This invention relates to modular decking systems.
It is a significant conventional construction project to install a deck or a similar structure such as a dock, boardwalk, or platform, whether it is a permanent installation or a temporary one. The equipment needed to install the conventional deck can be very disruptive to the ground surface affecting the appearance of a lawn or a park or affecting the ecosystem in wetlands. Also, the skill and care needed to precisely place and fasten together the components of the deck is time consuming and costly—especially when equipment must be submerged to reach a stable underground surface. Further adding to the cost and skill required, the deck is often custom built on site.
A modular deck system, such as the one described in U.S. Patent Application, Publication No. 2005/0025465 by Osfolk, allows the deck to be assembled in smaller portions. Pre-manufactured deck modules have the advantage of requiring less on-site assembly. However, such conventional modular or pre-manufactured decks require precise placing of piers or piles and either require significant fastening with screws or bolts, or are not significantly sturdy. Further, pre-manufactured decks tend to be quite heavy and cumbersome with regard to the shipping, handling, and placement of the decks. Even further, the length of time it takes to assemble conventional modules causes delays in the advancement of the equipment along the modules.
Conventional decking systems tend to have relatively weak connections between a wooden joist and a header. Such systems utilize joist hangers that are fastened to the side of a header and to the end of the joist. Such connections to the end of the joist lack significant shear strength and the connection may be a weak point in the system.
Therefore, a modular decking system that has a simple assembly and a minimal impact on the ground surface while being sturdy enough to support foot traffic and light vehicles is desired. Further, a decking system with structurally superior joints over conventional systems in critical areas is desired.
The invention comprises, in one form thereof, a system, method and components for assembling and disassembling boardwalks, decks, bridges, platforms and similar structures (“deck” will be generally used to denote a boardwalk, deck, bridge, platform, or similar structure hereinafter). The invention has a number of extruded and interlocking components. It is installed by driving piles, preferably helical piles, into a ground surface. The invention provides a comprehensive set of assembly members, including and not limited to brackets that attach to the piles, headers, joists, cross braces, decking, and decking fasteners for holding the decking in place. The components of the invention are useful together with each other and also with conventional structural members. In particular, a multiple-way adjustable bracket connects the piles to the rest of the structure. Piles often encounter subsurface impediments and cannot be set at their precise desired locations. The pile bracket adjusts for off-set piles.
More particularly, the invention includes a relatively lightweight modular decking system, comprising a plurality of piles (which may comprise aluminum) having a helical portion configured to be driven into a ground surface; a pile bracket that engages a top end of each of the piles; a plurality of headers, each attached to two of the pile brackets; a plurality of joists each being attached to two of the headers; and a plurality of deck planks that are attached to a top portion of the joists or decking connectors. The pile brackets are adjustable wherein each of the pile brackets are rotatable about a center axis of the pile and translatable along the center axis of the pile. Further, each of the pile brackets include a saddle assembly that is translatable along a slot in the pile bracket in a direction that is substantially perpendicular to the center axis of the pile. The saddle assembly is rotatable about a fastener and is capable of being leveled, such as by a plurality of set screws or a partial ball joint. The deck planks may be attached to the joists by an injection molded connector strip having a plurality of spacer posts separating said deck planks. The connector strip may further include a plurality of clips provided in pairs, wherein the deck planks each include a pair of tabs, and wherein each pair of clips is configured for mating with the pair of tabs on one of the deck planks. The header may include a plurality of joist holders, and the joists may be placed in said joist holders to attach the joists to the headers.
