Anchor rod assembly for use in concrete construction

Abstract

A plug for sealing one end of a threaded coupler from wet concrete includes a body having a flange portion for sealing around an outer edge of an opening of a coupler; and the body including a plug portion with radial projections for engagement inside a threaded coupler, the radial projections are configured to flex when the plug portion is pushed into or pulled out of the threaded coupler, the plug portion extending downwardly from the flange portion.

I claim: 
     
         1 . A plug for sealing one end of a threaded coupler from wet concrete, comprising:
 a) a body including a flange portion for sealing around an outer edge of an opening of a coupler; and   b) the body including a plug portion with radial projections for engagement inside a threaded coupler, the radial projections are configured to flex when the plug portion is pushed into or pulled out of the threaded coupler, the plug portion extending downwardly from the flange portion.   
     
     
         2 . The plug as in  claim 1 , wherein the radial projections comprises a thread for engagement with the threaded coupler. 
     
     
         3 . The plug as in  claim 2 , wherein:
 a) the thread includes a first portion at an upper portion of the plug portion and a second portion below the first portion; and   b) the first portion is thicker for greater rigidity than the second portion for screwing into the threaded opening of the coupler.   
     
     
         4 . The plug as in  claim 2 , wherein the thread has rounded crest portions. 
     
     
         5 . The plug as in  claim 2 , wherein the thread comprises a single revolution disposed at an upper portion and/or a lower portion of the plug portion. 
     
     
         6 . The plug as in  claim 1 , wherein the radial projections circular ring members. 
     
     
         7 . The plug as in  claim 1 , wherein the plug portion comprises crisscrossed wall members having respective outer edges. 
     
     
         8 . The plug as in  claim 7 , wherein the radial projections comprise knob projections on the outer edges. 
     
     
         9 . The plug as in  claim 1 , wherein the plug portion is hollow. 
     
     
         10 . The plug as in  claim 1 , wherein the plug portion is barrel-shaped. 
     
     
         11 . The plug as in  claim 1 , wherein the plug portion is cylindrical. 
     
     
         12 . The plug as in  claim 1 , wherein the plug portion is tapered. 
     
     
         13 . The plug as in  claim 1 , wherein:
 a) the plug portions includes a recessed top; and   b) a vertical member extends vertically from and outside the recessed top to indicate position of the coupler after concrete is poured, the vertical member is configured to flex and rebound when hit.   
     
     
         14 . The plug as in  claim 1 , wherein the plug portion includes a top surface for being disposed at a same level as a top edge of the coupler. 
     
     
         15 . The plug as in  claim 1 , wherein the flange portion includes a convex top surface. 
     
     
         16 . The plug as in  claim 1 , wherein the flange portion includes a sidewall extending downwardly. 
     
     
         17 . The plug as in  claim 1 , wherein a vertical member extends upwardly from the flange portion to indicate position of the coupler after concrete is poured, the vertical member is configured to flex and rebound when hit. 
     
     
         18 . The plug as in  claim 1 , wherein the flange portion includes a top surface and a bridge portion above the top surface, the bridge portion is configured to flex and rebound when hit, the bridge portion creating a gap above the surface for receiving a tool to pry the plug after concrete is cured. 
     
     
         19 . The plug as in  claim 18 , wherein a vertical member extends upwardly from the bridge portion, the vertical member being configured to flex and rebond when hit. 
     
     
         20 . The plug as in  claim 1 , and further comprising:
 a) a coupler having a first threaded end opening for receiving the plug portion and a second threaded end opening, the first threaded end opening for being accessible with respect to a concrete surface of a concrete structure after the plug is removed; and   b) an anchor rod having a first end portion received in the second threaded opening.   
     
     
         21 . The plug as in  claim 20 , wherein:
 a) the plug portion has a bottom end disposed inside the coupler; and   b) the anchor rod including a top end disposed inside the coupler, the bottom end of the plug portion providing a stop for the top end of the anchor rod at a position of minimum thread engagement of the anchor rod with the coupler.   
     
     
         22 . The plug as in  claim 20 , wherein the plug portion penetrates the coupler to a depth to provide minimum thread engagement of a rod when threaded to the first threaded opening after the plug is removed. 
     
     
         23 . The plug as in  claim 20 , and further comprising a holder for receiving a second end portion of the anchor rod. 
     
     
         24 . The plug as in  claim 23 , and further comprising an anchor body attached to the anchor rod. 
     
     
         25 . The plug as in  claim 21 , wherein:
 a) the coupler includes a sight hole at the position of minimum thread engagement; and   b) the anchor rod includes a top end which is visible in sight hole.   
     
     
         26 . The plug as in  claim 20 , wherein the anchor rod is locked to the coupler. 
     
     
         27 . The plug as in  claim 20 , wherein the first threaded end opening has a diameter different from a diameter of the second threaded end opening. 
     
     
         28 . The plug as in  claim 25 , wherein the bottom end of the plug portion is disposed above the sight hole. 
     
