CONCRETE ANCHORS

Abstract

A concrete anchor system is disclosed. A concrete anchor system can connect a structure to a concrete foundation or floor. The concrete anchor system can include a concrete anchor rod and an anchor rail that is designed to hold the anchor rod in place. The anchor rail can be installed prior to a concrete foundation being poured and can remain in the concrete foundation after the concrete has cured.

Description

INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 62/832,190 filed Apr. 10, 2019, the contents of which are incorporated by reference herein in their entirety and for all purposes.

BACKGROUND OF THE INVENTION

Field of the Invention

The present disclosure relates generally to concrete anchors and to systems, apparatuses, methods for installing concrete anchors.

Description of the Related Art

Concrete anchors can be used to secure structures to a concrete foundation. Concrete anchors can be individually installed in the concrete after the concrete is poured, but before the concrete is cured. Installing the concrete anchors at particular desired locations in the concrete can be challenging due to the flowability of uncured concrete. Accordingly, there remains a continuing need for improved concrete anchors.

SUMMARY

Various non-limiting aspects of the present disclosure will now be provided to illustrate features of the disclosed apparatus, methods, and systems. Examples of apparatus, methods, and systems for concrete anchors are provided.

In one embodiment, a concrete anchor rail is disclosed. The concrete anchor rail can comprise a vertical segment having a first hole therethrough, the first hole sized to receive a fastener; an upper segment extending non-parallel relative to the vertical segment, the upper segment having a second hole therethrough; and a lower segment extending non-parallel relative to and spaced apart from the vertical segment, the lower segment having a third hole therethrough. The second and third holes can be sized and substantially aligned so as to receive a concrete anchor rod through the second and third holes to restrain horizontal movement of the concrete anchor rod.

In another embodiment, a concrete anchor system is disclosed. The concrete anchor system can comprise an anchor assembly having an upper segment, a lower segment, and a vertical segment extending between the upper and lower segments. The upper segment can have a first hole therethrough, and the lower segment can have a second hole therethrough. The concrete anchor system can also comprise an anchor rod extending through the first and second holes. A first end of the anchor rod can be embedded in concrete and a second end of the anchor rod to be disposed above the concrete.

In another embodiment, a concrete anchor stand is disclosed. The concrete anchor stand can comprise a first plate having a first hole therethrough; a second plate spaced apart from the first plate, the second plate having a second hole therethrough, the first and second holes sized and substantially aligned so as to receive a concrete anchor rod through the first and second holes to restrain horizontal movement of a concrete anchor; a first leg connecting the first plate and second plate, the first leg having an opening therethrough; a second leg connecting the first plate and second plate, the second leg having an opening therethrough; and a vertical retention member configured to restrain vertical movement of the concrete anchor relative to the second plate.

In another embodiment, a method of installing a concrete anchor support system is disclosed. The method can comprise providing an anchor assembly having an upper segment, a lower segment, and a vertical segment extending between the upper and lower legs segments, the vertical segment having a first hole therethrough, the upper segment having a second hole therethrough, and the lower segment having a third hole therethrough; installing an anchor rod into the second and third holes; and pouring concrete over the anchor assembly.

In another embodiment, a concrete anchor system is disclosed. The concrete anchor system can comprise an anchor head having a top flange and a thread member, the top having a generally flat surface and the thread member extending downwards from the top flange; an anchor rod; and a structure having a top surface and a hole. The thread member can extend through the hole of the structure and engages the anchor rod within the hole. The top flange of the anchor head can be disposed on the top surface of the structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic side sectional view of a concrete anchor system, according to various embodiments.

FIG. 2 is a schematic perspective view of a concrete anchor system installed with a formboard, according to various embodiments.

FIG. 3 is a schematic perspective view of an installed concrete anchor system after removal of the formboard in FIG. 2.

FIG. 4 illustrates an isometric view of an example anchor rail, according to one embodiment.

FIG. 5 illustrates a top view of an example anchor rail, according to another embodiment.

FIG. 6 illustrates a side view of the anchor rail of FIG. 5.

FIG. 7 illustrates a bottom view of the anchor rail of FIGS. 5 and 6.

FIG. 8 illustrates an end view of the anchor rail of FIGS. 5-7.

FIGS. 9A-G illustrate example anchor holes that can be used with the anchor assemblies disclosed herein.

FIGS. 10A-B illustrate example concrete and fastener holes that can be used with the anchor assemblies disclosed herein.

FIG. 11 illustrates an example fastener hole, according to one embodiment.

FIG. 12 illustrates an example fastener hole, according to another embodiment.

FIG. 13 illustrates an anchor system with a vertical retention member, according to one embodiment.

FIG. 14 illustrates an anchor system with a vertical retention member, according to another embodiment.

FIG. 15 illustrates a top isometric view of an example anchor system, according to one embodiment.

FIG. 16 illustrates a bottom isometric view of the anchor system of FIG. 15.

FIG. 17 illustrates a concrete anchor system with a flat top anchor head.

FIG. 18A-B illustrate a flat top anchor head, according to various embodiments.

Throughout the drawings, reference numbers may be re-used to indicate a general correspondence between referenced elements. The drawings are provided to illustrate example embodiments described herein and are not intended to limit the scope of the disclosure

DETAILED DESCRIPTION

Concrete anchors play an important role in construction. Concrete anchors can be used to connect structures to a concrete foundation at grade or concrete floors above grade, for example, in single- and multi-story structures. Installing concrete anchors can be a time-consuming task. In some cases, the anchors are installed after the concrete has been poured, but before the concrete has set or cured. In these cases, workers will need to work quickly in order to ensure the anchors are properly positioned before the concrete sets. In other cases, concrete anchors are installed after the concrete is poured and has set. Installing anchors in these situations requires additional labor to drill holes into the concrete to position an anchor. Concrete anchors can also be installed before the concrete is poured. However, installing anchors in this manner can lead to several challenges, including ensuring the anchor remains properly positioned during the pour.

To improve the installation process, concrete anchors can be installed with a concrete anchor system. A concrete anchor system can allow for multiple anchors to be aligned and set in a foundation or concrete floor before the concrete is poured. The anchor system can utilize several features to hold an anchor rod in place while the concrete is poured and cured. Additionally, the concrete anchor system can remain in the foundation or floor, without needing to be removed. This type of anchor system can improve the concrete anchor installation process by making this process less labor intensive and more efficient.

FIG. 1 illustrates a concrete anchor system 100 installed in a concrete foundation or floor 10. The concrete anchor system 100 can include an anchor assembly that includes an anchor rail 200 and one or a plurality of anchor rods 102. The anchor rail 200 can be installed within the concrete foundation 10 and can be used to secure the anchor rods 102 within the concrete foundation 10. The anchor rail 200 can be used to secure one or more anchor rods 102 to the concrete foundation 10. The anchor rods 102 can be partially embedded within the concrete foundation 10 and can extend outside (e.g., above as shown in FIG. 1) the concrete foundation 10 where the anchor rods 102 can be connected to other external building structures. For example, as shown in FIG. 1, the rods 102 can comprise a first end 101 embedded in the concrete foundation 10 below the anchor rail 200 and a second end 103 extending outside (e.g., above) the concrete foundation 10 above the anchor rail 200. External building structures, such as a sill plate and/or other framing members, can be mechanically secured to the anchor rods 200, and the overall structure (e.g., a building or other structure) can be built up over the foundation 10.

