WO2023239673A1

WO2023239673A1 - Concrete embedded post anchor

Info

Publication number: WO2023239673A1
Application number: PCT/US2023/024489
Authority: WO
Inventors: Kevin T. Burt; Jonathan HORTA; Kevin Flatt; Geoff LUCZYCKI
Original assignee: Fortress Iron, Lp
Priority date: 2022-06-06
Filing date: 2023-06-05
Publication date: 2023-12-14

Abstract

A railing system includes a first support post spaced apart from a second support post and a rail panel supported by the first and second support posts. A railing system further includes a first mounting anchor and a second mounting anchor, each of the first and second mounting anchors having a standoff member a threaded bore configured to receive a post fastener and are coupled to a deck. A railing system further includes wherein each of the first and second mounting anchors are at least partially embedded within the concrete floor and wherein the post fastener is configured to couple each support post to each mounting anchor.

Description

CONCRETE EMBEDDED POST ANCHOR

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

[0001] This application claims priority to and the benefit of United States of America Priority Application 63/349485, filed 6/6/2022 including the specification, drawings, claims and abstract, is incorporated herein by reference in its entirety. This application claims priority to and the benefit of United States of America Priority Application 63/349493, filed 6/6/2022 including the specification, drawings, claims and abstract, is incorporated herein by reference in its entirety. This application claims priority to and the benefit of United States of America Priority Application 63/349490, filed 6/6/2022 including the specification, drawings, claims and abstract, is incorporated herein by reference in its entirety.

BACKGROUND

[0002] Rail panel systems are often installed by a professional contractor. While many applications require that the rail panel system be mounted directly to a wooden surface, such as a deck, other applications require that the rail panel system be mounted on top of a thinset concrete surface. The rail panel system may be formed primarily of steel or aluminum. In one example, a balcony may have a thinset concrete surface with railing panels secured around an exposed perimeter. In another example, a balcony may have a thinset concrete surface with railing panels secured to the exterior of the balcony, such that no posts encroach upon the walking surface of the landing of the balcony. To secure the railing panels, a contractor pours the concrete, removes a slug of concrete after it sets, and then inserts a post into the hole formed by the removed concrete slug. The contractor may use a diamond concrete-core drill to cut the slug from the concrete. The post is shimmed and secured in place by anchoring grout. Alternatively, a contractor can embed a weld plate in the thinset concrete. After the concrete is poured the contractor welds a post to the weld plate. Efficiency in installing railing panel systems may be increased if a mounting anchor is installed to the underlying structural frame prior to pouring the concrete. SUMMARY OF THE INVENTION

[0003] One aspect of the present disclosure relates to a railing system, the railing system including a first support post spaced apart from a second support post and a rail panel supported by the first and second support posts. The rail system further having a first mounting anchor and a second mounting anchor, each of the first and second mounting anchors having a standoff member with a threaded bore which receives a post fastener and is coupled to a deck. The rail system further having wherein each of the first and second mounting anchors are at least partially embedded within the concrete floor. The rail system further having wherein the post fastener is configured to couple each support post to each mounting anchor.

[0004] According to other embodiments, the railing system may also include wherein each standoff member is directly coupled to the deck by a deck fastener.

[0005] In other embodiments, the railing system may also include wherein each standoff member further comprises a height, the height of the standoff member is configured such that an upper surface of the standoff member is substantially flush with the upper surface of the concrete floor.

[0006] According to yet another other embodiment, the railing system may also include wherein the threaded bore is a female threaded bore.

[0007] According to some embodiments, the railing system may also include wherein the standoff member further includes a hex shaped outer profile.

[0008] According to another aspect, a post mounting system includes a plurality of standoff members, each having a threaded bore that is configured to accept a post fastener. The post mounting system further includes a deck fastener configured to couple the standoff member to a deck. The post mounting system further includes wherein the deck fastener and at least a portion of the standoff member is configured to be at least partially embedded within concrete.

[0009] In other embodiments, the post mounting system may also include wherein the standoff member is directly coupled to the deck by the deck fastener. [0010] In some embodiments, the post mounting system may also include wherein the standoff member further comprises a height, the height of the standoff member is configured such that an upper surface of the standoff member is substantially flush with the upper surface of the concrete.

[0011] In yet another embodiment, the post mounting system may also include wherein the threaded bore is a female threaded bore.

