Patent Application
20180202120
The invention relates to docks such as boat docks, in particular docks supported or retained by fixed posts anchored to an underlying lake or sea bed.
Boat docks, such as cottage docks, are typically floating or fixed. A non-floating (i.e. fixed) boat dock typically comprises a solid deck supported on pillars or similar supports. Typically, the pillars are sunk into the lake bed to a depth that is suitable for anchoring the dock to provide year-round stability.
Conventional fixed docks have certain advantages over floating docks, since they are less subject to damage or becoming unmoored from storms or high waves. As well, they can be better able to withstand factors such as ice, tides etc. that might disrupt a floating dock, and they form a more stable surface for the user. However, in many locations, it can be difficult to obtain regulatory approval to install a fixed dock, due to the disruption to the lake bed during the installation process. As well, installation of a fixed dock can be complex, time-consuming and costly.
On the other hand, conventional floating docks, which are anchored by various means to the lake bed or solid ground, tend to be easy to install and are useful in some applications. However, they tend to become unmoored and float away in storms or high waves. As well, they can lack stability when subjected to waves, and as well tend to tilt when unbalanced.
The prior art discloses various fixed dock assemblies and methods for fabricating and installing these. Examples include U.S. Pat. No. 4,647,257, which describes a dock assembly consisting of horizontal girders cross-linked by transoms. Sleeves are provided at the ends of the girders to receive and guide support posts. U.S. Pat. No. 8,529,158 describes a structure for driving pilings into the ground, such as a lakebed. The system includes a frame (a “cap structure”) having vertical sleeves for receiving the pilings. U.S. Pat. No. 8,668,407 describes a dock system having an open frame for supporting decking slabs. The frame also includes sleeves for receiving vertical posts for supporting the dock on a lakebed.
Boat docks and other platforms are typically provided with removable decking members to provide a useful surface, such as planks or other panels. These members may be pre-installed prior to installation of the dock or installed on-site. For on-site installation, a dock frame may be installed initially, followed by installing the decking on the frame, for example by screwing or bolting the panels onto the frame.
Traditional wood deck boards have drawbacks, such as limited lifespan, splinters and others problems. There exist various alternatives to wood in the market for deck materials, such as plastics and plastic composites, precast concrete and others. The use of precast concrete has particular advantages for outdoor decking surfaces. However, precast concrete panels can be heavy and consequently difficult to transport and install. As well, it can be difficult to install dock fixtures such as boat cleats onto a concrete surface.
According to one aspect, we disclose a method for installing a boat dock in which the dock comprises a deck and rigid deck pillars which engage the dock to a lake bed or other underlying surface. The method comprises the steps of:
Decking members may then be attached to the deck frame. We also disclose the option whereby the decking members comprise precast concrete members, as described herein, which are individually attached to the frame.
We further disclose a kit for installing a boat dock, which is useful for performing the method described herein. The kit comprises:
The kit may further comprise deck members that are configured to be attached to the deck frame. Optionally, the deck members may comprise the precast members described herein. Optionally, the kit may also comprise flotation members such as pontoons for floating the dock, for assembling a floating dock in which lateral and tilting movement is restrained by fixed pillars.
In one example, the decking members are installed on the deck frame independently of installing the deck to the pillars. According to one option, the deck members each comprise a frame with a precast reinforced concrete insert. The deck member frame may comprise a reinforcement structure that is partially embedded within the concrete and also partially external to the concrete insert.
We further describe kit for installing a boat dock to an underlying bed of a body of water, comprising:
Optionally, a deck surface such as a precast concrete slab, may be pre-installed on the deck frame. According to this aspect, the deck frame and concrete slab may consist of an assembly in which the slab is integral with the frame which is supplied in the kit as a pre-formed unit.
There also exists a need for improvements in precast concrete decking members, including but not limited to decking members that are relatively lightweight and which can be included within modules that include deck fixtures such as boat cleats.
According to one general aspect, we disclose a deck member which may be used to provide the decking surface on a boat dock, patio deck or other structure. In this general aspect, the deck member comprises a concrete panel and a reinforcement structure. The reinforcement structure comprises a frame composed of frame members arranged in opposition to each other configured to form the peripheral border extending around the edges of the concrete panel, at least one reinforcement member (such as a reinforcement rod or bar) extending between opposing ones of the frame members and at least one post extending from the reinforcement bar(s). The post(s) is/are at least partially embedded in the concrete and the reinforcement bar(s) is/are at least partially exposed to reinforce the concrete panel through the post(s). In this fashion, the reinforcement bars may be spaced apart from the concrete panel, or in contact with the concrete panel but not embedded in it, or partially embedded in the concrete panel.