The anchor rods 102 can be threaded and can be provided in a variety of different shapes and sizes. For example, the anchor rods 102 can have a major lateral dimension (e.g., a diameter) in a range of 0.1″ to 3″, in a range of 0.125″ to 3″, or in a range of 0.25″ to 3″. The anchor rods 102 can have any suitable length. For example, in various embodiments, the anchor rods 102 can have a length in a range of 6 inches to 10 feet, for example, in a range of 6 inches to 3 feet, in a range of 6 inches to 1.5 feet, or in a range of 1 foot to 3 feet. The anchor rods 102 may be straight rods or may have a curved end, such as a J or L rod. In some embodiments, the anchor rods 102 can comprise shear rods, which can be used to prevent the structure connected to the concrete foundation 10 from moving laterally. In various embodiments, the anchor rods 102 can comprise overturning-resisting or uplifting-resisting rods, which can be larger and/or longer than shear rods and can used to prevent the structure connected to the concrete foundation 10 from overturning. In some embodiments, anchor rods 102 of sizes and shapes that are different from those described herein can be used with the anchor rail 200. In various embodiments, the anchor rod 102 can include nuts, bolts, and washers along with the rod to secure the anchor rod 102 to the building structure. The anchor rail 200 can be positioned in several different locations within the concrete foundation 10. For example, as depicted, the anchor rail 200 can be completely embedded within the foundation 10, e.g., near the middle of the foundation 10. In some embodiments, the anchor rail 200 can be positioned near or at a bottom surface 107 of the foundation 10. In various embodiments, the anchor rail 200 can be positioned near or at a top surface 105 of the foundation 10. In some embodiments, the anchor rail 200 can be only partially embedded in the foundation 10, such that the anchor rail 200 can be about flush with the top surface 105 of the foundation 10. In various embodiments, portions of the anchor rail 200 can be exposed after the concrete foundation 10 has cured.

FIG. 2 illustrates a concrete anchor system 100 installed in a concrete foundation 10. As depicted, the concrete foundation 10 is surrounded by and attached to a formboard 12 along an outer edge 109a of the foundation 10. An upper segment 202 of the anchor rail 200 is exposed through the concrete foundation 10 (e.g. disposed approximately flush with the top surface 105 of the concrete foundation 10). The exposed upper segment 202 can be free of concrete and can provide a smooth finish over that section of the foundation 10. In the absence of the anchor rail 200, workers would typically smooth the top surface 105 of the foundation 10 around the individual rods 102 and other structures. The use of the anchor rail 200 and the smooth, exposed upper segment 202 can beneficially obviate the use of time-consuming finishing operations around individual rods 102 Part of the anchor rods 102 (e.g., the second ends 103) can extend above the upper segment 202 and concrete foundation 10, where they can be accessed for connection to other components of the structure. For example, as explained above, sill plates or other framing members can be secured to the anchor rods 102, and the building or other structure can be constructed over the foundation 10.

The concrete anchor system 100 can be installed before the concrete foundation 10 is poured. The concrete anchor system 100 can be installed by connecting the anchor rail 200 to a vertical formboard 12 or other system to hold the anchor rail 200 in place. For example, as explained herein, one or more fasteners 111 (such as nails, screws, bolts, etc.) can be inserted through corresponding fastener openings 212 in a vertical segment 206 of the rail 200 (see FIG. 3) to mechanically connect the rail 200 to the formboard 12. Anchor rods 102 can be placed into the anchor rail 200 at one or more locations. After the anchor rods 102 are secured, the concrete foundation 10 can be poured and cured (hardened). The anchor rail 200 can remain partially or completely embedded in the concrete foundation 10.

The concrete anchor system 100 can be installed at any suitable location and/or depth across and within the concrete foundation 10. As depicted, the anchor rail 200 of the concrete anchor system 100 is positioned at or near the outer edge 109a of the foundation 10. In some embodiments, the anchor rail 200 can be positioned at any location within the perimeter of the foundation 10 (e.g., within the perimeter defined at least in part by outer edges 109a-109d shown in FIG. 2). In various embodiments, multiple anchor rails 200 can be installed within the foundation 10. In some embodiments, the anchor rails 200 can be disposed in an annular arrangement that at least partially surrounds (e.g., entirely surrounds or surrounds a majority of) the perimeter of the foundation 10. In various embodiments, the anchor rails 200 can comprise a continuous ring around the perimeter of the foundation 10. In other embodiments, the anchor rails 200 can be spaced apart along the perimeter by intervening gaps. The anchor rails 200 may also be provided in any suitable combination of lengths and positions, which may correspond to the sill plates or other frame members to which the anchor rods 102 are to be secured. In various embodiments, the anchor rails 200 are installed with the concrete foundation 10 such that the concrete anchor system 100 can meet building codes. As explained above, the anchor rods can comprise shear rods or overturning-resistant rods, according to various embodiments. In some embodiments, the anchor rail 200 can be connected to the formboard 12 that surrounds that concrete foundation 10. For example, the anchor rail 200 can be connected to the formboard 12 through the fastener 111, such as a nail through fastener openings 212. It should be appreciated that the overall building structure may comprise numerous foundations 10 placed adjacent one another to form the overall foundation for the building.

FIG. 3 illustrates a concrete anchor system 100 installed in a concrete foundation 10 with the formboards 12 removed. As depicted, a vertical segment 206 of the anchor rail 200 can be exposed along the outer edge 109a of the foundation 10 (and may also be exposed along any of the other edges 109b-109d along which an anchor rail 200 is disposed). The vertical segment 206 can be approximately flush with the side edges 109a of the concrete foundation 10. In other embodiments, the vertical segment 206 can be completely embedded within the concrete foundation 10 and may not be exposed through the concrete foundation 10. In some embodiments, accordingly, the upper segment 202 and the vertical segment 206 of the rail 200 can both be fully or partially exposed. Moreover, as shown in FIG. 3, the system 100 can include artifacts that indicate a prior connection between the anchor rail 200 and a formboard 12. For example, when the formboard 12 is removed from the anchor rail 200, the fasteners 111 connecting the formboard 12 to the anchor rail 200 may be broken or otherwise exposed through the fastener openings 212 along the vertical segment 206 of the rail 200.

FIGS. 4-8 illustrate examples of anchor rails 200 that can be used in connection with the concrete anchor systems 100 disclosed herein. The anchor rail 200 can have an upper segment 202, a lower segment 204, a vertical segment 206, an anchor rod hole 208 in the upper segment 202, an anchor rod hole 210 in the lower segment, and a fastener hole 212 in the vertical segment 206. In some embodiments, additional hole(s) can be provided through one or more of the upper segment 202, the lower segment 204, and the vertical segment 206 to allow concrete to flow therethrough (e.g., in embodiments in which the rail 200 is embedded within the concrete foundation 10). The upper and lower segments 202, 204 can extend non-parallel relative to (e.g., approximately perpendicular to) the vertical segment 206. In some embodiments, the anchor rail 200 can include a wedge 213 disposed on one or both the upper and lower segments 202, 204. The upper segment 202 can be connected to the lower segment 204 by a vertical segment 206 that extends between the upper segment 202 and lower segment 204. The upper segment 202, lower segment 204, and vertical segment 206 can be connected together or integrally formed such that these components form a channel with a “C” shaped cross-section in some embodiments. For example, in the illustrated embodiments the upper segment 202 can extend from an upper end of the vertical segment 206, and the lower segment 204 can extend from a lower end of the vertical segment 206. In other embodiments, the upper and/or lower segments 202, 204 can extend from inner portions of the vertical segment 206, such that upper and/or lower ends of the vertical segment 206 extend above and/or below the respective upper and/or lower segments 202, 204. Moreover, in some embodiments additional horizontal segments can be provided between the upper and lower segments 202, 204 (or above and/or below the upper and lower segments 202, 204). For example, in some embodiments, three horizontally-extending segments can define an E-shaped profile extending from the vertical segment 206, with substantially aligned rod holes in each of the three horizontal segments.

