The present invention relates to a modular deck system.
Decks are an architectural feature provided to domestic and commercial buildings to enhance the function and usability of outdoor spaces. Decks are constructed against external walls, such that the deck can be accessed through an external door. At least part of the deck surface can be raised above the natural ground surface to approximately the same level as the floor immediately inside the external door. Occupants of the building find the deck to be an appealing feature in that it provides an easy space in which to enjoy being outside, for example when dining, outdoor cooking, and entertaining guests.
The need to satisfy building codes and standards has historically resulted in decks being individually engineered constructions. Furthermore, the fact that each deck is unique increases the time and complexity of its construction. These factors result in substantial costs associated with deck construction.
It is desired to provide a deck system that simplifies deck construction, and/or can at least provide a useful alternative.
According to a first aspect of the present invention there is provided a modular deck system comprising:
a plurality of base frames that each include four peripheral frame members that are to be fastened together into a rectangular box, and one or more internal frame members that each are to be secured within the box between opposing peripheral frame members; and
a plurality of frame legs that are each to be secured to one of the base frames to support the respective base frame above a ground surface,
wherein the plurality of base frames are fastened to one another to provide a support structure on which to secure deck material.
In certain embodiments, the peripheral frame members are fastened together into the rectangular box, and the internal frame members are each secured within the box between opposing peripheral frame members to form a deck module; and
the frame legs are each secured to one of the base frames to support the respective deck module above a ground surface;
wherein the base frames of the deck modules are fastened to one another to provide a support structure, and
the modular deck system further comprises deck material that is secured to the support surface.
Preferably, each base frame includes two primary peripheral frame members, and two secondary peripheral frame members, wherein when the peripheral frame members are assembled into the rectangular box, end surfaces of the secondary peripheral frame members are secured against side surfaces of the primary peripheral frame members. In at least some embodiments, the primary peripheral frame members are longer than the secondary peripheral frame members. In certain embodiments, each base frame forms a square box.
In certain embodiments, each of the primary peripheral frame members has a first set of holes pre-drilled in a direction perpendicular to a side surface to facilitate location of fasteners to secure the primary peripheral frame members to the secondary peripheral frame members.
In some embodiments, each internal frame member extends between the two primary peripheral frame members, and each of the primary peripheral frame members has a second set of holes pre-drilled in a direction perpendicular to a side surface to facilitate location of fasteners to secure the internal frame members to the primary peripheral frame members.
Preferably, the frame legs comprise:
a body that has an internally threaded hole;
a foot that has a ground contacting member, and an externally threaded shank that is received in the internally threaded hole such that the separation of the ground contacting member and the body is selectively adjustable; and
a support surface that provides vertical support to the base frame to which respective frame leg is secured.
The plurality of frame legs can include first frame legs in which the body is elongate with the internally threaded hole formed at a first end of the body, and the frame leg further comprises a head that is to be secured to a second end of the body, the head having a horizontal flange that forms the support surface, and one or more uprights that extend perpendicularly to the horizontal flange wherein peripheral frame members are secured to the uprights.
In some embodiments, the modular deck system includes at least two sets of frame leg bodies, the first set of frame leg bodies having a length that differs from the length of the bodies in the other set(s). More preferably, the modular deck system includes four sets of first frame leg bodies.
Preferably, the uprights project upwardly from the horizontal flange. More preferably, the head has two uprights that are orthogonal to one another.
Alternatively or additionally, each of the primary peripheral frame members can have at least one blind hole that opens onto a bottom surface of respective peripheral frame member, and the plurality of frame legs can include second frame legs in which the body has a cylindrical portion, and a flange formed at one end of the cylindrical portion, wherein the cylindrical portion is to be received within the blind hole, and flange forms the support surface such that the flange abuts the respective primary peripheral frame member about the blind hole.
