AU2005200682B1 - An Improved Fastening System - Google Patents
An Improved Fastening System Download PDFInfo
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- AU2005200682B1 AU2005200682B1 AU2005200682A AU2005200682A AU2005200682B1 AU 2005200682 B1 AU2005200682 B1 AU 2005200682B1 AU 2005200682 A AU2005200682 A AU 2005200682A AU 2005200682 A AU2005200682 A AU 2005200682A AU 2005200682 B1 AU2005200682 B1 AU 2005200682B1
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- top hat
- fastener
- concrete
- slab
- flange
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Description
An Improved Fastening System Field of the Invention.
This invention is directed to a fastening system, and is particularly directed to a
(N
00 fastening system to fasten a sliding window or sliding door on a support the support being fastened to a concrete surface. The invention is particularly directed to the C manner by which the support (which can also be called a top hat) is attached to the Sconcrete surface, and the invention is also particularly directed to a novel type of top 10 hat.
Background Art.
In the building industry, and particularly in the high-rise building industry, it is necessary to fit sliding doors which open up onto a balcony. It should be appreciated that in a high-rise, there may be hundreds of such doors to fit in place.
These doors can be quite large and quite long and it is typical for a door arrangement to have a length of between 1.5-8 metres and comprising at least one sliding door but sometimes two or more sliding doors.
Typically, the high-rise will contain a concrete internal floor and the balcony will comprise a concrete slab extension but the balcony will be spaced below the interior concrete floor, typically between 50-150 millimetres to provide a step up and therefore to prevent water from entering into the room.
The door assembly is not fitted to the interior concrete floor but is instead fitted indirectly to the balcony floor. The door assembly cannot be attached directly to the balcony floor as this will cause the door assembly to not be substantially flush with the internal slab. Therefore, it is necessary to pour a small concrete footing on top of the balcony slab which is sufficiently wide to accommodate the width of the door assembly. This small concrete footing does not come to the height of the interior concrete floor but instead is stepped down by a small distance such that when the door (assembly is fitted, the bottom door track will be substantially flush with the internal floor and therefore not present a tripping hazard. This step down is typically between S5-50 millimetres.
Once the concrete footing has been poured, it is usually a requirement to provide a 00 waterproof membrane. A metal sub sill is then fitted to the concrete footing, the sub sill typically comprising a thin extruded aluminium plate that is in a particular C configuration. The door frame is then fixed on top of the sub sill. The sub sill functions as a gutter to drain the water away from the bottom of the door frame.
-i It should be appreciated that the door assembly comprises a surround frame which is often known as a KDC frame, formed of aluminium extrusion and is exactly rectangular. Therefore, any irregularity in the concrete footing will affect the correct fitting of the door frame.
In practice, the concrete footing is poured by the concreting contractor while the door is fixed by a door and window or contractor. Often, the concrete footing is not poured correctly and is not exactly level or square. For instance, it is common for the footing to slope the wrong way, to be chipped, to have parts missing, to not be smooth on the top and the like.
For this reason, it is also known to provide a three millimetre galvanised metal member that approximates an inverted channel which is substantially frusto-conical, and which functions as the footing on which the door (or more correctly, initially the sub sill is fixed. The advantage of this metal member (which is sometimes known as a top hat) is that it provides a consistent support for the door.
The top hat typically has a length of about 100 millimetres and a height such that the top of the top hat is slightly below the interior floor level. A pair of spaced apart top hats is then fixed to the balcony concrete floor and the door frame can be fitted to the top hats. If desired, concrete can then be poured between the top hats to fill the gap, or alternatively a metal skirt can be fitted in place.
The present invention is directed to a better manner by which the top hats can be fixed 4to the balcony concrete.
Conventionally, the top hat is fixed to the concrete by a shot nail. To explain, a shot
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00 nail is a concrete nail that is shot from a gun using a powder charge. However, it has not been entirely successful to properly fit the top hat to the balcony concrete slab by I firing a concrete nail through the top hat. In practice, in order to shoot the nail Sthrough the three millimetre thickness of the top hat, the force has to be quite large C, 10 and it also results in concrete blowing out. This, in turn, results in incomplete or improper fixing of the top hat. To compensate, the door fitting person will shoot too many nails into the concrete in order to ensure fixing.