The anchor rod holes 208, 210 can extend along at least a portion of respective lengths of the upper segment 202 and the lower segment 204. The anchor rod holes 208 formed on the upper segment 202 can be generally aligned with corresponding anchor rod holes 210 formed on the lower segment 204. In some embodiments, the anchor rod holes 208, 210 can be generally aligned and disposed at approximately the same position along a longitudinal axis x of the anchor rail 200 and along a lateral axis y perpendicular to the longitudinal axis x. In such embodiments, the anchor rods 102 can extend vertically through the holes 208, 210 and may be disposed generally perpendicular to the upper and/or lower segments 202, 204. In other embodiments, the anchor rod holes 208, 210 can be generally aligned but slightly offset along the longitudinal axis x (and/or along the lateral axis y). In such embodiments, the general or substantial alignment of the rod holes 208, 210 can enable the anchor rods 102 to be inserted therethrough, but tilted at an angle relative to the upper and/or lower segments 202, 204.

The fastener hole 212 can be formed on the upper segment 202, the lower segment 204, and/or the vertical segment 206 and can be used to connect the anchor rail 200 to other components or systems. In the illustrated embodiment, the fastener hole 212 is disposed along the vertical segment 206 and can be connected to the formboard 12 by way of one or more fasteners 111. The upper segment 202, lower segment 204, and vertical segment 206 can have a wedge 213, or rib, formed on its inner surface. The wedge 213 can increase the rigidity of upper segment 202, lower segment 204, and/or vertical segment 206. For example, in embodiments in which the rails 200 are formed of a plastic or polymer, the wedge 213 can provide improved rigidity. In other embodiments (e.g., embodiments in which the rails 200 are formed of a metal), the wedge 213 may or may not be provided.

In some embodiments, the upper segment 202 and/or lower segment can extend out of the vertical segment 206 at different locations, For example, the upper segment 202 or lower segment 204 can be extend out of the vertical segment 206 closer to the center of the vertical segment 206 and away from an end of the vertical segment 206, creating an “F” shaped cross section. In other embodiments, the anchor rail 200 does not include an upper segment 202, or the anchor rail does not include a lower segment 204, leading to an “L” or “T” shaped cross section. In some embodiments, the anchor rail 200 can include additional segments. These additional segments can be used to form an “S” shaped cross section or an “E” shaped cross section. In other embodiments, the anchor rail 200 does not include the vertical segment 206, and instead, the upper segment 202 and lower segment 204 connect to each other and form a “V” shaped cross section. Other variations of an anchor rail 200 are possible.

The anchor rail 200 can be formed from a metal, such as steel, aluminum, or any other suitable metal. In some embodiments, the anchor rail 200 can be formed from plastic. In various embodiments, the anchor rail can be formed from a variety of materials. In some embodiments, the anchor rail 200 can be formed from plastic, but can include a steel, or hardened material, covering for the corners of upper segment 202. In other embodiments, the perimeter of the upper segment, lower segment, and vertical segment can be covered with a steel, or hardened material, covering. The steel covering can prevent damage to the corners or perimeter of the anchor rail 200.

The anchor rail 200 can horizontally and/or vertically support the anchor rods 102 within the anchor rod holes 208, 210. Anchor rods 102 can be placed within the anchor rod holes 208, 210 on the opposing upper and lower segments 202, 204. The anchor rod holes 208, 210 (and the corresponding upper and lower segments 202, 204) can be spaced apart vertically along a vertical axis z. When positioned within the anchor rod holes 208, 210, the anchor rod 102 can contact the anchor rail 200 at two locations (e.g., the two opposing anchor rod holes 208, 210). Because the anchor rod 102 contacts the anchor rail 200 at two locations, the anchor rail 200 can prevent or reduce horizontal movement or rotation of the anchor rod 102 while concrete is being poured into a foundation 10, while the concrete foundation 10 cures, or during other steps of the construction process. As will be described in further detail below, the anchor rail 200 can also include vertical retention members, which prevent or reduce vertical movement of the anchor rod 102 while concrete is being poured into a foundation 10, while the concrete foundation 10 cures, or during other steps of the construction process. By preventing or reducing both horizontal and vertical movement of an anchor rod 102, an anchor rail 200 can be used to ensure the anchor rods 102 are properly positioned during the process of forming a concrete foundation 10.

The anchor rail 200 can be made into a variety of different lengths. For example, the anchor rail 200 can have a length in a range of about 6 inches to about 24 feet, in a range of about 1 foot to about 24 feet, in a range of about 2 feet to about 10 feet, or in a range of about 4 feet to about 8 feet. In some embodiments, not every anchor rod hole 208, 210 is occupied by an anchor rod 102.

As illustrated in FIG. 4, the anchor rod holes 208, 210 can be formed in pairs 208a, 208b, 210a, 210b in some embodiments. For example, as shown in FIG. 4, inner holes 208a, 210a can be spaced apart from the corresponding outer holes 208b, 210b along the lateral axis y, such that the inner holes 208a, 210a are closer to the vertical segment 206 and the outer holes 208b, 210b are disposed farther from the vertical segment 206. As explained herein, any or all of the holes 208a, 208b, 210a, 210b can comprise vertical retention members configured to vertically restrain the rods 102 relative to the rail 200. In some embodiments, the upper 202 and lower 204 segments can include additional anchor rod holes 208a, 208b, 210a, 210b besides the pairs. For example, the anchor rod holes 208, 210 can be formed in sets of 3 or more holes.

FIG. 5 illustrates a top view of an anchor rail 200. The anchor rod holes 208 formed in the upper segment 202 can be spaced along the length of the upper segment 202 (e.g., along the longitudinal axis x). The anchor rod holes 208 can be spaced away from the vertical segment 206 along the lateral axis y at a distance 214. In some embodiments, the distance 214 can be in a range of 1 inch to 4 inches or in a range of 1.5 inches to 2.5 inches. The anchor rod holes 208 can be spaced apart along the longitudinal axis x by a distance 218. In some embodiments, the distance 218 can be in a range of 1 inch to 72 inches, in a range of 1 inch to 4 inches, or in a range of 2 inches to 12 inches. The anchor rod holes 208 can be spaced from the ends of the upper segment 202 by a distance 216. In some embodiments, the distance 216 can be in a range of 0.25 inches to 24 inches. As depicted in FIG. 5, the upper segment 202 can have a rectangular shaped profile. Other shaped profiles are possible.