[0012] According to other embodiments, the post mounting system may also include wherein the standoff member further includes a hex shaped outer profile.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements, in which:

[0014] FIG. 1 A-1C includes a front-side perspective view, a side profile view, and a bottom profile view of a concrete embedded post anchor washer, according to an embodiment of the present disclosure.

[0015] FIG. 2 is an exploded front-side perspective view of a concrete embedded post anchor system, according to an embodiment of the present disclosure.

[0016] FIG. 3 is a front-side perspective view of an embodiment of a concrete embedded post anchor system installed on a landing, according to an embodiment of the present disclosure.

[0017] FIG. 4 is a side cross-sectional view of a concrete embedded post anchor system installed on a landing, according to an embodiment of the present disclosure.

[0018] FIG. 5 is a front-side perspective view of another embodiment of a concrete embedded post anchor of the present disclosure. [0019] FIG. 6 is a front-side perspective view of a concrete embedded post bracket mounting system according to an embodiment of the present disclosure.

[0020] FIG. 7 is a top profile view of a of a concrete embedded post bracket mounting system utilized for end posts and line posts respectively, according to an embodiment of the present disclosure.

[0021] FIG. 8 is a top-side perspective view of another embodiment of a concrete embedded post bracket mounting system of the present disclosure.

[0022] FIG. 9 is a perspective cross-sectional view of an embodiment of the concrete embedded post bracket mounting system of the present disclosure.

[0023] FIGS. 10A-10B are front-side perspective and side profile views, respectively, of a concrete embedded flush fascia post mounting system according to an embodiment of the present disclosure.

[0024] FIG. 11 is a rear-side perspective view of a of a concrete embedded flush fascia post mounting system utilized for end posts and line posts of the present disclosure.

[0025] FIG. 12 is a front-side perspective view of an embodiment of a concrete embedded flush fascia post mounting system of the present disclosure.

[0026] FIG. 13 is a cross-sectional side profile view of an embodiment of a concrete embedded offset fascia post mounting system of the present disclosure.

[0027] FIG. 14 is a cross-sectional rear side perspective view of an embodiment of the concrete embedded offset fascia post mounting system installed on a landing.

[0028] FIG. 15 is a front profile view of an embodiment of a rail panel coupled to a pair of rail posts coupled to a system of the present disclosure. [0029] The drawings are not necessarily to scale and certain features may be shown exaggerated in scale or in somewhat schematic form in the interest of clarity and conciseness.

DETAILED DESCRIPTION

[0030] Embodiments disclosed herein provide a system, an apparatus, and a method for a concrete embedded post anchor system 100. According to an embodiment, the concrete embedded post anchor system 100 includes a washer 105 and a fastener 120. The assembled washer 105 and fastener 120 of the system 100 are shown in FIGS. 2-4. Embodiments disclosed herein provide a concrete embedded post anchor system 100 that can be easily utilized to secure a railing post 134 to a framing member 124, plywood substrate 126, or both. The concrete embedded post anchor systems 100 are then secured to a base of the rail support posts 134, and a rail panel (not shown) is installed onto the rail posts 134.

[0031] The rail panel may be pre-assembled and manufactured in various pre-determined or standard lengths before delivery to the job site. A contractor may cut a pre-assembled rail panel to fit a particular spacing between rail posts 134. In embodiments that utilize the concrete embedded post anchor washer 105, the washer 105 is secured to the underlying floor with the fastener 120. According to embodiments that utilize the concrete embedded post anchor system 100, the fastener 120 is installed into the underlying floor directly, as discussed in further detail below. A plurality of concrete embedded post anchor systems 100 support the installation of a single rail post 134.

[0032] The concrete embedded post anchor system 100 does not rely on the tensile strength of the overlaid concrete floor 136 for its structural integrity, instead relying primarily on the strength of the fasteners 120 in the underlying plywood substrate 126 and framing members 124.

[0033] In one embodiment, a hole may be drilled through the supporting wood or metal structure, and the concrete embedded post anchor system 100 (specifically, the fastener 120) may be secured to the supporting structure using a nut threaded to the fastener 120, which may be a lag screw or lag bolt. [0034] Referring now to FIGS. 1A-1C, which depict a front-side perspective view, a side profile view, and a bottom profile view of embodiments of the concrete embedded post anchor washer 105. The illustrated embodiments depict a body 110, a standoff 112, a threaded portion 114, for example a threaded aperture 114, inner surfaces 116, inner ledge 117, and a slot 118. The concrete embedded post anchor washer 105 is configured to be secured on top of a plywood substrate 126, moisture barrier 128, or other floor materials, and then be embedded within a concrete mixture 136, for example a thinset concrete mixture that forms a floor surface of a balcony for a building.