The use of the shoot down nails however is a much quicker and much more convenient manner to fix a metal member to a concrete slab. The alternative is to drill holes into the concrete slab and then to fit DYNABOLTS, which would be extremely time-consuming and labourious.
Therefore, there would be an advantage if it were possible to fasten the top hat to the concrete slab using a shoot down fastener, but in a manner that would reduce the need for excessive use of nails to compensate for the blowing out of concrete.
It will be clearly understood that if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.
Object of the Invention.
It is an object of the invention to provide a fastening system and particularly a fastening system to fasten a top hat to a concrete slab and which would overcome at least some of the above-mentioned disadvantages or provide a useful or commercial choice.
(In one form, the invention resides in a method for fastening a top hat to a concrete slab, the method comprising providing a top hat of the type which contains at least one opening through which the fastener can pass, marking the concrete slab to show where the openings would lie once the top hat is in position, shooting a particular type of fastener into the concrete, the fastener being of the type having a nail type body and
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OO a threaded head, passing the top hat over the threaded heads of the fasteners that have 0 been shot into the concrete, such that the threaded heads pass through the openings in I the top hat, and then locking the top head to the fastener by the use of nuts which Oengage with the threaded heads of the fasteners.
Thus, the present invention does not require the fastener to be shot through the wall of the top hat, but still retains the advantage of a shoot down fastener as opposed to a DYNABOLT type fastener. This reduces the incidence of concrete blowout. By providing a particular type of fastener with a threaded head, and by having the top hat formed with openings, the top hat can then be placed over the fasteners such that the threaded heads pass through the openings, and nuts can then be tightened to hold the top hat securely in place with a minimum of fasteners.
The particular type of fastener may comprise an M6 fastener which is commercially available under the trade mark RAMSET. This type of fastener comprises a main nail-like body that is strong enough to be shot into the concrete, and contains a threaded head.
The top hat may comprise a metal member having a particular configuration which can function to be substituted for the concrete footing. This type of metal member is available in the marketplace. One particular type of top hat is an inverted frustoconical member comprising galvanised steel having a wall thickness of approximately three millimetres, although it should be appreciated that no particular limitation should be placed on the invention merely by describing this particular type of top hat, and it is considered that members having configurations other than described above and which can be used as a substitute for a concrete footing may fall within the definition of "top hat".
The top hat may have a length of between 50-500 millimetres and will typically have a length of approximately 100 millimetres. Therefore, to support a door assembly, it is usually necessary to provide two or more top hats that are spaced apart.
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00 In another form, the invention resides in a top hat to support a sliding door or window onto a slab or other suitable floor, the top hat having a top wall, a pair of sidewalls, optionally each side wall having a substantially horizontal extending flange, and a part which is intermediate the sidewalls and which is at, or closely adjacent, the slab/floor 10 in use the part containing an opening to enable a fastener to attach the top hat to the slab/floor.
The top hat may comprise a top wall, a pair of sidewalls that diverge outwardly to define a frusto-conical shape, or which are substantially parallel to define a substantially inverted U-shaped configuration, and a pair of extending substantially horizontal flanges on the lower end of each side wall.
Each flange may extend outwardly relative to the side wall, inwardly relative to the side wall or one flange may extend outwardly and one flange may extend inwardly.
For convenience, it is envisaged that both flanges will either extend outwardly or both flanges will extend inwardly.
The top hat will typically contain at least one opening to enable it to be attached to the particular type of fastener that forms part of the present invention.
In one form, the top hat will contain an extended flange and at least one opening is provided in the flange to enable a fastener to pass through the opening.
In another form, the top hat will contain a part that extends between the flanges and which is adjacent the floor and which contains an opening to enable a fastener to pass through the opening.
SThe part may comprise a strip portion that contains a horizontal part or zone that is adjacent the floor and which contains an opening.
The part may further comprise a pair of upwardly extending wall portions that connect to the, or each, side wall of the top hat.
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00 INDI oO In a particularly preferred embodiment of the invention, the part may be pressed from N, the remainder of the top hat. Thus, the top hat may be perforated or cut and this Sperforated or cut portion forms the particular part in question. This will be described C 10 in greater detail below.
