Patent Application
20240026675
The present invention relates to a decking system comprising structural components arranged for assembly into a deck structure without requiring any wooden lumber for framing or finishing of the deck structure, and more particularly the present invention relates to a decking system in which joists, a ledger board, beams, upper deck boards, and finishing trim boards of the decking system are formed of molded materials that are shaped and configured for securement to one another using minimal fasteners.
A popular form of deck construction for buildings, for example residential houses, involves surface materials formed of various composites which simulate the appearance of a finished wooden deck without requiring painting or other on-going maintenance. Current decking systems of this configuration however generally require conventional wood construction joists and beams and the subsequent awkward manipulation of various mounting clips, nails, screws and the like to secure the deck surface to the joists and beams below.
The following US patents relate generally to various forms of decks and other similar structures. U.S. Pat. No. 5,101,737 belonging to Gomez; U.S. Pat. No. 5,417,167 belonging to Sadr; U.S. Pat. No. 4,019,298 belonging to Johnson, IV; U.S. Pat. No. 6,314,699 belonging to West; U.S. Pat. No. 6,802,267 belonging to Janus; U.S. Pat. No. 5,950,377 belonging to Yoder; and U.S. Pat. No. 3,914,913 belonging to Roberts. None of these examples provide an overall deck system in which all of the components can be manufactured of maintenance free materials and which can be readily assembled using minimal fasteners.
WO2009/089623 by SIGMA DEK LTD. discloses one example of a decking system in which the various structural components of the decking structure are formed of molded materials that are maintenance free; however, the connections between some of the components require uniquely shaped ends that cannot be readily cut to different lengths if desired. For example, the connection of the joists to the ledger board require uniquely shaped ends on the joist for hooking onto the ledger board and fascia board respectively.
According to one aspect of the present invention there is provided a decking system for use with a plurality of deck boards, the decking system comprising:
According to another important independent aspect of the present invention the decking system may comprise:
The ledger board may further include a fastener flange protruding from the ledge portion below the joists and receiving fasteners therethrough securing the joists to the fastener flange.
The hook flange of the joist mounting clip preferably extends upwardly above an upper surface of the joist.
Preferably each joist includes a mounting channel extending longitudinally along a top of the joist, the mounting flange of the joist mounting clip being recessed into the mounting channel and being fastened to the joist within the mounting channel of the joist.
According to another important independent aspect of the present invention the decking system may comprise: (i) a ledger board connected across the joists at the first end of the decking system so as to be arranged for connection to a building having flooring joist members; (ii) a first bracket member fastened to one of joists in proximity to the ledger board; (iii) a second bracket member arranged to be fastened to one of the flooring joist members internally within the building; and (iv) a connecting rod arranged to be connected under tension between the first bracket and the second bracket member so as to be arranged to secure the first end of the decking system against the building.
According to another important independent aspect of the present invention the decking system may comprise: (i) a ledger board connected across the joists at the first end of the decking system, the ledger board including: (ii) a main body portion which is arranged to be fastened against an upright supporting surface of a building; (iii) a ledge portion protruding from the main body portion upon which the joists are supported; and (iv) a flashing member at a top end of the main body portion extending upwardly and outwardly across a thickness of the main body portion from an inner side of the main body portion against which the joists are abutted to an outer side of the main body portion arranged to be abutted against the building.
According to another important independent aspect of the present invention the decking system may comprise: (i) a fascia member connected across the joists at the second end of the decking system, the fascia member including an upper portion engaged upon a top of the joists, a retainer flange supported on the upper portion, and a base flange secured to a bottom of the joists; (ii) a plurality of fascia mounting clips identical in configuration to the joist mounting clips, each fascia mounting clip including a fastener flange fastened to one of the joists and a hook flange hooked relative to the retainer flange of the fascia member so as to resist displacement of the fascia member away from the joists longitudinally of the joists.
According to another important independent aspect of the present invention the decking system may comprise: (i) a fascia member connected to one or more joists at one end of the decking system; (ii) the fascia member including an upper portion engaged upon a top of the joists, a wall portion extending downwardly from the upper portion across a height of the joists, and a trim slot formed at the bottom of the wall portion; (iii) the trim slot being open downwardly and being stepped in profile to define a narrow upper portion arranged to receive a first thickness of a first skirt panel therein, and a wider lower portion arranged to receive a second thickness of a second skirt panel that is thicker than the first skirt panel.
According to another important independent aspect of the present invention the decking system may comprise: (i) a fascia member connected to one or more joists at one end of the decking system; (ii) the fascia member including an upper portion engaged upon a top of the joists and a wall portion extending downwardly from the upper portion across a height of the joists; and (iii) a flashing member including an inner flange joined to the upper portion of the fascia member to extend inwardly over the joists at a location spaced above the joists by a height corresponding to a thickness of the deck boards so as to receive edge portions of the deck boards between the joists and the flashing member on the fascia member.
According to another important independent aspect of the present invention the decking system may comprise:
According to another important independent aspect of the present invention the decking system may comprise:
According to another important independent aspect of the present invention the decking system may comprise:
According to another important independent aspect of the present invention the decking system may comprise each joist including a mounting channel extending longitudinally along a top of the joist, and wherein each deck board is secured to the joists by board mounting clips, each board mounting clip including a mounting flange securable within the mounting channel of the joist and a retainer flange engaging one of the deck boards to secure the deck board to the joist.
The mounting channel of each joist may include two undercut portions along opposing sides respectively, each undercut portion forming a catch thereon, and wherein the mounting flange of each board mounting clip includes a pair of retainer surfaces thereon received below the undercut portions respectively so as to prevent upward displacement of the board mounting clip from the joist.
Each board mounting clip, prior to fastening to the joist, may be rotatable between a released position in which the retainer surfaces are aligned with opening in the mounting channel between the undercut portions and a mounted position in which the retainer surfaces are received below the undercut portions respectively.
The mounting flange of each board mounting clip may include a fastener slot formed therein receiving a fastener therethrough such that the fastener is received within the mounting channel of the joist and fastens the board mounting clip in fixed relation to the joist.
According to another important independent aspect of the present invention the decking system may comprise each deck board comprising:
According to another important independent aspect of the present invention the decking system may comprise a beam extending across the joists and supporting the joists thereon, the beam comprising (i) a web portion, and (ii) two top flanges at a top of the beam protruding laterally outwardly from opposing sides of the web portion, the top flanges being fastened to the joists.
According to another important independent aspect of the present invention the decking system may comprise: a beam extending across the joists and supporting the joists thereon, the beam including a mounting channel formed at a bottom of the beam; a post arranged to support the beam thereon above a foundation; a post connecting arrangement connected between the post and the mounting channel at the bottom of the beam; and at least one post brace including a first end coupled to the post and a second end coupled to the mounting channel at the bottom of the beam. The second end of said at least one post brace may include a beam mounting bracket arranged to be coupled to the mounting channel so as to be restricted to relative sliding within the mounting channel relative to the beam.
According to another important independent aspect of the present invention the decking system may comprise a beam extending across the joists and supporting the joists thereon, the beam comprising:
According to another important independent aspect of the present invention the decking system may comprise: (a) a beam extending across the joists and supporting the joists thereon, the beam including a mounting channel formed at a bottom of the beam; (b) a post arranged to support the beam thereon above a foundation; and (c) a post connecting arrangement comprising (i) a socket member defining a socket therein and having an exterior shape in mating connection with the mounting channel in the beam such that the socket member is restricted to longitudinal sliding relative to the beam, and (ii) a ball received within the socket to allow relative pivotal movement therebetween, the ball being mounted on the post.
According to another important independent aspect of the present invention the decking system may comprise a stair assembly connected to the decking system, the stair assembly comprising: (i) a plurality of tread members; (ii) a plurality of stringers extending outwardly from the decking system in parallel with one another to support the tread members thereon; (iii) each stringer being formed of a plurality of stringer sections; (iv) each stringer section including an upper connector formed along a top of the stringer section and a lower connector formed along a bottom of the stringer section, the upper connector being arranged to mate with the lower connector of an adjacent stringer section for relative horizontal sliding movement therebetween; (v) each stringer section supporting a portion of a respective one of the tread members thereon.
The stair assembly may further comprise a tread mount supported on each stringer section, the tread mount having a lower connector formed thereon which is arranged to mate with the upper connector of the stringer section for relative horizontal sliding movement therebetween and an upper supporting surface above the lower connector that is arranged to support the respective tread member thereon.