[0035] The concrete embedded post anchor washer 105 is secured to the plywood substrate 126 by first inserting the fastener 120 into the plywood substrate 126 or framing members 124, such that there is enough clearance for the slot 118 to engage with the shaft portion of the fastener 120. Then, the shaft portion of the fastener 120 is slipped through the slot 118 and the inner surfaces 116 engage a head 122 of the fastener 120, as shown in FIG. 2. Once the inner surfaces 116 are engaged with the head 122, any rotation of the concrete embedded post anchor washer 105 will result in rotation of the fastener 120. Thus, tightening the fastener 120 will cause the bottom surface of the head 122 to engage against the inner ledge 1 17. The concrete embedded post anchor washer 105 is then rotated to fully install the fastener 120 into the plywood substrate 126 or framing members 124. A floor surface of the washer 105 is compressed between the head 122 of the fastener 120 and the plywood substrate 126 or framing members 124.

[0036] The standoff 112 extends vertically from the top surface of the body portion 110 such that the upper surface of the standoff 112 will be level and flush with the concrete floor 136 once the concrete floor 136 is poured and cured. The height of the standoff 112 is such that after the concrete is poured over the concrete embedded post anchor washer 105, the standoff threaded portion 114 of the standoff 112 remains accessible.

[0037] The standoff 112 includes a standoff threaded aperture 114 that is configured to accept a threaded fastener such as a screw, bolt, nut, or any other threaded fastener. According to some embodiments, the standoff threaded aperture 114 consists of female threads, which are contained within the standoff 112. In some embodiments, no portion of the standoff threaded portion 114 extends above the upper surface of the standoff 112. In other embodiments, the standoff threaded portion 114 consists of male threads. In these embodiments, the height of the standoff 112 remains the same as in the embodiments that utilize female threads, however the male threads of the standoff threaded portion 114 extend vertically from the upper surface of the standoff 112 and the concrete floor 136.

[0038] The standoff 112 also can have an outer profile of a hex to allow for an installer to use a standard wrench or socket to fully install the fastener 120 while the concrete embedded post anchor washer 105 is connected to the fastener 120. The outer profile of the standoff 112 is not limited to only a hex profile and can have a square shaped outer profile, a spline shaped outer profile, a torx shaped outer profile, or any other suitable outer profile.

[0039] A thread protector can be placed on top of the standoff 112 to cover and protect the standoff threaded portion 114 during the pouring and curing of the concrete floor 136. The thread protector ensures that concrete does not inadvertently splash onto the standoff 112 and contaminate the threads of the standoff threaded portion 114. The thread protector can be a sticker that is placed on top of the standoff 112. In some embodiments that utilize female threads for the standoff threaded portion 114, the thread protector is a cup shaped plastic member that is inserted into the female threads of the standoff threaded portion 114. Once the concrete floor 136 has been poured over the concrete embedded post anchor system 100 and cured, the thread protector is removed to allow access and inspection of the standoff threaded portion 114.

[0040] FIG. 3 illustrates a plurality of concrete embedded post anchor systems 100 installed on a landing, prior to the pouring of the concrete floor 136. The concrete embedded post anchor systems 100 are installed in a pattern such that they align with a similar pattern with a base of a rail post 134. In use, after the concrete floor 136 has been poured, the concrete floor 136 does not extend above the upper surface of the standoff 112 and the standoff threaded portion 114 is still accessible.

[0041] The body 110 may be any suitable height. Similarly, the standoff 112 may also be any suitable height. A standoff 112 and/or a body 110 with a greater height dimension may accommodate a longer fastener received in the threaded aperture 114, a thicker concrete floor 136, or both.

[0042] Referring now to FIG. 4, which illustrates a side cross-sectional view of an embodiment of a concrete embedded post anchor system 100 installed through a plywood substrate 126 and a framing member 124. In the depicted embodiment, a moisture barrier 128 is installed on top of both the plywood substrate 126 and the concrete embedded post anchor washer 105.

[0043] In embodiments that utilize a concrete embedded post anchor system 100 installed on top of a moisture barrier 128, additional measures are generally taken to ensure that the concrete embedded post anchor system 100 does not allow for moisture ingress to the plywood substrate 126 from the concrete floor 136. Such measures can include adding a sealant to the bottom surface of the body portion 110, connecting a rubberized sealing washer to bottom surface of the body portion 110 or the fastener 120, or any other method that substantially prevents seepage of moisture from the concrete floor 136 into the plywood substrate 126.