FIG. 6 illustrates a side view of the anchor rail 200 of FIG. 5. The upper segment 202 can extend non-parallel relative to an upper end of the vertical segment 206. The upper segment 202 can be approximately perpendicular to the vertical segment 206 in some embodiments. In other embodiments, the upper segment 202 may be disposed at an acute or obtuse angle relative to the vertical segment 206. The lower segment 204 can be non-parallel relative to a lower end of the vertical segment 206. The lower segment 204 can be approximately perpendicular to the vertical segment 206 in some embodiments. In other embodiments, the lower segment 204 may be disposed at an acute or obtuse angle relative to the vertical segment 206. In some embodiments, the upper segment 202 and the lower segment 204 can be approximately parallel to each other. The upper segment 202, lower segment 204, and vertical segment can form a channel that is defined by the space between these components. A number of fastener holes 212 can be formed into the vertical segment 206 and can be spaced along the entire length of the vertical segment 206. The fastener hole 212 can be spaced away from the upper segment 202 by a distance 220 along the vertical axis z. In some embodiments, the distance 220 can be in a range of 0.25 inches to 3 inches. The fastener hole 212 can be spaced away from an end of the upper segment by a distance 222 along the longitudinal axis x. In some embodiments, the distance 222 can be in a range of 0.25 inches to 24 inches or in a range of 0.5 inches to 3 inches. The fastener holes 212 can be spaced apart from each other by a distance 224 along the longitudinal axis x. In some embodiments, the distance 224 can be in a range of 1 inch to 72 inches, in a range of 1 inch to 4 inches, or in a range of 1.5 inches to 6 inches. A major lateral dimension (e.g., a diameter) of the fastener hole 212 can be sized and shaped to receive a fastener (e.g., fastener 111, such as a nail, screw, bolt, etc.) therethrough. The major lateral dimension or diameter (e.g., the widest extent) of the fastener hole 212 can be in a range of 0.05 inches to 0.5 inches, or in a range of 0.125 inches to 0.25 inches. The fastener hole 212 can also have a slot with a length in the range of 0.25 inches to 2 inches. The side view of the anchor rail 200 forms a rectangular shaped profile. Other shaped profiles can exist. For example, the rail 200 can include a step in which the height of the anchor rail 200 increases and/or decreases along the length of the anchor rail 200.

FIG. 7 illustrates a bottom view of the anchor rail 200 of FIGS. 5-6. The anchor rod holes 210 formed in the lower segment 204 can be spaced along the length of the lower segment 204 (along the longitudinal axis x). In some embodiments, the anchor rod holes 210 can substantially align with the corresponding anchor rod holes 208 of the upper segment 202. The anchor rod holes 210 can be spaced away from the vertical segment 206 along the lateral axis y by a distance 226. In some embodiments, the distance 226 can be in a range of 1 inch to 4 inches, or in a range of 1.5 inches to 2.5 inches. The anchor rod holes 210 can be spaced apart from each other along the longitudinal axis y by a distance 230. In some embodiments, the distance 230 can be in a range of 1 inch to 72 inches, or in a range of 2 inches to 12 inches. The anchor rod holes 208 can be spaced from the ends of the lower segment 204 along the longitudinal axis x by a distance 228. In some embodiments, the distance 228 can be in a range of 0.25 inches to 24 inches. As depicted in FIG. 7, the lower segment 202 can have a rectangular shaped profile. Other shaped profiles are possible.

FIG. 8 illustrates an end view of the anchor rail 200 of FIGS. 5-7. The upper segment 202 can extend non-parallel relative to the upper end of the vertical segment 206. The lower segment 204 can extend non-parallel relative to the lower end of the vertical segment 202. The upper segment 202 and the lower segment 204 can extend away from the vertical segment 206 at a width 232. In some embodiments, the width 232 can be in a range of 1.5 inches to 18 inches, or in a range of 2 inches to 6 inches. In various embodiments, the upper and lower segments 202, 204 can have approximately the same width 232. In other embodiments, the upper and lower segments 202, 204 can have different widths 232. The anchor rail 200 can have a height 234. In some embodiments, the height 234 can be in a range of 1 inch to 18 inches, or in a range of 2 inches to 6 inches. The upper segment 202, lower segment 204, and vertical segment 206 can have a thickness 236. In some embodiments, the thickness 236 can be in a range of 0.03125 inches to 1 inch, or in a range of 0.0625 inches to 0.25 inches. In various embodiments, the upper segment 202, lower segment 204, and vertical segment 206 can have the same or different thicknesses 236. As depicted in FIG. 8, the end of the anchor rail 200 can form a “C” shaped cross section. As described herein, the anchor rail can form a variety of different shaped cross sections. In the illustrated embodiment, the rail 200 can be formed of a unitary structure or body, for example, through a metal forming operation, an extrusion operation, a stamping operation, etc. In other embodiments, the rail 200 can include multiple connected components.

FIGS. 9A-9G illustrate several example of anchor rod holes 208, 210 that can be used in any of the anchor assemblies described herein (e.g., in the anchor rails 200 or anchor stand 500 described herein). Although FIGS. 9A-9G reference anchor rod hole 208 in the upper segment 202, the examples illustrated can additionally or alternatively apply to anchor rod hole 210 in the lower segment 204 as well. The anchor rod holes 208, 210 can be sized to receive and support an anchor rod 102. In some embodiments, the anchor rod holes 208, 210 can be sized to form a friction fit around the anchor rod 102 and prevent the rod from tilting at an angle greater than about 5 degrees with respect to a true vertical axis. In other embodiments, the anchor rod hole 208, 210 can loosely fit around the anchor rod 102 and prevent the anchor rod 102 from tilting at an angle greater than about 15 degrees with respect to a true vertical axis. In various embodiments, the anchor rod hole 208, 210 can be sized to engage a threaded portion of the anchor rod 102. For example, the anchor rod hole 208, 210 can be sized smaller than an outer thread diameter of the anchor rod 102, but larger than the root diameter of the anchor rod 102. In such embodiments, the wall or perimeter of the hole 208, 210 can be disposed within the groove between the threads of the rod 102. In other embodiments, the anchor rod hole 208, 210, or parts of the anchor rod hole 208, 210 can engage any part of the anchor rod 102. By engaging the threads of the anchor rod 102, or another part of the anchor rod 102, the anchor rod hole 208, 210, or parts of the anchor rod hole 208, 210, can serve as vertical retention members by retaining the anchor rod 102 in its vertical position during installation. In various embodiments, the anchor rod hole 208, 210 can be sized to interact with a separate part that holds the anchor rod 102 in place. In some embodiments, the anchor rod hole 208 can be differently shaped and/or sized than the anchor rod hole 210. For example, the anchor rod hole 208 can be larger than the anchor rod hole 210.

FIG. 9A illustrates a round anchor rod hole 208. The anchor rod hole 208 can have a constant circular diameter defined by an inner boundary 227 of the upper segment 202. In some embodiments, the diameter of the anchor rod hole 208 can be in a range of about 0.25 inches to about 3 inches. Opposing rod holes 208, 210 in the corresponding upper and lower segments 202, 204 can serve to horizontally restrain the anchor rod 102 by provide two surfaces or contact locations against the rod 102.

FIG. 9B illustrates an anchor rod hole 208 with an inner boundary 238, an outer boundary 240, and a shoulder 239 extending radially outward to connect the inner and outer boundaries 238, 240. The inner boundary 238 can be sized differently from and can be disposed radially inward of the outer boundary 240. For example, the inner boundary 238 can be sized to be smaller than the outer diameter of an anchor rod 102 (e.g., the outer diameter of the threads of the rod 102) but larger than the root diameter of an anchor rod 102, while the outer boundary 240 can be sized to be larger than the outer diameter of the anchor rod 102. The inner boundary 238 can engage the threads of an anchor rod 102 to vertically support the anchor rod 102. The inner boundary 238 and outer boundary 240 of the upper and lower holes 208, 210 can cooperate to horizontally restrain the anchor rod 102.