The stair assembly may further comprise a footing member supported on a lowermost stringer section among the stringer sections of each stringer, the footing member having an upper connector formed thereon which is arranged to mate with the lower connector of the lowermost stringer section for relative horizontal sliding movement therebetween and a lower supporting surface below the upper connector that is arranged to be engaged upon a foundation.
The stair assembly may further comprise a deck mount coupled to an uppermost stringer section of each stringer, the deck mount comprising a mounting plate arranged to be secured to the joists and a first connector suspended below the mounting plate, the first connector being arranged to mate with a corresponding second connector formed on the uppermost stringer section for relative horizontal sliding movement therebetween.
Each stringer section may be adjustable in height between the upper connector and the lower connector thereof.
The system may further comprise a crossbar ledge supported along one side of each stringer section and a crossbar member supported at opposing ends on the crossbar ledges of two of the stringers respectively, a top side of the crossbar member being substantially flush with a top side of the tread portions to provide support to the tread members being supported on the tread portions.
According to another important independent aspect of the present invention the decking system may comprise a railing post assembly connected to the decking system, the railing post assembly comprising: (a) a lower mounting member spanning between two supporting joists among the joists and being fastened to the two supporting joists at a bottom of the joists; (b) an upright post; (c) a post base secured to a bottom end of the upright post, the post base including (i) an upper flange portion fastened to the two supporting joists at circumferentially spaced positions about the upright post and (ii) a shaft portion fixed to the upper flange portion and connected to the lower mounting member.
The railing post assembly may further comprise an upper mounting member fastened to the two supporting joists below the deck boards, the upper mounting member including at least one shaft opening receiving the shaft portion of the post base vertically slidable therethrough so as to provide lateral support to the shaft portion of the post base.
The at least one shaft opening may be arranged to support the shaft portion of the post base at two different locations relative to the upper mounting member.
According to another important independent aspect of the present invention there may be provided a decking system for use with a plurality of joists arranged to be supported to extend parallel to and spaced apart from one another to support a plurality of deck boards extending across the joists, the decking system comprising:
In this instance, each joist mounting member may comprise: (i) a first flange arranged to be fastened to the ledger board; and (ii) a second flange arranged to be fastened to a side surface of the respective joist; (iii) the follower element protruding from one of the first flange or the second flange.
The ledger board may further comprise a ledge supporting the joists thereon.
The track may comprise a bottom channel formed in the ledge in which the at least one follower element comprises a bottom follower received within the bottom channel. Alternatively, the track may comprise a bottom channel and a top channel spaced above the bottom channel, in which the at least one follower element comprises a top follower received in the top channel at a top of the joist mounting member and a bottom follower received within the bottom channel at a bottom of the joist mounting member.
There may be two joist mounting members mounted on opposing sides of each joist. The two joist mounting members may be identical to one another.
Each joist mounting member may be mountable on the respective joist in two opposing orientations, in which each joist mounting member comprises two follower elements at opposing top and bottom ends, the two follower elements being arranged to be received within the track in the two opposing orientations respectively.
According to a further aspect of the present invention, any of the noted independent aspects of the present invention as described above may be combined in any manner with any of the other noted independent aspects of the present invention.
Some embodiments of the invention will now be described in conjunction with the accompanying drawings in which:
In the drawings like characters of reference indicate corresponding parts in the different figures.
Referring to the accompany figures, there is illustrated a decking system generally indicated by reference numeral 10. The decking system 10 in each instance comprises a plurality of joists 12 which are supported to extend longitudinally between opposing first and second ends of the assembled deck structure in parallel to one another at laterally spaced apart locations. The joists 12 are typically supported on one or more beams 14 spanning laterally across the joists between opposing sides of the assembled deck structure. A plurality of deck boards 16 are then supported to extend across the joists 12 to form an upper deck surface of the assembled deck structure. Two different embodiments of the deck boards 16 can be supported on the same configuration of joists as described in the following.
When mounted adjacent an upright structure such as a building wall, the joists are typically supported at one end on a common ledger board 18 extending laterally across the width of the assembled deck structure. In this instance, a single beam may be provided at a location nearer to the opposing end of the joists that are opposite from the ledger board. The beam 14 in this instance can be supported on a plurality of posts 20 to support the decking system elevated from a foundation, for example the ground. When the decking system is elevated from the ground, an additional stair assembly 22 may be used for connection between one end of the decking system and the ground. An example of an elevated deck structure supported on a ledger board 18 and using a stair assembly 22 is shown in
Alternatively, the decking system 10 may be supported at ground level as shown in
In either embodiment, any exposed ends of the joists 12 can be covered with an end fascia member 24. At laterally opposing sides of the assembled deck structure, the outermost joist 26 among the plurality of joists 12 is configured differently than the remaining joists and is suitably arranged for supporting a side fascia member 28 thereon so that the end fascia members and the side fascia members collectively form a perimeter edge about the decking system providing a finished appearance.
In either embodiment, each joist 12 extends in a respective longitudinal direction between the opposing ends of the joist which can be cut to a desired length such that an end of each joist terminates within a plane lying perpendicularly to the longitudinal direction of the joist. The joist thus has a consistent cross-sectional profile fully spanning the length of the joist between the opposing ends thereof by forming the joist of an extruded member which has been cut to length.
The joist 12 includes a web portion 30 formed of two connecting walls spanning a full height of the joist between a top end and a bottom end of the joist. The two walls 32 each have a concave outer surface in profile so that the walls 32 taper inwardly towards one another from each of the top and bottom ends towards a centre of the joist. A connecting web 34 spans horizontally between the two walls 32 at an intermediate location along the height thereof for structural rigidity of the joist.
Each joist further includes two top flanges 36 protruding laterally outwardly from the walls 32 forming the web portion in respective opposing lateral directions. Similarly, two bottom flanges 38 protrude laterally outwardly from the walls 32 forming the web portion in respective opposing lateral directions. The bottom flanges 38 each extend laterally outward beyond the corresponding top flanges thereabove to provide a large surface through which fastening screws can be readily accessed and penetrated through the bottom flange to attach the joists to the beams 14 as required.
A mounting channel 40 is formed in the top of each joist to be recessed into the web portion. A mounting channel of similar dimension is also mounted at the bottom of each joist at a position which is laterally centred between the two top flanges 36. The mounting channel 40 has an inverted T-shape including a narrow opening at the top of the joist so that an internal dimension of the channel widens towards the bottom of the channel. In this manner, a pair of side flanges are effectively defined at the top of the mounting channel so that an undercuts portion 42 results under each side flange at laterally opposing sides of the mounting channel. Each undercuts portion 42 forms a catch upon which various mounting hardware can be secured as described in further detail below.
An identical channel can be mounted at a central location along the bottom side of the joist between the bottom flanges as shown in further embodiments below.
When used with a ledger board 18, the ledger board typically includes a main body portion 44 in the form of an upright plate spanning laterally the full length of the ledger board. The plate forming the main body portion spans the full height of the ledger board and includes a plurality of ribs 46 formed at the exterior or rear surface thereof for abutment against an upright supporting surface upon which the ledger board is mounted. The ribs 46 extend longitudinally across the full length of the ledger board at vertically spaced apart positions to provide some structural rigidity to the plate forming the main body portion of the ledger board.
A ledge 48 is defined on the ledger board as a rigid plate fixed onto the main body portion to protrude inwardly or forwardly from the front face of the main body portion at an intermediate height which is spaced below the top edge of the main body portion 44 by a height which is greater than the height of the joist, and which is also spaced slightly above the bottom edge of the main body portion. A supporting brace 50 is provided as an additional plate extending upwardly and forwardly from the bottom edge of the ledger board to an underside of the plate forming the ledge 48 of the ledger board to provide structural support to the ledge 48. A portion of the ledge plate protruding beyond the brace 50 defines a fastener flange 52 which is coplanar with the upper supporting surface of the ledge 48 but which is unsupported below by the brace 50 so that a bottom side of the fastener flange is exposed and accessible for penetrating fasteners therethrough.
In a mounted position, one end of each joist is engaged upon and rests on the upper supporting surface of the ledge 48 while the end of the joist is abutted against the front face of the main body portion 44 of the ledger board. Fasteners can be penetrated through the bottom flanges 38 of each joist at a region of overlap with the fastener flange 52 of the ledger board to assist in fixing the joist relative to the ledger board.
