U.S. patent application number 11/051302 was filed with the patent office on 2006-08-10 for rail mounting apparatus and method.
Invention is credited to Michael G. Burkart, Jeffrey G. Herion.
Application Number | 20060175594 11/051302 |
Document ID | / |
Family ID | 36777990 |
Filed Date | 2006-08-10 |
United States Patent
Application |
20060175594 |
Kind Code |
A1 |
Burkart; Michael G. ; et
al. |
August 10, 2006 |
Rail mounting apparatus and method
Abstract
A method and apparatus is disclosed for mounting a rail (e.g.,
fence, stair or banister) to a support structure (e.g., a post,
wall, etc.), wherein a rail mounting bracket is provided that
allows the rail to be supported within an interior of the bracket
in a desired position until the rail can be fixedly secured to the
bracket in the desired position. The bracket provides various
projections from its face that allows a rail to be supported and
fixed to the bracket at an upwardly and/or downwardly inclined
angle relative to the bracket face. The bracket is designed to
withstand various loads specified by building standards for
composition fences and banisters.
Inventors: |
Burkart; Michael G.;
(Denver, CO) ; Herion; Jeffrey G.; (Watkins,
CO) |
Correspondence
Address: |
SHERIDAN ROSS PC
1560 BROADWAY
SUITE 1200
DENVER
CO
80202
US
|
Family ID: |
36777990 |
Appl. No.: |
11/051302 |
Filed: |
February 4, 2005 |
Current U.S.
Class: |
256/65.02 |
Current CPC
Class: |
E04H 17/1452 20210101;
E04F 11/1817 20130101; E04H 17/1448 20210101; E04H 17/1447
20210101; E04H 17/1417 20130101; E04F 2011/1819 20130101; E04F
2011/1821 20130101; E04F 11/1834 20130101 |
Class at
Publication: |
256/065.02 |
International
Class: |
E04H 17/14 20060101
E04H017/14 |
Claims
1. A rail support for supporting at least a portion of a rail on a
support structure, comprising: front and back faces, wherein the
back face fixedly faces the support structure so that at least a
portion of the rail weight is transferred to the support structure;
first and second rail side supports extending from said front face,
wherein the first and second rail side supports are spaced apart a
distance for providing at least a portion of an exterior end of the
rail therebetween, and for restricting horizontal movement of the
end of the rail; first and second lower supports extending from
said front face, wherein the first lower support is spaced
vertically above the second lower support when the back face
fixedly faces the support structure; wherein the first lower
support is effective for supporting the exterior end of the rail
when the rail is in a substantially horizontal orientation, and the
second lower support is effective for supporting the exterior end
of the rail when the rail is angled from horizontal by more than
approximately 30 degrees.
2. A method for supporting at least a portion of a rail on a
support structure, comprising: attaching a bracket having front and
back faces to the support structure, wherein the back face fixedly
seats against the support structure so that at least a portion of
the rail weight is transferred to the support structure;
positioning an end of the rail between first and second rail side
supports extending from said front face, wherein the first and
second rail side supports are spaced apart a distance for providing
an exterior of the end of the rail therebetween, and for
restricting horizontal movement of the end of the rail; supporting
the end of the rail on one of first and second lower supports
extending from said front face, wherein the first lower support is
spaced vertically above the second lower support when the back face
is fixedly seated against the support structure; wherein the first
lower support is used for supporting the exterior end of the rail
when the rail is in a substantially horizontal orientation, and the
second lower support is used for supporting the exterior end of the
rail when the rail is angled from horizontal by more than
approximately 30 degrees.
3. A support bracket for supporting at least a portion of a rail on
a support structure, comprising: front and back faces, wherein the
back face fixedly seats against the support structure so that at
least a portion of the rail weight is transferred to the support
structure; first and second rail side supports extending from said
front face, wherein the first and second rail side supports are
spaced apart a distance for providing an exterior end of the rail
therebetween, and for restricting horizontal movement of the end of
the rail; first and second lower supports extending from said front
face, wherein the first lower support is spaced vertically above
the second lower support when the back face is fixedly seated
against the support structure; wherein the first lower support is
effective for supporting the exterior end of the rail when the rail
is in a first orientation, and the second lower support is
effective for supporting the exterior end of the rail when the rail
is in a second orientation; and wherein the first lower support is
supported on a remainder of the bracket along a predetermined edge
so that the first lower support is separable from the remainder of
the bracket along the predetermined edge.
