The present invention relates to free-standing deck apparatus. More particularly, the present invention relates to modular deck apparatus that readily assembles with one or more component frames and decking for a deck module, a deck ramp module, and a stairs module.
Often residential homes, shopping facilities, community centers such as pools and outdoor facilities, and office building complexes feature elevated deck structures. These decks provide ornamental and architectural appearances for the buildings and grounds as well as stable expanded usable space for entertaining, work, play and access to the adjacent facility and grounds. Typically, deck structures are designed and constructed with foundational supports, joists and decking secured for bearing loads imposed by persons engaged in activities on the deck. Stairs facilitate access to the elevated deck, and decks offer ornamental and structural features including multiple levels, deck board placements for designs, and built-in seating.
Typically, decks for home, offices and grounds are constructed according to engineering designs that account for loading, wind resistance, and stable foundational support. Alternatively, low height decks may be constructed as free-standing structures, in which the deck mass provides resistance to movement. There are a variety of components available for constructing decks including elongated boards for decking, beams for foundational support. stair risers that support in spaced-relation vertically and lateral offset treads, and railings that attach together with fasteners to support post. Stability requirements may necessitate foundational supports for low-height decks such as poured concrete footers having metal connecters to beams and molded concrete stabilizer blocks arranged in space-relation. Metal brackets, connectors, hangers, and fasteners join components of the decks together for a rigid stable structure. Deck boards may be wood or alternatively in recent years, plastic or composite material boards have become popular for longevity and weather resistance which may reduce periodic maintenance requirements.
Deck structures may be a desired feature for manufactured buildings such as mobile homes or offices. These manufactured buildings are typically installed above grade and supported by piers and ground anchors that connect to elongated longitudinal support beams of the manufactured building. The support beams are spaced-apart and provide a support for a floor having transverse joists and floor decking and from which the side walls extend to a roof for enclosing the building. During installation of the manufactured building at a site, a crew of installers place a foundation of a plurality of vertical piers between the ground surface and the support beams, for transferring loading from the manufactured building to the ground. The pier may seat on a rigid ground pan or connect to a footer in the ground such as for areas subject to ground freeze in winter weather. Because these buildings are installed at a height relative to the underlying ground surface, stairs or steps may be required for entrance and egress.
U.S. Pat. No. 6,634,150 discloses a foundation that provides resistance to lateral or longitudinal forces that may be exerted on the manufactured building, such as by strong winds or earthquakes. A lateral brace pivotably attaches at a lower end to the ground pan under one of the support beams and attaches at an upper end to the other of the support beams. A separate pier is installed on the ground pan contacts the support beam above the ground pan. The lateral brace enables the ground pan to resist lateral forces on the manufactured building while the pier supports the manufactured building. Similarly, the brace may be connected between the ground pan and the support beam over the ground pan, for resisting movement caused by longitudinal forces on the manufactured building.
The ground surface typically slopes, so the piers are of different heights for positioning the manufactured building level. The height of the doorway into building is in a range of about 1 foot to about 4 feet above the ground surface, and typically in a range of about the 2 feet to 3 feet height relative to the ground. Depending on the height of the door opening to the manufactured building, the stairs structure, or stairs with a small landing area, may be installed, for access to the building. Also, persons using mobility devices (crutches, canes, wheelchairs or scooter devices (powered or manual)) may find stairs difficult, and so buildings may be provided with ramps gently sloped to facilitate entrance and egress. Many organizations and construction guidelines provide for a 4 to 7 degree incline, preferably 1:12 or about 5 degrees incline.
Alternatively, an owner of the building may contract separately for construction of a deck with stairs for an area proximate the building and for a landing area for entrance into the building and egress. Often the deck is installed by a separate decking installation crew, and it may be some several days or weeks between the installation of the manufacture building, for example, and the installation of a deck and stairs. For the interim period, temporary stairs may be used, but such is not preferred.
Also, as noted above, component products from which decks and stairs may be constructed are typically available from home improvement stores. These components include wooden stair risers, deck boards (both wood and composite) for treads and deck surface, metal braces, hangers and fasteners, railings and posts, and blocks, support beams, and concrete for foundations and supports. Nevertheless, these deck components have the drawback of in-field custom measuring, cutting and constructing.