The ledger board further includes a retainer flange 54 which is supported on the forward face of the main body portion 44 of the ledger board at a location spaced above the ledge 48 by the height of the joist such that the end of each joist can be received between the ledge 48 and the retainer flange 54 thereabove. The retainer flange 54 is anchored at a top end relative to the main body portion 44 to extend downwardly to a bottom free end of the retainer flange which is spaced forwardly from the front face of the main body portion 44 by a thickness corresponding approximately to a thickness of the plate material forming the main body portion 44 or the ledge 48 for example.
A joist mounting clip 56 is used to assist in securing each joist to the ledger board. Each joist mounting clip includes a fastener flange 58 in the form of a flat plate which fits through the opening at the top of the mounting channel 40 and which includes a fastener aperture therein so that a fastener can be penetrated through the fastener flange 58 and threaded into the bottom of the mounting channel 40 in the joist. The mounting channel has sufficient depth to receive the thickness of the fastener flange 58 and the head of the corresponding fastener received therein so that the fastener flange and the fastener head remain recessed below the upper supporting surface of the top flanges 36 of the joist upon which the deck boards 16 can be supported. The fastener flange 58 can be readily adjusted by sliding along the length of the mounting channel prior to fastening so that the joist mounting clip 56 can be secured at any one of numerous positions along the joist subsequent to cutting of the joist.
Each joist mounting clip 56 further includes a hook flange 60 mounted generally perpendicularly to the fastener flange 58 at one end thereof to protrude upwardly relative to the elevation of the fastener flange 58. The fastener flange has a width which can also be received through the narrow top opening of the mounting channel 40. The hook flange has a sufficient height that the hook flange protrudes upwardly above the upper supporting surface of the joist when the fastener flange 58 is fastened to the bottom of the mounting channel. The hook flange 60 is arranged to be received within the space between the retainer flange 54 and the main body portion 44 on the ledger board in a mounted position. The mounting location of the joist mounting clip 56 on the joist is selected such that when the hook flange 60 of the mounting clip is received in hooked relation under the retainer flange 54, the joist is abutted against the front face of the main body portion 44 of the ledger board.
In order to install each joist on the ledger board, the joist mounting clip 56 may be initially fixed within the mounting channel at the top side of the joist using a fastener followed by inserting the hook flange 60 under the retainer flange while the joist extends away from the ledger board at an upward slope. With the hook flange 60 retained under the retainer flange, the joist can be pivoted downwardly into a horizontal orientation about a lateral pivot axis substantially at the free end of the retainer flange 54 on the ledger board until the end of the joist is abutted with the front face of the ledger board. Additional fasteners can then secure the bottom flanges of the joist to the fastener flange of the ledger board. Alternatively, the joist mounting clip 56 can be slidably inserted into the mounting channel as the end of the joist is horizontally slid onto the ledge until the end of the joist abuts the front face of the ledger board, followed by fastening both the joist mounting clip 56 to the top of the joist and the bottom flanges of the joist to the fastener flange of the ledger board.
In either embodiment, each beam 14 extends in a longitudinal direction between opposing ends of the beam which can be cut to any desired length such that each end of the beam lies flat within a respective plane oriented perpendicularly to the longitudinal direction. The cross-sectional shape of the beam 14 is thus continuous along the full length of the beam between the opposing ends thereof.
In each instance, the profile of the beam includes a web portion 62 formed of two connecting walls 64 spanning a full height of the beam between a top end and a bottom end of the beam. The two walls 64 each have a concave outer surface in profile so that the walls taper inwardly towards one another from the top end towards an intermediate height along the beam and similarly from the bottom towards the intermediate height along the beam. Intermediate walls within the interior of the web portion 62 between the walls 64 provide some structural rigidity to the beam while defining a generally triangular shaped hollow passage 66 extending through the web portion 62 along the full length of the beam.
The hollow passage of the web portion 62 is enclosed at the top of the beam where the beam includes two top flanges 68 which protrude laterally outwardly from opposing sides of the web portion 62 to protrude laterally outwardly beyond bottom flanges 70 at the bottom of the beam at both opposing sides of the beam. The top flanges 68 are unobstructed in the area underneath each top flange alongside opposing sides of the beam for ready access to penetrate fasteners through the top flanges 68 into overlapping bottom flanges of joists supported on the beam.
Each beam may be formed in a plurality of beam sections 71 which are mounted end to end in longitudinal alignment with one another so that the hollow passages 66 within the web portions are aligned coaxially with one another. In this instance a joiner member 73 is provided having an outer shape that fits non-rotatably and mates within the interior dimensions of the hollow passage 66 of each beam. The joiner member has a length which is shorter than the overall length of each beam section but which is mounted at the junction between two beam sections so that the joiner member is partly received within each of the two beam sections. For example, the joiner member may extend several feet into each beam section with the beam sections being nearly abutted with one another. Fasteners are penetrated through the top wall of the beam in alignment with the hollow passage in the web portion to fix the joiner member 74 relative to each beam section.
Turning now more particularly to the embodiment in
A post connecting arrangement is mounted on the top end of each post 20 to collectively form a post assembly joined to the beam. The post itself is a rigid member having top and bottom plates 76 and a rigid load bearing structure 78 connected vertically therebetween. A sleeve with an internally threaded bore 80 is fixed at the top end of the rigid post for receiving a threaded shaft 82 threaded into the sleeve. A ball 84 is fixed onto the top end of the shaft to be received within a socket member 86 which is in turn mounted within the mounting channel 72 to form the post connecting arrangement described herein. The socket member has an interior socket which is semi-spherical in shape to receive the ball 84 therein while allowing some relative pivotal movement therebetween.
A retainer plate 88 is mounted below the ball having an aperture therein which receives the shaft 82 extending therethrough but which is smaller in diameter than the ball so that the ball is retained above the retainer plate 88. The retainer plate can then be fastened to the underside of the socket member about the periphery of the socket therein for retaining the ball within the socket while allowing relative pivotal movement therebetween. The exterior shape of the socket member follows the semi-spherical shape of the interior socket while defining exterior dimensions which fit closely within the semi-circular boundary of the mounting channel 72 in the bottom of the beam.
Close to the bottom of the socket member 86, the exterior surface is provided with grooves formed therein which are aligned with the ribs 74 of the mounting channel when the socket member is fully received within the mounting channel such that the mating profiles of the exterior of the socket member and the interior of the mounting channel mate to restrict relative movement between the socket member and the beam to a longitudinal sliding movement along the mounting channel 72. The socket member 86 further includes an exterior flange 90 extending radially outward from the interior socket for overlapping the flat bottom of the beam when the socket member is slidably received within the mounting channel of the beam. In this manner, the socket member can be slidably displaced along the beam to a desired location, followed by penetration of fasteners through the exterior flange 90 of the socket member and into the bottom flanges 70 of the beam to subsequently fix the socket member relative to the beam. Thereafter, the post is limited to pivotal movement relative to the beam about the centre of the ball 84 of the post connecting arrangement.
As best shown in
When the joists are wider in lateral width towards the bottom end as compared to the top end thereof, as shown in
As shown in
As best shown in
The overall shape of the mounting flange 108 is such that the mounting flange can be inserted through the narrow opening at the top of the mounting channel 40 in the joist with a lateral direction of the mounting flange extending between the opposing ends 112 being aligned in the longitudinal direction of the joist so that the fastener region 114 lies beneath one of the undercut regions 42 of the mounting channel. Two diagonally opposed corners of the mounting flange form rounded corners 116 which readily allow the board mounting clip 106 to be pivoted about upright access through 90 degrees from the released position upon initial insertion of the mounting clip within the mounting channel to a mounted position as shown in
As noted above, in the released position the lateral direction of the mounting flange extending between the opposing ends 112 is aligned with the longitudinal direction of the mounting channel in the joist. In the mounted position however, the lateral direction extending between the opposing ends 112 of the clip is oriented perpendicularly to the longitudinal direction of the joist such that the two retainer surfaces defined on the upper side of the mounting flange at the opposing ends 112 are received directly below the catches formed on the undercut portions 42 at laterally opposing sides of the mounting channel 40 to thereby resist the board mounting clip 106 from being lifted upwardly relative to the joist. Diagonally opposing corners of the mounting flange between the two rounded corners 116 respectively define square corners 118 which function as stops to prevent rotation of the mounting flange beyond either one of the released position or the mounted position.
