U.S. patent application number 10/943038 was filed with the patent office on 2005-12-29 for deck system.
Invention is credited to Smith, Brent A..
Application Number | 20050284082 10/943038 |
Document ID | / |
Family ID | 35504016 |
Filed Date | 2005-12-29 |
United States Patent
Application |
20050284082 |
Kind Code |
A1 |
Smith, Brent A. |
December 29, 2005 |
Deck system
Abstract
A deck system includes an interconnected subframe operable to
engage a ground surface and provide an elevated substantially
horizontal support surface. A subfloor is coupled to the subframe
and defines a working surface. A masonry floor surface including a
plurality of brick pavers, for example, is disposed on the working
surface. The masonry floor surface provides the advantages of
durability and low maintenance while the subframe and subfloor
allow construction at an elevated location, such as a second story
of a home.
Inventors: |
Smith, Brent A.; (Howell,
MI) |
Correspondence
Address: |
HARNESS, DICKEY & PIERCE, P.L.C.
P.O. BOX 828
BLOOMFIELD HILLS
MI
48303
US
|
Family ID: |
35504016 |
Appl. No.: |
10/943038 |
Filed: |
September 16, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60583421 |
Jun 28, 2004 |
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Current U.S.
Class: |
52/650.3 |
Current CPC
Class: |
E04F 15/18 20130101;
E04B 1/003 20130101; E04F 15/08 20130101 |
Class at
Publication: |
052/650.3 |
International
Class: |
E04H 012/00 |
Claims
What is claimed is:
1. A deck system comprising: an interconnected subframe operable to
engage a foundation and provide a substantially horizontal support
surface in an elevated orientation relative to a ground surface; a
subfloor supported by said subframe and defining a working surface;
and a deck surface comprising a masonry material disposed on said
working surface.
2. The deck system of claim 1, further comprising a fascia arranged
on at least a portion of a perimeter of the deck system.
3. The deck system of claim 1, further comprising a semi-permeable
barrier disposed between said subfloor and said plurality of
masonry material.
4. The deck system of claim 3 wherein said semi-permeable barrier
comprises a fabric material.
5. The deck system of claim 1 wherein said subframe comprises wood
and defines at least one support post extending in a generally
vertical orientation between said ground surface and said
horizontal support surface.
6. The deck system of claim 1 wherein said subfloor comprises a
plurality of passages defined through said working surface.
7. The deck system of claim 6 wherein said subfloor comprises
plastic and defines a plurality of recess portions for accepting a
fastener head in an installed position.
8. The deck system of claim 1 wherein said masonry material is
selected from the group consisting of brick paving blocks; cultured
stone; natural stone; slate; fieldstone; marble; and conventional
brick.
9. A deck assembly comprising: a subframe supported by a foundation
on a first end and presenting a substantially horizontal support
surface elevated above a ground surface on an opposite end; a
subfloor extending across and coupled to said support surface of
said subframe, said subfloor defining a working surface; a
semi-permeable barrier disposed over said working surface; a
masonry material arranged upon said working surface; and a fascia
arranged on at least a portion of a perimeter of the deck
assembly.
10. The deck assembly of claim 9 wherein said fascia comprises
synthetic material.
11. The deck assembly of claim 9 wherein said semi-permeable
barrier comprises fabric.
12. The deck assembly of claim 9 wherein said subframe comprises
wood and defines at least one support post extending in a generally
vertical orientation between said ground surface and said
horizontal support surface.
13. The deck assembly of claim 9 wherein said subfloor comprises a
plurality of passages defined through said working surface.
14. The deck assembly of claim 6 wherein said subfloor defines a
plurality of recess portions for accepting a fastener head of a
fastener in an installed position, said fastener extending entirely
through said subfloor and engaging said subframe in an installed
position.
15. The deck assembly of claim 9 wherein said subfloor comprises
plastic.
16. The deck assembly of claim 9 wherein said masonry material is
selected from the group consisting of brick paving blocks; cultured
stone; natural stone; slate; fieldstone; marble; and conventional
brick.