The part may be provided at one end of the top hat, or at each end of the top hat, or intermediate the ends of the top hat, or any combination thereof.
An advantage of this particular configuration is that the top hat can now be fastened at the position which is between a position of the outwardly extending flanges.
The top wall may be rectangular when viewed in plan. Each side wall may be rectangular when viewed in plan. Each flange may be rectangular when viewed in plan. The top wall may have a width of between 50-300 millimetres and will typically have a width which is large enough to enable the door frame to be attached relative to the top wall. Each side wall may have a height of between 50-200 millimetres, and the height will depend on the "step up" distance between the balcony floor and the internal floor. The flange may have a width of between 5-50 millimetres and will typically have a width of between 5-20 millimetres. As mentioned previously, the entire top hat may have a length of between 50-500 millimetres and will typically have a length of approximately 100 millimetres. Also as mentioned previously, the top hat may be formed of three millimetre galvanised steel although it should be appreciated that no particular limitation is meant thereby, and the top hat may be made of materials other than galvanised steel such as different types of metals, plastics, composite materials and the like, and may have a thickness other than three millimetres, although for reasons of economy, it is considered that galvanised steel (will be the most suitable.
The top hat is provided with at least one, and preferably two or more, openings through which the particular type of fastener can pass. These openings may be preformed in the top hat, or may be formed afterwards, and will typically comprise
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oo small round openings having a diameter of between 3-10 millimetres and typically 0 between 4-8 millimetres such that the fastener can pass through the opening without i the fastener needing to "punch" through the metal.
10 The fastener, as mentioned previously, may comprise a commercially available fastener having a nail-type body that can be shot into concrete, and a threaded head.
In a broad form of the invention, the fastener may comprise a body portion that can be shot into concrete and therefore that will typically comprise a nail type body, and a head portion that is threaded but may also be otherwise configured to enable it to pass through the opening in the top hat and which will enable the top hat to be fastened to the fastener.
Although it is considered that a thread will be quite suitable as this can enable a nut to attach the top hat to the fastener, it is envisaged that the fastener may comprise other configurations that can achieve a similar result. For instance, the fastener may be provided with some form of lock arrangement that enables the top hat to be snap locked to the fastener. Alternatively, the fastener may comprise some form of toggle that can pass through the opening in the top hat and then enables the toggle to be moved to a position where the top hat can no longer be removed from the fastener.
In another form of the invention, there is provided a system that has a top hat as described above, and which is adapted to be fastened to a balcony slab, or some other floor portion, a sill that is attached to the top hat, typically by fasteners, and a flashing that is provided on the at least part of the side wall of the top hat that faces the balcony slab (and which will be tiled or otherwise covered), the flashing containing a turned out horizontal flange that can act as a levelling and position indicator for the tiles on the balcony.
To explain, bedding tiles on the balcony slab can be quite a fiddly procedure if there is
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not a level that can be used. Typically, the tiles are bedded into a grout.
00 With the above system, the top hat now enables, for the first time, an easily achievable
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level to be provided. Consequently, when the flashing is attached to the top hat and Ci or/sill, the flashing is also level. Thus, the turned out flange of the flashing will Spresent a good horizontal level which can be used for screeding grout. Previously, CI 10 this has been a time-consuming and fiddly procedure.
Brief Description of the Drawings.
Embodiments of the invention will be described with reference to the following drawings in which: Figure 1 illustrates a top hat according to an embodiment of the invention.
Figure 2 illustrates a conventional concrete support to which a KDC frame is fitted.
Figure 3 illustrates a particular type of fastener that forms part of the present invention and which contains a threaded head.
Figure 4 illustrates a top hat that can be used in place of the conventional top hat support and to which a KDC frame is fitted.
Figure 5 illustrates a slightly different top hat design.
Figure 6 illustrates a modified top hat design having a pressed down part formed with an opening to enable the top hat to be attached to a slab (typically a balcony slab).
Figure 7 illustrates an embodiment of a system containing the top hat, a sill, and flashing, the flashing having a turned out horizontal flange to provide a good level indicator for tiling on the balcony slab.
Figure 8 illustrates a plan view of a top hat having two press down parts, one on each end of the top hat.
