RAIL MOUNTS FOR DECKS

Information

  • Patent Application
  • 20250237059
  • Publication Number
    20250237059
  • Date Filed
    September 30, 2024
    10 months ago
  • Date Published
    July 24, 2025
    11 days ago
  • Inventors
    • METZGER; James R. (Santa Ana, CA, US)
Abstract
Described herein are rail mounts that are attached to a structure, such as a deck. The disclosed rail mounts include threaded rods that mate with holes in a railing post to allow the railing post to be attached to the structure using the threaded rods. The disclosed rail mounts are attached to the structure prior to applying any layers designed to protect the structure such that the rail mounts, including the threaded rods, receive the protective layers. A waterproof layer can be applied to the structure after the rail mounts have been affixed so that the threaded rods of the rail mounts extend past the waterproof layer without compromising the waterproofing of the structure. In other words, the waterproof layer forms a waterproof barrier even with the threaded rods extending from the rail mounts through the waterproof layer.
Description
BACKGROUND
Field

The present disclosure generally relates to rail mounts for decks.


Description of Related Art

A deck is typically an outdoor surface with a railing attached that can be free standing or adjacent to a building, such as a house, hotel, or office building. Railing is typically attached to a deck using one or more posts along the side of the deck and/or one or more posts at the corners of the deck. The railing is designed to prevent people from falling from the deck. Other than decks, railings can be used with stairs, balconies, patios, and the like.


SUMMARY

According to a number of implementations, the present disclosure relates to a rail mount for a deck, the rail mount configured to enable installation of a post on the deck. The rail mount includes a baseplate forming one or more holes through which fasteners are configured to extend to secure the baseplate to a top of the deck; a plurality of threaded rods affixed to the baseplate and extending perpendicularly to the baseplate; and a support plate extending perpendicularly from the baseplate in a direction opposite the plurality of threaded rods, the support plate forming one or more holes through which fasteners are configured to extend to secure the support plate to a side of the deck. The rail mount is configured to be secured to the deck along an edge of the deck in such a way that the plurality of threaded rods extends vertically to pass through holes of a base of a post to be secured to the deck.


In some embodiments, the rail mount further includes a second support plate extending perpendicularly from the baseplate in a direction opposite the plurality of threaded rods and extending perpendicularly from the support plate, the second support plate forming one or more holes through which fasteners are configured to extend to secure the second support plate to a second side of the deck at a corner of the deck.


For purposes of summarizing the disclosure, certain aspects, advantages and novel features have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any particular embodiment. Thus, the disclosed embodiments may be carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.





BRIEF DESCRIPTION OF THE DRAWINGS


FIGS. 1A, 1B, 1C, 1D, 1E, and 1F illustrate various views of an example of a rail mount for a corner of a deck.



FIGS. 2A, 2B, 20, 2D, 2E, and 2F illustrate various views of an example of a rail mount for a side of a deck.



FIGS. 3A, 3B, 3C, 3D, 3E, and 3F illustrate various views of an example of a rail mount configured to be mounted to a beam.



FIGS. 4A, 4B, 4C, 4D, 4E, 4F, 4G, 4H, and 4I illustrate a process of installing railing on a deck using the disclosed rail mounts.



FIG. 4J illustrates the rail mount of FIGS. 3A-3F being installed on a beam in a similar fashion to the process illustrated in FIGS. 4A-4I.



FIGS. 5A, 5B, 5C, and 5D illustrate top and side views of an example of an adjustable installation guide for installing the disclosed rail mounts.





DETAILED DESCRIPTION OF SOME EMBODIMENTS

The headings provided herein, if any, are for convenience only and do not necessarily affect the scope or meaning of the claimed invention.


Overview

Structures such as decks, patios, porches, balconies, staircases, and the like can use railings to prevent people from falling over the edge of such structures. To secure the railing to the structure, posts can be used. These posts can be secured to the structure by driving bolts into the top layer of the structure. This may result in the bolts penetrating one or more layers designed to protect the structure, such as a waterproofing layer. This can disadvantageously compromise the structural integrity of the structure. Alternatively, posts can be attached to the structure by attaching mounting hardware to a fascia of the structure, which may result in posts that lack strength and resilience. This can disadvantageously result in a railing that is unable to withstand forces applied to the railing.


Accordingly, described herein are rail mounts that are attached to a structure, such as a deck, prior to a waterproofing layer. The disclosed rail mounts include threaded rods that mate with holes in a railing post to allow the railing post to be attached to the structure using the threaded rods. The disclosed rail mounts are attached to the structure prior to applying any layers designed to protect the structure such that the rail mounts, including the threaded rods, receive the protective layers. For example, a waterproof layer can be applied to the structure after the rail mounts have been affixed to the structure. In this situation, the threaded rods of the rail mounts extend past the waterproof layer without compromising the waterproofing of the structure because the threaded rods and the rail mounts have been treated with the waterproof layer. In other words, the waterproof layer forms a waterproof barrier even with the threaded rods extending from the rail mounts through the waterproof layer.