17. A deck installation associated with a building and adapted to
provide a floor space elevated from a ground surface and accessible
from the building comprising: an interconnected subframe defining a
working surface; a subfloor supported by said subframe and defining
a working surface; and a masonry material disposed on said working
surface and defining a floor surface.
18. The deck installation of claim 17 wherein said floor surface is
accessible from a second story of the building.
19. The deck installation of claim 17 wherein said floor surface is
accessible from a third story of the building.
20. The deck installation of claim 17 wherein said subframe is
coupled to the building.
21. The deck installation of claim 20 wherein said subframe is
cantilevered to the building.
22. A method of constructing a deck comprising: assembling a
subframe engaging a ground surface and presenting a substantially
horizontal support surface at an elevated location relative to said
ground surface; attaching a subfloor to said frame structure; and
arranging a plurality of paving blocks onto said subfloor.
23. The method of claim 22 wherein assembling said subframe
comprises: arranging at least one support post in a generally
vertical orientation between said ground surface and said
horizontal support surface.
24. The method of claim 22, further comprising: arranging a fascia
on at least a portion of a perimeter of the deck in a substantially
transverse orientation to said horizontal support surface.
25. The method of claim 22 wherein attaching said subfloor
comprises: driving at least one fastener through said subfloor
whereby a distal end of said at least one fastener penetrates said
subframe and a proximal end of said at least one fastener nests
into a recess defined on said subfloor.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/583421, filed on Jun. 28, 2004. The disclosure
of the above application is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to decks and more specifically
to an elevated deck system supporting a deck surface of masonry
materials, such as brick pavers.
BACKGROUND OF THE INVENTION
[0003] Decks are constructed on buildings to provide additional
outdoor floor space for residential and commercial applications.
Conventional decks are typically constructed of wood and are
adapted to provide some degree of elevation relative to the ground.
Often decks are arranged relative to a doorway such that convenient
access between the building and the deck may be achieved. In some
instances, a doorway may be provided on an upper level of a
building whereby a deck is constructed having support structure
consisting of vertical posts anchored in the ground and extending
upward to the upper level to provide a raised deck surface.
[0004] Occasionally, decks are constructed on homes having multiple
levels and/or walk-out style basements. On such homes it is common
to construct a deck accessible from a main level of the home, or
even levels above the main level, such as those extending off a
bedroom located on an upper floor of the home. Many times such a
deck includes an elevated portion that provides useable space
underneath. For example, a walk-out basement may be accessed by
walking under an elevated deck. In such a configuration, useable
elevated floor space is created on the deck above the walkout
access.
[0005] One alternative to constructing a conventional deck to
increase outdoor living space includes laying a paver stone patio.
Paver stone patios have become increasingly popular due to
increased durability and reduced maintenance. Furthermore, paver
stones provide a variety of color and pattern options available for
personal customization.
[0006] Laying a paver stone patio requires a smooth ground surface
for providing a solid foundation for the paver stones. In some
instances compacted sand or crushed stone is used to form a
substantially flat bed to accept the paver stones on top. As a
result, preparing the ground including digging out portions of dirt
and/or adding portions of dirt can become time consuming, costly
and labor intensive. In addition, paver stone patios conventionally
have been limited solely to preparation and creation directly on a
ground surface.
[0007] In some instances retaining wall blocks have been used to
provide a raised ground surface. However, such configurations tend
to be cost prohibitive above two feet in elevation. Once a ground
surface has been adequately prepared, the paver stones are arranged
on top in a desired pattern. In many instances, the preparation of
the ground surface accounts for a substantial amount of the overall
installation time and expense.
[0008] It, therefore, would be desirable to provide an elevated
deck system while providing the durability and low maintenance
advantages associated with a masonry surface such as a paver stone
patio. Specifically, it would be desirable to provide such a system
that is cost effective system at elevations.
