Rough-in Box for Creating Penetrations in Poured Concrete Flooring and Method of Use

Abstract

A rough-in box kit ( 100 ) for creating a rough-in box ( 200 ) to create a penetration in poured concrete flooring during the construction of concrete buildings. The rough-in box kit ( 100 ) includes a single unitary piece ( 1 ) having a flat section ( 5 ) with: a top end; a bottom end opposite to the top end; an inside surface ( 5 a ) located between the top end and the bottom end, and configured to form an inside surface of the rough in box ( 200 ); and an outside surface ( 5 b ) opposite to the inside surface ( 5 a ), and configured to form an outside surface of the rough in box ( 200 ). The single unitary piece ( 1 ) also has a top flange ( 3 ) connected to and extending away from the top end of the flat section ( 5 ), and perforations, through-holes, or slots ( 2 ) that are formed in the flat section ( 5 ). The single unitary piece ( 1 ) is configured to be bent at locations corresponding to and lining up with the perforations, through-holes, or slots ( 2 ) so as to form the rough-in box ( 200 ).

1 . A rough-in box kit ( 100 ) for creating a rough-in box ( 200 ) to create a penetration in poured concrete flooring during the construction of concrete buildings, comprising:
 a single unitary piece ( 1 ) having:
 a flat section ( 5 ) that has:
 a top end; 
 a bottom end opposite to the top end; 
 an inside surface ( 5   a ) located between the top end and the bottom end, and configured to form an inside surface of the rough-in box ( 200 ); and 
 an outside surface ( 5   b ) opposite to the inside surface ( 5   a ), and configured to form an outside surface of the rough-in box ( 200 ); and 
 
 a top flange ( 3 ) connected to and extending away from the top end of the flat section ( 5 ); 
 perforations, through-holes, or slots ( 2 ) that are formed in the flat section ( 5 ); 
   wherein the single unitary piece ( 1 ) is configured to be bent at locations corresponding to and lining up with the perforations, through-holes, or slots ( 2 ) so as to form the rough-in box ( 200 ).   
     
     
         2 . The rough-in box kit ( 100 ) of  claim 1 ;
 wherein the top flange has:
 a first extension ( 3   a ) that extends from the flat section ( 5 ) at approximately a 90° angle; and 
 a second extension ( 3   b ) that extends from the first extension ( 3   a ) at approximately a 90° angle. 
   
     
     
         3 . The rough-in box kit ( 100 ) of  claim 2 ;
 wherein the perforations, through-holes, or slots ( 2 ) are formed in the first extension ( 3   a ).   
     
     
         4 . The rough-in box kit ( 100 ) of  claim 2  or  3 ;
 wherein the perforations, through-holes, or slots ( 2 ) are not formed in a distal end of the second extension ( 3   b ) opposite to and distal from the first extension ( 3   a ). 
 
     
     
         5 . The rough-in box kit ( 100 ) of one of  claims 2 - 4 ;
 wherein the perforations, through-holes, or slots ( 2 ) are formed in a proximal end of the second extension ( 3   b ) adjacent and proximal to the first extension ( 3   a ).   
     
     
         6 . The rough-in box kit ( 100 ) of  claim 2  or  3 ;
 wherein the perforations, through-holes, or slots ( 2 ) are not formed in any portion of the second extension ( 3   b ). 
 
     
     
         7 . The rough-in box kit ( 100 ) of one of  claims 1 - 5 ;
 wherein the single unitary piece ( 1 ) additionally has:
 a bottom flange ( 4 ) connected to and extending away from the bottom end of the flat section ( 5 ) opposite to the top end of the flat section ( 5 ). 
   
     
     
         8 . The rough-in box kit ( 100 ) of  claim 7 ;
 wherein the bottom flange extends from the flat section ( 5 ) at approximately a 90° angle.   
     
     
         9 . The rough-in box kit ( 100 ) of  claim 2 ;
 wherein the single unitary piece ( 1 ) additionally has:
 a bottom flange ( 4 ) connected to and extending away from a bottom end of the flat section ( 5 ) opposite to the top end of the flat section ( 5 ); and 
   wherein the bottom flange ( 4 ) extends approximately parallel to the a first extension ( 3   a ) of the top flange ( 3 ).   
     
     
         10 . The rough-in box kit ( 100 ) of  claim 7 - 9 ;
 wherein the perforations, through-holes, or slots ( 2 ) are not formed in a distal end of the bottom flange ( 4 ) opposite to and distal from the flat section ( 5 ).   
     
     
         11 . The rough-in box kit ( 100 ) of one of  claims 7 - 9 ;
 wherein the perforations, through-holes, or slots ( 2 ) are formed in a proximal end of the bottom flange ( 4 ) adjacent and proximal to the flat section ( 5 ).   
     
     
         12 . The rough-in box kit ( 100 ) of  claim 7 - 9 ;
 wherein the perforations, through-holes, or slots ( 2 ) are not formed in any portion of the bottom flange ( 4 ).   
     
     
         13 . The rough-in box kit ( 100 ) of one of  claims 1 - 12 ;
 wherein the perforations, through-holes, or slots ( 2 ) form vertical arrays ( 2   a ) in the flat section ( 5 ), each vertical array ( 2   a ) extending in a vertical direction from the top end to the bottom end of the flat section ( 5 ).   
     
     
         14 . The rough-in box kit ( 100 ) of  claim 13 ;
 wherein the vertical arrays ( 2   a ) of perforations, through-holes, or slots ( 2 ) are spaced apart from each other in a horizontal direction perpendicular to the vertical direction so that the perforations, through-holes, or slots ( 2 ) additionally form horizontal arrays ( 2   b ) in the flat section ( 5 ) extending in the horizontal direction.   
     