The disclosed rail mounts include a baseplate with one or more support plates attached to the baseplate. The baseplate is configured to be secured to a top part of the structure (e.g., a floor of a deck) while the support plates are configured to be secured to a side part of the structure. This configuration of the rail mounts enhances the strength and resilience of posts attached to the structure using the disclosed rail mounts.


In addition, the disclosed rail mounts can be secured to the structure by recessing portions of the structure where the rail mounts are to be secured. As a result, the disclosed rail mounts can be flush with the surfaces of the structure. This facilitates application of one or more layers, such as a waterproof layer, to the structure without having multiple different surface levels on the structure.


The disclosed rail mounts provide a number of advantages. Certain of these advantages arise because the rail mounts provide an alternative to mounting posts within the deck or structure and/or using fascia-mounted posts.


The rail mounts do not mount posts within the deck or structure (e.g., the fasteners for the post do not screw into the deck itself, the post is not set inside a clamp within the deck). For posts mounted within a deck, movement of the post can crack or otherwise deteriorate the waterproof layer. In addition, it is difficult to change posts without causing damage or requiring the waterproof layer to be reapplied. Thus, due at least in part to the posts being mounted to the disclosed rail mounts, the above disadvantages or drawbacks are avoided.


The rail mounts allow for posts to not be mounted to the fascia of the deck. Posts that are fascia mounted are typically not strong enough to be up to code or safety standards. As a result, fascia-mounted posts typically require the posts to also be attached to a building to achieve the required strength. Thus, due at least in part to the posts being mounted to the disclosed rail mounts, the resulting installation of the posts is sufficiently strong so that the posts do not have to be attached to a building.


Another advantage of the disclosed rail mounts is that it facilitates the use of interchangeable posts. The disclosed rail mounts make it easy to remove installed posts, to service installed posts, to change installed posts, etc. In such instances, it is not required to reapply waterproofing because the rail mounts maintain their waterproofing layer when a post is removed. In addition, the disclosed rail mounts increase the longevity of a deck (or similar structure) because the deck can be serviced without causing structural damage or altering the structural integrity of the deck. In addition, the waterproofing warranty may be unaffected by servicing, removing, or changing posts because the waterproof layer is unaffected by the service, replacement, or change in posts.


Another advantage of the disclosed rail mounts is the increased strength of the resulting posts and rails mounted to a deck. The disclosed rail mounts are stronger than mounting hardware attached just to the top of the deck and/or stronger than mounting hardware attached just to the side of the deck. The inventor found that combining the baseplate with the disclosed one or more side plates resulted in unexpected increases in strength and stability of the rail mounts when posts and rails were mounted using the disclosed rail mounts. Advantageously, this allows a longer warranty to be offered, and it also reduces risk and liability. In addition, because the rail mounts provide a strong base for posts and rails, the rail can be free standing (e.g., the rail does not have to be secured to a building to achieve targeted or required strength, as is typically required for fascia-mounted posts).


In some embodiments, a block can be used underneath a deck to facilitate mounting the disclosed rail mounts. Such blocking can increase strength and resilience of the disclosed rail mounts. In certain implementations, the deck can use ¾″ plywood and/or 1⅛″ plywood. The disclosed rail mounts can have a footprint that is between 3″ per side to around 24″ per side. In some embodiments, the disclosed rail mounts can have a continuous run along the side of a deck or other similar structure. In certain embodiments, this can also include corners in addition to a continuous run along the side of the deck. In some embodiments, the disclose rail mounts can also be used with a square cap that is applied with the post to cover the screws and threaded rods of the disclosed rail mounts. This can increase the safety of the rail mounts by reducing exposure to any threaded rods extending above the baseplate of the installed posts.


Example Rail Mounts


FIGS. 1A, 1B, 1C, 1D, 1E, and 1F illustrate various views of an example of a rail mount 100 for a corner of a deck or other similar structure (e.g., a patio, balcony, staircase, porch, etc.). The rail mount 100 is configured to support a post secured to the deck, the post configured to support a railing attached between posts. The rail mount 100 includes threaded rods 110 extending from a baseplate 102. A post to be attached to the deck includes holes that can be placed over the threaded rods 110 to allow a nut or bolt to be threaded over the threaded rods 110 to secure the post to the rail mount 100, thereby securing the post to the deck.


The rail mount 100 includes the baseplate 102 with a first support plate 104 and a second support plate 106 extending perpendicularly downward from the baseplate 102. The first support plate 104 and the second support plate 106 extend from adjacent sides of the baseplate 102 so that the first support plate 104 and the second support plate 106 are perpendicular to each other as well as the baseplate 102. This enables the rail mount 100 to be attached to a corner of the deck in a way that the rail mount 100 is attached to perpendicular sides of the deck as well as the top surface of the deck.