FIG. 9C illustrates an anchor rod hole 208 arranged as a butterfly hole. The anchor rod hole 208 can have a central aperture 242, a plurality (e.g., two) peripheral apertures 244, and a projection 245. The projection 245 can be formed between the peripheral apertures 244. In some embodiments, the projection 245 can be sized to engage the threads of the anchor rod 102. In some embodiments, the central aperture 242 can be larger than the outer diameter of the anchor rod 102. In various embodiments, the projection 245 can be filed down, or can be formed at a thickness that is smaller than the thickness 236. By decreasing the thickness of the projection 245, the projection 245 can have increased flexibility and/or improved thread engaging properties (e.g. the projection can fit between the threads of the anchor rod 102 or has more space between the threads of the anchor rod 102). For example, the projection 245 can exert a spring-like force against the rod 102 to vertically and horizontally restrain the anchor 102. This increase in flexibility and improved thread engaging properties allows for easier insertion of the anchor rods 102 into the anchor rod holes 208, 210 during installation and improved vertical and/or horizontal retention.

FIG. 9D illustrates an anchor rod hole 208 comprising a serrated boundary. The anchor rod hole 208 can include one or more teeth 246, which can be positioned around the circumference of the anchor rod hole 208. The teeth 246 can be sized such that the teeth 246 engage the threads of the anchor rod 102. As explained herein, the teeth 246 can serve to vertically and/or horizontally retain the anchor rod 102.

FIG. 9E illustrates an anchor rod hole 208 having a slotted profile 252. The slotted profile 252 can include an insertion hole boundary 251, an anchor hole boundary 253, and a slot 255 extending between the insertion hole boundary 251 and the anchor hole boundary 253. An anchor rod 102 can be placed into the insertion hole boundary 251 and can be slid over to the anchor hole boundary 253 along the slot 255, where the anchor rod 102 can be held in place by slot 255 and anchor hole boundary 253. In some embodiments, the insertion hole boundary 251 can be larger in diameter than the anchor hole boundary 253. In various embodiments, the slot 255 can be smaller in width than the diameter of the anchor hole boundary 253. In some embodiments, the insertion hole boundary 251 can be larger than the outer diameter of the anchor rod 102 (e.g., larger than the diameter of the threaded region of the rod 102), while the anchor hole boundary 253 can be smaller than the outer diameter of the anchor rod 102 (e.g., smaller than the diameter of the threaded region of the rod 102). In various embodiments, the slot 255 can be smaller than the root diameter of the anchor rod 102, while the anchor hole boundary 253 can be larger than the root diameter of the anchor rod 102. Because the slot 255 can be smaller than the root diameter of the anchor rod 102, the slot 255 can prevent the anchor rod 102 from sliding over to the insertion hole boundary 251 from the anchor hole boundary 253.

In some embodiments, the slotted profile 252 can be used to indicate that an anchor rod has been displaced during the installation process. For example, the upper segment 202 can use an anchor rod hole 208 with a slotted profile 252 while the lower segment utilizes an anchor rod hole 210 without a slotted profile. The anchor rod hole 210 can be aligned with the anchor rod hole 208, but not with the insertion hole boundary 251 of the hole 108. Accordingly, if an anchor rod 102 gets displaced horizontally, and transitions from the anchor hole boundary 253 to the insertion hole boundary 251 of the slotted profile 252, the anchor rod 102 will be angled. An angled anchor rod 102 can visually indicate to a worker that the anchor rod 102 has been displaced and can be readjusted before the concrete foundation 10 cures.

FIG. 9F illustrates an anchor rod hole 208 with an inner boundary 238 and an outer boundary 240, according to another embodiment. The inner boundary 238 can be sized differently than the outer boundary 240. For example, the inner boundary 238 can be sized to be smaller than the outer diameter of an anchor rod 102 but larger than the root diameter of an anchor rod 102, while the outer boundary 240 can be sized to be larger than the outer diameter of the anchor rod 102. The inner boundary 238 can engage the threads of an anchor rod 102 while the outer boundary 240 may not engage the threads of the anchor rod 102.

FIG. 9G illustrates an anchor rod hole 208 having a plurality of opposing teeth 254 according to another embodiment. The anchor rod hole 208 can have a hexagon-shaped boundary 257 with a gap 259 along at least two opposing sides of the hole 208. The teeth 254 can be positioned at a different height than the anchor rod hole 208. For example, the teeth 254 can be connected to two arms (not shown), which can be connected to the upper segment 202. These arms can extend downwards from the upper segment and towards the lower segment 204 (or vice versa). The teeth 254 can connect to one of the arms and extend toward the opposite arm. The teeth 254 can be used to engage the threads of the anchor rod 102. In some embodiments, the arms are connected to the lower segment 204 and extend downwards from the lower segment 204. In other embodiments, the arms are connected to the lower segment 204 and extend upwards towards the upper segment 202. In various embodiments, the arms can contain a plurality of teeth 254 that are spaced apart along the length of the arms.

FIGS. 10A and 10B illustrate a side view of an anchor rail 200 with concrete holes or openings 248. The concrete holes 248 can be formed on the vertical segment 206 and can be spaced apart from each other along the length of the vertical segment 206. In some embodiments, the vertical segment contains one concrete hole 248. The concrete hole 248 allows for concrete to flow easily into the channel that is defined by the upper segment 202, lower segment 204, and vertical segment 206. In some embodiments, the concrete hole 248 can be oval shaped. In other embodiments, the concrete hole 248 can be rectangular shaped. In various embodiments, the concrete hole is circular shaped. Other variations of the concrete hole 248 shape are possible. To ensure no interference between the concrete hole 248 and the fastener hole 212, the fastener hole 212 can be positioned away from the concrete hole 248. In some embodiments, the concrete hole 248 can have an area between about 0.5 in² to about 6 in². In some embodiments, the concrete holes are utilized when the anchor rail 200 is completely embedded within the concrete.

FIG. 11 illustrates a fastener hole 212. The fastener hole 212 can be formed on the vertical segment 206. Additionally, or alternatively, the fastener hole 212 can be formed on the upper segment 202 and/or lower segment 204. The fastener hole 212 can be sized to fit a variety of fasteners, which can include, for example, bolts, screws, and nails. The fastener hole 212 can have an elliptical shape. In various embodiments, the fastener hole 212 can be shaped in a different manner. For example, the fastener hole 212 can be circular, oval, or rectangular shaped. Other shapes are possible. The fastener hole 212 can be used to connect the anchor rail 200 to another component or system. For example, the fastener hole 212 can be used to connect the vertical segment 206 to the formboard 12. A nail, or other fastener, can partially extend through the fastener hole 212 and into the formboard 12. By connecting the anchor rail 200 to the formboard 12, the anchor rail 200 can be positioned in the foundation before the concrete is poured into the foundation. In some embodiments, the fastener hole 212 can have a major lateral dimension 261 (e.g., a dimension of maximum lateral extent or a diameter) or slot length in a range of about 0.05 inches to about 2 inches or in a range of about 0.125 inches to about 0.25 inches. A transverse dimension 263 of the hole 212 can be in a range of about 0.25 inches to about 4 inches or in a range of about 0.25 inches to about 0.5 inches .