The modular deck system can further comprise a plurality of deck panels that have a plurality of deck boards secured to at least two support members. Preferably, each deck panel has at least one a length or width that corresponds with the length or width of the base frames. More preferably, each deck panel has a length that is equal to the width of the base frames. Even more preferably, each deck panel has a width that that is equal to the half length of the base frames.
According to a second aspect of the present invention there is also provided a method of constructing a modular deck, the method comprising:
Where the final deck level is to be continuous across two adjacent base frames, step (c) can involve:
Where the final deck level is to be stepped across two adjacent base frames, step (c) can involve:
Preferably, step (c)(ii) further involves fastening at least one vertical connector to the outer surface of the peripheral frame member of the lower base frame, and fastening the at least one vertical connector to the internal surface of the peripheral frame member of the upper base frame.
In some embodiments, the length of each frame member is adjustable, and the method further involves:
In some embodiments, the frame legs comprise:
a body that has an internally threaded hole;
a foot that has a ground contacting member, and an externally threaded shank that is received in the internally threaded hole such that the separation of the ground contacting member and the body is selectively adjustable; and
a support surface that provides vertical support to the base frame to which respective frame leg is secured;
and step (b) the method further involves, for each frame leg:
The plurality of frame legs can include first frame legs in which the body is elongate with the internally threaded hole formed at a first end of the body, and the frame leg further comprises a head that has a horizontal flange that forms the support surface;
and in the method:
step (b)(i) can further involve securing the head to the body; and
step (b)(ii) can further involve securing the head to the base frame such that the horizontal flange provides vertical support to the base frame.
The head can further include one or more uprights that extend perpendicularly to the horizontal flange, and step (b)(ii) can further involve securing at least one of the uprights to the side surface of at least one of the peripheral frame members of the respective base frame.
The plurality of frame legs can alternatively or additionally include second frame legs in which the body has a cylindrical portion, and a flange formed at one end of the cylindrical portion, the flange forming the support surface; and at least some of the peripheral frame members have at least one blind hole that opens onto a bottom surface of respective peripheral frame member;
and in the method:
step (b)(ii) can further involve locating the cylindrical portion within the blind hole, such that the flange abuts the respective primary peripheral frame member about the blind hole.
The deck can include a plurality of deck panels that have a plurality of deck boards secured to at least two support members, and in the method step (d) can further involve securing the deck panels to the base frames
The method can further involve:
Step (f) can involve:
Alternatively or additionally step (f) can involve securing the cladding material to the frame legs and/or base frame.
The method can further involve:
It will be understood that steps of the method do not necessarily have to occur in the order that is set out in this document. For example, step (g) is likely to be executed before step (a).
According to a third aspect of the present invention there is also provided a kit for a modular deck system, the kit including:
a modular deck system according to the first aspect, and
instructions to perform the method of the second aspect.
In order that the invention may be more easily understood, embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which:
In the embodiment shown in
The base frame 14 also includes two internal frame members 20 that, in the assembled deck module 12, are each secured within the box between opposing peripheral frame members 16. This arrangement is shown in
In this particular embodiment, each deck module 12 includes deck panels 22, as shown in
The deck panels 22 of this embodiment have a length that is equal to the width of the base frames 14, and a width that that is equal to the half length of the base frames. Accordingly, each deck module 12 has two deck panels 22. Constructing a modular deck 10 with deck panels 22 has the benefit of significantly reducing the number of fasteners required to secure the deck boards to the support structure. In this particular embodiment, seven fasteners are required to secure each deck panel 22 to a respective base frame 14. In addition, the deck panel 22 can readily be sized (by geometric size and/or weight) to be lifted by a single person and carried in the rear luggage compartment of a sedan.
In some alternative embodiments, individual deck boards can be secured directly to the base frames 14.
As shown in
In this particular embodiment, the dimensions of the frame members 16, 18, 20 are set out in Table 1. As is evident from
In one alternative embodiment, the dimensions of the frame members are set out in Table 2. A deck constructed with base frame members of this alternative can satisfy Australian domestic building regulations, but not the commercial building regulations.