The post 110 of the board mounting clip 106 extends upwardly from the mounting flange 108 from an exterior boundary of the mounting flange 108 opposite the fastener region 114. The fastener region includes a fastener slot 120 formed therein at the boundary edge of the mounting flange to receive the shaft of a fastener therein so that a fastener can fix the mounting flange 108 of the board mounting clip to the base of the mounting channel 40 in the mounted position of the board mounting clip. The post 110 may extend upwardly from the mounting flange at a slight slope angled upwardly and away from the fastener slot to ensure that the fastener slot is readily accessible for inserting a fastener therein. Furthermore, the inner side of the post 110 nearest the fastener slot is concave in profile along the height thereof also to improve fastener access to the fastener slot in the mounted position.
The board mounting clip 106 is secured relative to the joist in the mounted position by both the retainer surfaces at opposing ends 112 of the mounting flange 108, while the fastener received within the fastener slot serves primarily to fix the longitudinal position of the clip relative to the joist. The board mounting clip 106 secures a pair of adjacent deck boards 100 to the top side of the joists using a first retainer flange 122 and a second retainer flange 124 protruding in opposing directions from the top end of the post 110. More particularly, the first retainer flange 122 protrudes rearward from the rear side of the post opposite the fastener region 114 at the front side of the post. The second retainer flange 124 is anchored on the first retainer flange 122 at a location laterally offset from the post 110 to extend forwardly in the direction of the fastener region 114 and opposite to the first retainer flange 122. In this manner the second retainer flange 124 protrudes forwardly beyond the post at a location which is laterally offset in relation to the fastener region 114 so as not to restrict access to alignment of a fastener with the fastener slot 120 during installation of the board mounting clip. The first and second mounting flanges are substantially coplanar with one another at a location parallel and spaced above the mounting flange 108.
The mounting post 110 has a thickness dimension (between a rear side from which the first retainer flange 122 protrudes and the front side from which the second retainer flange 124 protrudes) which corresponds approximately to the recommended spacing between adjacent composite deck boards 100 such that opposing side edges 102 of the boards can be abutted against opposing front and rear sides of the post 110 in the mounted position.
In order to install composite deck boards 100 with the board mounting clip 106, a starter board is initially installed on the joist followed by insertion of board mounting clips 106 on each joist at the exposed side edge of the already installed deck board 100. Each board mounting clip 106 is inserted into the respective mounting channel 40 in the released orientation followed by rotation of the board mounting clip through 90 degrees into the mounted orientation at a location spaced from the exposed edge of the installed deck board 100.
The mounting clip 106 can be rotated by insertion of a screwdriver bit into a socket 125 formed at the top end of the post 110. The socket 125 extends downwardly into the body of the mounting clip from an open top end of the socket so as to be arranged to mate non-rotatably with the driver bit to drive rotation of the board mounting clip 106 between the released and mounted positions thereof.
The board mounting clip 106 is then slidably displaced longitudinally along the mounting channel of the joist until the first retainer flange 122 at the rear side of the board mounting clip is fully inserted into the groove 104 of the installed deck board. A fastener can then be inserted through the fastener slot and fastened into the bottom wall of the mounting channel 40 and the joist to fix the longitudinal positioning of the board mounting clip with the post 110 of the clip abutted against the side edge of the installed deck board 100. A subsequent deck board 100 can then be positioned on the top side of the joist and slid in the longitudinal direction of the joist into abutment with the post 110 of the board mounting clip so that the two adjacent deck boards are situated at the recommended space therebetween. The second retainer flanges 124 of the board mounting clips are received within the corresponding groove of the second composite deck board 100 as the second composite deck board is laid into position. An additional set of board mounting clips 106 can then similarly be installed on the exposed side edge of the second composite deck board 100.
In other embodiments, the deck boards 16 may comprise auxiliary deck boards 126 as shown in
The body panel 128 of each deck board includes a panel member 134 the form of a flat rigid plate spanning nearly the full width of the deck board and spanning the full length of the deck board. A plurality of ribs 136 protrude down from the bottom side of the panel member to form legs which terminate in a common plane forming the bottom side of the deck board that is engaged upon the upper supporting surface of the joists in use.
A first flange 138 extends upwardly from a first side edge of the panel member 130 and a second flange 140 extends upwardly from a second side edge of the panel member opposite to the first flange. The first flange 138, the second flange 140, and the panel member 134 collectively form the U-shaped recess that receives the panel of finishing material 130 therein. The second flange 140 has a height which corresponds approximately to the height of the finishing panel 130 so as to be substantially flush at the top side thereof. The first flange is shorter in height than the second flange for terminating at a location spaced below the top side of the finishing panel 130. The second flange further includes a protruding rib 142 formed thereon which protrudes laterally outwardly over top of the first flange of an adjacent deck board when two deck boards are abutted laterally adjacent one another in the assembled configuration. The rib 142 protrudes laterally outwardly from the second flange and upwardly to a top end that is substantially flush with the top end of the second flange so that the rib and the second flange form two parallel edges spaced apart by a groove 144 therebetween. The top end of the rib 142 is directly above the top end of the first flange 138 of the adjacent deck board so that the top end of the rib 142 is located directly adjacent the corresponding edge of the finishing panel received within the channel 132 of the adjacent deck board.
Each panel body 128 of the auxiliary deck boards 126 further includes a male interlocking element 146 in the form of a flange protruding outwardly beyond the lateral boundary defined by the first flange 138 at a location slightly below the elevation of the panel member 134. At the opposing second side of the panel body 128, a female interlocking element 148 is formed as a groove in the panel body immediately below the second flange 140 at the second side of the panel member 134 so as to be suited for receiving the male interlocking element 146 of an adjacent deck board inserted therein. The panel body 128 further includes a fastener flange 150 extending laterally outward from the second side of the panel body 128 below the female interlocking element 148 in a common plane with the bottoms of the ribs 136 so that the fastener flange 150 is abutted against the top side of the joist.
Each deck board is typically installed by initially inserting the male interlocking element 146 into the female interlocking element 148 of an adjacent already installed deck board or of a perimeter finishing element of the deck board such as a fascia member as described in further detail below. Upon insertion of the male interlocking element 146 into a corresponding female interlocking element on the deck structure, the remainder of the deck board can be positioned flat against the top side of the joist followed by penetration of fasteners through the fastener flange 150 into the top side of the corresponding joists. An adjacent deck board 126 can then be installed by similar insertion of the male interlocking element into the female interlocking element of an already installed component of the deck structure.
As best shown in
A mounting channel 156 is also recessed into the top side of the outermost joist to extend longitudinally along the joist; however, the mounting channel in this instance is much larger in lateral dimension than the mounting channels of the joists 12. In this manner, the same joist mounting clips 56 used for securing the joist to the ledger board can be used as fascia mounting clips 158 by mounting the fastener flange 58 thereof recessed into the mounting channel together with the head of a corresponding fastener so that the hook flange protrudes upwardly beyond the top side of the outermost joist while being oriented in the longitudinal direction of the joist for hooking relation with a corresponding side fascia member 28 as described below.
The outermost joist further includes a bottom flange 160 which is substantially flush with the bottom side of the outermost joist and which protrudes outwardly to a free end below the outer wall of the web portion 146 of the joist. The outermost joist may also include a pair of outer ribs 162 extending longitudinally along the outer wall of the web portion 146 at spaced positions along the height thereof to terminate at outer free edges lying in a common plane with the free end of the bottom flange 160 to collectively support the side fascia member 28 engaged thereon in a mounted position of the deck structure.
A common profile can be used interchangeably as either an end fascia member 24 mounted across the ends of the joist opposite the ledger board or a side fascia member 28 mounted alongside each of the outermost joists. Each fascia member includes an upper portion 164 having an enlarged thickness between inner and outer sides of the profile as compared to a remaining wall portion 166 extending downwardly from the upper portion. The upper portion 164 supports the wall portion 166 to extend downwardly from the outer side of the upper portion such that a bottom shoulder 168 is defined below the upper portion at the inner side of the fascia member which is spaced below the top of the profile by a height corresponding approximately to the thickness of either embodiment of the deck boards.
When used as a side fascia member, the upper portion 164 is thus arranged to abut a portion of the outermost joist at the top side thereof so as to be substantially flush with the ends of the deck boards also engaged upon the outermost joist with the ends of the joists abutted with the inner side of the upper portion 164 of the fascia member. In this instance, the inner surface of the wall portion 166 of the fascia member abuts against the outer ribs 162 at the outer side of the outermost joist in the mounted position.
When used as an end fascia member, the upper portion 164 has the bottom shoulder thereof engaged upon the top side of the ends of a plurality of joists.