The deck member may further comprise a gasket on an exposed rim of the frame members, such that the gasket extends upwardly therefrom to be flush with a surface of the concrete panel. The gasket can provide a seal between adjacent deck members.
The concrete may overlie the reinforcement bar(s) such that the reinforcement bars are beneath the concrete panel in a horizontal installation of the deck member and the post(s) protrudes upwardly into the concrete.
The reinforcement structure optionally includes a fixture such as boat cleat attached thereto which is configured to project from the concrete panel.
According to another aspect, we disclose a method of fabricating a deck member, comprising the steps of:
We further disclose a method for installing a dock to an underlying bed of a body of water, wherein the dock comprises a deck frame, rigid deck pillars for connecting the deck frame to an underlying surface and a plurality of guide members connected to the deck and configured to secure the deck frame to the pillars. According to this aspect, the method comprises the steps of:
The present dock, its component parts and its installation method, including the improved deck member, will now be further described and illustrated by a detailed description of embodiments thereof, which is not intended to limit the scope of the invention in any respect.
In the present specification, directional references are provided for ease of description and clarity; these are not intended to limit the scope of the invention. For example, such references include terms such as “horizontal”, “vertical” and the like. Such terms are by reference to a dock having a horizontally-disposed main deck. It will be understood that in practice, the dock may depart from such angles. Furthermore, any dimensions, materials and fabrication methods described herein are by way of example unless otherwise stated, and are not intended to limit the scope of the invention.
Referring to
Dock 10 comprises a dock platform 20 which comprises a flat surface which is configured for being supported above the water surface. For directional reference, as shown in
Frame 22 is composed of opposing lateral frame members 23 which are parallel to longitudinal axis 28 and end frame members 25 which are parallel to transverse axis 29. As discussed below, frame 22 may be secured to pillars 60 which support the installed dock above a lake bed or the like.
A pair of spaced apart parallel stringers 24 are attached to frame 22 and extend the length of dock 10, parallel to longitudinal axis 28, to provide attachment surfaces for the decking members, described below. Stringers 24 are supported by frame 22 and form load-bearing members for the assembled dock.
The frame members of platform 20, including frame 22 and stringers 24, are configured to bear a substantial load without deformation. The load that the frame is designed to bear will depend on the projected use of the dock, as well as its overall size, and will usually include a conventional margin of safety. The configuration and dimensions of platform are designed in accordance with known methods for engineering such structures to accommodate a projected load and other stresses. As seen in
Frame 22 further comprises cross bracing members 32 which extend from the corners of frame 22 to form an X-shaped structure meeting in the middle of frame 22.
The various frame members of platform 20 may be fabricated from any suitable material such as steel or other metal which inherently resists can corrosion or is coated to do so, or these can be fabricated from a synthetic material such as a composite or suitable polymer, or wood.
Frame 22 further comprises an array of sockets 34, seen in detail in
Sockets 34 each comprise a box-shaped member having vertical side walls 47, an open upper end 44 and an opposing open lower end 45. Socket 34 is capped at its upper end with a ring plate 50 (seen in detail in
As seen in
Pilot sleeves 40 are temporarily attached to frame members 23 and 25 by any convenient temporary attachment means, for example with removable clamps. For example, a tubular, cylindrical bracket 55 may be provided at the base of socket 34, having an L-shaped cross-section as seen in
According to another method, pillars 60 are initially slid into sleeves 40 to form an assembly. The sleeve/pillar assembly is then inserted into socket 34, where sleeve 40 is snugly retained. Pillar 60 is then accurately lowered to the lake bed by sliding this within sleeve 40, and may then be drilled into the lake bed while being held accurately in position by sleeve 40. After installation of pillar 60, sleeve 40 may then be removed from pillar 60 and socket 34, for re-use. Pillar 60 is then permanently fastened to socket 34 by attachment to ring plate 50.
As shown more particularly in
Support pillars 60 are then inserted vertically through sockets 34 and into sleeves 40 whereby a separate pillar 60 is inserted into each sleeve 40. Pillars 60 and sleeves 40 are configured to provide a moderately snug fit to precisely guide the pillars 60 in a selected orientation (such as vertical), but whereby a small gap is provided to permit pillars 60 to easily slide through the sleeves even if there is contamination or irregularities that would otherwise restrict pillars 60 from easily sliding through sleeves 40.