The first support plate 104 and the second support plate 106 can be secured to the baseplate 102 using any suitable means including, for example and without limitation, fasteners, welding, adhesives, joint hardware, or any combination of these or the like. In some embodiments, the first support plate 104 and/or the second support plate 106 can be integrally formed with the baseplate 102. For example, the baseplate 102 can be formed from a larger material a portion of which is bent at 90 degrees to form the first support plate 104, with a similar process being performed for the second support plate 106. In some embodiments, the first support plate 104 can be affixed to the second support plate 106 using any suitable means including, for example and without limitation, fasteners, welding, adhesives, joint hardware, or any combination of these or the like.


The rail mount 100 also includes the threaded rods 110 that extend upward from the baseplate 102. The threaded rods 110 are secured to the baseplate 102 through any suitable means including, for example and without limitation, fasteners, welding, adhesives, friction fit, or any combination of these or the like. In some embodiments, the threaded rods 110 can be integrally formed with the baseplate 102.


A plurality of baseplate holes 108 are formed in the baseplate 102 to allow screws, nails, bolts, or other such fasteners to be used to secure the baseplate 102 to the top of the deck. Similarly, the first support plate 104 forms one or more first side holes 112 to allow screws, nails, bolts, or other such fasteners to be used to secure the first support plate 104 to the side of the deck; and the second support plate 106 forms one or more second side holes 114 to allow screws, nails, bolts, or other such fasteners to be used to secure the second support plate 106 to the side of the deck (a side of the deck that is perpendicular to the side of the deck where the first support plate 104 is secured).


Each component of the rail mount 100 can be made from a suitable material. Examples of suitable materials include, without limitation, steel, plastic, aluminum, carbon fiber, wood, composites, metal alloys, and the like. In some embodiments, different components of the rail mount 100 are made from different materials or different combinations of materials. In some embodiments, the baseplate 102 is ¼-inch steel and the support plates 104, 106 are ⅛-inch steel.


Thus, the rail mount 100 can be configured to be mounted to a deck. The rail mount 100 can be configured to enable installation of a post on the deck. In some embodiments, the rail mount 100 includes a baseplate 102 forming one or more baseplate holes 108 through which fasteners are configured to extend to secure the baseplate 102 to a top of the deck. The rail mount 100 includes a plurality of threaded rods 110 affixed to the baseplate 102 and extending perpendicularly to the baseplate 102. The rail mount 100 includes a first support plate 104 extending perpendicularly from the baseplate 102 in a direction opposite the plurality of threaded rods 110, the first support plate 104 forming one or more side holes 112 through which fasteners are configured to extend to secure the first support plate 104 to a side of the deck. The rail mount 100 is configured to be secured to the deck along an edge of the deck in such a way that the plurality of threaded rods 110 extends vertically to pass through holes of a base of a post to be secured to the deck. The rail mount 100 further includes a second support plate 106 extending perpendicularly from the baseplate 102 in a direction opposite the plurality of threaded rods 110 and extending perpendicularly from the first support plate 104, the second support plate 106 forming one or more second side holes 114 through which fasteners are configured to extend to secure the second support plate 106 to a second side of the deck at a corner of the deck.



FIGS. 2A, 2B, 20, 2D, 2E, and 2F illustrate various views of an example of a rail mount 200 for a side of a deck. The rail mount 200 is similar to the rail mount 100 described herein with reference to FIGS. 1A-1F except that the rail mount 200 is suitable for use along an edge of a deck whereas the rail mount 100 is specifically designed for a corner of the deck. The rail mount 200 is also configured to support a post secured to the deck, the post configured to support a railing attached between posts. The rail mount 200 includes threaded rods 210 extending from a baseplate 202. A post to be attached to the deck includes holes that can be placed over the threaded rods 210 to allow a nut or bolt to be threaded over the threaded rods 210 to secure the post to the rail mount 200, thereby securing the post to the deck.


The rail mount 200 includes the baseplate 202 with a support plate 204 extending perpendicularly downward from the baseplate 202. This enables the rail mount 200 to be attached to side of the deck in a way that the rail mount 200 is attached to the side of the deck as well as the top surface of the deck. It should be noted that the rail mount 200 can also be attached to a corner of the deck, similar to the rail mount 100.


The support plate 204 can be secured to the baseplate 202 using any suitable means including, for example and without limitation, fasteners, welding, adhesives, joint hardware, or any combination of these or the like. In some embodiments, the support plate 204 can be integrally formed with the baseplate 202. For example, the baseplate 202 can be formed from a larger material a portion of which is bent at 90 degrees to form the support plate 204.


The rail mount 200 also includes the threaded rods 210 that extend upward from the baseplate 202. The threaded rods 210 are secured to the baseplate 202 through any suitable means including, for example and without limitation, fasteners, welding, adhesives, friction fit, or any combination of these or the like. In some embodiments, the threaded rods 210 can be integrally formed with the baseplate 202.


A plurality of baseplate holes 208 are formed in the baseplate 202 to allow screws, nails, bolts, or other such fasteners to be used to secure the baseplate 202 to the top of the deck. Similarly, the support plate 204 forms one or more side holes 212 to allow screws, nails, bolts, or other such fasteners to be used to secure the support plate 204 to the side of the deck.