As shown in
As shown in
The modular deck system 10 further has frame legs that are each secured to one of the base frames 14 to support the respective deck module 12 above a ground surface.
The head 48 has a horizontal flange 56 that forms the support surface, and a pair of orthogonal uprights 58a, 58b that extend perpendicularly to the horizontal flange 56. On the opposite side of the horizontal flange 56 to the uprights 58 is a square tube 60, which is to be received within upper end of the body 44. The upper end of the body 44 has a pair of transverse holes 62 in which fasteners can be secured to retain the head 48 on the body 44. Further, each of the uprights 58 has a pair of holes 64 that are to be used for securing the head 48, and thus the first frame leg 42, to a base frame 14.
The first frame legs 42 of the modular outdoor deck 10 can have a set of bodies 44 of different lengths. Accordingly, first frame legs 42 of a variety of lengths can be provided, such that base frames 14 can be supported at a variety of heights above the ground surface. In particular, four different lengths of bodies 44 can be provided.
Each of the primary peripheral frame members 16 has a pair of blind holes (not shown) that opens onto a bottom surface. The cylindrical portion 70 is received within the blind hole of a peripheral frame member 16, with the flange abutting the primary peripheral frame member 16 about the blind hole. The cylindrical portion 70 also has an internally threaded hole formed in its lower end. A foot 46, as described previously with a ground contacting member 52 and an externally threaded shank 54, is connected to the cylindrical portion 70. Rotating the foot 46 adjusts the separation of the ground contacting member 52 and the cylindrical portion 70, and thus the height of the primary peripheral frame member 16 above the ground surface. In this way, the length of the second frame leg 68 is adjustable to accommodate for height changes in the ground surface. The cylindrical portion 70 has a series of longitudinal ribs 74 to prevent rotation of the cylindrical portion 70 within the peripheral frame member 16 when the foot 46 is rotated.
In
At A: first frame legs 42 are used with long length bodies 44;
At B: first frame legs 42 are used with intermediate length bodies 44;
At C: first frame legs 42 are used with short length bodies 44; and
At D: second frame legs 68 are used.
As shown in
At appropriate locations, droppers 78 are secured to peripheral frame members 16, 18 of the base frame 14, and the timber lengths 76 are secured to droppers 78. The droppers 78 extend from the base frames 14 towards the ground surface, and the timber lengths 76 (or other cladding material) is secured to the droppers 78.
In this embodiment, each dropper 78 consists of an outer member 80 that has an outer face flush with the peripheral edge of the base frame 14 to which it is secured, and an inner member 82 that is secured to the base frame 14. The droppers 78 can be conveniently made from two lengths of timber that are fastened to one another, in a parallel fashion with the inner member 82 projecting upwardly beyond the upper end of the outer member 80. The inner member 82 is then to be secured to an internal face of the peripheral frame members 16, 18 of the respective base frame 14. The outer member 80 has a thickness that corresponds with that of the peripheral frame member 16, 18. The dropper 78 is also illustrated in
Alternatively or additionally, the cladding material can be secured to peripheral frame members 16, 18 of the base frames 14, and/or to first frame legs 20.
As shown in
The construction of each base frame (step 102) involves fastening four peripheral frame members together into a rectangular box, and securing one or more internal frame members within the box between opposing peripheral frame members.
Following step 104, the frame legs can be placed on a ground surface, such that the respective base frame is supported above that ground surface.
In one embodiment, components of the modular deck system 10 are provided in a flat-pack for on-site installation, together with directions to construct a modular deck according to the method 100.
The various embodiments described above can be combined to provide further embodiments. Aspects of the embodiments can be modified, if necessary to employ concepts of the various patents, applications and publications to provide yet further embodiments.
These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.
Number | Date | Country | Kind |
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2013263734 | Nov 2013 | AU | national |
Filing Document | Filing Date | Country | Kind |
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PCT/AU2014/050382 | 11/27/2014 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2015/077841 | 6/4/2015 | WO | A |
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