In another form, the invention includes a method for installing a modular deck. The method comprises the steps of driving a first set of helical piles and a second set of helical piles (which may be aluminum) into a ground surface, wherein the piles each have an adjustable pile bracket on a top end of the pile; providing a plurality of headers having a plurality of header brackets; affixing one of the headers to each of the first and second sets of piles via the pile brackets such that the header brackets of the header affixed to the first set of piles are aligned with the header brackets of header affixed to the second set of piles; inserting a joist into each of the aligned header brackets; and placing a plurality of deck planks on the joists. The method may further comprise the steps of driving a third set of helical piles into the ground surface, wherein the piles of the third set each have an adjustable pile bracket on a top end of the piles; affixing a header to the third set of piles via the pile brackets such that the header brackets of the header attached to the third set of piles are aligned with the header brackets of the header attached to the second set of piles; inserting an additional joist into each of the aligned header brackets of the headers attached to the second and third sets of piles; and placing a plurality of additional deck planks on the additional joists. The method may further include installing additional modules as needed. In a temporary application of the decking system, the method includes the further step of disassembling the deck planks from the joists, the joists from the headers, and the headers from the piles, and then removing the piles from the ground surface. A further step of reinforcing the joists with cross-braces may also be included. The step of placing the deck planks may comprise the steps of connecting a plurality of connector strips to one or more of the joists, the connector strips having a plurality of pairs of clips; and, for each of the deck planks, snapping a pair of tabs integral with the deck plank into one of the pairs of clips.
In another form, the invention includes an adjustable decking bracket having multiple degrees of freedom. The bracket comprises a base plate defining a slot; a collar affixed to a bottom surface of the base plate, which is rotatable about a center axis of the collar; a saddle assembly that has a protuberance connected to the base plate by a fastener through the slot; and a vertical adjustment fastener engaging the base plate and a support structure. The saddle assembly may include a plurality of set screws or a hub, such as a partial ball joint, in a saddle base for leveling the saddle assembly relative to the base plate. Further, the saddle assembly is translatable along the slot of the base plate and rotatable about the fastener connecting the protuberance to the slot of the base plate.
In another form, the invention includes an end cap for a plurality of decking planks. The end cap comprises a tube providing a chase-way; a lens-receiving portion on a side of the tube; a connection portion on a bottom surface of the tube, the connection portion being configured to be attached to a frame element. The connection portion may be configured to snap into a groove in a joist. The end cap may include a plurality of lamps within said tube, and it may form an ADA-compliant curb.
In another form, the invention includes a helical pile comprising an aluminum shaft and an inclined plane extending from a portion of the shaft in a helical shape. The inclined plane may be made of aluminum and may be welded to or integral with the shaft. The helical pile may also include a second inclined plane extending from a second portion of the shaft, extensions to add length, or both.
In another form, the invention includes a header for a modular decking system. The header comprises a header beam having a first side and a second side; and a plurality of joist holders welded to or integral with the first side of said header beam. The header beam may be made of extruded metal or structural steel and the header beam and the joist holders may be made of aluminum. Alternatively, the header may be cast or molded material. A second plurality of joist holders may be welded to or integral with the second side of the header beam. The joist holders define a pair of aligned notches for engaging a fastener through an end of a joist to guide the placement of the joist.
In another form, the invention includes a connector strip for affixing deck planks to a joist. The connector strip comprises a base configured for engaging a joist; a plurality of spacer posts projecting upward from the base; and a plurality of pairs of clips, wherein each pair of clips is configured for engaging a pair of tabs associated with a deck plank. The connector strip may further include a first end with a male connector and a second end with a female connector such that the male connector connects to a female connector of another connector strip. The base may be configured for sliding into a groove in an extruded joist. The connector strip may be configured such that no fasteners are required to connect the connector strip to the joist or to connect the deck plank to the connector strip. The connector strip may also be connected to conventional lumber.
It is an advantage of the invention that the boardwalk, deck or platform provides a support for pile installation equipment. As one section of the platform is assembled, the installation machine may advance to the end of the platform to install piles for the next section. The decking system according to the present invention may be rapidly installed and the equipment may advance without stalling for significant periods of time to wait for a new module to be installed. The invention may also be used as a bridge.
The structures made in accordance with the invention may be installed in protected environments, such as wetlands, nature preserves, swamps, marshes and beaches. The installation provides minimal disruption to the environment. The structures may also be installed as decks for home use. In another embodiment the structures may be installed temporarily at a location that needs a hardstand to support a number of people, such as a stage for a band in a park. After the event is over, the structure may be disassembled and removed.