The profile forming the fascia members also includes a base flange 170 which protrudes inwardly from the wall portion at a location spaced below the shoulder by a height of the joist such that the base flange 170 is engaged directly below the bottom side of the outermost joist or the bottom side of the ends of a plurality of joists 12 depending upon the mounting location as a side fascia member or an end fascia member. The inner surface of the base flange 170 includes a catch 172 formed thereon which is engaged by the hook at the end of the bottom flange 160 of the outermost joist when used as a side fascia member. In either mounting location of the fascia member, the base flange 170 overlaps the bottom flanges of the corresponding joist to enable a fastener to be penetrated therethrough at an overlapping region of the flanges to fix the bottom of the fascia member relative to the joist(s).
The upper portion 164 of the profile forming the fascia members further includes a groove formed in the bottom side thereof adjacent to the inner side such that a remaining portion of the profile to the interior of the groove comprises a retainer flange 174 having a bottom free edge terminating in a common plane with the bottom shoulder 168 at a location spaced inwardly therefrom so that a corresponding retainer groove is formed between the retainer flange 174 and the bottom shoulder 168.
When used as a side fascia member, the fascia mounting clips 158 are secured within the mounting channel of the outermost joist with the hook flange 60 of the clips extending upwardly in alignment with the retainer groove so as to be in hooked relation with the retainer flange 174 of the fascia member. Fasteners penetrated through the fastener flanges 58 of the mounting clips fix the mounting clips to the bottom wall of the mounting channels in the outermost joist to fix the upper portion of the fascia member relative to the outermost joist.
When used as an end fascia member, the same fascia mounting clips 158 are secured within the mounting channel of each joist 12 at the outer end of the joist similarly to the mounting arrangement of the joist mounting clips hooked relative to the ledger board. More particularly, each fascia mounting clip 158 is mounted within the mounting channel of a respective joist so that the hook flange 60 thereof protrudes upwardly beyond the top side of the joist perpendicularly to the longitudinal direction of the joist for alignment with the retainer groove formed by the retainer flange 174 in the upper portion of the end fascia member. In this manner, the fascia mounting clips 158 are fastened to the joists followed by placement of the fascia member over top of the ends of the joists to abut the bottom shoulder 168 with the top of the joist and insert the hook flanges 60 of the mounting clips into the retainer groove. The base flange 170 is then aligned and inserted below the ends of the joist by slightly rotating the fascia member until the wall portion 166 of the fascia member is abutted against the ends of the joist. Fasteners can then be penetrated through the base flange 170 of the fascia member into the bottom flanges of the joist to fix the fascia member to the joist.
The upper portion 164 of the fascia member is further provided with a female interlocking element 176 formed as a groove along the inner side of the upper portion to extend along the full length thereof immediately above the retainer flange 174. When used as a side fascia member, the female interlocking element is merely covered by the ends of the deck boards abutted against the upper portion of the fascia member; however, when used as an end fascia member, the fascia member can first be secured to the ends of the joist prior to mounting of any deck boards. The first row of deck boards to be mounted are then positioned with the male interlocking element of the deck board first inserted into the female interlocking element 176 on the fascia member to secure the first side of the deck board relative to the joists, followed by use of fasteners to secure the fastener flange at the second side of the deck boards to the joists. This is further followed by mounting of subsequent rows of deck boards in a similar manner across the length of the deck.
Moulded corner caps 178 are provided which span the height of the fascia members and which include sockets formed at opposing ends at right angles to one another such that the sockets of each corner cap receive the ends of one end fascia member 24 and one side fascia member 28 inserted therein respectively.
The profile forming the fascia members further includes a trim flange 180 extending downward from the base flange 170 at a location which is recessed inwardly from the outer surface of the profile. The trim flange 180 serves as a mounting surface for securing additional panelling and the like for enclosing the area beneath the deck structure if desired.
The stair assembly 22 includes modular stringers that are each formed of a plurality of stringer sections 182. Each stringer section is an extruded profile having a cross-section which is continuous along the length thereof such that the profile forming each stringer section can be cut to various lengths as desired. Each stringer section 182 includes a main body 184 forming a hollow passage therein spanning the full length in the longitudinal direction of the profile. An upper connector 186 is formed above the main body as a tubular body similar in width to the main body 184 therebelow. The tubular body of the upper connector is generally square in cross-section and is joined to the main body therebelow so that a longitudinal groove is formed on each of the laterally opposing sides of the stringer section at the junction of the upper connector 186 with the main body 184 of the profile. Each of the grooves defines an undercut edge 188 forming a part of the upper connector that assists in securing the stringer section 182 to an adjacent stringer section thereabove as described in further detail below.
In this regard each stringer section further includes a lower connector 190 formed in the profile to extend longitudinally along the bottom of the stringer section. The lower connector is a generally U-shaped channel open to the bottom of the stringer section and having interior dimensions of height and lateral width that closely fits with the exterior dimensions of the tubular body of the upper connector 186 that the upper connector of an adjacent stringer section can be received within the lower connector 190. A protruding edge 192 is formed on the inner surface at both laterally opposing sides of the channel adjacent the bottom end thereof for alignment with and for being received into the grooves of the upper connector that form the undercut edges 188. Accordingly, when the lower connector of a stringer section receives the upper connector of an adjacent stringer section therein, the protruding edges engage below the laterally opposed undercut edges 188 serve to retain the upper connector within the lower connector. The mating connection between upper and lower connectors thus limits any relative movement between two coupled stringer sections to a horizontal sliding movement only. Transverse screws can then be penetrated through the walls of the upper and lower connectors to fix the longitudinal position of adjacent stringer sections relative to one another.
When adjacent stringer sections are coupled together, a tread portion of each stringer section is defined as a portion of the stringer section protruding beyond an adjacent stringer section thereabove. The horizontal sliding connection allows a depth of the tread portion of each stringer section to be adjusted. Once the tread depth has been selected, the rear end of each stringer section may be cut at a slope extending upwardly and rearwardly for alignment with similarly sloped rear edges of adjacent stringer sections above and below if desired.
The stair assembly further includes a footing member 194 secured to the bottom end of a lowermost one of the stringer sections. The footing member defines a tubular structure extending along the top side thereof with undercut edges so as to be substantially identical to the upper connector 186 of each stringer section. The footing member further includes bottom flanges 196 protruding laterally outward from the bottom of the upper connector 186 of the footing member at a location spaced below the undercut edges 188 thereof. The bottom flanges 196 define a lower supporting surface which is generally horizontal for engagement upon a suitable foundation. The footing member is coupled to the lowermost stringer section by insertion of the upper connector 186 of the footing member into the lower connector of the stringer section so that the mating connection limits relative movement to a horizontal sliding movement therebetween. Transverse screws inserted through the walls of the upper and lower connectors at the junction of the footing member to the stringer section fixes the stringer section relative to the footing member.
The stair assembly further includes a tread mount 198 secured to the top end of each stringer section that supports a tread member 200 thereon. The tread mount includes a U-shaped channel extending along the bottom side thereof which is open to the bottom so as to be substantially identical to the lower connector 190 of each stringer section, including the protruding edges 192 thereof. In this manner, the lower connector 190 of the tread mounts are arranged for mating connection with the upper connector 186 of any stringer section so that the mating connection is limited to a relative horizontal sliding movement therebetween. The tread mount 198 further includes a top flange 202 at a location above the lower connector 190 to protrude laterally outward from both sides of the lower connector along the full length of the tread mount. The top flange 202 defines an upper supporting surface upon which a tread member can be engaged.
Each tread member 200 may be identical to the auxiliary deck boards 126 so as to be mounted across a plurality of stringers by being supported directly upon the tread mounts 198 of respective stringer sections supporting the tread member thereon. The tread member is mounted such that the male interlocking element 146 thereof protrudes forwardly for cooperating with a riser member 204 that is somewhat similar to the profile of the fascia member.
The riser member 204 includes an upper portion 206 defining a maximum lateral width of the riser member at the top end thereof and a wall portion 208 which extends downwardly from the upper portion 206. The upper portion 206 protrudes inwardly beyond the inner surface of the wall portion to define a bottom shoulder 210 at the bottom side of the upper portion which is engaged upon and overlaps the top surface at the end of a plurality of stringer sections 182 of the stair assembly at a common elevation. The inner side of the upper portion 206 defines a female interlocking element 212 therein as a groove that mates with the corresponding male interlocking element at the leading edge of the tread member 200 similar to the interlocking connection between adjacent deck boards 126.