There is a need in the art for a deck, ramp, and stairs apparatus that readily assembles and installs in the field for buildings with minimal different components that do not require alterations or the use of specialized tools. It is to such that the present invention is directed.
The present invention meets the need in the art by providing a deck module readily assembled and installed in the field to provide a deck structure for a building. The deck module comprises a deck apparatus, comprising a pair of opposing brace frames, each brace frame having two opposing vertical members connected by a transverse member. The opposing brace frames connect together in spaced relation with a pair of opposing connector bases. Each connector base has an elongated member with a pair of posts extending in a first direction from respective end portions of the elongated member, the posts for being received in a respective open end of the aligned vertical members of the opposing brace frames to hold the brace frames in spaced-relation. A deck walking surface is provided by a deck board top frame having opposing end members and opposing side members attached at respective distal ends, with a plurality of projecting posts each extending from a respective connection of one of the end members and one of the side members. A plurality of deck boards are disposed between the end members. Each of the posts for being received in an opposing upper end of a respective one of the vertical members of the opposing brace frames. Objects, advantages and benefits of the invention may be readily ascertained upon a reading of the following detailed description in conjunction with the drawings.
With reference to the drawings, in which like parts have like identifiers,
The stairs module 24 has a stair riser 34 with a pair of opposing spaced-apart riser arms 36 from which supports extend for holding a pair of deck boards as treads 38. A railing 40 orientated at an angle attaches to the riser arms 36 for lateral framing of the stairs module 34 (one railing 40 is shown).
With reference to
The opposing brace frames 26, (66), the connector bases 28, and the top frame 90 define a deck module box for the deck module 22. The boxes of adjacent deck modules 22 interconnect together for rigidity and stability of the free-standing deck and to maintain the deck surface level, with fasteners that connect adjacent braces, adjacent connector bases, and adjacent portions of the respective top frames.
Decks above the ground surface 25 may require side railings for preventing persons from stepping off or falling off the elevated deck. The modular deck apparatus of the present invention includes an elongated railing 150 (discussed below and shown in
The end post 112, midpost 114 and the corner post 116 connect to and support the railing 150 illustrated in perspective view in
The modular decking apparatus 20 assembles as a deck that may be free-standing on the ground 25 with one or more deck modules 22 connected together and may include at least one stairs module 24. With reference to
With reference to
A second brace frame is prepared with adjustable legs 80. If the deck is to have another deck module 22 positioned adjacent to the first, the brace frame 26 is used. The brace frame 26 includes receivers 54, 56 for interconnecting with the adjacent deck module. Otherwise, the brace frame 66 may be used. The legs 80 are similarly inserted and secured in the leg receivers 58 sufficiently to maintain the deck surface level. That is, a height is determined for the brace frame next to the building so that the adjustable leg 80 inserts sufficiently into the receiver 58. The height outward of the building is similarly determined and the leg 80 inserted and secured in the opposing leg receiver 58 outwardly of the building.
The opposing brace frames then connect together using a pair of the connector bases 28. The legs 72 of the bases 28 insert into the opposing lower open ends of the vertical members 50 on the opposing brace frames. The deck frame 90 with the attached deck boards sits on top with the posts 98 inserted into the open upper ends of the vertical members 50. A stake or screw as appropriate inserts through the opening 86 of the plate 84 to secure the leg 80 to the ground (or ground surface such as concrete, asphalt or wood) and resists movement of the deck.
If the deck is to have an adjacent module, the brace frame 26 or 66 is prepared. The brace frame 26 is used if that module is to continue to a subsequent module; otherwise the brace frame 66 may be used. The brace frame in the prior deck module is also used for the support brace frame for the next adjacent deck module.
Adjacent deck modules 22 connect together with fasteners that secure the adjacent components of the deck module boxes together; i.e., fasteners secure through the aligned openings 100 in the end members 92 of end-to-end adjacent deck modules; of aligned openings 102 in the side members 94 and/or aligned openings 74 in the connector bases 28 of side-to-side adjacent deck modules; and adjacent posts 50 and spans 50 of adjacent deck modules. Also, a respective set of openings 100 or 102 may be used for attaching the stair riser 160 to an end or a side of a particular deck module 22.