A further advantage of the invention is that the header comprises integral or pre-welded joist holders that have significantly higher shear strength than conventional joist hangers. Thus the header provides an improved long-range structural integrity over conventional systems, which may be compromised at this junction.
The present invention is disclosed with reference to the accompanying drawings, wherein:
d are views of a connector strip;
Corresponding reference characters indicate corresponding parts throughout the several views. The examples set out herein illustrate several embodiments of the invention but should not be construed as limiting the scope of the invention in any manner.
Referring to
Though any bracket may be used to connect the pile 12 to the header 14 (or joists 16), the pile bracket 24 of the present embodiment is adjustable by rotation about the axis of the pile 12, elevation relative to the pile 12, distance from the axis of the pile 12, and rotation about an axis offset from the axis of the pile 12. The pile bracket 24 includes a collar 26, a base plate 28, and a saddle assembly 30. The base plate 28 is supported by the collar 26 and supports 32 that are welded or otherwise affixed to the collar 26 and the base plate 28. A fastener 34 engages a tapped hole in the base plate 28 and is substantially aligned with the axis of the collar 26. A disk 36 having a tapped hole for mating with the fastener 34 is welded or otherwise affixed to the top end 22 of the pile 12. When assembled to the pile 12, the collar 26 and base plate 28 may be rotated about the axis of the pile 12. The collar 26 and base plate 28 also may be raised and lowered in relation to the pile 12 by turning the fastener 34. In alternative embodiments, the collar may be other shapes, such as the square collar shown in
The saddle assembly 30 is best shown in
It should be noted that multiple pile extensions may be coupled together with the piles to allow deeper penetration into the ground surface as may be required by the application.
The header 14 is best shown in
In the case that the joist holders 50 are welded onto the header beam 48, they may be cut from a flat piece of material and bent into the U-shape shown in the figures with a bending break or other machine. An angled notch 54 in each side of the joist holder 50 guides a fastener through the end of the joist 16 to provide proper placement of the joist within the joist holder 50. The fastener is tightened to secure the joist 16 to the header 14 and no other fasteners are required, though additional fasteners may be used.
The joist 16 is a tubular beam similar to the header beam 48, though the joist 16 may have a different length. The cross-section and the end of the joist 16 are shown in
The deck planks 18 are affixed to the joists 16 via a connector strip 60 shown in
The connector strips 60 guide the evenly spaced placement of the deck planks 18 along the joists 16 with spacer posts 70. Each connector strip 60 accommodates several deck planks 18. The deck planks 18 may be any substantially rigid material, such as hard plastic, wood, plastic molded with wood, aluminum, or other materials. In one embodiment, the deck planks 18 have a cross-section as shown in
In an alternative embodiment, the connector strips 60 are fastened to conventional lumber and the deck planks 18 may be affixed atop.
An end cap 76, shown in
A joining strip 86, shown in cross-section in
The joists 16 may be reinforced by cross-brace assemblies 92, shown in
The structural elements of the deck module 10, such as the piles 12, the headers 14, the joists 16, and the cross-brace assemblies 92, are made of aluminum, aluminum alloy, or a similarly strong, lightweight material according to the present embodiment. Further, these components are generally tubular as shown in the figures, to keep the weight of the components down. Other elements of the module are made of lightweight materials such as lightweight plastics and wood. Therefore the components of the module 10 may be easily transported by a person or a light vehicle.
In use, the modular deck system may be assembled in a variety of locations, such as in a field, in wetlands, or in a body of water, without significantly affecting the location. In an example, the deck system is installed as a dock in a body of water or a boardwalk through wetlands and the deck modules 10 are installed with the personnel and equipment situated on a previously installed deck module. No equipment is required to be submerged or driven though the wetlands to install the modules. Thus, the only impact on the ground surface by the deck system is the driving of the piles 12 into the ground surface. However, as the application warrants and allows, the system may also be installed at ground level.