Pillars 60 are of sufficient length to extend from the lake bed to frame 22, with a portion of the pillars 60 extending above frame 22 for penetrating into the lake bed during installation. The required depth of penetration is based on properties of the lake bed and other factors which determine the penetration depth of pillars 60 required to adequately support the dock. For example, if the lake bed is highly unconsolidated to a relatively large depth, such as a deep layer of sediment with no bedrock or other hard surface for a large distance, it will be necessary to install pillars 60 relatively deeply into the lake bed. Alternatively, if the lake bottom is underlain by shallow bedrock or other hard surface below the lake bed, the pillars maybe shorter in length. The selected depth by which pillars 60 are sunk into the lake bed will be determined by engineering factors that are known to the art. Typically, one should over-estimate the length of the pillars 60, which may be trimmed after installation to be flush with the deck surface.
Pillars 60 are sunk into the lake bed by various means, for example pile-driving or drilling pillars 60 into the lake bed using conventional methods. Pillar 60 may be provided with a sacrificial bit 62 (see
At this point, sleeves 40 are then detached from deck frame 22 and removed from pillars 60. For this step, the temporary securements of sleeves 40 are released, for example by unclamping them from frame 22 or grinding off temporary brackets 55 that may have been used to attach sleeves 40 to frame 22. Once detached from frame 22, sleeves 40 may be slid upwardly to remove them from pillars 60. Pillars 60 are then fastened to frame 22 as discussed below. In order to retain frame 22 in position without slipping downwardly during this stage, especially in cases where the temporary deck support may be susceptible to movement, sleeves 40 may be removed one at a time, with pillars 60 being individually attached to frame 22 as each sleeve 40 is removed. In this fashion, the position of frame 22 is retained without downward movement as sleeves 40 are removed. Sleeves 40 may be re-used in another deck installation.
Pillars 60 are permanently secured to frame 22 by securing the upper ends of pillars 60 to ring plate 50, for example by welding. Pillars 60 are further secured to frame 22 by a permanently welded bracket 62 (see
Once deck frame 22 has been permanently attached to pillars 60, the temporary deck support may be detached such that deck platform 20 bears on pillars 60.
If necessary, any surplus lengths of pillars 60 extending upwardly from frame 22 is trimmed.
At this stage, stringers 24 may be attached to frame 22, for example by welding, bolting or any other suitable attachment means. Stringers 24 may be provided in a pre-set length or cut to size after installation.
Turning to
Slabs 70 are secured to stringers 24 by any suitable means, for example slabs 70 may be secured using J-bolts or clamps that fasten brackets on the slabs to stringers 24.
In one embodiment, slabs 70 may be pre-installed onto stringers 24, whereby the assembled combination of stringers 24 and slabs 70 is installed onto frame 22.
As seen in
As seen in
Turning to
Reinforcement structure 112 may be coated with a suitable corrosion-resistant coating (examples include paint and galvanized coatings) to prevent corrosion or oxidation of the metal from exposure to air, water, salt etc. Alternatively, reinforcement frame 112 may be fabricated from a corrosion resistant material which does not require a coating and which also provides suitable reinforcement for the concrete component of member 110. As discussed below, the reinforcing structural members of structure 112 are external to concrete layer 114 and are integrated with layer 114 through posts 130 embedded within layer 114.
Reinforcement structure 112 comprises a rectangular frame having side members 116 and opposing end members 118, welded together to form a rectangular frame. Reinforcement structure 112 is defined by a longitudinal axis 105 that extends between opposing end members 118 and a transverse axis 106 that is perpendicular thereto, extending between side members 116 (see
Referring to
An array of vertical metal posts 130 protrude upwardly from reinforcement bars 24. Posts 130 are recessed from the upper rim of sidewalls 116 and 118. In this fashion, when frame 112 is filled with concrete, posts 130 are fully embedded within the concrete 142 that fills frame 112. The embedded portions of posts 130 are thus not exposed to the elements in the finished assembly. In the present example, each reinforcement bar 124 is provided with five posts 130. However, this number may vary. Posts 130 provide a structural link between the concrete 114 and reinforcement frame 112 whereby the concrete is effectively reinforced by the frame 112.
