method for installing a post stand, comprising the steps of:

providing a post stand comprising a base plate, spaced apart first and second side supports extending upwardly from an upper surface of the base plate, and having aligned apertures therethrough, and a plurality of anchors in spaced relation extending downwardly from a lower surface of the base plate;

drilling holes in a hardened concrete slab or masonry corresponding to a desired installation location of the plurality of anchors;

partially filling the holes with an epoxy or quick setting cement mixture; and

inserting the anchors into the holes.

13. The method of claim 12, wherein the providing step includes the step of providing a post stand having a plurality of anchors each having a free end tapering to a point.

14. The method of claim 13, including the step of applying a downward force to the tapered and pointed ends of the anchors to create marks on the hardened concrete slab or masonry corresponding to the desired installation location of the plurality of anchors.

15. The method of claim 14, wherein the applying downward force step includes the step of hitting the post stand with a hammer.

16. The method of claim 12, wherein the providing step includes the step of providing a post stand having a plurality of anchors each having projections extending from an outer surface thereof.

17. The method of claim 16, wherein the projections comprise external threads.

18. The method of claim 16, wherein the anchors are generally cylindrical in configuration, and wherein the hole drilling step comprises drilling holes of a greater diameter than an outer diameter of the anchors.

19. The method of claim 12, including the steps of drilling an aperture through a wooden post and inserting a bolt through the aligned apertures of the first and second side supports and the wooden post.