The deck module 10 is assembled by driving a first set of piles 12 and a second set of piles 12 into a ground surface. In the current embodiment, each set of piles includes two piles 12; however, additional piles 12 may be used to further support the headers 14, the joists 16, or both. The helical piles 12 are installed by applying vertical force and rotating the pile 12 to screw it into the ground or wetland floor. A pile bracket 24 is assembled onto the top of each pile 12 and adjusted so that the saddle assembly 30 is level and the headers 14 may be aligned substantially parallel to each other. One header 14 is fastened to the saddle assemblies 30 of the first set of piles 12 and the second header 14 is fastened to the saddle assemblies 30 of the second set of piles 12. The pile brackets 24 are finely adjusted such that the headers 14 are level and aligned and the joist holders 50 of one header 14 are each aligned with a joist holder 50 of the opposite header 14. A bolt or other fastener is inserted through a hole near each end of each joist 16 such that the bolt extends through both sides of the joist. Each joist is then placed into two aligned joist holders 50 with the bolts engaging the notches 54. The bolts are mated with nuts and tightened to secure the joist 16. Four joists 16 are used in the illustrated embodiment, though more or less may be required in specific applications. Several of the cross-brace assemblies 92 are assembled between each pair of adjacent joists 16 as needed.
The walls 62 of the connector strips 60 are inserted into grooves in the tops two or more of the joists 16 and connected in series by the connector ends 66, 68. The connector strips 60 may be secured to the joists 16 by fasteners. The deck planks 18 are placed between the spacer posts 70 and connected to the connector strips 60 by a snap connection, fasteners, or both. The end caps 76 are connected to the outermost joists 16 and over the edges of the deck planks 18. The railings 58 may then be inserted into the railing supports 56.
A subsequent module is assembled from the first module by driving a third set of piles 12 into the ground surface relatively aligned with the first and second sets of piles 12. Imprecise placement of the piles 12 is compensated by the adjustable pile brackets 24. A third header 14 is attached to the pile brackets 24 of the third set of piles and the brackets are adjusted such that the header is level and aligned with the second header 14. Several joists 16 are placed into the joist holders 50 of the second and third headers 14. The remaining components are assembled as described with the first module 10 above. Additional modules are likewise added as required. Because interlocking, preformed components are used in the construction of the deck module 10 and few fasteners are required, disassembly of the deck module 10 is made simple.
In an alternative embodiment, the components of the deck module are made of a stronger, heavier materials, such as steel. The system retains its advantages of rapid installation and strong joints, though heavier equipment may be required to transport the heavier materials. This alternative embodiment would be useful, for example, for a temporary, high-strength bridge for heavy equipment in a military setting.
It should be particularly noted that certain deck modules 10 may have angled planks and curved joists for turning corners. In this case, the headers 14 are aligned such that the curved joists may be placed in the joist holders 50. Further, the headers 14 may be aligned for gradual changes in elevation. In this case, the joist holders 50 may be slanted to accommodate the angled joists 16.
It should be further noted that several of the components of the deck module 10 of the present invention may be used separate from the other components of the module. The header 14 with the integral or welded-on joist holders 50 may be used to support conventional wooden joists or the header may be supported by structural elements other than piles. The connector strip 60 may be configured to engage dimensional lumber or other materials instead of the extruded joists 16. The pile bracket 24 may be used in any application that may benefit from a wide range saddle bracket. The aluminum helical piles 12 may be used in any situation requiring a lightweight or corrosive resistant pile.
While the invention has been described with reference to preferred embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof to adapt to particular situations without departing from the scope of the invention. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope and spirit of the appended claims.
This application is a divisional of U.S. Ser. No. 11/490,795, filed Jul. 21, 2006 which claims priority from U.S. Provisional Patent Application Ser. No. 60/701,666, filed Jul. 22, 2005. The content of these applications is hereby incorporated by reference into this specification.
Number | Date | Country | |
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60701666 | Jul 2005 | US |
Number | Date | Country | |
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Parent | 11490795 | Jul 2006 | US |
Child | 13274514 | US |