Method and Device for Pre-Casting Conduit Holes in Building Foundations

Abstract

A method of constructing multiple conduits in building foundations that eliminates the process of core drilling after the foundation has been poured and set. This method creates optional openings for possible future connections. The process uses removable conduit molds installed before the foundation is poured. Once the foundation has set, conduit molds are removed to explose conduits in the foundation as needed.

1 . A construction system for pre-casting conduit holes in a building foundation, the system comprising:
 a plurality of concrete molds installed around the building foundation, wherein the plurality of concrete molds are configured to support a poured foundation concrete mix;   a plurality of lightweight conduit molds installed within the plurality of concrete molds at locations designated for conduits within the building foundation;   wherein each conduit mold comprises a unitary cylindrical bar, a cylindrical central ring surrounding the cylindrical bar, and a rubber surface on each end of the cylindrical bar;   wherein the foundation concrete mix is poured in the plurality of concrete forms around the plurality of conduit molds and sets;   wherein the plurality of concrete forms are removed, and the rubber surfaces on each end of each cylindrical bar are substantially flush with an interior and exterior wall of the building foundation; and   removing the conduit mold from the building foundation to open a conduit hole, and installing a conduit within the conduit hole in the foundation wall.   
     
     
         2 . The system of  claim 1 , wherein the conduit mold is removed from the foundation wall through drilling. 
     
     
         3 . The system of  claim 1 , wherein the conduit mold is removed from the foundation wall through melting with an acetone based solution. 
     
     
         4 . The system of  claim 1 , wherein the conduit mold remains in the foundation wall indefinitely without substantially destabilizing the foundation wall. 
     
     
         5 . The system of  claim 1 , wherein the conduit hole is a conduit for the group of lines consisting of power lines, low voltage lines, cable lines, telephone lines, water supply, sewage, line sets condensers, heat pumps, or any other utility line. 
     
     
         6 . The system of  claim 1 , wherein the rubber ends of the conduit mold provide a substantially water tight seal on the the foundation until the conduit mold is removed. 
     
     
         7 . The system of  claim 1 , wherein the conduit mold is composed of a material selected from the group of consisting of high density Styrofoam, Polystyrene Foam (both EPS and XPS), Polystyrene Plastic, Polystyrene Film, Polyisocyanurate ISO, Polyvinyl Chloride(PVC), Chlorinated Polyvinyl Chloride (CPVC), Unplasticide Polyvinyl Chloride(UPVC), Natural Isoprene, Ethylene Propylene Diene (EPDM), Nitrile Rubber (NBR), Styrene Butadiene Rubber (SBR), Silicone Rubber, Butyl Rubber, Polybutadiene, Aflas, Hypalon Rubber, Epichlorohydrin Rubber, Polyurethane, Polyethylene, lightweight solid wood, plywood, and fire retardant foams. 
     
     
         8 . The system of  claim 1 , wherein the cylindrical bar of the conduit mold comprises diameters of 1.5 to 58 inches. 
     
     
         9 . The system of  claim 1 , wherein the cylindrical bar of the conduit mold comprises lengths of 4 to 48 inches. 
     
     
         10 . A method for pre-casting conduit holes in a building foundation, the method comprising:
 a) installing a plurality of concrete molds around the building foundation, wherein the plurality of concrete molds are configured to support a poured foundation concrete mix;   b) installing a plurality of lightweight conduit molds within the plurality of concrete molds at locations designated for conduits within the building foundation, wherein each conduit mold comprises a unitary cylindrical bar, a cylindrical central ring surrounding the cylindrical bar, and a rubber surface on each end of the cylindrical bar;   c) pouring the foundation concrete mix in the plurality of concrete forms around the plurality of conduit molds;   d) setting the foundation concrete mix;   e) removing the plurality of concrete forms, wherein the rubber surfaces of each cylindrical bar are substantially flush with an interior and exterior wall of the building foundation;   f) removing the conduit mold from the building foundation to open a conduit hole; and   g) installing a conduit within the conduit hole in the building foundation.   
     
     
         11 . The method of  claim 10 , wherein the conduit mold is removed from the foundation wall through drilling. 
     
     
         12 . The method of  claim 10 , wherein the conduit mold is removed from the foundation wall through melting with an acetone based solution. 
     
     
         13 . The method of  claim 10 , wherein the conduit mold remains in the foundation wall indefinitely without substantially destabilizing the foundation wall. 
     
     
         14 . The method of  claim 10 , wherein the conduit hole is a conduit for the group of lines consisting of power lines, low voltage lines, cable lines, telephone lines, water supply, sewage, line sets condensers, heat pumps, or any other utility line. 
     
     
         15 . The method of  claim 10 , wherein the rubber ends of the conduit mold provide a substantially water tight seal on the the foundation until the conduit mold is removed. 
     
     
         16 . The method of  claim 10 , wherein the conduit mold is composed of a material selected from the group of consisting of high density Styrofoam, Polystyrene Foam (both EPS and XPS), Polystyrene Plastic, Polystyrene Film, Polyisocyanurate ISO, Polyvinyl Chloride(PVC), Chlorinated Polyvinyl Chloride (CPVC), Unplasticide Polyvinyl Chloride(UPVC), Natural Isoprene, Ethylene Propylene Diene (EPDM), Nitrile Rubber (NBR), Styrene Butadiene Rubber (SBR), Silicone Rubber, Butyl Rubber, Polybutadiene, Aflas, Hypalon Rubber, Epichlorohydrin Rubber, Polyurethane, Polyethylene, lightweight solid wood, plywood, and fire retardant foams. 
     
     
         17 . The method of  claim 10 , wherein the cylindrical bar of the conduit mold comprises diameters of 1.5 to 58 inches. 
     
     
         18 . The method of  claim 10 , wherein the cylindrical bar of the conduit mold comprises lengths of 4 to 48 inches.