SUMMARY OF THE INVENTION
[0009] A deck system includes an interconnected subframe operable
to engage a ground surface and provide an elevated substantially
horizontal support surface. A subfloor is coupled to the subframe
and defines a working surface. A masonry floor surface including a
plurality of brick pavers, for example, is disposed on the working
surface. The masonry floor surface provides the advantages of
durability and low maintenance while the subframe and subfloor
allow construction at an elevated location, such as a second story
of a home.
[0010] The subframe can comprise wood and have at least one support
post extending in a generally vertical orientation between the
ground and the horizontal support surface. Also, the subfloor can
comprise a plurality of passages defined through the working
surface. The subfloor, which may comprise plastic, can include a
plurality of recess portions for accepting a fastener head in an
installed position. The subfloor provides a high strength-to-weight
ratio and is easily workable with conventional woodworking tools.
The masonry materials are generally selected from readily available
materials, such as brick paving blocks, cultured stone, natural
stone, slate, fieldstone, marble and conventional brick. According
to other features, the deck system may include a fascia arranged
around a perimeter of the deck system. A semi-permeable barrier
comprised of a fabric material can be disposed between the subfloor
and the plurality of masonry materials to retain sand and enable
moisture pass through.
[0011] A method of constructing a deck includes assembling a
subframe engaging a ground surface and presenting an elevated
substantially horizontal support surface. A subfloor is attached to
the frame structure. A plurality of paving blocks are arranged onto
the subfloor.
[0012] According to still other features, assembling the subframe
can include arranging at least one support post in a generally
vertical orientation between the ground surface and the horizontal
support surface. Alternatively, the subframe can be attached to an
upper level of a building through a cantilever arrangement.
Attaching the subfloor includes driving a fastener through the
subfloor whereby a distal end of the fastener nests into a recess
defined on the subfloor. A fascia is subsequently arranged on at
least a portion of a perimeter of the deck, if desired.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present invention will become more fully understood from
the detailed description and the accompanying drawings,
wherein:
[0014] FIG. 1A is a perspective view of showing a partially
constructed deck system according to the teachings of the
invention;
[0015] FIG. 1B is a perspective view of a building including
exemplary deck systems constructed according to the invention;
[0016] FIG. 2 is an exploded view of the deck system of FIG. 1;
and
[0017] FIG. 3 is an enlarged, partial perspective view of a
subfloor of the deck system of FIG. 1 according to the
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The following description of the preferred embodiment(s) is
merely exemplary in nature and is in no way intended to limit the
invention, its application, or uses.
[0019] With initial reference to FIGS. 1A-2, a deck system
according to the present teachings is shown and identified
generally at reference 6. The deck system 6 generally includes an
elevated substructure 8 and a masonry deck surface 10. The elevated
substructure 8 includes a subframe 12 and a subfloor 14. The
masonry deck surface 10 includes a plurality of paving blocks 20. A
semi-permeable barrier 22 is disposed between the subfloor 14 and
the paving blocks 20. Fascia segments 26 are arranged around a
periphery of the deck system 6.
[0020] As will become appreciated from the discussion herein, the
deck system 6 provides an improved alternative to traditional
decking or paving block patios. The deck system 6 provides the low
maintenance advantages associated with paving blocks while
providing a substructure for locating the paving blocks at
elevation. The deck system 6 also provides considerable assembly
advantages. In one advantage, a level working surface necessary for
accommodating paving blocks may be constructed with less time and
expense as compared to the ground surface preparation associated
with traditional brick paver patios.
[0021] With reference to FIG. 1B, exemplary deck systems 6 are
shown associated with a portion of an exemplary building B. The
building B includes access doors D1, D2 and D3. In the exemplary
building B, the access doors D1-D3 correspond to respective stories
or floor levels of the building B. As shown, the deck system 6
associated with the access door D2 is arranged above the access
door D1 (such as in a walk-out style basement configuration). Of
note, the deck system 6 associated with the door D3 is shown in a
cantilever arrangement attached directly to the building B. It is
appreciated that the posts 30 shown associated with the deck system
6 arranged adjacent to the door D2 may additionally be provided on
the deck system 6 arranged adjacent to the door D3.