Each component of the rail mount 200 can be made from a suitable material. Examples of suitable materials include, without limitation, steel, plastic, aluminum, carbon fiber, wood, composites, metal alloys, and the like. In some embodiments, different components of the rail mount 200 are made from different materials or different combinations of materials.


Thus, the rail mount 200 can be configured to be mounted to a deck. The rail mount 200 can be configured to enable installation of a post on the deck. In some embodiments, the rail mount 200 includes a baseplate 202 forming one or more baseplate holes 208 through which fasteners are configured to extend to secure the baseplate 202 to a top of the deck. The rail mount 200 includes a plurality of threaded rods 210 affixed to the baseplate 202 and extending perpendicularly to the baseplate 202. The rail mount 200 includes a support plate 204 extending perpendicularly from the baseplate 202 in a direction opposite the plurality of threaded rods 210, the support plate 204 forming one or more side holes 212 through which fasteners are configured to extend to secure the support plate 204 to a side of the deck. The rail mount 200 is configured to be secured to the deck along an edge of the deck in such a way that the plurality of threaded rods 210 extends vertically to pass through holes of a base of a post to be secured to the deck.



FIGS. 3A, 3B, 3C, 3D, 3E, and 3F illustrate various views of an example of a rail mount 300 configured to be mounted to a beam. The rail mount 300 is similar to the rail mount 100 described herein with reference to FIGS. 1A-1F and/or the rail mount 200 described herein with reference to FIGS. 2A-2F except that the rail mount 300 is suitable for being attached to a beam, such as a PARALLAM® or GLULAM® beam, whereas the rail mount 100 is specifically designed for a corner of the deck and the rail mount 200 is designed for a side of the deck. The rail mount 300 is also configured to support a post secured to the deck, the post configured to support a railing attached between posts. The rail mount 300 includes threaded rods 310 extending from a baseplate 302. A post to be attached to the deck includes holes that can be placed over the threaded rods 310 to allow a nut or bolt to be threaded over the threaded rods 310 to secure the post to the rail mount 300, thereby securing the post to the beam, which can be part of a deck or other similar structure.


The rail mount 300 includes the baseplate 302 with a first support plate 304 extending perpendicularly downward from the baseplate 302 and a second support plate 306 extending perpendicularly downward from the baseplate on a side opposite the first support plate 304. This enables the rail mount 300 to be attached to a beam that is part of a deck or other similar structure in a way that the rail mount 300 is attached to the beam that forms part of the top surface of the deck.


The first support plate 304 can be secured to the baseplate 302 using any suitable means including, for example and without limitation, fasteners, welding, adhesives, joint hardware, or any combination of these or the like. In some embodiments, the first support plate 304 can be integrally formed with the baseplate 302. For example, the baseplate 302 can be formed from a larger material a portion of which is bent at 90 degrees to form the first support plate 304. Similarly, the second support plate 306 can be secured to the baseplate 302 using any suitable means including, for example and without limitation, fasteners, welding, adhesives, joint hardware, or any combination of these or the like. In some embodiments, the second support plate 306 can be integrally formed with the baseplate 302. For example, the baseplate 302 can be formed from a larger material a portion of which is bent at 90 degrees to form the second support plate 306.


The rail mount 300 also includes the threaded rods 310 that extend upward from the baseplate 302. The threaded rods 310 are secured to the baseplate 302 through any suitable means including, for example and without limitation, fasteners, welding, adhesives, friction fit, or any combination of these or the like. In some embodiments, the threaded rods 310 can be integrally formed with the baseplate 302.


A plurality of baseplate holes 308 are formed in the baseplate 302 to allow screws, nails, bolts, or other such fasteners to be used to secure the baseplate 302 to the top of the beam. Similarly, the first support plate 304 forms one or more first side holes 312 to allow screws, nails, bolts, or other such fasteners to be used to secure the first support plate 304 to a first side of the beam. Similarly, the second support plate 306 forms one or more second side holes 314 to allow screws, nails, bolts, or other such fasteners to be used to secure the second support plate 306 to a second side of the beam.


Each component of the rail mount 300 can be made from a suitable material. Examples of suitable materials include, without limitation, steel, plastic, aluminum, carbon fiber, wood, composites, metal alloys, and the like. In some embodiments, different components of the rail mount 300 are made from different materials or different combinations of materials.


It should be understood that the baseplate holes described herein with respect to the rail mount 100, the rail mount 200, and/or the rail mount 300 can be excluded from the rail mounts. Similarly, the number of support plates that extend downward (e.g., in a direction opposite the threaded rods) can be 1 (e.g., the rail mount 200), 2 (e.g., the rail mount 100 or the rail mount 300), 3 (e.g., configured to be attached to the end of a beam), or 4 (e.g., configured to be attached to an endcap of a beam).