     
         29 . The plug as in  claim 25 , wherein the top end of the anchor rod is disposed even with or past a top part of the sight hole. 
     
     
         30 . An anchor rod assembly for being embedded in a concrete, comprising:
 a) a coupler having a first threaded end opening and a second threaded end opening, the coupler including a top edge, the first threaded end opening for being accessible with respect to a concrete surface of a concrete structure after concrete is poured;   b) a seal for sealing the first threaded end opening from wet concrete, the seal having a top surface disposed above the top edge of the coupler, the top surface for being on a same level as the concrete surface to position the top edge below the concrete surface, the seal being configured to flex and rebound when hit; and   c) an anchor rod including a first end portion threaded to the second threaded end opening.   
     
     
         31 . The anchor rod assembly as in  claim 30 , wherein the seal comprises a plug portion disposed inside the first threaded end opening of the coupler. 
     
     
         32 . The anchor rod assembly as in  claim 30 , wherein the seal comprises a cap. 
     
     
         33 . The anchor rod assembly as in  claim 32 , wherein the cap includes a top wall and a peripheral sidewall extending downwardly from the top wall, the sidewall engaging the coupler. 
     
     
         34 . The anchor rod assembly as in  claim 33 , wherein the top wall is convex. 
     
     
         35 . The anchor rod assembly as in  claim 33 , wherein the top wall includes a plurality of intersecting grooves to weaken the top wall for breakage by a rod when inserted into the coupler through the top wall. 
     
     
         36 . The anchor rod assembly as in  claim 32 , wherein:
 a) the first threaded end opening of the coupler includes a top edge and a cylindrical surface below the top edge;   b) the cap includes a top wall and a peripheral sidewall extending downwardly from the top wall; and   c) the sidewall engages the cylindrical surface inside the coupler.   
     
     
         37 . The anchor rod assembly as in  claim 36 , wherein the sidewall includes a rib disposed in a corresponding groove in the cylindrical surface. 
     
     
         38 . The anchor rod assembly as in  claim 36 , wherein the top wall is convex. 
     
     
         39 . The anchor rod assembly as in  claim 33 , wherein the sidewall is disposed outside the coupler and the top wall is convex. 
     
     
         40 . The anchor rod assembly as in  claim 33 , wherein:
 a) the first threaded end opening includes a top edge; and   b) the top wall extends over the top edge.   
     
     
         41 . The anchor rod assembly as in  claim 33 , wherein a vertical member extends upwardly from the top wall, the vertical member is configured to flex and rebound when hit. 
     
     
         42 . The anchor rod assembly as in  claim 36 , wherein:
 a) the first threaded end opening includes a top edge;   b) the top wall includes a projection disposed below the top wall; and   c) the projection is received in a corresponding groove in the top edge of the first threaded end opening.   
     
     
         43 . The anchor rod assembly as in  claim 36 , wherein:
 a) the sidewall is disposed outside the coupler;   b) the first threaded end opening includes a top edge; and   c) the sidewall includes a projection received in a corresponding groove in the coupler below the top edge.   
     
     
         44 . A cap for sealing one end of a threaded coupler to be embedded in concrete, comprising:
 a) a flexible body including a top wall for covering one end of a coupler; and   b) a side wall extending downwardly from the top wall, the side wall for sealing engagement of the coupler.   
     
     
         45 . The cap as in  claim 44 , wherein the top wall is convex. 
     
     
         46 . The cap as in  claim 44 , wherein the top wall includes a plurality of intersecting grooves to weaken the top wall for breakage by a rod when inserted into the coupler through the top wall. 
     
     
         47 . The cap as in  claim 44 , wherein the sidewall is disposed inside the coupler for engaging a cylindrical surface inside the coupler. 
     
     
         48 . The cap as in  claim 44 , wherein the top wall comprises an exterior convex top surface. 
     
     
         49 . The cap as in  claim 47 , wherein the sidewall includes a rib for being received in a corresponding groove in the cylindrical surface. 
     
     
         50 . The cap as in  claim 44 , wherein the sidewall is disposed outside the coupler and the top wall includes an exterior convex top surface. 
     
     
         51 . The cap as in  claim 44 , wherein the body includes a vertical member extending upwardly from the top wall. 
     
     
         52 . The cap as in  claim 44 , wherein:
 a) the sidewall is disposed outside the coupler; and   b) the sidewall includes a projection for being received in a corresponding groove in the coupler.   
     
     
         53 . An anchor rod assembly for being embedded in a concrete, comprising:
 a) a coupler having a first threaded end opening and a second threaded end opening, the first threaded end opening for being accessible with respect to a concrete surface of a concrete structure after concrete is poured, the coupler having a top edge;   b) a seal for sealing the first threaded end opening from wet concrete, the seal having a top surface disposed at a same level as the top edge of the coupler, the top surface for being on a same level as the concrete surface, the seal being configured to flex and rebound when hit; and   c) an anchor rod including first end portion threaded to the second threaded end opening.