Figure 9 illustrates a plan view of a different type of top hat having three press down parts, one on each end of the top hat, and one intermediate the ends of the top hat.
Figures 10-12 illustrates a perspective view, a bottom view, and a side elevation view of a top hat generally as illustrated in figure 6.
Figure 13 illustrates a top hat having inwardly directing flanges as opposed to outwardly directing flanges.
Best Mode.
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oO Referring to figure 1, there is illustrated a top hat. The top hat 10 is made of three millimetres galvanised steel and comprises a substantially horizontal rectangular top wall 11, a pair of outwardly diverging sidewalls 12 and a pair of substantially Shorizontal flanges 13. The top wall roughly defines an inverted frusto-conical shape.
10 The top wall has a length of approximately 100 millimetres which results in its name as a "top hat".
Each flange 13 is provided with openings 14 (only one opening illustrated in figure 1) through which fasteners 15 (see figure 3) can pass to connect the top hat to a slab.
Figure 2 illustrates a conventional arrangement. Figure 2 illustrates an internal concrete slab floor 16 and a balcony slab floor 17 which is lower than the internal slab floor 16 to define a vertical step up 18 which is typically between 50-200 millimetres.
A concrete support 19 is poured on the balcony floor 17 and adjacent the step up 18, and the concrete support 19 terminates just below the level of the internal slab 16.
The concrete support 19 is usually waterproofed by a membrane (not illustrated).
Afterwards, an aluminium extruded sub sill 20 is fastened to the top of the concrete support 19. A door assembly and typically a door frame such as a KDC frame 21 is attached to sub sill 20 using TEK screws. This arrangement is quite conventional but suffers from the disadvantage that the concrete support 19 is not always poured correctly.
The sub sill 20 functions to drain water out of the lower horizontal frame member of the door assembly, basically by slightly spacing the lower frame member of the door assembly from the lowermost wall of the sub sill. The sub sill 20 is a known product.
More recently, the concrete support 19 has been less used and instead a top hat 10 is placed on the balcony floor 17 and is attached to the balcony floor 17.
Conventionally, this is done using concrete nails shot from a gun (not illustrated), and the concrete nails are simply punched through the flange 13 and into the balcony concrete slab. This is not entirely successful for the reasons described previously.
(N
00 The present invention is directed to the use of a slightly modified top hat and a particular type of fastener, the fastener being illustrated in figure 3. The top hat will Ci typically be as described above with the modification that in each flange 13 is provided one or more preformed openings 14 into which the modified fastener is C 10 illustrated in figure 4 can pass. The fastener comprises a substantially nail-like main body portion 25 that is adapted to be shot into the concrete using a gun, and has a threaded head portion 24 that can accommodate a nut 26.
In use, it will be necessary to mark on the balcony slab where the openings 14 will be.
Typically, the top hat position can be determined and a pencil can be pushed through each opening 14 to mark the balcony slab. The top hat can then be removed. The particular type of fastener illustrated in figure 3 can then be shot into the concrete using a gun which is much more efficient than the use of DYNABOLTS. Once the fastener has been shot into the concrete, they will present a threaded head portion 24 which will be above the concrete slab. The top hat can then be replaced such that the threaded head portions 24 pass through the openings in the top hat. Nuts 26 can then be used to securely fasten the top hat to the balcony slab via the fasteners. Washers/ spring washers can also be utilised.
Additionally, it is possible to add spacing members (packers) between the top hat and the balcony floor to position the top hat in exactly the right place. These spacing members may be made of plastic/neoprene etc and will typically have a thickness of between 1-5 mm, although it is possible to have spacing members which might be up to 20 mm in thickness.
Figure 5 illustrates another top hat 30 which is quite similar to the top hat described previously and again which contains a top wall 31, a pair of opposed parallel sidewalls (Z 32, each side wall containing a horizontal outwardly extending flange 33. This top hat can be perforated and cut to form a novel top hat design, one version of which is illustrated in figure 6.
In figure 6, there is illustrated a novel top hat design where one end of the top hat has
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00 been perforated and pressed down to form a part 34 that enables the top hat to be attached to the concrete floor other than via the flanges 33 which is illustrated in the Ci previous embodiment. Part 34 contains a horizontal floor portion 35 that contains an Sopening 36 through which a fastener that has been described previously can pass.