As illustrated in FIG. 9E, the fastener hole 212 can be formed on surfaces other than, or in addition to, the vertical segment 206. For example, the fastener hole 212b can be formed on the upper segment 202 (or on the lower segment 204). In some embodiments, fastener hole 212b on the upper segment 202 can be generally aligned along the longitudinal axis x with fastener hole 212a on the vertical segment 206 such that the fastener holes 212a, 212b. In some of these embodiments, the same fastener can be inserted into the fastener hole 212b and fastener holes 212a. For example, a fastener 111 can be inserted at an angle through the holes 212a, 212 be through both the upper segment 202 (or the lower segment 204) and the vertical segment 206. Arranging the fastener holes 212a, 212b on both the upper segment 202 and vertical segment 206 allows workers to access and insert fasteners from above the upper segment 202 on the outside surface of the formboard 10, as opposed to fastening the rail 200 from inside the perimeter of the formboards 10.

FIG. 12 illustrates a fastener hole 250 according to another embodiment. The fastener hole 250 can be formed on the vertical segment 206. In some embodiments, the fastener hole 250 can be formed on the upper segment 202 and/or lower segment 204. Multiple fastener holes 250 can be formed in the vertical segment 206 and can be spaced apart along the length of the vertical segment 206. The fastener hole 250 can be sized to fit a variety of fasteners, which can include, for example, bolts, screws, and nails. The fastener hole 250 can be used to assist with connecting the anchor rail 200 to another component or system. The fastener hole 250 can include two or more prongs, for example, in an E-shaped profile as shown. These multiple prongs can provide options for where to install a fastener. In some embodiments, multiple fasteners can be installed in each fastener hole 250.

FIG. 13 illustrates an anchor rail 200 with a vertical retention member according to various embodiments. As depicted in FIG. 13, the vertical retention member can comprise a push washer 300 connected to the anchor rod 102. The push washer 300 can have serrated teeth, or other vertical retaining features, which can engage the anchor rod 102 (e.g., threads of the anchor rod 102) and prevent the anchor rod 102 from moving vertically. The push washer 300 can be installed so that the push washer 300 is disposed on top of the anchor rail 200, for example, on the upper segment 202. In other embodiments, the push washer 300 can additionally or alternatively be provided on the lower segment 204. In some embodiments, multiple push washers 300 can be used for a single anchor rod 102. For example, a push washer 300 can be used above the anchor rod hole 208, below the anchor rod hole 208, above the anchor rod hole 210, and/or below the anchor rod hole 210. The push washer 300 can be used with other vertical retention members described herein to improve vertical retention of the anchor rods 102. In some embodiments, a nut and washer can be used as a vertical retention member. The nut and washer can be used in lieu of, or in addition to, a push washer 300. The nut and washer can be installed on an anchor rod 102 and can be provided on the upper segment 202 or lower segment 204. By providing the nut and/or washer on the upper segment 202 or lower segment 204, the nut and washer can prevent the anchor rod 102 from moving vertically.

FIG. 14 illustrates an anchor rail with a vertical retention member, according to another embodiment. More specifically, FIG. 14 illustrates an anchor rail 200 with a vertical retention member comprising a rod stop 400. The rod stop 400 can include a bottom stop surface 402, a connector 404, and a body 406. The bottom stop surface 402 and connector 404 can extend from opposite end portions of the body 406. The connector 404 can be used to connect the rod stop 400 to the anchor rail 200 (e.g., to the upper or lower segments 202, 204). The bottom stop surface 402 can be used to contact the first end 101 (e.g., bottom end) of the anchor rod 102 that is placed with the anchor rail 200 and can prevent the anchor rod 102 from extending further below the lower segment 204. The rod stop 404 can be sized so as to maintain the anchor rod 102 at an appropriate height relative to the anchor rail 200. For example, the rod stop 400 can be sized to extend a specified distance below the anchor rail 200, which prevents the anchor rod 102 from extending beyond the rod stop 400. As a result, the part of the anchor rod 102 that extends above the concrete foundation 10 can be the proper height for attaching other components to the anchor rod 102. The rod stop 400 can be increased in height, which can, in turn, reduce the amount of the anchor rod 102 that extends above the concrete foundation 10 and increase the length of anchor rod 102 that is embedded in the concrete foundation 10. Conversely, the rod stop can be decreased in height, which can, in turn, increase the amount of the anchor rod 102 that extends above the concrete foundation 10 and decrease that length of anchor rod 102 that is embedded in the concrete foundation 10.

FIGS. 15 and 16 illustrate a concrete anchor assembly comprising an anchor stand 500, according to various embodiments. The concrete anchor stand 500 can include an upper segment or upper plate 502, a lower segment or lower plate 504, two legs 506, an anchor rod hole 508 in the upper segment 502, an anchor rod hole 510 in the lower segment 504, a rod stop 512 extending below the lower segment 504, a plurality of (e.g., two) rod stop arms 514, a plurality of (e.g., four) concrete holes or openings 516, a plurality of (e.g., two) feet 518, and a plurality of (e.g., four) fastener holes 520. The upper segment 502 can be positioned at a top end portion of the concrete anchor system 500. The two legs 506 can extend downwards from the upper segment 502 at opposite ends of the upper segment 502. The lower segment 504 can connect to the legs 506 and can be positioned below the upper segment 502. A foot 518 extends outward from an end of each of the legs 506. The fastener holes 518 can be formed in each of the feet 518. Fastener(s) can extend through the fastener holes 518 to connect the anchor stand 500 to a formboard 12 (which may be at the bottom of the foundation 10). In some embodiments, fastener holes 518 can be formed in other components, such as the upper segment 502, lower segment 504, or legs 506. Anchor rod holes 508, 510 are installed in the upper 502 and lower 504 segments. The anchor rod holes 508, 510 can be generally aligned with each other so as to receive the anchor rod 102 therethrough. The anchor rod holes 508, 510 can be similarly sized and shaped as anchor rod holes 208, 210 and can function similarly as anchor rod holes 208, 210. In the illustrated embodiment, the holes 208, 210 may be generally similar in shape to the butterfly holes shown and described in connection with FIG. 9A. In other embodiments, the holes 208, 210 can be any suitable shape, including any of the hole shapes described herein. In various embodiments, the anchor stand 500 can include a plurality of anchor rod holes 508, 510, such that the anchor stand 500 can accommodate one or more anchor rods 102. The rod stop 512 can be installed below the lower segment 504. The rod stop arms 514 can connect to the lower segment 504 and can extend below the lower segment 504. The rod stop 512 can be positioned below the anchor rod hole 510 and can serve as a vertical retention member to vertically restrain movement of the rod 102.

The concrete anchor stand 500 can be used in lieu of, or in addition to, the anchor rail 200. The concrete anchor stand 500 can be used to hold a single anchor rod 102 in some embodiments. In other embodiments, more than one anchor rod can extend through a corresponding plurality of pairs of holes in the stand 500. Accordingly, in some embodiments, the concrete anchor stand 500 can have a smaller footprint than an anchor rail 200, and can thus be used in scenarios where an anchor rail 200 would not be appropriate due to the anchor rail's 200 size. The concrete anchor stand 500 can be sized such that the upper segment 502 is about flush with the top of the concrete foundation 10. The concrete anchor stand 500 can have an exposed, or partially exposed, upper segment 502 after the concrete foundation 10 cures. In some embodiments, one or more legs 506 can also be exposed along the side of the concrete foundation 10 after the concrete foundation 10 cures. The concrete anchor stand 500 can be installed at any location along the base of the concrete foundation 10. One or more concrete anchor stands 500 can be installed in a concrete foundation 10. In some embodiments, the anchor stand 500 can be completely embedded within the concrete foundation 10.