[0044] FIG. 5 illustrates another embodiment of the present disclosure, specifically a concrete embedded post anchor member 200. The concrete embedded post anchor member 200 utilizes some of the same features of the concrete embedded post anchor washer 105, integrated into a single fastening member. The concrete embedded post anchor member 200 includes a standoff 212, a standoff threaded portion 214, for example a threaded aperture 214, and a substrate-threaded portion 234. The standoff 212 and standoff threaded portion 214 utilize common characteristics and features as discussed above with respect to the concrete embedded post anchor system 100.

[0045] Installation of the concrete embedded post anchor member 200 requires no extra training than would be required to install the fastener 120 of the concrete embedded post anchor system 100. First, the installer would place the substrate-threaded portion 234 on the desired location. Then the installer will engage the outer profile of the standoff 212 with a tool and drive the concrete embedded post anchor member 200 into the plywood substrate 126 and/or framing member 124. In use, the top surface of the concrete floor 136 is substantially level with the top of the standoff 212. [0046] Other embodiments disclosed herein provide a system, an apparatus, and a method for a concrete embedded post bracket mounting system 300. In particular, embodiments disclosed herein provide a concrete embedded post mounting system 300 that can be easily utilized to repeatedly position railing panel support posts 134. A rail support post 134 may be a line post, an end post, or a corner post, depending on which face or faces of the post the brackets are secured. Railing panel brackets are secured to the support posts 134, and a rail panel (not shown) is installed into the railing panel brackets. The rail panel may be pre-assembled and manufactured in standard lengths before delivery to the job site. A contractor may cut to pre-assembled rail panel to fit the particular spacing between end posts 134. The concrete embedded post mounting system 300 is secured to the underlying floor with a series of fasteners that are installed through pre-drilled mounting holes 312 or positioning holes 316. The concrete embedded post mounting system 300 does not rely on the weight of the overlaid concrete for any of its structural integrity, instead relying primarily on the strength of the fasteners in the underlying plywood substrate 126 and framing members 124.

[0047] Referring now to FIG. 6, which depicts a front side perspective view of the concrete embedded post bracket mounting system 300. The illustrated embodiment depicts a mounting plate 310, pre-drilled mounting holes 312, positioning portions 314, positioning holes 316, and standoff members 318. The mounting plate 310 is configured to be secured on top of a plywood substrate 126, or other floor materials, and then be embedded within a thinset concrete mixture. The mounting plate 310 is secured to the substrate by installing fasteners through the pre-drilled mounting holes 312 and into the substrate and framing members 124. According to an embodiment, the mounting plate 310 is powder-coated galvanized steel for corrosion protection.

[0048] The pre-drilled mounting holes 312 have a pattern of a series of concentric circles with each circle having a larger radius than the previous, as shown in FIGS. 6-7. The purpose of the plurality of pre-drilled mounting holes 312 are to increase the likelihood that the mounting plate 310 can be positioned as desired with some of the pre-drilled mounting holes 312 aligning with an underlying framing member 124 underneath the plywood substrate 126. According to some embodiments, pre-drilled mounting holes 312 can be arranged into any pattern or no pattern at all. In other embodiments, pre-drilled mounting holes 312 can be any pattern that allows for adjustment in fastener locations without having to alter the overall location of the mounting plate 310.

[0049] The positioning portions 314 extend from the mounting plate 310 to contact the edge of the landing 324. By contacting the edge of the landing 324, the positioning portions 314 allow for multiple posts 134 to be placed along the edge of the landing 324 with a common gap to the edge of the landing 324. The positioning portions 314 have a common size to ensure the repeatable placement of the mounting plate 310 in relation to the edge of the landing 324. Positioning portions 314 can be placed along all edges of the mounting plate 310 as depicted in FIGS. 6-7. However, positioning portions 314 can also be placed along only a single edge for line posts 134 or along two adjoining edges for end posts 134. Having positioning portions 314 extend from all edges increases the number of applications that the concrete embedded post bracket mounting system 300 can be utilized in.

[0050] FIG. 7 depicts an embodiment of a concrete embedded post bracket mounting system 300 used for an end post 134 (otherwise referred to as a corner post 134) and a line post 134. For an end post 134, positioning portions 314 extend from two adjoining edges of the mounting plate 310 to contact the edges of the landing 324. For a line post 134, positioning portions 314 extend from a single edge of the mounting plate 310 to contact the edge of the landing 324.