The upper portion 206 of the riser member further protrudes forwardly beyond the front face of the wall portion 208 to define a stair nosing.
The wall portion 208 spans below the upper portion 206 by a height of a stringer section 182 such that the bottom end of the riser member abuts the top surface of a tread mount 198 of a subsequent stringer section therebelow. A base flange 214 of the riser member protrudes forwardly from the bottom end of the wall portion 208 to define a fastener flange that receives fasteners penetrated therethrough for securing the bottom of the riser member to the tread mount of the stringer section below. The base flange 214 is subsequently overlapped by and covered by the subsequent mounting of a tread member 200 on the stringer section below.
The upper portion of each riser member further includes a retainer groove formed at the bottom of the upper portion adjacent the inner end thereof as defined by a retainer flange 216 identical to the retainer flange 174 at the inner side of the profile of the fascia members. In this manner, a riser mounting clip 218 can be mounted in recessed relation into a mounting channel 219 recessed into the top side of each tread mount 198. The riser mounting clip is identical to the joist mounting clips 56 so that the fastener flange 58 and the corresponding fastener head can be fully recessed into the mounting channel 219 while the hook flange 60 thereof extends upwardly beyond the top side of the tread mount in perpendicular relation to the longitudinal direction of the tread mount to be received within the retainer groove defined by the retainer flange 216 formed into the profile of the riser member 204.
Once the stringers of the stair assembly are formed by joining of stringer sections 182, the riser members are then secured to the stringer sections by use of riser mounting clips at the top end of each riser member together with fasteners through the base flange 214 to secure the bottom end of each riser member to a second tread mount 198 of a stringer section therebelow. Deck boards forming the tread members 200 can then be mounted in place by inserting the male interlocking element of the tread member 200 into the female interlocking element of the riser member to secure the leading edges of the tread members. Fasteners can then be penetrated through the overlapping of the flanges of the tread mounts with corresponding flanges at the bottom the tread members.
In the illustrated embodiment, the tread members 200 differ from the deck boards 126 in that no female interlocking element is required at the second or rear edge of the tread member. The illustrated tread member thus comprises an end deck board used as a finishing board forming the last row of deck boards installed against the ledger board. Optionally, each stringer section can be extended in length so that the resulting tread surface is formed by two or more rows of deck boards. In this instance only the deck board nearest to the riser member lacks a female interlocking element while the remaining deck boards forming the tread are identical to the deck boards 126 described above including both male and female interlocking elements.
The stair assembly is secured relative to the joists of the deck structure by a deck mount 220. More particularly, each stringer assembled from multiple stringer sections is secured to a respective pair of joists by a respective deck mount 220. Each deck mount includes a mounting plate 222 which spans between two joists such that opposing edges of the mounting plate can be fastened directly beneath corresponding bottom flanges of the two supporting joists. The deck mount further includes a main body 224 fixed to the bottom side of the mounting plate so as to be supported at a central location spaced between two joists. The main body 224 is substantially identical in cross-section and shape to the main body 184 of each stringer section so that a hollow passage within the main body 224 is identical to the hollow passage within the main body 184 of any stringer section. Due to the same cross-sectional shape with similar interior dimensions, a joiner member 226 can be slidably inserted at opposing ends into the hollow passages of the deck mount and an uppermost one of the stringer sections. The joiner member functions as a rigid beam mounted in horizontal sliding connection with each of the deck mount and the uppermost stringer section so that movement between the deck mount 220 and the uppermost stringer section is limited to a horizontal sliding movement. Transverse fasteners can be penetrated through the walls of the main bodies and into the joiner member at opposing ends thereof to selectively fix the longitudinal position of the joiner member relative to each of the deck mount 220 and the upper stringer section. The deck mount 220 and the joiner member 226 received therein thus define a first connector forming a mating sliding connection with a second connector defined as the hollow passage of the stringer section. The first and second connectors mate for relative horizontal sliding movement as described above.
The deck structure can also include a railing post assembly 228 for securing railing posts 233 about the perimeter of the deck structure, and specifically at laterally opposing sides of the stair assembly. Each railing post assembly includes a lower mounting member 230 in the form of a horizontal plate spanning between two supporting joists 12 to overlap the top sides of the bottom flanges thereof. The lower mounting member further includes two upright flanges 232 extending upwardly from the bottom plate at spaced apart positions to collectively define a U-shaped mounting channel that is open upwardly to the post above.
A post base 234 is used to support a respective railing post 233 thereabove. The post base 234 includes an upper flange portion 236 in the form of a horizontal plate which fits in place of the insert body or finishing panel 130 in the top side of one of the deck boards 126 mounted on the deck structure. The upper flange portion 236 may only occupy a portion of the length of the deck board as illustrated such that the remainder of the length of the deck board remains occupied by one or more finishing panels 130 with the finishing panels being substantially flush at the top side thereof with the plate forming the upper flange portion 236.
The post base 234 further includes a shaft portion 238 which is fixed to the upper flange portion at a central location thereon to extend downwardly through a corresponding aperture formed in the panel body of the deck board 126. The shaft portion has a suitable length and is suitably positioned for alignment and receipt into the mounting channel formed in the lower mounting member 230 therebelow. A suitable fastener can then be penetrated through the bottom end of the shaft portion 238 and through the upright flanges 232 to fix the post base 234 to the lower mounting member.
The railing post assembly 228 may also include an upper mounting member 240 in the form of a plate which is similar in size to the upper flange portion 236 of the post base but is arranged to be received immediately below the upper flanges of the two supporting joists to fully span the lateral distance between the two joists. Opposing edges of the upper mounting member 240 can then be secured immediately below the top flanges of two adjacent supporting joists by fasteners penetrated therethrough. As illustrated, the upper mounting member 240 can be sized to match the dimensions of the upper flange portion of the post base 234 so that the same set of fasteners that secures the upper mounting member to the joists can also be penetrated down through the upper flange portion for likewise securing the upper flange part of the post base to the same top flanges of the two adjacent supporting joists. A central opening is provided in the upper mounting member 240 that receives the shaft portion 238 of the post base extending therethrough. The shaft opening 242 is sized to closely match the dimensions of the shaft portion received therein so that the upper mounting member provides lateral support in all directions to the shaft portion and in turn the post base 234.
The bottom end of the post includes a post leveling plate 244 fixed thereon which can be fastened by a centre bolt 245 to a central location on the upper flange portion 236 of the post base 234. Four additional leveling screws 246 are threaded into the post leveling plate 244 at circumferentially spaced positions about the centre bolt 245 to allow angular orientation of the post leveling plate 244 to be adjusted slightly relative to the upper flange portion 236 of the post base 234. Each leveling screw 246 is received within a corresponding threaded bore so that rotation of the screw adjusts the amount that the screw protrudes beyond the bottom side of the post leveling plate. The post 233 is fixed to the post leveling plate to extend upwardly therefrom so that the angular orientation of the post varies with the adjustment of the orientation of the post leveling plate 244. An annular cap 248 extends over a perimeter portion of the post leveling plate 244 that locates the leveling screws therein for covering the plate and leveling screws subsequent to installation.
In the illustrated embodiment, the ledger board, the deck boards 126, the joists, the beams, the fascia members, and the components of the stair assembly including the stringer sections, are all formed of rigid extruded metal which is continuous in profile along the full length thereof so that the components can be cut to various lengths while maintaining the ability to interconnect the components as described above.
Turning now to
When mounted at ground level, the joists 12 including the outermost joists are substantially identical in general configuration to the previous embodiment but are reduced in height relative to the previous embodiment so that mounting of the flanges of the joists to the flanges of the beams remains identical and use of mounting clips within the mounting channels of the joists also remains identical.
When mounted at ground level, end fascia members are installed at both ends of the joists using the fascia mounting clips described above. Likewise, side fascia members are mounted at both sides of the deck structure. The profile forming the end and side fascia members in the second monument remain identical to one another; however, they differ from the previous embodiment in that the fascia members span the combined height of the joists and the beams upon which the joists are supported. More particularly, the fascia member remains configured with the same upper portion 164; however, the wall portion 166 in this instance extends down to the elevational of the bottom of the beam. The base flange 170 is located to protrude inward from the wall portion 166 at an intermediate height along the wall portion to again overlap the bottom of the corresponding joist with a similar catch hooking onto the outermost joist as described in the previous embodiment. The fascia member according to the second embodiment effectively replaces the trim flange 180 at the bottom of the fascia member with an extended lower portion of the wall portion 166 which remains flush at the exterior with the remainder of the wall portion above.