The concrete anchor system 500 can be installed before the concrete foundation 10 is poured. The concrete anchor system 500 can be installed by inserting fasteners into the fastener holes 518 to connect the concrete anchor system 500 to a horizontal formboard, vertical formboard 12, or other system. Concrete holes 516 allow for concrete to flow through and surround the entire concrete system 500. The concrete anchor system 500 can remain partially or completely embedded in the concrete foundation 10 after the concrete foundation 10 cures.

The concrete anchor system 500 can hold anchor rods 102 within the anchor rod holes 508, 510. When positioned within the anchor rod holes 508, 510, the anchor rod 102 contacts the concrete anchor system at two locations (the anchor rod holes 508, 510). Because the anchor rod 102 contacts the concrete anchor system 500 at two locations, the concrete anchor system 500 can prevent or reduce horizontal movement or rotation of the anchor rod 102 while concrete is being poured into a foundation 10 or while the concrete foundation 10 cures. The concrete foundation can also include vertical retention members, such as the rod stop 512, which can prevent or reduce vertical movement of the anchor rod 102 while concrete is being poured into a foundation 10 or while the concrete foundation 10 cures. Other vertical retention members, such as the anchor hole profiles illustrated and described in FIGS. 9B-9G, can be used instead of or in addition to the rod stop 512 to vertically restrain the anchor rod 102. By preventing or reducing both horizontal and vertical movement of an anchor rod 102, a concrete anchor stand 500 can be used to ensure the anchor rods 102 are properly positioned during the process of forming a concrete foundation 10.

The concrete anchor stand 500 can be formed from a metal, such as steel or aluminum. In some embodiments, the concrete anchor stand 500 can be formed from plastic. In various embodiments, the concrete anchor stand 500 can be formed from a variety of materials.

FIGS. 17, 18A, and 18B illustrate a flat top anchor head 600 for use in any of the embodiments disclosed herein. A flat top anchor head 600 can be used to secure a structure (such as a frame member like a sill plate) to the embedded anchor rod 102. Typically, when securing a structure to an anchor rod 102, a standard nut and washer are used. A standard nut and washer are commonly used to connect the anchor rods 102 from the concrete foundation 10 to a structure, such as a sill plate 14 of a wooden frame. The sill plate 14 is usually a bottom, horizontal member of the wooden frame that can be treated with chemicals to prevent termite and water damage. These treated chemicals can cause problems to anchor rods 102, such that these rods are typically galvanized. Furthermore, the top of the rod, the nut, and the washer can all protrude through the sill plate 14, which often interferes with subsequent construction activity in which workers have to avoid the protruding anchor rods 102 above the sill plate to install other devices. A flat top anchor head 600 can be used to avoid these issues.

As illustrated in FIGS. 18A and 18B, the flat top anchor head 600 can include a top flange 602 and a threaded portion 604. The threaded portion 604 extends downward from the top flange 602. The threaded portion 604 can have female threads that are designed to mate with the male threads of the anchor rod 102. In other embodiments, the threaded portion 604 can have male threads that are designed to mate with the female threaded portion of the anchor rod 102. In various embodiments, the flat top anchor head 600 can include a countersink portion 606. The countersink portion 606 can be used to engage a wooden frame 14 or other structure to hold the flat top anchor head 600 in place. The countersink portion 606 can comprise one or a plurality of radially-inwardly stepped surfaces as shown in FIG. 18B. In some embodiments, the countersink portion 606 can dig into the sill plate 14 as the flat top anchor head 600 is installed, which can allow for the top flange 602 to be flush with the sill plate 14 or extend below (recessed relative to) the top surface of the sill plate 14.

As illustrated in FIG. 17, the flat top anchor head 600 can be used to secure the anchor rod 102 to the sill plate 14. The flat top anchor head 600 can extend downward into a hole formed in the sill plate 14. The anchor rod 102 can engage the threaded portion 604 of the flat top anchor head 600 within the hole of the sill plate 14. Additionally, the top 602 of the flat top anchor head can have a low profile that rests on the top surface of the sill plate 14, but that does not extend far above the top surface of the sill plate 14. In some embodiments, the top 602 can extend above the sill plate 14 by a distance in a range of 1/32″ to 3″, in a range of 1/32″, or in a range of 1/32″ to ½″. In other embodiments, the flat top anchor head 600 can be about flush with the top of the sill plate 14. In various embodiments, the flat top anchor head 600 extends below the top of the sill plate 14.

In various embodiments, the flat top anchor head 600 allows the anchor rod 102 to connect to the sill plate 14 while avoiding contact with the sill plate 14. Thus, the anchor rod may not be galvanized.

In various embodiments, a mounting anchor rod 104 can be used to mount an anchor rail 200. As illustrated in FIG. 17, the mounting anchor rod 104 can extend downwards towards the base of the concrete foundation 10. In some embodiments, the mounting anchor rod 104 can connect to a horizontal formboard, which allows for the anchor rail to be held in place before the concrete foundation 10 is poured. In some embodiments, the mounting anchor rod 104 can utilize anchor rod holes 208, 210 of the anchor rail 200.

A method of using a concrete anchor assembly 100, 500 will now be described. A boundary for a concrete foundation 10 can be formed to define part or all of the footprint of the structure to be built. The boundary can be formed by placing vertical formboards 12 and horizontal formboards together. Any suitable number of anchor rails 200 and/or concrete anchor stands 500 can be installed. The anchor rail 200 can be installed by fastening the anchor rail 200 to the vertical formboard 12, horizontal formboard, or another system or component. The anchor rail 200 can be connected to these systems by utilizing a fastener hole 212 or the mounting anchor rods 104. The concrete anchor stand 500 can be installed by fastening the concrete anchor stand 500 to the vertical formboard 12, horizontal formboard, or another system or component. The concrete anchor stand 500 can be connected to these systems by utilizing a fastener hole 518. After the anchor rails 200 and/or concrete anchor stand 500 are secured, anchor rods 102 can be placed into the anchor rod holes 208, 210, 508, 510. Vertical retention members can be provided to vertically restrain the anchor rods 102. As explained herein, the vertical retention members can comprise a profile or boundary of the anchor holes 208 and/or 210. The vertical retention members can additionally or alternatively comprise a rod stop structure that physically restrains the end 101 of the anchor rod 102. Once the anchor rods 102 are secured, the concrete can be poured into the boundary for the concrete foundation 10. Once the concrete foundation 10 cures, the horizontal and/or vertical formboards 12 can be removed. The fasteners used to connect the anchor rail 200 and or concrete anchor stand 500 can optionally be removed. In some embodiments, a flat top anchor head 600 can be installed after the concrete foundation is poured and/or cured. The flat top anchor head 600 can be installed into a sill plate 14, which can be placed over the concrete foundation 10. The anchor rods 102 can be connected to a flat top anchor head 600 within the sill plate 14.

While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the disclosure. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions and changes in the systems and methods described herein may be made without departing from the spirit of the disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosure. Accordingly, the scope of the present inventions is defined only by reference to the appended claims.

Features, materials, characteristics, or groups described in conjunction with a particular aspect, embodiment, or example are to be understood to be applicable to any other aspect, embodiment or example described in this section or elsewhere in this specification unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The protection is not restricted to the details of any foregoing embodiments. The protection extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Furthermore, certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can, in some cases, be excised from the combination, and the combination may be claimed as a subcombination or variation of a sub combination.