[0051] The positioning portions 314 can include positioning holes 316. The positioning holes 316 are located such that a fastener installed through the positioning hole 316 should be aligned with a framing member 124 underneath the plywood substrate 126. According to some embodiments, the positioning portions 314 provide a gap of 1.5 inches from the edge of the mounting plate 310 to the edge of the landing 324. Those of skill in the art will appreciate that the positioning portions 314 can provide for any suitable or desirable gap between the edge of the mounting plate 310 and the edge of the landing 324.

[0052] The standoff members 318 extend vertically from the top surface of the mounting plate 310 such that the top of the standoff member 318 will be level and flush with the concrete floor 136 once the concrete floor 136 is poured and cured. According to an embodiment, the standoff members 318 are cylindrical bodies that are welded to the mounting plate 310. The standoff members 318 include a female threaded portion 320 that is configured to accept a male threaded fastener such as a screw, bolt, or any other male threaded fastener. The height of the standoff members 318 is such that after the concrete is poured over mounting plate 310, the female threaded portion 320 of the standoff members 318 remains accessible.

[0053] Referring now to FIG. 8, which illustrates a top-side exploded perspective view of another embodiment of a concrete embedded post bracket mounting system 400. The depicted embodiment includes standoff members 418 that are not fixed in a single location on the mounting plate 410 and thread protectors 426. The standoff members 418 can be positioned in any of the standoff mounting holes 436 to adjust for posts 134 of different sizes. The standoff members 418 are secured in the standoff mounting holes 436 with a standoff mounting member 428. The standoff mounting member 428 is depicted in this embodiment as a screw, but the standoff mounting member 428 can alternatively be any fastener that allows for the standoff member 418 to be secured to the mounting plate 410.

[0054] The standoff member 418 can have the outer profile of a hex to allow for an installer to use a standard wrench or socket to hold the standoff member 418 in place while the standoff mounting member 428 is connected to the standoff member 418. The outer profile of standoff member 418 is not limited to only a hex profile and can have a square shaped outer profile, a spline shaped outer profile, a torx shaped outer profile, or any other suitable outer profile.

[0055] According to some embodiments, a removable standoff member 418 has a circular outer profile with fins that extend radially from the standoff member 418. The removable standoff member 418 is connected to the standoff mounting member 428 as described above and then the concrete embedded post bracket mounting system 400 is covered with concrete. The concrete fills the area between the fins of the standoff member 418 and aid in securing the rotational orientation of the standoff member 418 as a fastener is installed into the female threaded portion 420 to connect to a post 134. [0056] The thread protector 426 is placed on top of the standoff member 418 and covers the female threaded portion 420 during the pouring and curing of the concrete. The thread protector 426 ensures that concrete does not inadvertently splash onto the standoff member 418 and contaminate the threads of the female threaded portion 420. The thread protector 426 can be a sticker that is placed on top of the standoff member 418. In other embodiments, the thread protector is a cup shaped plastic member that is inserted into the female threaded portion 420. Once the concrete has been poured over the mounting plate 410 and cured, the thread protector 426 is removed to allow access and inspection of the female threaded portion 420.

[0057] The edge of the mounting plate 410 acts as the positioning portion 314, as there are no portions of the mounting plate 410 that extend from the mounting plate 410. The mounting plate 410 is installed directly on top of a moisture barrier 128 that substantially covers the plywood substrate 126. In embodiments that utilize a concrete embedded post bracket mounting system 400 installed on top of a moisture barrier 128, additional measures are generally taken to ensure that the concrete embedded post bracket mounting system 400 does not allow for moisture to leach down to the plywood substrate 126 from the concrete. Such measures can include adding a sealant to the bottom surface of the mounting plate 410, adding a rubberized sealing washer to the fasteners that secure the mounting plate 410 to the underlying floor, or any other method that substantially prevents seepage of moisture from the concrete floor 136 into the plywood substrate 126.