[0022] The subframe 12 generally includes a series of
interconnected horizontal support members 28 and vertically
disposed posts 30. The horizontal support members 28 collectively
define various beams and joists. The posts 30 are configured to be
recessed and secured into the ground G according to conventional
methods to provide foundational support. As is readily appreciated,
the posts 30 may vary in length to compensate for uneven terrain.
In an installed configuration (FIGS. 1A and 1B), the subframe 12 as
a whole defines an elevated substantially horizontal support
surface 32. The subframe 12 is made from a durable weather
resistant material such as, but not limited to, pressure treated
lumber. Of course other materials such as synthetic or composite
materials, may be utilized.
[0023] While not specifically shown, traditional hardware such as
joist hangers, screws, nails, bolts and nuts may be employed to
operatively interconnect the horizontal support members 28 and
posts 30 of the subframe 12 in a secure manner with the appropriate
load bearing capacity. Those skilled in the art will appreciate
that the subframe 12 may be constructed according to conventional
construction techniques with conventional woodworking tools. As a
result, the size and shape of the subframe 12 may present complex
shapes, as desired, and is not limited to any constrained
dimensional specifications.
[0024] With continued reference to FIGS. 1A-2 and further reference
to FIG. 3, the subfloor 14 will be described in greater detail. The
subfloor 14 is adapted to securedly rest on the support surface 32
of the subframe 12. The subfloor 14 defines a working surface 36
and a plurality of passages 38 (FIG. 3). While the passages 38 of
the subfloor 14 are represented as having a generally rectangular
shape, the passages 38 may define other shapes such as, but not
limited to circular, triangular and honeycomb.
[0025] The working surface 36 provides a level template for
positioning the paving blocks into a desired pattern. A plurality
of recessed screw pockets 40 are arranged across the working
surface 36 (as best viewed in FIG. 3). The screw pockets 40 provide
a recess for accommodating fasteners such as fasteners 44. In this
way, a head 46 of the fastener 44 nests within the screw pocket 40
so as to maintain a smooth working surface 36. A distal end 48 of
the fastener 44 passes beyond the subfloor 14 to threadably engage
the subframe 12 (FIG. 3). It is appreciated that a greater or
lesser amount of screw pockets 40 may be arranged in any pattern or
variation across the subfloor 14.
[0026] Those skilled in the art will appreciate that any suitable
technique may be used to secure the subfloor 14 to the subframe 12.
In this way, while threaded fasteners are shown to be utilized for
securing the subfloor 14 to the subframe 12, other fastening
methods may be employed such as, but not limited to, chemical
adhesives or other mechanical fastening methods. Alternatively, the
subfloor 14 may be held in a secure relationship with the subframe
12 by way of locating members (not shown) such as vertical posts or
pegs extending upward from the subframe 12 and adapted to locate
through one or more of the passages 38 (FIG. 3). The subframe 12
and subfloor 14 of the elevated substructure 8 are configured to
meet or exceed the local building codes for load bearing.
[0027] The subfloor 14 may comprise a durable material such as, but
not limited to, plastic. The material and configuration of the
subfloor 14 provides a high strength-to-weight ratio. It is
contemplated that the subfloor 14 is available in preformed
segments such as, but not limited to, 4 foot by 8 foot sheets. The
material of the subfloor 14 is suitable for use with conventional
woodworking tools. Because the subfloor 14 is made of material
suitable for conventional tools, the subfloor 14 may be easily
manipulated and/or cut into preferred dimensions on-site to
accommodate a variety of desired deck geometries.
[0028] The semi-permeable barrier 22 (FIG. 2) may comprise any
suitable material such as, but not limited to, a fabric material or
a plastic sheet. The semi-permeable barrier 22 is adapted to pass
moisture through while retaining filler material, such as sand
disposed between the respective paving blocks 20. The
semi-permeable barrier 22 is also workable with conventional tools
such that any desired shape may be easily cut or otherwise created
to place over the subframe 14, as desired.