Example Process for Installing Rail Mounts on a Deck


FIGS. 4A, 4B, 4C, 4D, 4E, 4F, 4G, 4H, and 4I illustrate a process of installing railing 479 on a deck 450 using a corner rail mount 400 and a side rail mount 420. The deck 450 includes a top surface 452 and a side surface 453. The corner rail mount 400 is similar to the rail mount 100 described herein with reference to FIGS. 1A-1F and the side rail mount 420 is similar to the rail mount 200 described herein with reference to FIGS. 2A-2F.



FIGS. 4A and 4B illustrate a top view and a side view, respectively, of the deck 450 prepared to receive the corner rail mount 400 and the side rail mount 420. The top surface 452 and the side surface 453 can be formed or cut to form a first recessed portion 454 that mates with the corner rail mount 400 and a second recessed portion 456 that mates with the side rail mount 420. The first recessed portion 454 and the second recessed portion 456 can be formed such that when the corner rail mount 400 and the side rail mount 420 are secured to the deck 450, the baseplate of each rail mount 400, 420 is flush with the top surface 452 of the deck 450. Similarly, the first recessed portion 454 and the second recessed portion 456 can be formed such that when the corner rail mount 400 and the side rail mount 420 are secured to the deck 450, the respective support plates of each rail mount 400, 420 is flush with the side surface 453 of the deck 450.



FIGS. 4C and 4D illustrate a top view and a side view, respectively, of the corner rail mount 400 and the side rail mount 420 secured to the deck 450. Securing the corner rail mount 400 and the side rail mount 420 to the deck 450 can be accomplished using fasteners through holes in the baseplates and support plates of the corner rail mount 400 and the side rail mount 420. When the corner rail mount 400 and the side rail mount 420 are secured to the deck 450, threaded rods 410 of the corner rail mount 400 and threaded rods 430 of the side rail mount 420 extend upward from the top surface 452 of the deck 450.


In some embodiments, securing the corner rail mount 400 and/or the side rail mount 420 to the deck 450 includes using an epoxy or other adhesive in addition to fasteners. For example, an epoxy can be used under the corner rail mount 400 and/or side rail mount 420 that is a wet set epoxy. In some implementations, an adhesive or epoxy is used that does not contain water to avoid inducing rust on the corner rail mount 400 and/or side rail mount 420. In some embodiments, flashing can be used under the corner rail mount 400 and/or the side rail mount 420 to increase waterproofing.



FIGS. 4E and 4F illustrate a top view and a side view, respectively, of a skirt 458 attached to the side surface 453 of the deck 450. The skirt 458 covers the support plates of the corner rail mount 400 and the side rail mount 420. The skirt 458 sits flush against the side surface 453 of the deck 450 due at least in part to the first recessed portion 454 and the second recessed portion 456 allowing the support plates of the corner rail mount 400 and the side rail mount 420 to be flush with the side surface 453 of the deck 450. The skirt 458 can be secured or affixed to the side surface 453 using any suitable means including adhesives and fasteners.



FIGS. 4G and 4H illustrate a top view and a side view, respectively, of one or more layers 460 being applied to the top surface 452 of the deck 450. The one or more layers 460 can include, for example and without limitation, a waterproof layer, a structural support layer (e.g., a wire or metal mesh), a cementitious product, stucco, varnish, paint, or the like. In some embodiments, one or more of the one or more layers 460 can be applied to the skirt 458 as well. After application of the one or more layers 460, the threaded rods 410 of the corner rail mount 400 and the threaded rods 430 of the side rail mount 420 protrude upward through the one or more layers 460. Where the one or more layers 460 includes a waterproof layer, the threaded rods 410, 430 are also treated with the waterproof layer such that the waterproof layer forms a waterproof barrier that surrounds and includes the threaded rods 410, 430. Thus, even though the threaded rods 410, 430 extend upward through the one or more layers 460, waterproofing is not compromised.


In some embodiments, the one or more layers 460 includes a finish layer such as concrete or a cementitious product (e.g., poured gypsum). The finish layer can be poured over support mesh. In some embodiments, the one or more layers 460 completely encapsulates the corner rail mount 400 and/or side rail mount 420 (while still allowing the threaded rods 410, 430 to be exposed).



FIG. 4I illustrates a side view of a corner post 470 and a side post 475 being secured to the deck 450 using the corner rail mount 400 and the side rail mount 420, respectively. Railing 479 runs between the corner post 470 and the side post 475. It should also be understood that additional corner posts and side posts can be installed on the deck 450 using corner rail mounts and side rail mounts as described herein.


