Non-Corrosive Form Setting Stake and Permanent Leak-Proof Vapor Barrier Plugging Method

Abstract

A non-corrosive form setting stake and a permanent leak-proof plugging method of using the stake in cases where soil conditions are such that a vapor barrier is required to prevent potentially harmful elements in the soil from escaping and harming anything or anyone above the barrier. The stake comprises a slender elongated body, a wedge-shaped leading end for piercing the earth, a plurality of holes through which nails are driven to attach the form board to the stake, and a trailing end that serves as a striking surface for driving the stake into the ground. In the forming of a slab on grade foundation, a plurality of stakes is driven through the vapor barrier and into the earth in order to hold the form boards in place. Next, a seal is created around the stakes to the vapor barrier. Once the stakes are sealed, each stake acts as a permanent leak-proof plug in the vapor barrier that prevents elements in the soil from escaping through or around the stake. After governing agencies have inspected the vapor barrier and the forms are removed, a top section of the stake is cut off above the stake's sealed portion and below the slab's finished surface. The concrete is then finished with the lower portion of each stake left permanently embedded in the earth and beneath the finished concrete.

1 : A non-corrosive stake, vapor barrier, and sealing material for form setting a slab on grade foundation comprising:
 a) an elongated body formed from a non-corrosive material, said elongated body having an essentially solid cross-section;   b) at least one attachment member positioned along said elongated body;   c) a leading end located at a first end of said elongated body, said leading end adapted for penetrating the a vapor barrier, positioned adjacent the earth, and the earth in a plurality of angular directions;   d) a trailing end located at a second end of said elongated body, said trailing end adapted to serve as a striking surface for driving said leading end of said stake into said earth at the plurality of angular directions; and   e) a surface portion on said elongated body adapted for contact with the sealing material coating located on said surface portion and/or said vapor barrier, said sealing material adapted for permanently sealing at least a portion of the elongated body to the vapor barrier to prevent elements in the soil from escaping through a penetration point caused by penetration of said leading end through the vapor barrier.   
     
     
         2 : The non-corrosive stake of  claim 1 , wherein the elongated body, the leading end, and the trailing end are formed from a plastic material. 
     
     
         3 : The non-corrosive stake of  claim 1 , having a diameter of approximately 1.5-4 centimeters. 
     
     
         4 : The non-corrosive stake of  claim 1 , having an approximately cylindrical shape. 
     
     
         5 : The non-corrosive stake of  claim 1 , wherein the leading end has a pointed end. 
     
     
         6 : The non-corrosive stake of  claim 1 , wherein the non-corrosive stake is formed from a material adapted to be cut at a predetermined location. 
     
     
         7 : The non-corrosive stake of  claim 1 , wherein the attachment member for securing a form board to said non-corrosive stake comprises at least one hole. 
     
     
         8 : The non-corrosive stake of  claim 1 , wherein the non-corrosive stake is adapted for acting as a permanent leak-proof plug to prevent elements in the soil from escaping and is formed from a single piece of non-corrosive material. 
     
     
         9 : The non-corrosive stake of  claim 1 , wherein the non-corrosive stake is configured to be cut such that the leading end of the non-corrosive stake remains permanently embedded in said earth and within a slab on grade foundation. 
     
     
         10 : The non-corrosive stake of  claim 1 , wherein the non-corrosive stake is configured to be driven into the earth at a 45 degree angle. 
     
     
         11 : A method for supporting forms in the construction of a slab on grade foundation comprising providing a plurality of non-corrosive elongated stakes as defined in  claim 1  and securing the plurality of non-corrosive elongated stakes to a plurality of form boards. 
     
     
         12 : The method of  claim 11 , comprising providing a vapor barrier adjacent to the earth and driving the plurality of non-corrosive elongated stakes through the vapor barrier and the earth. 
     
     
         13 : The method of  claim 12 , comprising providing a sealing material on a surface of the vapor barrier and driving the plurality of non-corrosive elongated stakes through the sealing material to permanently seal at least a portion of the elongated body to the vapor barrier and to prevent elements and vapors in the soil from escaping through a penetration point caused by penetration of the elongated stakes through the vapor barrier. 
     
     
         14 : The method of  claim 12 , wherein the driving of the leading ends of the non-corrosive elongated stakes into the earth comprises driving at least one of the non-corrosive elongated stakes at the angular direction not perpendicular with respect to a planar surface of the earth such that the at least one of the non-corrosive elongated stakes is positioned in the earth at an angular direction not perpendicular with respect to a planar surface of the earth. 
     
     
         15 : The method of  claim 12 , comprising driving the non-corrosive elongated stakes into the earth such that at least one of the non-corrosive elongated stakes is perpendicular to the form boards and at least a second non-corrosive elongated stake rests at approximately a 45 degree angle to the form boards. 
     
     
         16 : The method of  claim 11 , comprising providing a wedge-shape to the leading ends of the non-corrosive elongated stakes to reduce twisting of the non-corrosive elongated stakes while being driven into the earth.