Concrete Panel Bolted Foundation Connection and Method

This application is based on and claims priority of provisional patent application Ser. No. 63/646,013 filed May 13, 2024.

This invention deals with anchoring of a concrete panel or member to a concrete foundation without the use of welding. In the past, welding metal connectors between the concrete panel or member and the foundation has been the predominant method. Others have attempted to solve the problem, but the solutions do not utilize a one piece embedded material such as described herein. These earlier attempts by others require the panel to be bolted outside the panel, or the embedment was composed of a fabricated assembly of steel parts. Applicant has developed an alternate variation of the previously and commonly used steel connector allowing it to be cast into the base of precast concrete wall panels in conjunction with a plastic recess-forming block-out.

Applicant's invention utilizes a single piece of stamped steel connector with a matching concrete block-out that positions the steel connector for optimal installation and allows for bolting the concrete wall panel to the foundation. Applicant's solution utilizes the steel connector cast in the wall panel along with a block-out or former that keeps the concrete from filling the void to be created in the wall panel which allows access to the steel connector. This allows the installer to insert a drill and eventually bolt through the void and steel connector as will be described herein.

A steel connector is embedded in the concrete wall panel when the wall is cast. A block-out forms a void and keeps the concrete from filling the inside of the steel connector during the casting process. The angle at which the base of the steel connector is disposed within the concrete wall panel provides the proper angle for a fastening bolt to be inserted through the steel connector and into the foundation. The fastening bolt passes through a hole in the base of the steel connector into the concrete foundation to securely attach the wall panel to the foundation.

Turning first to, we see a steel connectorembedded within a wall panel. Mechanical anchors or a fastening boltpasses through the steel connectorand into a concrete foundation. This enables the secure attachment of the wall panelto the foundationusing the mechanical anchors or fastening bolts. The fastening boltis illustrated in two positions, more clearly illustrated in. A first positionis with the boltintroduced into a voidformed in the wall panel with the fastening boltnot yet inserted into the foundation. A second positionillustrates the fastening boltinserted into the foundationwith a headof the fastening boltcontacting a bottom plateof the steel connector, as will be more fully described herein.

illustrate the steel connector. The steel connectorcan be manufactured from a one-piece steel plate. The steel connectorhas opposite sides and a top edgefrom which a pair of top legsextend. It also has a bottom edgefrom which a pair of bottom legsextend. The top legsand bottom legsare bent downwardly at their distal ends to assist in anchoring the steel connector in the concrete wall panel. There is an openingbetween the opposed pair of top legsthe propose of which will be described herein. The bottom platemay have a holecentrally located. The holemay assist the fastening boltin passing through the steel connector, serving as the mechanical anchor's point of attachment from the precast wall paneland into the supporting cast in place concrete foundation.

provides perspective views of the steel connectorsand block-outattached to a formbefore casting concrete delineating the precise positioning of the steel connectorswithin the wall panel's edge. The block-outis first inserted between the opposite pair of top legs. The top legshave their bent distal ends wrapped around a reinforcing bar to help securely position the steel connector in the form at the proper angle. As the block-outis has a hollow center that creates the void, the top surface of the plastic block-outhas a covering, such as taping, to keep concrete from filling the hollow center of the block-outduring the casting process. The configuration of the plastic block-outallows it to fit snugly between the top legsof the steel connector, with both components able to be securely attached to the formusing nails of other conventional fasteners. The plastic block-outenables the steel connectorto be set at both a predefined angle and distance within the thickness of the concrete panel. It should be noted that the steel connectoris mounted in the formso that bottom plateis oriented at an acute angle “A” (see) with respect to the bottom of the wall panel. This is necessary as it facilitate installation of the fastening boltat a proper angle into the foundation. The bolthas a long central axis that is perpendicular to the bottom plate. This allows the headof the fastening boltto engage the bottom platein a flush manner for assisting in securely fastening the concrete panelto the foundation.

illustrates pouring concreteinto the formwith the steel connectorsmounted in the form.shows the formwhen it is substantially filled with concretewith the steel connectorsembedded in the concrete panel. The top surface of the steel connectoris substantially level with the top surface of the concrete. The coveringkeeps the concretefrom filling the hollow center of the block-out.

illustrates the voidcreated by the block-outwhen embedded in the concrete panel. This voidserves as a conduit through which precast erectors or general contractors can guide a hammer drill bit down through the precast panel and into the cast in place foundation. It can also be seen that the block-outhas bottom portionthat rests flush upon the base plate. There is a reinforcing pieceextending between the side walls of the block-out to support the block-out side walls when the concrete is poured into the form. Optionally the bottom portionmay be provided with a small location hole that aligns with the holeso that the installer has a visual indication as to where to drill for placement of the fastening bolt. There is also a back platethat is perpendicular to the base plate. This provides a guide for the installer to properly orient the drill at a proper angle when drilling down into the foundation. The fastening boltis then inserted with the help of an impact wrench driver into the hole drilled in the foundation.

illustrates an installer drilling a hole in the foundation. The angle in the hole in the foundationis predetermined by the angle of the steel connectorwhen set and fastened on the form. As seen in, the angle A allows the fastening boltto be inserted at the proper angle in the concrete panelso that the fastening boltis inserted at the proper angle and depth into the foundation. It is preferable for the angle A to be between 24-28 degrees.

Thus, there has been provided a concrete panel bolted foundation connection and method of installing the concrete panel to the foundation as described above. While the invention has been described in conjunction with a specific embodiment, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as fall within the spirit and scope of the appended claims.