Side walls 116 and 118 of wall 120 have an exposed upper rim that is capped with a resilient gasket 138, as seen in
As seen in detail in
Installation of fixture 132 is preferably performed after a deck has been fully assembled within a boat dock or the like.
A method of fabricating a deck member 110 is illustrated in
In one example of a fabrication method, a reinforcement structure 112 is provided. Optionally, reinforcement structure 112 may have one or more fixture-mounting bases 152 pre-installed for mounting a dock fixture. Alternatively, a base 152 may be welded onto structure 112 at a desired location. Next, a gasket 138 is installed onto the upper rim of walls 120 so as to fully encircle structure 112. Gasket 138 may be provided from a large roll which is cut to the appropriate length and the opposing ends glued together where these meet. Alternatively, gasket 138 may be provided as a loop of a pre-set size which is fitted onto structure 112.
Next, reinforcement structure 112 is then positioned in an inverted position (i.e. posts 38 protruding downwardly) on a surface 140, as seen in
When reinforcement structure 112 is placed on surface 140 in an inverted position as seen in
Reinforcement structure 112, in the inverted position, is then partially filled with liquid concrete to a level whereby reinforcement bars 124 and 125 are exposed above the uppermost surface of the concrete 114. In this fashion, the finished deck member 10 comprises exposed reinforcement bars 124. Reinforcement bars 124 and 125 may be fully exposed whereby the concrete layer 114 is out of contact there with, leaving a gap between concrete layer 142 and bars 124.
Concrete panel 114 is fabricated to leave a gap between lower concrete surface 117 and bars 124 and 125. This gap is represented as dimension “e” in
The value for NU depends on stress properties of the concrete layer 114 and the external reinforcement structure 112 which is structurally connected to the concrete layer 114 via posts 130. As such, the external reinforcement of concrete layer 114 by structure 112 provides essentially the same degree of structural reinforcement as a conventional fully embedded reinforcement structure. Distance “d” is determined based on the principle that in a conventional reinforced concrete panel in which the reinforcement mesh is embedded within the concrete, a layer of concrete of thickness “NU” exists, consisting of the embedded region and a region extending partially into the concrete layer, that does not provide significant structural support. The value for NU may comprise the smallest thickness of concrete that is necessary to provide a selected stress block for the panel.
In the present example, layer NU is hypothetical, and its value is determined in order to determine a suitable (maximum) value for distance “e” for fabricating a panel 110.
Hypothetical layer NU equals the distance between the reinforcement mesh and the center of the concrete panel. The present invention is thus based on the principle that at least some of this concrete layer may be eliminated without substantially affecting the structural integrity or strength of the reinforced panel. As such, distance “e” in assembly 10 may be the same as or less than hypothetical distance NU as determined for the particular configuration of concrete layer 114 and reinforcement structure 112.
According to one aspect, the values for NU and d may be calculating according a conventional methodology of structural engineering. An example of such calculation is shown by reference to the following diagram:
An initial step in the calculations of NU and d is to determine a factored moment. Following this determination, one generates a concrete layer with sufficient reinforcement to create the necessary resistance member to equilibrate that factored moment.
=54.55 <=thickness of layer that may be free of concrete between the reinforcement bars and the concrete layer.
Distance “e” may be less than its hypothetical maximum value of NU. In one aspect, layer 114 may contact reinforcement bars 124 and 125 or even partially embed them.
Optionally, the concrete layer 114 may be dyed or otherwise coloured, for example to emulate natural wood or other desirable visual effect.
The concrete is allowed to harden and cure on surface 140, following which the fully assembled deck assembly no is then lifted off of surface 140.
It will be seen that after concrete layer 114 hardens and deck member no is inverted into its normal “use” position, exposed reinforcement bars 124 and 125 are located to be beneath the lower surface of concrete layer 114. As well, the upper surface of concrete layer 114 in the finished structure 10 is flush with the upper surface of gasket 138.
In the completed assembly 110, gasket 138 comprises an exposed upper edge extending around the periphery of the dock member. Gasket 138 effectively seals the finished assembly against water leakage that might penetrate into frame 212. As well, gasket 138 forms a seal between adjacent deck assemblies 110, whereby assemblies 110 are assembled into a finished dock or other structure in which the respective deck members no are installed in abutment, the respective gaskets 138 of adjacent members 110 contact each other to seal against penetration by the elements through the surface of the assembled deck.