The stairs module 24 attaches to one of the deck modules 22. First, the vertical spacing of the stair riser 160 is accommodated by installing a respective one of the legs 80 into the leg receiving tubes 176. The leg 80 is secured with a fastener in a selected position based on the determination discussed above for the height of the deck. The stair riser attaches to the deck module 22 by inserting the upper railing support tubes 174 into the open end of the respective receivers 54. It is to be noted that the brace frame 26 is used for the deck module 22 that engages the stairs module 24, with the receivers 54, 56 outwardly for receiving the upper railing support tubes 174 of the stair riser 160. With each of the end members 92 and side members 94 having the openings 100, 102 respectively, the stair riser 160 readily installs on either the end or the side of the deck module with bolts that extend through the respective openings (100 or 102) into the upper transverse member 166 of the stair riser 160. The upper transverse member 166 includes openings that align the respective openings 100 or paired openings 102 in the end and side members 92, 94, respectively.
Railings may attach to an upper surface of the deck 20 on perimeter portions for preventing persons from stepping off or falling off the elevated deck. The railings assemble with a plurality of the elongated railing 150 that interconnect with end posts 112, midposts 114, and corner posts 116. One of the end posts 112 positions on the deck as a starting point for the railing. Fasteners through the openings 126 secure the end post 112 to a deck board 32. For an adjacent corner, one of the corner posts 116 attaches to a first end of one of the railings 150 by insertion of the stubs 128 into the open ends of the top and bottom rails 152, 154. The stubs 128 in the end post 112 insert into the open ends of the top and bottom rails 152, 154 at the opposing end of the railing 150. The corner post 116 positions on a corner of the deck module and secures in place with fasteners though the openings 126 into the deck board 32. The stubs 128 received in the open ends of the rails, with placement and securing of the post to the deck board, assembles the side perimeter railing without having to separately fasten the rails to the posts such as with set screws. In an alternate embodiment, the stubs 128 are open-ended tubes that extend laterally from the post as an open collar. The top and bottom rails insert into the respective collar. A fastener (such as a screw threadly inserted from a bottom portion) may secure the top and bottom rails within the collar.
The midpost 114 connects intermediate two railings 150 on portions of the deck having two adjacent deck modules 22. Continuing with the example in the preceding paragraph, one of the midposts 114 connects to an end of another railing 150. The stubs 128 insert into the open ends of the top and bottom rails. The stubs 128 extending from the corner post 116 extend into the opposing open ends of the rails. The midpost 114 stands on the proximate deck board 32. Fasteners extend through the openings 126 to secure the midpost 114 to the deck board.
The railing members are further similarly joined with the stubs 128 and the open ends of the railings 152, 154 in perimeter portions of the deck with the appropriate end posts 112, midposts 114 and corner posts 116 secured to the deck boards.
The stairs railing 180 attaches to the stair riser 160. The upper railing support tube 174 receives the leg 188 of the stairs railing 180 and the lower railing support tube 178 receives the leg 192. The railing 180 may be secured with fasteners, such as self-drilling screws drilled through the support tube 174, 178 and into the leg 188, 192, respectively.
A first U-channel 232U mounts to a forward portion of a first tread 32 while an opposing second U-channel 232L mounts to a rearward portion of a second adjacent lower tread 32. The panel 234 slides laterally into the opposing channels 232 for closing the open gap between the treads. Similar U-channels may gainfully close the open side between the deck boards and the connector base 28 of the deck modules 22.
The brace frames may be provided selectively for different base heights adjustable within a range by the adjustable legs 80. The vertical members 50 in the illustrated embodiment have lengths selected as 22.5 inches, 30 inches, and 37.5 inches, in order to provide for deck heights when using the legs 80 in ranges of between about 22.5 inches to about 30 inches, from about 32 inches to about 39.5 inches, and from about 37.5 inches to about 45 inches, respectively. These ranges accommodate a step gap between the deck board 32 and the threshold of the doorway into the building. Also, the brace frames 26, 66 in the different heights allows decks made with multiple modules to have a portion of a first height and a second portion of a second height.