     
         15 . The rough-in box kit ( 100 ) of one of  claims 1 - 14 ;
 wherein the singe unitary piece ( 1 ) made of an aluminum alloy.   
     
     
         16 . The rough-in box kit ( 100 ) of one of  claims 1 - 15 , further comprising:
 a lid ( 6 ) formed configured to supporting a weight of at least approximately 2,000 pounds when placed on top of the formed rough-in box ( 200 ).   
     
     
         17 . The rough-in box kit ( 100 ) of  claim 16 ;
 wherein the lid ( 6 ) is formed of resin-impregnated fiberglass.   
     
     
         18 . The rough-in box kit ( 100 ) of  claim 17 ;
 wherein the resin-impregnated fiberglass is impregnated with an epoxy resin.   
     
     
         19 . The rough-in box kit ( 100 ) of  claim 17 ;
 wherein the lid ( 6 ) comprises 18 to 40 fiberglass layer strands of fiber.   
     
     
         20 . A rough-in box ( 200 ) comprising:
 the rough-in box kit ( 100 ) of one of  claims 16 - 19 ;   wherein the single unitary piece ( 1 ) is bent at locations corresponding to and lining up with the perforations, through-holes, or slots ( 2 ) so as to form the rough-in box ( 200 ) with the lid ( 6 ) being flush with a poured concrete floor.   
     
     
         21 . The rough-in box ( 200 ) of  claim 20 , further comprising:
 a seal arranged between the lid ( 6 ) and the top flange ( 3 ) to create a waterproof or water-resistant seal when the lid ( 6 ) is arranged on the top flange ( 3 ).   
     
     
         22 . A method of constructing a penetration in a concrete floor ( 300 ), comprising:
 bending the single unitary piece ( 1 ) of the rough-in box kit ( 100 ) of one of  claims 1 - 19  at locations corresponding to and lining up with the perforations, through-holes, or slots ( 2 ) so as to form a rough-in box ( 200 );   placing the rough-in box ( 200 ) in a location on a formed deck corresponding to a predetermined location for the penetration in the concrete floor ( 300 );   pouring concrete around the rough-in box ( 200 ) to form the concrete floor ( 300 ).   
     
     
         23 . A method of constructing a penetration in a concrete floor ( 300 ), comprising:
 bending a single unitary piece ( 1 ) so as to form a rough-in box ( 200 );   placing the rough-in box ( 200 ) in a location on a formed deck corresponding to a predetermined location for the penetration in the concrete floor ( 300 );   placing a lid ( 6 ) on top of the rough-in box ( 200 );   pouring concrete around the rough-in box ( 200 ) to form the concrete floor ( 300 ).   
     
     
         24 . The method according to  claim 23 ;
 wherein one end ( 8   a ) of the single unitary piece ( 1 ) is secured and affixed to an opposite end ( 8   b ) of the single unitary piece ( 1 ) to form the rough-in box ( 200 ).   
     
     
         25 . The method according to  claim 23  or  24 , further comprising:
 cutting a top flange ( 3 ) of the single unitary piece ( 1 ) at multiple first locations; and 
 cutting a bottom flange ( 4 ) of the single unitary piece at multiple second locations; 
 wherein the single unitary piece ( 1 ) is bent along multiple bending lines ( 18 ) so as to form a rough-in box ( 200 ), each bending line ( 18 ) extending from one of the first locations to one of the second locations. 
 
     
     
         26 . The method according to  claim 25 , further comprising:
 wherein each bending line ( 18 ) corresponds to an array of perforations, through-holes, or slots ( 2 ) single unitary piece ( 1 ) so that the single unitary piece ( 1 ) is bent along the arrays of perforations, through-holes, or slots ( 2 ).   
     
     
         27 . The method according to one of  claim 23 - 26 ;
 wherein the concrete is poured around the rough-in box ( 200 ) to form the concrete floor ( 300 ) so that the lid ( 6 ) is flush with the poured concrete floor.   
     
     
         28 . A kit for a platform to securely hold a lid ( 6 ) over a penetration in a concrete floor ( 300 ), comprising:
 multiple single unitary pieces ( 12 ) having:
 a first extension ( 12   a ) extending along a first plane; 
 a second extension ( 12   b ) extending from an end of the first extension ( 12   a ) along a second plane intersecting with the first plane; and 
 a third extension ( 12   c ) extending from an end of the second extension ( 12   b ) opposite to the first extension ( 12   a ) along a third plane approximately parallel to the first plane. 
   
     
     
         29 . The kit according to  claim 28 :
 wherein a height of the second extension ( 12   b ) extending between the first and third extensions ( 12   a ,  12   c ) in a direction perpendicular to the first plane corresponds to a thickness dimension of a lid ( 6 ).   
     
     
         30 . The kit according to  claim 28  or  29 :
 wherein at least one of the first and third extensions ( 12   a ,  12   c ) includes through holes ( 19 ), each through hole ( 19 ) being configured to accept a screw or bolt ( 13 ) so that the multiple single unitary pieces ( 12 ) can be screwed or bolted to the concrete floor ( 300 ). 
 
     
     
         31 . A platform for securely holding a lid ( 6 ) over a penetration in a concrete floor ( 300 ), comprising:
 the multiple single unitary pieces ( 12 ) of the kit according to one of  claims 28 - 30 ;   wherein each single unitary piece ( 12 ) is arranged around an edge of the penetration so that at least a portion of an end ( 12   d ) of each single unitary piece ( 12 ) overlaps with at least a portion of an end ( 12   d ) of an adjacent single unitary piece ( 12 ).