A further embodiment of the dock is shown in
Dock 200 includes an array of vertically aligned sockets 210, seen in detail in
Socket 210 may have a square outer configuration to provide contact surface with frame 202. Socket 210 may further comprise an inner tubular sleeve having a circular cross section to receive a cylindrical pillar 212.
Dock 200 is supported on a water surface by flotation on an array of floating pontoons 214, which consist of hollow sealed tubes that extend substantially the length of frame 202. Frame 202 may be attached to pontoons 214 by welding, straps or other suitable attachment means. Horizontal movement of dock 200 is limited by pillars 212 that are sunk into the lake bed or otherwise anchored to the bed. As well, pillars 212 minimize tilting of dock 200, for example when unbalanced by a person diving from the dock or other unbalancing of the dock, by maintaining dock 200 on a level plane.
Pillars 212 are similar in structure to pillars 60 of the first embodiment. However, unlike the first embodiment in which pillars bear the weight of the dock, pillars 212 are not weight bearing but are instead provided only to anchor dock 200 in a selected position. Dock 200 is thus free to travel vertically, guided by pillars 212 but with lateral and tilting movement of dock 200 being restricted by pillars 212.
Installation of dock 200 comprises the initial step of floating frame 202 on a water surface in its desired location on pontoons 214 at a selected location and optionally anchoring frame 202 in this position with guy lines, anchors or other temporary fixation means. Pillars 212 are then inserted into sleeves similar to the first embodiment described above. The sleeve and pillar assemblies are then inserted through sockets 210 and pillars 212 brought into contact with the underlying lake or sea bed or other surface, as described above for the first embodiment. Pillars 212 are then sunk into the surface or otherwise securely and permanently anchored to the surface. Following this step, the sleeves are removed, as in the first embodiment. However, in contrast with the first embodiment, pillars 212 are then slideably engaged within sockets 210 whereby pillars 212 may freely slide vertically through sockets 210 such that frame 202 may travel vertically to accommodate tidal movement, waves and other sources of vertical movement of frame 202. As well, any guy lines or other temporary anchors or other restraints may be removed, such that horizontal travel and tilting of frame 202 is afterwards restrained solely by pillars 212.
According to this embodiment, pillars 212 project upwardly above frame 202 to permit vertical travel of frame 202. The extent of such projection depends on the expected amount of vertical travel, for example a more substantial projection is required in a location of high tidal or seasonal water level movement.
The deck assembly of dock 200 according to the present embodiment is shown in more detail in
Sockets 210 are attached to frame 202 at the frame corners where sidewalls 262 meet joists 266. In the present example, frame 202 has six sockets, although this number may be increased or decreased based on the overall size of the dock 200 and other factors. Sockets 210 protrude through concrete slab 250 whereby the open upper and lower ends of sockets 210 are exposed. As such, pillars 212 may be inserted through sockets 210 for installation of dock 200 on a lake bed or other surface.
As seen in
Dock 200 is fabricated in a manner similar to the first embodiment, wherein reinforcement structure 270 is initially secured to deck frame 202 whereby structure 270 is overlaid on joists 266 and is thus recessed from the uppermost edge of frame 204. Frame 202 is then placed in an inverted position on a smooth forming surface, which optionally has a pattern for embossing into the upper surface of slab 250. Concrete is then poured into frame 202 and allowed to harden and cure to form the finished slab 250, which incorporates reinforcement structure 270 embedded therein. The uppermost layer of concrete covering frame 202 is clear of the reinforcement structure 270. The exposed upper surface of slab 250 is optionally embossed with a pattern during the concrete forming step. In the assembled dock 200, frame 202 fits tightly around slab 250 with no natural deformations.
In the above example, frame 202 and slab 250 form an integral assembly that may be fabricated in advance and shipped as a unit to the dock installation site. Furthermore, additional dock components may be assembled prior to shipping, such as pontoons 214. The assembled dock unit may then be installed on-site with pillars 212 as described herein.
The scope of the present invention should not be limited by specific embodiments or examples set forth in the description or elsewhere but should be given the broadest interpretation consistent with the specification as a whole. The claims are not limited in scope to any preferred or exemplified embodiments of the invention.
This application claims Convention priority to U.S. application Nos. 62/445,854, filed on Jan. 13, 2017 and 62/446,010, filed on Jan. 13, 2017. The contents of said applications are incorporated herein by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62445854 | Jan 2017 | US | |
| 62446010 | Jan 2017 | US |