In a further embodiment as illustrated in
A set of two joist mounting members 276 are mounted on the end of each joist 262. Each joist mounting member 276 is formed of a rigid metal plate which has been folded to define a first flange 278 and a second flange 280 oriented perpendicularly to one another. The first flange 278 is intended to be abutted flat against the front face of the main body portion 264 of the ledger board when the corresponding joist is similarly abutted against the front face of the main body portion of the ledger board. The first flange 278 receives fasteners through the first flange, through the ledger board, and into the supporting surface of an upright structure upon which the ledger board is carried.
The second flange lies flat against a corresponding side surface of the joist 262 and includes fastener apertures therein to enable screws to be penetrated into the joist through the apertures for fastening the second flanges to opposing side surfaces of the joist. Each joist mounting member further includes two follower elements 282 formed of the same plate material forming the second flange 280 such that the follower elements lie coplanar with the second flange but protrude beyond opposing top and bottom edges of the second flange at opposing top and bottom ends of the joist mounting member.
Each second flange is mounted against the joist such that the bottom edge of the flange 280 lies substantially flush with the bottom side of the joist while the lowermost follower element 22 protrudes below the bottom of the joist. The overall height of the joist mounting member is arranged such that the opposing upper follower element does not protrude above the top of the joist. The follower element 282 is a tab of rigid metal which is trapezoidal in shaped to have exterior dimensions closely matching the interior dimensions of the channel forming the track such that the follower element mates with the track for longitudinal sliding movement therealong prior to fastening of the first flange 278 to the ledger board 260. The mating connection of the follower elements with the track prevent outward displacement of the joist away from the ledger board while the weight of the joist is supported primarily on the ledge 268 of the ledger board.
As illustrated, each joist mounting member is reversible in orientation between a first orientation on a first side of the joist with a first one of the follower elements protruding below the bottom side of the joist for mating connection with the track while the opposing follower element at the top of the joist mounting member is not in use, and a second orientation on a second side of the joist with a second one of the follower elements protruding below the bottom side of the joist for mating connection with the track while the opposing follower element at the top of the joist mounting member is not in use. The reversible orientations are permitted by the structure of the joist mounting member having opposing top and bottom ends which are symmetrical with one another about a horizontal plane intersecting the joist mounting member at a central location between the top and bottom ends of the joist mounting member.
Turning now to
In this instance, the ledger board 18 is shown supported on the exterior wall 300 of a building structure 302. As shown in
Each of the bracket members 308 and 310 includes a first flange 312 with fastener apertures therein for fastening flat against the sidewall of the joist 12 or floor joist member 306. Each bracket member further includes a second flange 314 fixed perpendicularly at one end of the first flange and supported to remain at right angles by a pair of side gussets plates 316 joined between the first and second flanges at opposing top and bottom edges thereof. Each second flange includes a central mounting aperture formed therein to receive a connecting rod 318 extending therethrough in communication between the first and second bracket members. In the illustrated embodiment, the connecting rod 318 is a threaded shaft enabling a threaded nut 320 to be threaded onto opposing ends of the rod.
When arranged as shown in
The ledger board 18 is substantially identical to the previous embodiment described above with the exception of an additional flashing member 322 being provided at the top end of the ledger board. When the ledger board comprises a main body portion 44 in the form of a plate having an inner side against which the joists are abutted and an outer side supporting ribs 46 thereon that engage the building structure, an overall thickness of the main body portion as defined by the combined thickness from the inner surface of the main body portion and the outer ends of the ribs 46 abutted against the building. The flashing member 322 is supported at the top end of the main body portion to extend upwardly and outwardly across a thickness of the main body portion from the inner side of the main body portion to the outer side that is abutted against the building. In this manner, any precipitation or moisture directed onto the top of the ledger board is further directed by the flashing member away from the building onto the deck surface to discourage moisture penetration between the ledger board and the exterior of the building.
The arrangement of the posts 20 below the deck system also differ somewhat from the prior embodiment by the addition of additional brace members 324. Additionally, the bottom plate 76 can be modified to include anchors depending therefrom which are suitable for being embedded into a concrete footing. With regard to the brace members 324, as shown
The first beam bracket includes a U-shaped channel member 330 extending around three sides of the square cross section of the post but with the sides of the channel member extending only partway across the thickness of the post so as not to interfere with the corresponding channel member 330 of the other brace member mounted diametrically across from the first brace member. The channel members 330 of the two braces collectively extend substantially about the full perimeter of the post. The sides of the channel members include mounting apertures therein for receiving threaded fasteners in alignment with corresponding vertical grooves 332 formed in the post corresponding to each side portion of each channel member. Each vertical groove 332 provides an interrupted surface on the post that more readily accepts self tapping screws to be penetrated into the post when fastening the channel members 330 to the post. Two mounting flanges 334 extend outwardly from the central portion of the channel member 330 in parallel and spaced apart relationship with one another to receive the first end of the brace member 324 therebetween for securement by corresponding threaded fasteners penetrated through the flanges and the end of the brace member.
Each second beam bracket includes a mounting plate 336 arranged to be secured flat against the bottom side of the beam and a follower element 338 protruding upwardly from the mounting plate having a cross-sectional shape that matches the cross-sectional shape of the mounting channel 72 at the bottom side of the beam while accommodating for the ribs 74 at each side of the mounting channel. Accordingly the follower element 338 mates with the mounting channel so as to be restricted to longitudinal sliding movement along the beam to ensure alignment of the second beam brackets with the beam. A pair of mounting flanges 340 extend downwardly from the mounting plate 336 in parallel and spaced apart relation to receive the corresponding second end of the brace member 324 therebetween for securement with corresponding fasteners penetrated through the mounting flanges and the end of the brace member. Additional fasteners are penetrated through the corners of the mounting plate 336 to fix the mounting plate at a selected longitudinal position along the beam spaced outwardly from the ball and socket arrangement coupling the top end of the post 20 to the beam.
Turning now to
Turning now to
In the illustrated example, the shaft portion comprises tube of circular cross-section for cooperating with a shaft opening 242 in the upper mounting member 240 which is shaped to mate with the circular cross-section at a plurality of different locations relative to the upper mounting member. The shaft opening 242 includes a first circular portion locating the circular cross-section of the shaft portion therein at a central location on the upper mounting member 240 when mounting at the ends of the joists according to
In the illustrated example, the upper flange portion 236 of the post base above the deck boards similarly includes a shaft opening receiving the shaft portion 238 extending upwardly therethrough at two different locations corresponding to the two different mounting configurations described above. The shaft portion 238 in this instance extends upwardly through the post leveling plate 244 above the height of the deck surface to be concentrically received within the post 220 to provide further support to the post. The post leveling plate 244 is fastened to the upper flange portion 236 of the post base above the deck surface using a set of four corner fasteners. A set of four corner fasteners can also be used to secure the leveling plate 244 at the bottom of the posts according to the previous embodiments.
When securing railing posts to the stairs, an inner post bracket 352 and an outer post racket 354 are supported on a corresponding stringer section 182 upon which the post is to be supported. Each of the inner and outer post brackets includes a first flange 356 with fastener apertures therein to accept fasteners which secure the bracket to the corresponding upright side wall of the stringer section, and a second flange 358 extending perpendicularly outward from the top edge of the first flange so as to be substantially flush with or slightly below the upper supporting surface of the tread mounts 198 that support corresponding tread members 200 of the stairs thereon. Supporting gusset plates 360 are connected between the first and second flanges to support the first flanges relative to the second flanges. Each inner post bracket 352 is larger in height than the corresponding outer post bracket 354 so as to provide a stronger anchoring at the interior of the stair assembly. The tread members 200 are supported on the stringers in this instance to protrude slightly outward beyond the outermost stringers at opposing sides of the stair assembly by a distance corresponding approximately to the lateral width of the second flanges 358 of the outer post brackets. The post leveling plate 244 at the bottom of a post 228 is supported above the tread member 200 such that the four corner fasteners 354 securing the leveling plate are penetrated downwardly through the tread member for connection to the second flanges 358 of the inner and outer post brackets. More particularly, two outer corner fasteners 350 are fastened to the second flange of the outer post packet 354 and two inner corner fasteners are fastened to the second flange of the inner post bracket 352. Cover plate 362 can be mounted overtop of the exterior side of the outer post brackets 354 to conceal the threaded fasteners securing the first and second flanges to respective components of the stair assembly when viewed from the exterior.