[0058] FIG. 9 illustrates a cross-sectional rear side perspective view of an embodiment of a concrete embedded post bracket mounting system 400 installed on a landing. As shown, the top surface of the concrete is substantially level with the top of the standoff members 418. The thread protectors 426 are similarly depicted as the concrete has not yet cured and the female threaded portion 420 is still at risk of being contaminated by concrete that has not yet cured. After the concrete has cured, the thread protectors 426 can be removed and the concrete embedded post bracket mounting system 400 is fully installed. The system 400 is fully embedded within the cured concrete and is ready to accept the rail post 134. [0059] Embodiments disclosed herein provide a system, an apparatus, and a method for a concrete embedded flush-fascia post mounting system 500. In particular, embodiments disclosed herein provide a concrete embedded flush-fascia post mounting system 500 that can be easily utilized to repeatedly position line posts 134 in line with other line posts 134, and end posts 134 in line with the related line posts 134. Railing panel brackets are secured to the rail posts 134, and a rail panel (not shown) is installed into the railing panel brackets. The rail panel may be pre-assembled and manufactured in standard lengths before delivery to the job site. A contractor may cut to preassembled rail panel to fit the particular spacing between rail posts 134. The concrete embedded flush-fascia post mounting system 500 is secured to the underlying floor with a series of fasteners 120 that are installed through pre-drilled mounting holes 512. The concrete embedded flush-fascia post mounting system 500 does not rely on the weight of the overlaid concrete for any of its structural integrity, instead relying primarily on the strength of the fasteners 120 in the underlying plywood substrate 126 and framing members 124.

[0060] Referring now to FIGS. 10A-10B, which depict a front side perspective view and a sideprofile view of the concrete embedded flush-fascia post mounting system 500, respectively. The illustrated embodiment depicts a concrete embedded flush-fascia post mounting system 500 which includes a mounting plate 510, pre-drilled mounting holes 512, positioning portion 526, post aperture 514, post catch tooth 516, and fascia plate 518. The mounting plate 510 is configured to be secured on top of a plywood substrate 126, moisture barrier 128, or other floor materials, and then be embedded within a thinset concrete mixture. The mounting plate 510 is secured to the substrate by installing fasteners 120 through the pre-drilled mounting holes 512 and into the plywood substrate 126 and framing members 124. The positioning portion 526 contacts both the interior surface of the edge of the landing 324 and the exterior fascia such that the fascia plate 518 sits flush with the exterior surface of the fascia. According to an embodiment, the mounting plate 510 is powder-coated galvanized steel for corrosion protection.

[0061] Once the concrete embedded flush-fascia post mounting system 500 is installed onto a landing and the concrete floor 136 has been poured and cured, a rail post 134 is inserted into post aperture 514. The rail post 134 moves unimpeded through post aperture 514 until the bottom surface of rail post 134 contacts post catch tooth 516. Post catch tooth 516 limits the furthest downward movement that the rail post 134 can move within post aperture 514.

[0062] The pre-drilled mounting holes 512 depicted in FIG. 10A are shown to have a pattern where each pre-drilled hole 512 is positioned at the corner of a square. The purpose of the plurality of pre-drilled mounting holes 512 are to align with a framing member 124 underneath the plywood substrate 126. A fastener 120 can be received through the pre-drilled mounting hole 512 and installed into the framing member 124 and plywood substrate 126, thereby securing the mounting plate 510 to the plywood substrate 126. According to some embodiments, pre-drilled mounting holes 512 can be arranged into any pattern or no pattern at all. In other embodiments, pre-drilled mounting holes 512 can be any pattern that allows for adjustment in fastener locations without having to alter the overall location of the mounting plate 510.

[0063] The positioning portions 526 extend vertically from the mounting plate 510, contact the interior surface of the edge of the landing 324, then the positioning portion 526 extends down over the edge of the landing 324, such that the fascia plate 518 is flush with the exterior fascia By contacting the edge of the landing 324, the positioning portions 526 allow for multiple posts 134 to be placed along the edge of the landing 324 with a common gap from the edge of the landing 324. The positioning portions 526 have a common size to ensure the repeatable placement of the mounting plate 510 in relation to the edge of the landing 324. According to some embodiments, the positioning portions 526 provide a gap of 1.5, 3, or 4 inches from an edge of the rail post 134 to the edge of the landing 324. The positioning portion 526 can create any suitable gap from the edge of the landing 324 to rail post 134 that is desired. Those of skill in the art will appreciate that the positioning portions 526 can provide for any suitable or desirable gap between the edge of the rail post 134 and the edge of the landing 324.

[0064] Referring now to FIG. 11, which depicts an embodiment of a concrete embedded flushfascia post mounting system 500 used for an end post 134 (otherwise referred to as a comer post 134) and a line post 134. For the end post 134 (shown in position A), positioning portions 526 extend from an edge of the mounting plate 510 to contact the edges of the landing 324. Similarly, for a line post 134 (shown in position B) positioning portions 526 extend from an edge of the mounting plate 510 to contact the edges of the landing 324. Fasteners 120 are installed through pre-drilled mounting holes 512 into the plywood substrate 126, securing the concrete embedded flush-fascia post mounting system 500.