With reference to
The ramp 250 assembles with deck ramp modules 22a in which adjacent brace frames 26 (or brace frame 66 at the lower leading end of the ramp) are of different heights and interconnected by opposing connector members 254 shown in perspective view in
In assembly of the ramp 250, the brace frames are sequenced selectively with decreasing heights (i.e, by decreasing the length of the vertical members 50, for example, or adjusting with the adjustable legs 200 (or 210) for progressively sloping the ramp from the deck level to a leading lower end of the ramp proximate the ground surface. As an illustrative example, a brace frame 26 at a first end of a deck ramp module 22a that has a run length of four (4) feet positions the deck at 36 inches; an opposing brace frame 26 (or 66) would be of a shorter length to position the deck at 32 inches; thus, the deck ramp slopes from the first end to the second end on a 1:12 slope. A plurality of the ramp modules interconnect in sequential adjacent relation to form the ramp of appropriate length. In an alternate embodiment, a deck module or multiple deck modules define an intermediate transition or switch-back between first and second ramp portions in the event the ground space does not accommodate a single run ramp in its full length. In such embodiment, the first portion has a downward slope in a first longitudinal direction and the second portion has a downward slope in a second longitudinal direction, for example, opposing and parallel to but spaced-apart from the first longitudinal direction or alternatively, at an angle to the first longitudinal direction such as an L-shaped ramp structure.
The adjustable legs 200 and 210 discussed above in reference to
The present disclosure of the brace frames in a range of heights, the connector braces interconnect opposing brace frames, and the top frame, which interconnect as a deck module box, for deck boards to define a decking surface, the stairs risers, with railings and posts for perimeter deck installation, and for ramp connector braces for defining a sloped ramp, provide simple and readily assembled components for the modular deck apparatus, with multiple modules securely connected together for rigidity and stability of a deck, free-standing or ground secured, for an ornamental and structural addition for buildings and grounds. The elongated tubes used for the components are open-ended and of appropriate cross-section length and width for respective members to receive engaging portions as discussed above. Generally, the structural members and posts are 1 inch×1 inch square steel tubing, 1.25 inch×1.25 inch square steel tubing, or 0.75 inch×0.75 inch square steel tubing. The feet 84, 124 may be 3 inch by 3 inch by 0.1875 steel plate. The stubs 128 are 0.75 inch round tubing. The deck boards 32 may be 5/4 pressure treated wood or a plastic or composite material suitable for outdoor deck applications.
The disclosed invention provides a deck apparatus in a first form as a deck module that assembles from a pair of opposing brace frames, each brace frame having two opposing vertical members connected by a transverse members. The opposing brace frames are held in spaced-apart relation by a pair of opposing connector bases, each connector base having an elongated member with a pair of posts extending in a first direction from respective end portions of the elongated member, the posts for being received in a respective open end of the aligned vertical members of the opposing brace frames to hold the brace frames in spaced-relation. A plurality of deck boards attached to a deck board top frame provides a walking surface for the deck assembly, which deck board top frame has opposing end members and opposing side members attached at respective distal ends, and a plurality of projecting posts each extending from a respective connection of one of the end members and one of the side members, each of the posts for being received in an opposing upper end of a respective one of the vertical members of the opposing brace frame and the plurality of deck boards disposed between the end members. In an alternate embodiment, the deck board top frame further comprises at last one transverse member connected at opposing distal ends to the opposing side members, to provide intermediate support for the deck boards.
In another aspect, the deck apparatus comprises a second deck module configured for attaching to the first deck module to provide a larger deck area. The second deck module connects to one of the brace frames of the first deck module in which each of the vertical members of at least one of the brace frames further comprises a lower receiver and an upper receiver attached in spaced-apart relation to a respective first side of the vertical member. The second deck module uses a third brace frame having the two opposing vertical members connected by the transverse member. A second pair of opposing connector bases interconnect the third brace frame and the at least one base frame of the first module. Each connector base of the second pair have the elongated member with the pair of posts extending in the first direction from respective end portions of the elongated member. A respective first one of the pair of posts of the second pair of opposing connector bases are received in a respective open end of the lower receiver of the vertical members of the at least one of the brace frames and a respective second of the pair of posts of the second pair of opposing connector bases are received in a respective open end of the vertical members of the third brace frame to hold the at least one of the brace frames in spaced-relation to the third brace frame. A second deck board top frame has deck boards for the second deck module, which deck boards are disposed on the opposing end members and the opposing side members that attach at respective distal ends to form the deck board top frame. The plurality of projecting posts each extend from the respective connection of one of the end members and one of the side members. The posts are received in an open upper end of a respective one of the vertical members of the at least one of the brace frames and the third brace frame.