10 Floor portion 36 is connected to a pair of upwardly extending and outwardly diverging wall portions 37 that connects to, and are bent from, each side wall 32. With this novel top hat, the top hat can now be attached through opening 36 which is different to that described in the previous embodiment where the opening is through flange 33.
It should be appreciated however that the top hat as described in figure 6 may also contain openings through flange 33 as well as opening 36, should this be desired.
In practice, the concept of the pushed down part 34 need not be limited to one end of the top hat illustrated in figure 6. Thus, figure 8 illustrates a plan view of a top hat which has a pressed down part on each end of the top hat and therefore contains two openings 36.
In figure 9, there is illustrated another design of the top hat that now contains three pressed down parts 34 to contain three openings 36.
Figure 7 illustrates a system that has various advantages. The system contains a top hat 40 which may be of either design described above and which again contains a top wall 31, a pair of sidewalls 32 and outwardly extending flanges 33. In this particular embodiment, the top hat is fastened using the pushed down portion 34 which contains opening 36 to accommodate the fastener A sill 37 can be attached to top wall 31 in the normal manner, this sill having a vertically depending terminal flange 38. A flashing 39 can be fitted to the sill/top hat to provide waterproofing, and the flashing 39 has a lower extending horizontal flange Because the top hat 40 can be positioned almost exactly level (that is the top wall 31
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00 will be almost exactly level), flashing 39 can also be attached such that flange 40 is horizontal. The flashing can be attached such that flange 40 is positioned above the balcony concrete slab 41 by a precise distance to correspond to the thickness of grout S42 that will be poured onto slab 41 and into which tiles (not illustrated) will be fitted.
C-i Thus, after the grout has been poured, the flange 40 can be used as a level for screeding the grout level. This will provide an advantage to the entire assembly arrangement.
Figures 10-12 illustrate a top hat design generally as described above, but it should be appreciated that no particular limitation should be placed on the invention merely by illustrating this particular type of top hat design.
Figure 13 illustrates a top hat design where the flanges extend inwardly instead of outwardly. It should be appreciated that the top hat may also contain one inwardly extending flange and one outwardly extending flange should this be considered desirable.
The system is superior to the use of conventional nails that need to be shot through the flange in the top hat and which has the disadvantage as described previously. It is found that the particular fastener that can attach the top hat using a nut creates a vastly superior force of attachment which means that much fewer fasteners will be required than hitherto possible. The attachment force can approximate that of a DYNABOLT without needing to predrill holes in the concrete.
The invention provides a large number of benefits. Firstly, it is no longer necessary to pour a concrete footing (hob) onto which the door/window will be supported, as the top hat can now replace the concrete footing. This provides enormous advantages in the timing to install doors/windows especially in high-rise buildings. There is a large cost saving in not needing to pour the concrete footing, and all the problems with concrete footings (which have been described previously) are now overcome. These problems include curing time, capillary action through the concrete, the need to
(N
00 waterproof the concrete, the need to patch the concrete, the need to often cut the N concrete to get the levels right and the like.
tc-I OThe top hat provides a water barrier and therefore there is less penetration of water N1 10 into the inside of the building.
In the system illustrated in figure 7, there is a large time-saving in tiling the balcony slab because of the level provided by the arrangement that includes the flashing 39. It is no longer necessary to provide an upstanding tile to provide a level (it being appreciated that the upstanding tile often needs to be cut in half to provide the proper height, and this is a time-consuming process and not very accurate).
Throughout the specification and the claims (if present), unless the context requires otherwise, the term "comprise", or variations such as "comprises" or "comprising", will be understood to apply the inclusion of the stated integer or group of integers but not the exclusion of any other integer or group of integers.
Throughout the specification and claims (if present), unless the context requires otherwise, the term "substantially" or "about" will be understood to not be limited to the value for the range qualified by the terms.
It should be appreciated that various other changes and modifications can be made to any embodiment described without departing from the spirit and scope of the invention.