[0065] Referring now to FIG. 12, which illustrates a front-side perspective view, of an embodiment of a concrete embedded flush-fascia post mounting system 500 installed as a line post 134 (shown in position B) and end post 134 (shown in position A). The same concrete embedded flush-fascia post mounting system 500 can be utilized for either line post 134 or end post 134. The features of the concrete embedded flush-fascia post mounting system 500 are utilized in the same ways for use with line posts 134 or end posts 134. After the concrete floor 136 has been poured and cured, the fasteners 120 and mounting plate 510 of the concrete embedded flush-fascia post mounting system 500 are fully embedded within the concrete floor 136, while other features or components of the concrete embedded flush-fascia post mounting system 500 are not embedded within the concrete floor 136.

[0066] According to other embodiments, the positioning portion 526 has a height that extends above the height of the edge of the landing 324 as shown in FIG. 12. In other embodiments, the height of the positioning portion 526 is equal to the height of the edge of the landing 324. In such embodiments where the height of the positioning portion 526 is equal to the height of the landing 324, the uppermost surface of the positioning portion 526 can be covered with concrete of the concrete floor 136.

[0067] To fully secure the rail post 134 to the post aperture 514, an installer could insert a rail post 134 into post aperture 514, then drill a hole through both sides of post aperture 514 and rail post 134. Then the installer would insert a bolt through the aforementioned hole and secure a nut to one end of the bolt, thereby securing the rail post 134 to the post aperture 514. Rail post 134 can also be secured to post aperture 514 with self-drilling screws with adequate length to penetrate both the outer wall of post aperture 514 and rail post 134. [0068] FIG. 13 illustrates a side profile cross-sectional view of an embodiment of a concrete embedded offset-fascia post mounting system 600 installed onto a landing, prior to the concrete floor 136 being poured over the system 600. The positioning portion 626 extends vertically from the mounting plate 510, however, the positioning portion 626 does not contact the edge of the landing 324 to position the concrete embedded offset-fascia post mounting system 600 in relation to the edge of the landing 324. Instead, the male positioning member 640 is installed into the female positioning member 642 and an end of the male positioning member 640 contacts the edge of the landing 324 to set the size of the gap from the post aperture 614 from the edge of the landing 324. Many like components between the concrete embedded flush-fascia post mounting system 500 serve like purposes with regards to concrete embedded offset-fascia post mounting system 600.

[0069] As shown in the depicted embodiment, the male positioning member 640 can be a bolt, however in other embodiments the male positioning member 640 can be a screw or other type of threaded fastener. For embodiments that utilize a threaded male positioning member 640, the gap between the post aperture 614 and the edge of the landing 324 can be specified by predetermining how many threads of the male positioning member 640 will be showing after it is installed into the female positioning member 642. The female positioning member is shown in the depicted embodiment as a nut, but female positioning member 642 can be any female component that interfaces with male positioning member 640.

[0070] In the depicted embodiment, the mounting plate 510 is installed under a moisture barrier 128 that substantially covers the plywood substrate 126. In embodiments that utilize a concrete embedded flush-fascia post mounting system 500 or a concrete embedded offset-fascia post mounting system 600 installed under the moisture barrier 128, additional measures are generally taken to ensure that the brackets do not allow for moisture to leach down to the plywood substrate 126 from the concrete floor 136. Such measures can include adding a sealant to the bottom surface of the mounting plate 510, adding a rubberized sealing washer to the fasteners 120, which secure the mounting plate 510 to the underlying floor, or any other method that substantially prevents seepage of moisture from the concrete floor 136 into the plywood substrate 126. However, those of skill in the art would recognize that the moisture barrier 128 can alternatively be placed on top of the concrete embedded flush-fascia post mounting system 500 or concrete embedded offsetfascia post mounting system 600.

[0071] FIG. 14 illustrates a rear side perspective cross sectional view of a concrete embedded offset-fascia post mounting system 600 that has been fully installed. The system 600 is fully embedded within the cured concrete and is ready to accept the rail post 134. FIG. 15 illustrates a front profile view of a rail panel 111 coupled to a pair of rail posts 134. The rail panel 111 may or may not contact the concrete floor 136 directly.

[0072] Although embodiments of concrete embedded post anchor systems, apparatus, and method have been described in detail, those skilled in the art will also recognize that various substitutions and modifications may be made without departing from the scope and spirit of the appended claims.