The side fascia member 28 shown in
To ensure a finished appearance between the ends of the deck boards and the facia members, an additional flashing member 368 may be provided for cooperation with the female interlock element 176 formed at the inner side of the upper portion 164 of each fascia member. In this instance a small retainer flange 370 is formed at the inner side of the fascia member in close proximity to the top of the fascia member, spaced slightly above the female interlock element 176. The retainer flange 370 forms a catch extending longitudinally along the inner side of the upper portion of the fascia member. The flashing member 368 has an outer side that includes a male interlocking element 372 at the bottom side thereof extending outwardly to be received into the corresponding female interlocking element 176 of the inner side of the upper portion of the fascia member. A hook flange 374 also protrudes slightly from the outer side of the flashing member at the top end thereof above the male interlock element for alignment with the retainer flange 370. In this manner the outer side of the flashing member mates with the inner side of the upper portion of the fascia member by receiving a section of the fascia member from the female interlock element 176 to the retainer flange 370 between the corresponding male interlocking element 372 and the hook flange 374 of the flashing member. When mated in this manner, a cover flange 376 of the flashing member overlaps the perimeter of the deck boards. The cover flange 376 forms an upper portion of the flashing member 368 that extends inwardly from the coupling components at the outer side of the flashing member. The cover flange 376 is positioned to be parallel and spaced above the top surface of the outermost joist by a distance corresponding to the thickness of the deck boards when the flashing member is mated to the fascia member. The ends or an outer side edge forming edge portions of the deck boards are thus arranged to be received by insertion between the top of the joists therebelow and the cover flange 376 of the flashing member thereabove to provide a finished appearance. An additional horizontal strip of gasket material (not shown), for example a flat strip of rubber or other similar resilient material that is moisture resistant, can be mounted between the bottom surface of the cover flange 376 and the top surface of the deck boards that are overlapped by the cover flange to provide an effective seal that resists moisture penetration between the deck boards and the fascia member.
Turning now to
Turning now more particularly to
As best shown in
To accommodate the use of a conventional deck board 388 inserted into the riser member, the riser member in this instance may include an upper portion 394 that is identical to the upper portion 206 of the riser member 204, but instead of a connected wall portion 208 therebelow, the bottom side of the upper portion 394 that forms a stair nosing includes a riser channel 396 formed therein having a dimension which is sized to receive the top edge of the conventional deck board 388 inserted therein. The deck board 388 is inserted upwardly through the open bottom end of the riser channel to be inserted partly into the body of the upper portion 394 of the modified riser. A bottom trim member 398 mounts and the bottom of the board 388 and comprises a U shaped channel having dimensions that accept the opposing bottom edge of the deck board 388 inserted therein. The bottom trim member mounts against the upper tread supporting surface of the stringer section therebelow and is retained against the forward end of the corresponding stringer section by the mounting of a tread member onto the next stringer section below.
A similarly modified fascia member 400 as shown in
As further illustrated in
A riser end cap member 416 is similarly formed of a first mounting flange 418 and a second capping flange 420. The first mounting flange 418 is located against the leading face of a corresponding stringer section against which the corresponding riser is supported and protrudes laterally outward beyond the stringer section by the same amount that the riser and corresponding tread protrudes in the lateral direction. The first mounting flange may be secured by fastening to the rear of the riser. The second capping flange 420 is mounted perpendicularly along the outer edge of the first mounting flange 418 to extend forwardly therefrom in overlapping arrangement with the outer edge of the riser member. The capping flange 420 has a perimeter shape that matches the shape of the upper portion 394 forming the stair nosing of the modified riser as well as the depending board 388 and bottom trim member 398 forming the remainder of the riser to provide a finished appearance at the end of the riser.
The tread end cap member 410 and the riser end cap member 416 may be modified slightly in shape and dimension to correspond with the shape of the riser members 204 and the tread members 200 of any previous embodiments of the stair assembly as described above to provide a similarly finished appearance at both sides of the stair assembly.
A set of beam end caps 500 as shown in
When using auxiliary deck boards 126 that are fastened to the top surface of the joist using threaded fasteners, a gasket such as a rubber washer may be secured under the head of each fastener to form a seal about the resulting whole caused by penetration of the fastener through the retainer flange in the deck board when fastening.
Turning now to
A bottom channel 274 is formed as a recessed groove between the junction of the upper surface 270 of the ledge and the main body portion 264 to define a lower portion of a track extending longitudinally along the length of the ledger board directly adjacent the forward face of the main body portion against which the joists are mounted. A retainer flange 275 protrudes from the front face of the main body portion 264 at a location spaced above the ledge portion by a height which is near to the height of the joist such that the retainer flange is located closer to the top of the ledger board than the bottom of the ledger board. The retainer flange extends outwardly and downwardly to form a top channel 277 under the retainer flange which is open downwardly to define part of the track in a common plane with the bottom channel 274 spaced therebelow, directly against the forward face of the ledger board.
Similarly to the embodiment of
The second flange 280 lies flat against a corresponding side surface of the joist 262 and includes fastener apertures therein to enable screws to be penetrated into the joist through the apertures for fastening the second flanges to opposing side surfaces of the joist.
A pair of end plates 279 are formed integrally with opposing top and bottom ends of the second flange 280 respectively. Each end plate extends perpendicularly from the exterior face of the corresponding second flange 280 such that depending upon the orientation of the joist mounting member 276, a lowermost one of the end plates 279 lies flush at the bottom side with the joist so as to be engaged upon the upper supporting surface 270 of the ledge in a mounted position.
Each joist mounting member 276 further includes two follower elements 282 formed of the same plate material forming the first flange 278 such that the follower elements lie coplanar with the first flange but protrude beyond opposing top and bottom edges of the second flange at opposing top and bottom ends of the joist mounting member. Accordingly the follower elements 282 include a top follower protruding above the upper surface of an uppermost one of the end plates 279 and a bottom follower protruding below the bottom surface of a lowermost one of the end plates 279.
Each second flange 280 is mounted against the joist such that the bottom edge of the flange lies substantially flush with the bottom side of the joist while the lowermost follower element 282 protrudes below the bottom of the joist. The overall height of the joist mounting member is arranged such that the opposing upper follower element does not protrude above the top of the joist.
The top and bottom follower elements 282 comprise rectangular protruding portions of the plate forming the first flange 278 for alignment with the top channel 277 and the bottom channel 274 of the track respectively in a mounted position. The overall height of the plate forming the top and bottom follower elements is arranged to be received within the top and bottom tracks when the bottom one of the end plates 279 and the bottom of the joist is abutted against the upper supporting surface 270 of the ledge 268.
Furthermore, the depth and dimension of the channel forming the top track 277 is sufficient to allow insertion of the top follower into the top channel 277 such that the bottom edge of the opposing bottom follower has sufficient clearance above the upper supporting surface 270 of the ledge locating the bottom channel 274 therein that the bottom end of the joist mounting member 276 can be rotated towards and away from the ledger board while the top follower remains engaged within the top channel 277 as shown in
The joist mounting members for mounting on laterally opposing sides of each joist are identical to one another with the exception of one of the joist mounting members 276 being flipped 180° about a horizontal axis relative to the other. Once both of the joist mounting members have been mounted within the top and bottom channels of the track, the joist mounting members can be abutted against laterally opposing sides of the of the joist 266 for fastening of the second flanges 280 to the sides of the joist.
Additional fasteners can be penetrated through the first flanges 278 into the ledger board and the building structure against which the ledger board is mounted.
Fasteners can also be penetrated through corresponding apertures in the end flanges 279 at the bottom of each joist mounting member for penetration into the corresponding upper supporting surface 270 of the ledge 268. Fastener grooves 283 may be formed in the upper supporting surface 270 and in the forward face of the main body portion 264 to allow self tapping screws to more readily penetrate into the material of the ledger board when fixing the joist mounting members 276 to the ledger board.
In a further embodiment of the joist mounting members 276, each first flange 278 may be joined to the corresponding second flange 280 by a vertical hinge 285 allowing relative pivotal movement of the first flange relative to the second flange. In this instance, the first flange can remain mounted within the track in the usual manner lying flat against the front face of the ledger board, however, the second flange can extend outward at an adjustable non-perpendicular angle relative to the ledger board. This allows the joist to be similarly oriented non-perpendicularly to the ledger board as illustrated in
Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/CA2021/051508 | 10/26/2021 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63105544 | Oct 2020 | US |