The corner post 470 includes a base 471 with holes that fit over the threaded rods 410. Installing the corner post 470 thus includes placing the base 471 in a way that the threaded rods 410 pass through the holes and securing the corner post 470 to the deck 450 using fasteners 472 nuts or bolts that thread on the threaded rods 410. Similarly, the side post 475 includes a base 476 with holes that fit over the threaded rods 430. Installing the side post 475 thus includes placing the base 476 in a way that the threaded rods 430 pass through the holes and securing the side post 475 to the deck 450 using fasteners 477 such as nuts or bolts that thread on the threaded rods 430. In this way, the posts 470, 475 are secured to the deck 450 on top of the one or more layers 460 without penetrating the one or more layers 460 or any portion of the deck 450. This allows the functionality of the one or more layers 460 to be maintained and/or to be uncompromised as part of the installation of the railing 479. In some embodiments, the bases 471, 476 can have templates that vary and the corner rail mount 400 and/or side rail mount 420 can have the threaded rods 410, 430 vary according to the template. This allows different hole patterns, positioning, spacing, etc. to be employed for the bases 471, 476.


Advantageously, the rail mounts 400, 420 allow posts to be attached to the deck 450 without compromising waterproofing. This is due at least in part to the threaded rods 410, 430 being present during the waterproofing process and being treated with the waterproofing material. This is in contrast to a process that uses screws or nails or other such fasteners that penetrate into the deck 450, which would also penetrate through the waterproof layer thereby compromising waterproofing of the deck. This may be beneficial where there is a breach of the post (e.g., water penetrates into the interior of the post) because the water is still unable to penetrate the deck 450 because of the waterproofing that is maintained by the disclosed rail mounts.


Advantageously, the corner rail mount 400 and the side rail mount 420 increase the strength and resilience of the posts secured to them. The corner rail mount 400 and the side rail mount 420 are secured to the deck 450 on both the top surface 452 and the side surface 453 of the deck 450, thereby increasing the strength and resilience of the posts 470, 475. In some embodiments, this allows the posts 470, 475 to be secured solely to the deck and not to the building to which the deck is attached. The increased resilience and strength also improves the longevity of the posts 470, 475, the railing 479, and the deck 450 by extension.


The increased strength and resilience of the posts 470, 475 and railing 479 when secured to the deck 450 via the corner rail mount 400 and side rail mount 420 is particularly evident when compared to fascia-mounted posts that are mounted just to the sides of the deck 450. In a fascia mount configuration, the post sits on the side of the structure (e.g., the deck frame) and a fascia mount bracket attaches to the side of the structure. In such a configuration, only one face is secured to the structure, resulting in a lack of structural integrity. Furthermore, posts typically slide into brackets that are attached to the fascia, rather than attaching to the structure itself. If this bracket is then covered in the one or more layers 460 (e.g., stucco), it may be difficult to service the posts without destroying a portion of the structure.


In contrast, the corner rail mount 400 and side rail mount 420 allow the posts 470, 475 and the railing 479 to be serviced without affecting the corner rail mount 400, side rail mount 420, or the deck 450. For example, the posts 470, 475 can include a seal cap that can be removed and the bolts or nuts can be tightened. Similarly, the bolts or nuts can be easily removed to replace the post. After which, the seal cap can be replaced. This process again does not affect the structure and leaves unchanged the one or more layers 460 that may provide desired functionality, such as waterproofing or structural integrity, or aesthetics.


In some embodiments, the process of installing the disclosed rail mounts can include routing out the wood so that the rail mounts are flush with the wood. Flashing detail can then be added and an epoxy can be applied to the wood to wet set the rail mount. Being prepared in this way, the rail mount can then be attached to the wood. Fasteners, such as screws, can then be used to further secure the rail mount to the wood. Once attached with fasteners, the surface can be covered in sand or other material so that additional layers adhere better to the surface of the rail mount and threaded rods. In some implementations, the material that is added makes a superior surface for polymers to bond to. A wire lath can then be installed. In some implementations, the wire lath comprises a wire mesh. In certain instances, the wire lath does not cover the rail mounts. In various instances, the wire lath covers the rail mounts as well. Being prepared in this way, a polymer or other material can be applied to coat the wood and the rail mounts. In some embodiments, the polymer or other material can be a waterproofing agent or other material that bestows desirable properties on the rail mounts and deck. The coating applied can be five or six layers in combination, for example. A top coat applied over everything can be a polymer cement, cementitious product, epoxy, urethane, asphalt emulsion, aliphatic material, etc.



FIG. 4J illustrates the rail mount of FIGS. 3A-3F being installed on a beam 490 in a similar fashion to the process illustrated in FIGS. 4A-4I. The rail mount 300 is secured to the beam using fasteners that pass through the support plate holes, as described herein. The beam 490 can be configured so that the rail mount 300 is flush to the edges of the beam 490 when installed on the beam 490. In some embodiments, the baseplate holes are not included on the rail mount 300. In such embodiments, the fasteners through the support plate holes can be sufficient to secure the rail mount 300 to the beam 490.


Example Adjustable Installation Guides


FIGS. 5A, 5B, 5C, and 5D illustrate top and side views of an example of an adjustable rail mount tool 500 for installing the disclosed rail mounts. The length of the adjustable rail mount tool 500 can be adjusted to accommodate different spacing between rails for a deck or other similar structure. In some embodiments, the adjustable rail mount tool 500 can be a telescopic rail mount tool.