[0073] In the foregoing description of certain embodiments, specific terminology has been resorted to for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes other technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as “left” and right”, “front” and “rear”, “above" and “below” and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

[0074] In this specification, the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of’. A corresponding meaning is to be attributed to the corresponding words “comprise”, “comprised” and “comprises” where they appear.

[0075] In addition, the foregoing describes some embodiments of the disclosure, and alterations, modifications, additions and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive. [0076] Furthermore, the disclosure is not to be limited to the illustrated implementations, but to the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the disclosure. Also, the various embodiments described above may be implemented in conjunction with other embodiments, e g., aspects of one embodiment may be combined with aspects of another embodiment to realize yet other embodiments. Further, each independent feature or component of any given assembly may constitute an additional embodiment.

Claims

WHAT IS CLAIMED IS:

1. A railing system, comprising: a first support post spaced apart from a second support post; a rail panel supported by the first and second support posts; a first mounting anchor and a second mounting anchor, each of the first and second mounting anchors comprising a standoff member defining a threaded bore, the threaded bores configured to receive respective post fasteners extending through a base of the first support post; a first threaded shaft coupled to the first mounting anchor and a second threaded shaft coupled to the second mounting anchor, the first threaded shaft securing the first mounting anchor to a framing member and the second threaded shaft securing the second mounting anchor to the framing member; and wherein each of the first and second mounting anchors are at least partially embedded within a concrete floor.

2. The railing system of claim 1, wherein each standoff member has an outer hex shape and is integral with the first and second threaded shafts respectively.

3. The railing system of claim 1, wherein each standoff member further comprises a height, the height configured such that an upper surface of the standoff member is substantially flush with an upper surface of the concrete floor.

4. The railing system of claim 1, wherein the first threaded shaft is a portion of a lag bolt and the first mounting anchor further comprises a body from which the standoff member extends, the body defining a slot and inner surfaces, the inner surfaces configured to engage a head of the lag bolt.

5. The railing system of claim 1, wherein the standoff member further includes a hex shaped outer profile.

6. The railing system of claim 1, wherein each mounting anchor has an inner profile that is configured to engage with a head of a deck fastener.

7. The railing system of claim 6, wherein the head of the deck fastener has a hex shaped outer profile.

8. The railing system of claim 1, further comprising a moisture barrier positioned about the outer surface of each mounting anchor.

9. A post mounting system, the system comprising: a mounting plate supporting a plurality of standoff members, each defining a threaded bore, the threaded bores configured to receive respective post fasteners extending through a base of a support post; and the mounting plate defining a plurality of through holes.

10. The post mounting system of claim 9 further comprising a plurality of deck fasteners configured to be received through the plurality of through holes to secure the mounting plate to a framing member.

11. The post mounting system of claim 9, wherein each standoff member further comprises a height, the height configured such that an upper surface of the standoff member is substantially flush with an upper surface of concrete.

12. The post mounting system of claim 9, wherein each standoff member further includes a hex shaped outer profile.

13. The post mounting system of claim 9 further comprising positioning portions to position the standoff members a predetermined distance from a deck frame.

14. The post mounting system of claim 9, further comprising a rail post coupled to the plurality of standoff members.

15. The post mounting system of claim 9 wherein the mounting plate further comprises a plurality of standoff mounting holes configured to mount ones of the respective standoffs at multiple positions to accommodate multiple post base sizes.

16. The post mounting system of claim 15 further comprising a plurality of standoff mounting members, each securing a respective standoff member to the mounting plate.

17. The post mounting system of claim 9 further comprising a plurality of thread protectors, each covering a respective threaded bore.

18. A railing post mounting system, comprising: a first support post spaced apart from a second support post; a rail panel supported by the first and second support posts; a first mounting anchor and a second mounting anchor each secured to the first support post, each of the first and second mounting anchors, comprising: a body portion having a bottom surface and inner surfaces, a standoff extending from the body portion and having outer surfaces configured to receive a fastening tool, the standoff further comprising a threaded bore; wherein the bottom surface defines a slot configured to receive a shaft of a fastener; wherein the inner surfaces are configured to engage with a head of the fastener; and wherein the standoff has a height to position an upper most surface generally level with a surface of concrete.

19. The railing post mounting system of claim 18, wherein each mounting anchor is configured to be coupled to the deck by the respective fastener.

20. The railing post mounting system of claim 18 further comprising a plurality of thread protectors, each covering a respective threaded bore.