In another aspect, the deck apparatus may be configured with extension legs to accommodate seating of the brace frames in firm contact with a support surface, typically a ground surface proximate a building such as a manufactured building. This is accomplished by providing each of the vertical members of at least one of the brace frames a second lower receiver attached to a respective second side of the vertical member. The second lower receiver receives a leg member of a leg device. The leg device includes a plate a plate for bearing support on a surface and a leg member such as an elongated tube, connected at a first end to the plate and an opposing second end for being received in the open lower end of a respective one of the second lower receivers. The leg member is received into the second lower receiver and positioned with the plate in contact with the ground. A fastener driven through the vertical of the base frame and into the leg member secures the leg device at a selected length. The plate may further include an opening for receiving a support connector therethrough. The support connector may be a ground anchor with a threaded end that extends through the opening and receives a nut, a stake driven through the opening into the ground, a screw driven through the opening into the ground, or other fastener to secure the plate in contact with the ground.
The deck apparatus may include a stairs riser assembly for being attached at a first end to the deck board top frame and an opposing second end for bearing on a support surface vertically lower than the deck board top frame after attaching the first end to the deck board top frame. The stairs riser comprises a pair of opposing riser arms, each riser arm having an upper post attached at an oblique angle at the first end. A plurality of transverse supports are disposed in spaced-apart relation and connect at opposing ends between the pair of opposing riser arms. A plurality of pairs of tread support arms attach at a first end in aligned relation to the opposed riser arms and extend outwardly as a cantilever. The pairs of tread support arms are disposed in space-apart relation to the riser arms and a tread member, such as a wood, plastic, or metal planar member or board attaches to a respective pair of aligned tread support arms. One or more leg members may further support the stair risers based on ground slope. A leg receiving member attaches to a respective one of the riser arms proximate the opposing second end of the stair risers, for receiving a leg member in the receiving member and positioned for bearing contact with a support surface. A fastener secures the leg member to the leg receiving member.
In another aspect, the deck apparatus uses a ramp assembly to provide a walkable ramp sloped at an angle appropriate for wheelchairs and personal walking mobility devices. The ramp assembly assembles with a plurality of ramp brace frames. Each ramp brace frame has two opposing vertical members connected by a transverse member and sequentially the ramp brace fames has differing heights. The ramp frame braces are disposed in spaced-apart relation along the rampway sequentially to define a slope line across the upper ends of the ramp brace frames. The vertical members in a first one of the plurality of ramp brace frames has a first length and the vertical members in each of the subsequent ones of the plurality of ramp brace frames have a respective second length, which said respective second length is less than the first length and said respective second length of a first one of the subsequent plurality of the ramp brace frames greater than the second length of a second one of the subsequent plurality of ramp brace frames. The ramp assembly includes a plurality of ramp connector bases for connecting adjacent ramp brace frames. Each ramp connector base has an elongated member with a pair of posts extending at an oblique angle in a first direction from respective end portions of the elongated member, The posts are received in a respective open end of a respective first vertical member of a first one of the plurality of ramp brace frames and in a respective open end of a respective second vertical member of a second one of the plurality of ramp brace frames to hold said first and second one of the plurality of ramp brace frames in spaced apart relation. In embodiments having more than two ramp brace frames, the intermediate ramp brace frames include a lower receiving tube attached to a face of the vertical member for receiving the post of the adjacent connector base for securing the spacing to the adjacent brace frame. A ramp deck board top frame has opposing end members and opposing side members which attach at respective distal ends. A plurality of projecting posts each extend from a respective connection of one of the end members and one of the side members at an oblique angle to conform to the slope of the ramp defined by the ramp brace frames. A plurality of deck boards disposed between the end members attach with fasteners to the end and side members. Each of the posts for being received in an opposing upper end of a respective one of the vertical members of said first and second ones of the plurality of ramp brace frames in spaced apart relation.
The foregoing has disclosed a deck apparatus readily assembled on site at a building such as a just-installed manufactured building and provides convenient access into the building with the optional stairs and/or ramp modules disclosed herein, while railings may be secured to the deck board surface to restrict persons from stepping off of the deck surface at a height above the ground, including corner posts, end posts, and midposts for supporting elongate railing assemblies. Variations and changes thereto may be made to deck apparatus and its components within the scope of the appended claims.
Number | Date | Country | |
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62821058 | Mar 2019 | US | |
62963312 | Jan 2020 | US |