The adjustable rail mount tool 500 includes two rail mount footprints 510a, 510b attached between a telescopic rail 505 comprising a first telescoping segment 502 and a second telescoping segment 504. The adjustable rail mount tool 500 is configured to help align rail mounts on a structure. That is, the configurable distance between the rail mount footprints 510a, 510b can be used as a guide or to create a template for drilling holes or otherwise preparing the deck for installation of the disclosed rail mounts. The configurable distance can be used to set the distance between posits on a deck by configuring the distance between rail mounts.


The adjustable rail mount tool 500 includes the telescopic rail 505 with the first telescoping segment 502 secured to a first anchor 506 that is attached to a first rail mount footprint 510a. The second telescoping segment 504 is secured to a second anchor 508 that is attached to a second rail mount footprint 510b. The two rail mount footprints 510a, 510b each include holes 520 that coincide with the baseplate holes of the disclosed rail mounts 100, 200, 300. The distance between the two rail mount footprints 510a, 510b can be adjusted from a maximum distance, D1, to a minimum distance, D2. In some embodiments, the maximum distance is about 8 feet, about 6 feet, or about 4 feet. In some embodiments, the minimum distance is at least 1 foot, at least 2 feet, at least 3 feet, or at least 4 feet.


If the desired distance between posts on a structure, such as a deck, is 6 feet, the distance between the two rail mount footprints 510a, 510b can be set to 6 feet. The adjustable rail mount tool 500 can be placed on the structure and the holes 520 can be used to mark drilling locations on the structure. For different post spacing, different distances can be used between the two rail mount footprints 510a, 510b. In some embodiments, alignment holes 512 can be included in the first telescoping segment 502 and the second telescoping segment 504. In such embodiments, a pin or other component can be placed through a particular pair of alignment holes 512 that passes through both the first telescoping segment 502 and the second telescoping segment 504 to lock in the distance between the two rail mount footprints 510a, 510b.


Additional Embodiments and Terminology

The present disclosure describes various features, no single one of which is solely responsible for the benefits described herein. It will be understood that various features described herein may be combined, modified, or omitted, as would be apparent to one of ordinary skill. Other combinations and sub-combinations than those specifically described herein will be apparent to one of ordinary skill, and are intended to form a part of this disclosure. Various methods are described herein in connection with various flowchart steps and/or phases. It will be understood that in many cases, certain steps and/or phases may be combined together such that multiple steps and/or phases shown in the flowcharts can be performed as a single step and/or phase. Also, certain steps and/or phases can be broken into additional sub-components to be performed separately. In some instances, the order of the steps and/or phases can be rearranged and certain steps and/or phases may be omitted entirely. Also, the methods described herein are to be understood to be open-ended, such that additional steps and/or phases to those shown and described herein can also be performed.


Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to.” The word “coupled”, as generally used herein, refers to two or more elements that may be either directly connected, or connected by way of one or more intermediate elements. Additionally, the words “herein,” “above,” “below,” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. Where the context permits, words in the above Detailed Description using the singular or plural number may also include the plural or singular number respectively. The word “or” in reference to a list of two or more items, that word covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list. The word “exemplary” is used exclusively herein to mean “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations.


The disclosure is not intended to be limited to the implementations shown herein. Various modifications to the implementations described in this disclosure may be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other implementations without departing from the spirit or scope of this disclosure. The teachings of the invention provided herein can be applied to other methods and systems, and are not limited to the methods and systems described above, and elements and acts of the various embodiments described above can be combined to provide further embodiments. Accordingly, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made without departing from the spirit of the disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosure.