Claims (15)
1. A method for fastening a top hat to a concrete slab, the method comprising providing a top hat of the type which contains at least one opening through which a fastener can pass, marking the concrete slab to show where the at (N 00 least one opening would lie once the top hat is in position, shooting a particular type of fastener into the concrete, the fastener being of the type having a nail type body and Ci a threaded head, passing the top hat over the threaded head of the fastener that has Sbeen shot into the concrete, such that the threaded head passes through the opening in 10 the top hat, and then locking the top head to the fastener by the use of a nut which engages with the threaded head of the fastener.
2. The method as claimed in claim 1, comprising a plurality of fasteners, and where the top hat is provided with a plurality of openings through which the fasteners can pass.
3. The method as claimed in claim 1, or claim 2, wherein the fastener is a M6 type fastener (as hereinbefore described).
4. The method of any one of the preceding claims, wherein the top hat has a length of between 50-500mm, a width of between 50-400mm and a height of between 50-400mm.
The method as claimed in any one of the preceding claims, wherein the top hat comprises a substantially horizontal top wall, a pair of sidewalls depending from the top wall to define a substantially inverted U shaped configuration, each side wall having an extending substantially horizontal flange, the flange adapted to sit on the concrete, the at least one opening being provided in the or each flange.
6. The method as claimed in any one of claims 1-4, wherein the top hat comprises a substantially horizontal top wall, a pair of sidewalls depending from the top wall to define a substantially inverted U-shaped configuration, each side wall Shaving an extending substantially horizontal flange, the top hat having a part that extends between the flanges and which is adjacent the floor and which contains an opening to enable the fastener to pass through the opening.
7. The method as claimed in claim 6, wherein the part comprises a lower 00 horizontal part adjacent the floor, and upwardly extending wall portions that connects to the, or each side wall of the top hat, the lower horizontal part containing the CI opening. C 10
8. The method as claimed in claim 7, wherein the part is pressed from the remainder of the top hat.
9. The method as claimed in any one of claims 6-8, wherein the top hat comprises two or more said parts.
A method for installing a top hat as described in any one of the preceding claims, wherein the concrete slab is a balcony slab, the method comprising attaching the top hat to the balcony slab, attaching a still to the top hat, attaching a flashing that is that is provided on at least part of the side wall of the top hat that faces the balcony slab (and which will be tiled or otherwise covered), the flashing containing a turned out horizontal flange that can act as a levelling and position indicator for the tiles on the balcony.
11. A top hat to support a sliding door or window onto a slab or other suitable floor, the top hat having a top wall, a pair of sidewalls, optionally each side wall having a substantially horizontal outwardly extending flange, and a part which is intermediate the sidewalls and which is at, or closely adjacent, the slab/floor in use, the part containing an opening to enable a fastener to attach the top hat to the slab/floor.
12. A method as claimed in any one of claims 1-9 substantially as hereinbefore described.
13. A top hat as claimed in claim 11 and substantially as hereinbefore Sdescribed and as illustrated. \D
14. A top hat as claimed in claim 5 or claim 6, where each flange extends (N OO outwardly relative to the side wall. NO C
15. A top hat as claimed in claim 5 or claim 6 where each flange extends Sinwardly relative to the side wall. 0 (N DATED this 16 th day of February 2005 G G Aluminium Glass Installations Pty Ltd By its Patent Attorneys Cullen Co.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2005200682A AU2005200682B1 (en) | 2005-01-24 | 2005-02-16 | An Improved Fastening System |
Applications Claiming Priority (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2005900273 | 2005-01-24 | ||
| AU2005900273A AU2005900273A0 (en) | 2005-01-24 | A Fastening System | |
| AU2005900471A AU2005900471A0 (en) | 2005-02-03 | An Improved Fastening System | |
| AU2005900471 | 2005-02-03 | ||
| AU2005200682A AU2005200682B1 (en) | 2005-01-24 | 2005-02-16 | An Improved Fastening System |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| AU2005200682B1 true AU2005200682B1 (en) | 2005-05-12 |
Family
ID=34595483
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| AU2005200682A Ceased AU2005200682B1 (en) | 2005-01-24 | 2005-02-16 | An Improved Fastening System |
Country Status (1)
| Country | Link |
|---|---|
| AU (1) | AU2005200682B1 (en) |
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2005
- 2005-02-16 AU AU2005200682A patent/AU2005200682B1/en not_active Ceased
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