Moreover, while operations may be depicted in the drawings or described in the specification in a particular order, such operations need not be performed in the particular order shown or in sequential order, or that all operations be performed, to achieve desirable results. Other operations that are not depicted or described can be incorporated in the example methods and processes. For example, one or more additional operations can be performed before, after, simultaneously, or between any of the described operations. Further, the operations may be rearranged or reordered in other implementations. Those skilled in the art will appreciate that in some embodiments, the actual steps taken in the processes illustrated and/or disclosed may differ from those shown in the figures. Depending on the embodiment, certain of the steps described above may be removed, others may be added. Furthermore, the features and attributes of the specific embodiments disclosed above may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure. Also, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products.

For purposes of this disclosure, certain aspects, advantages, and novel features are described herein. Not necessarily all such advantages may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the disclosure may be embodied or carried out in a manner that achieves one advantage or a group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.

Conditional language, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and/or steps are included or are to be performed in any particular embodiment.

Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require the presence of at least one of X, at least one of Y, and at least one of Z.

Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately”, “about”, “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of the stated amount. As another example, in certain embodiments, the terms “generally parallel” and “substantially parallel” refer to a value, amount, or characteristic that departs from exactly parallel by less than or equal to 15 degrees, 10 degrees, 5 degrees, 3 degrees, 1 degree, or 0.1 degree. Unless indicated otherwise, language describing an exact value of a measurable attribute of a component (e.g. weight, distance, height, volume, surface area, angle, etc.) is intended to mean that the component can have the exact value of that attribute in one embodiment and the approximate value of that attribute in another embodiment. For example, language describing the length of an object as being “10 feet” is intended to mean that the object can have a length of 10 feet, a length within 10% of 10 feet, a length within 5% of 10 feet, a length within 1% of 10 feet, or a length within 0.1% of 10 feet.

The scope of the present disclosure is not intended to be limited by the specific disclosures of preferred embodiments in this section or elsewhere in this specification, and may be defined by claims as presented in this section or elsewhere in this specification or as presented in the future. The language of the claims is to be interpreted broadly based on the language employed in the claims and not limited to the examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive.

Claims

1. A concrete anchor rail comprising:

a vertical segment having a first hole therethrough, the first hole sized to receive a fastener;

an upper segment extending non-parallel relative to the vertical segment, the upper segment having a second hole therethrough; and

a lower segment extending non-parallel relative to and spaced apart from the vertical segment, the lower segment having a third hole therethrough, the second and third holes sized and substantially aligned so as to receive a concrete anchor rod through the second and third holes to restrain horizontal movement of the concrete anchor rod.

2. The concrete anchor rail of claim 1, further comprising a plurality of pairs of second and third holes through the upper and lower segments, respectively, the plurality of pairs being spaced along a length of the anchor rail.

3. The concrete anchor rail of claim 2, wherein the plurality of pairs of second and third holes are spaced apart along the length of the rail at a distance of about 1 inch to about 4 inches.

4. The concrete anchor rail of claim 1, further comprising a plurality of first holes through the vertical leg, the plurality of first holes being spaced along the length of the anchor rail.

5. (canceled)

6. The concrete anchor rail of claim 1, wherein the upper and lower segments are substantially perpendicular relative to the vertical leg.

7. (canceled)

8. The concrete anchor rail of claim 1, wherein the upper segment comprises a first and second corner, the first and second corners having a metal covering.

9. The concrete anchor rail of claim 1, further comprising a vertical retention feature configured to restrain vertical movement of the concrete anchor rod.

10. The concrete anchor rail of claim 9, wherein at least one of the second hole and the third hole comprises the vertical retention feature.

11. The concrete anchor rail of claim 10, wherein the vertical retention feature includes teeth projecting radially inward.

12. (canceled)

13. The concrete anchor rail of claim 9, wherein the vertical retention feature comprises a rod stop connected to and extending below the lower segment, the rod stop configured to restrain vertical movement of the concrete anchor rod.

14. The concrete anchor rail of claim 1, wherein the vertical segment comprises a fourth hole, the fourth hole being configured to allow concrete to flow through the vertical segment.

15. (canceled)

16. The concrete anchor rail of claim 1, wherein the upper segment extends from a first end of the vertical segment and wherein the lower segment extends from a second end of the vertical segment, the second end being opposite the first end.

17. (canceled)

18. (canceled)

19. A concrete anchor system, comprising:

an anchor assembly having an upper segment, a lower segment, and a vertical segment extending between the upper and lower segments, the upper segment having a first hole therethrough, and the lower segment having a second hole therethrough; and

an anchor rod extending through the first and second holes, a first end of the anchor rod to be embedded in concrete and a second end of the anchor rod to be disposed above the concrete.

20. The concrete anchor system of claim 19, wherein the anchor assembly comprises a rail extending along a longitudinal direction.

21. The concrete anchor system of claim 20, wherein the anchor assembly comprises a plurality of pairs of first and second holes through the upper and lower segments, respectively, the plurality of pairs being spaced along a length of the anchor assembly.

22. (canceled)

23. (canceled)

24. (canceled)

25. (canceled)

26. (canceled)

27. (canceled)

28. The concrete anchor system of claim 19, wherein at least a portion of the vertical segment is exposed through the concrete.

29. The concrete anchor system of claim 28, wherein vertical segment further comprises a third hole, the third hole configured to receive a fastener and exposed through the concrete.

30. The concrete anchor system of claim 29, wherein at least a portion of a fastener is disposed within the third hole and exposed through the concrete.

31. The concrete anchor system of claim 19, wherein at least a portion of the upper segment is exposed through the concrete.

32. The concrete anchor system of claim 19, further comprising a vertical retention member configured to restrain vertical movement of the anchor rod during installation.

33. The concrete anchor system of claim 32, wherein one or both of the first and second holes comprises the vertical retention member.

34. The concrete anchor system of claim 33, wherein the vertical retention member comprises teeth or projections, the teeth or projections being configured to restrain vertical movement of the anchor rod during installation.

35. The concrete anchor system of claim 32, wherein the vertical retention member comprises a rod stop positioned below the second hole.

36. The concrete anchor system of claim 19, wherein the anchor assembly further comprises an anchor stand, the anchor stand having first and second legs connected to both the upper segment and lower segment.

37. A concrete anchor stand comprising:

a first plate having a first hole therethrough;

a second plate spaced apart from the first plate, the second plate having a second hole therethrough, the first and second holes sized and substantially aligned so as to receive a concrete anchor rod through the first and second holes to restrain horizontal movement of a concrete anchor;

a first leg connecting the first plate and second plate;

a second leg connecting the first plate and second plate; and

a vertical retention member configured to restrain vertical movement of the concrete anchor relative to the second plate.

38. The concrete anchor stand of claim 37, further comprising a first foot and a second foot, the first foot having a third hole and second foot having a fourth hole, the first foot and second foot connecting to the first leg and second leg, respectively, the first and second foot configured to positioned on a support surface, wherein the third and fourth hole are sized to receive a fastener.

39. (canceled)

40. (canceled)

41. (canceled)

42. The concrete anchor stand of claim 37, wherein the vertical retention member comprises a rod stop connected to the second plate, the rod stop having a portion spaced below the second plate.

43. The concrete anchor stand of claim 37, wherein the first and second legs comprise respective openings therethrough, the respective openings configured to allow concrete in flowable form to flow therethrough.

44.-55. (canceled)