Claims
  • 1. A rail mount for a deck, the rail mount configured to enable installation of a post on the deck, the rail mount comprising: a baseplate forming one or more holes through which fasteners are configured to extend to secure the baseplate to a top of the deck;a plurality of threaded rods affixed to the baseplate and extending perpendicularly to the baseplate; anda support plate extending perpendicularly from the baseplate in a direction opposite the plurality of threaded rods, the support plate forming one or more holes through which fasteners are configured to extend to secure the support plate to a side of the deck,wherein the rail mount is configured to be secured to the deck along an edge of the deck in such a way that the plurality of threaded rods extends vertically to pass through holes of a base of a post to be secured to the deck.
  • 2. The rail mount of claim 1 further comprising a second support plate extending perpendicularly from the baseplate in a direction opposite the plurality of threaded rods and extending perpendicularly from the support plate, the second support plate forming one or more holes through which fasteners are configured to extend to secure the second support plate to a second side of the deck at a corner of the deck.
  • 3. The rail mount of claim 1 further comprising a second support plate extending perpendicularly from the baseplate in a direction opposite the plurality of threaded rods and on a side opposite the support plate, the second support plate forming one or more holes through which fasteners are configured to extend to secure the second support plate to a beam of the deck.
  • 4. The rail mount of claim 1, wherein the plurality of threaded rods is adapted so that the post is secured to the baseplate rather than a fascia of the deck.
  • 5. The rail mount of claim 1, wherein the plurality of threaded rods is adapted so that a first post with a first configuration is interchangeable with a second post of a different configuration provided that a hole configuration of the second post is identical to a hole configuration of the first post, the hole configuration configured to be compatible with the plurality of threaded rods.
  • 6. The rail mount of claim 1, wherein a combination of the baseplate and the support plate results in a stronger mount for the post relative to a post solely mounted to a top of the deck or solely mounted to a side of the deck.
  • 7. The rail mount of claim 1 further comprising a cap adapted to be applied to the post to cover the plurality of threaded rods.
  • 8. The rail mount of claim 1, wherein the support plate is integrally formed with the baseplate.
  • 9. The rail mount of claim 1, wherein the support plate is a separate component that is secured to the baseplate.
  • 10. The rail mount of claim 1, wherein the plurality of threaded rods is integrally formed with the baseplate.
  • 11. The rail mount of claim 1, wherein the plurality of threaded rods is a separate component that is secured to the baseplate.
  • 12. The rail mount of claim 1, wherein the baseplate is twice as thick as the support plate.
  • 13. A method of installing a railing on a deck, the method comprising: forming a top recessed portion on a top portion the deck;forming a side recessed portion on a side portion of the deck;installing a side rail mount to a top and side of the deck, the side rail mount comprising: a baseplate forming one or more holes;a plurality of threaded rods affixed to the baseplate and extending perpendicularly to the baseplate; anda support plate extending perpendicularly from the baseplate in a direction opposite the plurality of threaded rods;positioning a post on the top portion of the deck by passing the plurality of threaded rods of the side rail mount through corresponding holes formed in a base of the post; andsecuring the post to the top portion of the deck by threading fasteners to the plurality of threaded rods of the side rail mount to hold the base of the post against the baseplate of the side rail mount,wherein installing the side rail mount includes: passing fasteners through the one or more holes of the baseplate to secure the baseplate to the top recessed portion of the top portion of the deck; andpassing fasteners through one or more holes formed by the support plate to secure the support plate to the side recessed portion of the side portion of the deck.wherein the baseplate is level with the top portion of the deck and the support plate is level with the side portion of the deck after installation of the side rail mount.
  • 14. The method of claim 13 further comprising: forming a second top recessed portion on a top portion the deck at a corner of the deck;forming a second side recessed portion and a third side recessed portion at the corner of the deck;installing a corner rail mount to the top and the corner of the deck, the corner rail mount comprising: a baseplate forming one or more holes;a plurality of threaded rods affixed to the baseplate and extending perpendicularly to the baseplate;a first support plate extending perpendicularly from the baseplate in a direction opposite the plurality of threaded rods; anda second support plate extending perpendicularly from the baseplate in a direction opposite the plurality of threaded rods, the second support plate perpendicular to the first support plate;positioning a second post on the top portion of the deck by passing the plurality of threaded rods of the corner rail mount through corresponding holes formed in a base of the post; andsecuring the second post to the top portion of the deck by threading fasteners to the plurality of threaded rods of the corner rail mount to hold the base of the post against the baseplate of the corner rail mount,wherein installing the corner rail mount includes: passing fasteners through the one or more holes of the baseplate of the corner rail mount to secure the baseplate of the corner rail mount to the second top recessed portion of the top portion of the deck;passing fasteners through one or more holes formed by the first support plate of the corner rail mount to secure the first support plate to the second side recessed portion of the corner of the deck; andpassing fasteners through one or more holes formed by the second support plate of the corner rail mount to secure the second support plate to the third side recessed portion of the corner of the deck,wherein the baseplate is level with the top portion of the deck and the support plate is level with the side portion of the deck after installation of the side rail mount.
  • 15. The method of claim 13 further comprising an adhesive to the top recessed portion and to the side recessed portion prior to installing the side rail mount.
  • 16. The method of claim 13 further comprising installing flashing to the top recessed portion and to the side recessed portion prior to installing the side rail mount to enhance waterproofing.
  • 17. The method of claim 13 further comprising installing a skirt to the side of the deck such that the skirt covers the support plate of the side rail mount.
  • 18. The method of claim 13 further comprising applying a waterproof layer over the top of the deck such that the waterproof layer covers the baseplate of the side rail mount and leaves the plurality of threaded rods exposed.
  • 19. The method of claim 18 wherein the waterproof layer coats the plurality of threaded rods while allowing the plurality of threaded rods to be exposed.
  • 20. The method of claim 13 further comprising applying a structural support layer over the top of the deck such that the structural support layer covers the baseplate of the side rail mount and leaves the plurality of threaded rods exposed.
CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. Prov. App. No. 63/586,255 filed Sep. 28, 2023 and entitled “RAIL MOUNTS FOR DECKS,” the entire contents of which is incorporated by reference herein for all purposes.

Provisional Applications (1)
Number Date Country
63586255 Sep 2023 US