[0029] The paving blocks 20, while represented in the drawings as
brick paving blocks, may similarly comprise other masonry
materials. By way of example, cultured stone, natural stone, slate,
fieldstone, marble, conventional brick or other units of various
natural or artificial mineral products may be used.
[0030] The fascia 26 may comprise a plurality of segmented
longitudinal members. The fascia 26 may be attached to the frame 12
and/or the subfloor 14 by any suitable method, such as conventional
threaded fasteners for example. In an installed configuration
(FIGS. 1A and 1B), the fascia 26 not only provides pleasing
aesthetic properties to the deck system 10, but may also facilitate
lateral retention of the paver blocks 20 in a secure position atop
the subfloor 14. In one form, the fascia 26 is comprised of
synthetic material for reduced maintenance. The fascia 26 may also
comprise conventional materials such as pressure treated lumber or
other woods.
[0031] While the deck system 6 illustrated in the drawings provides
a fascia 26 for decorative purposes, a deck system 6 may
alternatively be backfilled around at least portions of a perimeter
thereof. Such a configuration would provide a raised paver stone
patio supported by an elevated substructure while having at least
portions of the perimeter accessible from a ground surface.
[0032] A method of constructing a deck according to the present
teachings will now be described. At the outset, a plan is
determined that satisfies functional and aesthetic goals as well as
local building codes. One exemplary building code requires a
structure suitable to accommodate at least 40 pounds per square
foot, live load. First, the proper size of the horizontal support
members 28 are determined based on the on-center (OC) spacing
between the horizontal support members 28 and the overall length,
or span, of the support members 28. In one example, 4 inch by 4
inch posts, 8 foot OC are utilized with 2 inch by 12 inch beams and
2 inch by 10 inch joists, 16 inches OC to provide a live load of 94
pounds per square foot.
[0033] Conventional paver blocks weigh approximately 28 pounds per
square foot. As a result, it is appreciated that a variety of frame
configurations may be engineered and constructed to support the
paver blocks while still meeting or exceeding applicable building
codes. Once the appropriate materials have been selected, the
subframe 12 is engineered and constructed to meet code. Next, the
subfloor 14 is suitably attached to the subframe 12 as described
above. It is appreciated that portions or all of the subfloor 14
may be configured, as necessary, to fit appropriately across the
horizontal support surface 32.
[0034] The fabric barrier 22 is then placed over the working
surface 36 of the subfloor 14. At this point, the paver blocks 20
are laid on the fabric barrier 22 in the desired pattern. It may be
necessary to cut portions of the paver blocks 20, such as those
located at a perimeter or border. Optionally, sand may be applied
to fill any gaps between adjacent paver blocks 20. As previously
noted, the fabric barrier 22 facilitates the sanding process by
retaining the sand above the subfloor 14. The fascia 26 are then
attached to the frame 12 and/or subfloor 14 as desired.
[0035] While the invention has been described in the specification
and illustrated in the drawings with reference to various
embodiments, it will be understood by those skilled in the art that
various changes may be made and equivalents may be substituted for
elements thereof without departing from the scope of the invention
as defined in the claims. Furthermore, the mixing and matching of
features, elements and/or functions between various embodiments is
expressly contemplated herein so that one of ordinary skill in the
art would appreciate from this disclosure that features, elements
and/or functions of one embodiment may be incorporated into another
embodiment as appropriate, unless described otherwise above.
Moreover, many modifications may be made to adapt a particular
situation or material to the teachings of the invention without
departing from the essential scope thereof. Therefore, it is
intended that the invention not be limited to the particular
embodiment illustrated by the drawings and described in the
specification as the best mode presently contemplated for carrying
out this invention, but that the invention will include any
embodiments falling within the foregoing description and the
appended claims.
* * * * *