4. A method for supporting at least a portion of a rail on a
support structure, comprising: attaching a bracket having front and
back faces to the support structure, wherein the back face fixedly
seats against the support structure so that at least a portion of
the rail weight is transferred to the support structure;
positioning an end of the rail between first and second rail side
supports extending from said front face, wherein the first and
second rail side supports are spaced apart a distance for providing
an exterior of the end of the rail therebetween, and for
restricting horizontal movement of the end of the rail; supporting
the end of the rail on one of first and second lower supports
extending from said front face, wherein the first lower support is
spaced vertically above the second lower support when the back face
is fixedly seated against the support structure; and separating the
first lower support from a remainder of the bracket when the second
lower support is used to support the end of the rail.
5. A rail support for supporting at least a portion of a rail on a
support structure, comprising: front and back faces, wherein the
back face fixedly seats against the support structure so that at
least a portion of the rail weight is transferred to the support
structure; first and second rail side supports extending from said
front face, wherein the first and second rail side supports are
spaced apart thereby providing a recess for receiving an exterior
of an end of the rail; wherein each of the first and second rail
side supports has: (a) a rail contacting side that contacts the end
of the rail in the recess for restricting horizontal movement of
the rail, and (b) a side facing away from the end of the rail; at
least one lower support extending from said front face, wherein the
at least one lower support supports the end of the rail; for each
rail side support of the first and second rail side supports, there
are one or more guide slots exterior to the recess and adjacent to
the rail side support; a cover having an opening for receiving the
rail therein, said cover extending about the opening an effective
amount for covering the front face, said cover including a
plurality of guides wherein each guide enters a corresponding one
of the guide slots when the cover attaches over the front face;
wherein for at least one of the guide slots and a corresponding one
of the guides, the one guide frictionally engages the at least one
guide slot, and wherein the cover is removable from the remainder
of the rail support with a force in the range of five to twenty
pounds.
6. A method for supporting at least a portion of a rail on a
support structure, comprising: attaching a bracket having front and
back faces to the support structure, wherein the back face fixedly
seats against the support structure so that at least a portion of
the rail weight is transferred to the support structure;
positioning an end of the rail between first and second rail side
supports extending from said front face, wherein the first and
second rail side supports are spaced apart thereby providing a
recess for receiving an exterior of an end of the rail; wherein
each of the first and second rail side supports has: (a) a rail
contacting side that contacts the end of the rail in the recess for
restricting horizontal movement of the rail, and (b) a side facing
away from the end of the rail; wherein for each rail side support
of the first and second rail side supports, there is at one or more
guide slots exterior to the recess and adjacent to the rail side
support; supporting the end of the rail on at least one lower
support extending from said front face; attaching a cover over the
front face, the cover having an opening for receiving the rail
therein, said cover including a plurality of guides, and wherein
each guide enters a corresponding one of the guide slots when the
cover attached over the front face; wherein for at least one guide
slot and a corresponding one of the guides, the one guide
frictionally engages the one guide slot, and wherein the cover is
removable from the remainder of the rail support with a force in
the range of five to twenty pounds.
Description
RELATED FIELD OF THE INVENTION
[0001] The present invention relates to fence rail mounting
apparatus and method, and in particular, to rail mounting bracket
that is capable of withstanding substantial fence loadings without
failure, and that allows rails to be mounted at various angles to
the bracket.
BACKGROUND
[0002] Synthetic fences and railings having at least their
exteriors made of vinyl, PVC, plastic or other synthetic materials
(e.g., materials that can be molded in an injection mold, extruded
or pultruded) are used as cost effective replacements for wood
and/or metal fences and railings in numerous circumstances. Such
synthetic fences and railings can be easier to install, and are
substantially maintenance free. Such synthetic fences and railings
are typically assembled from post and railing components, each such
component made of a synthetic material(s) which typically can be,
e.g., a molded, extruded or pultruded. Such synthetic post and
railing components typically have a rigid exterior and a hollow
interior for receiving various reinforcing components made of,
e.g., plastic, wood, or metal, or in some cases reinforced with
concrete. Once the composite posts and rails are
assembled/constructed, they are secured together to obtain a
synthetic fence or railing.
[0003] Numerous techniques have been developed for assembling such
synthetic fences and railing, and in particular, for securing a
composite rail to a post or other support structure (e.g., the side
of a building). Most such techniques require a mounting bracket for
attaching a synthetic railing to a post (more generally, to a
"support structure"), the bracket is first secured to its support
structure, and then a synthetic rail end is secured to the bracket.
However, various esthetic and structural difficulties have not been
heretofore adequately addressed for securing such a synthetic rail
and a bracket together. For example, securing a synthetic rail end
with the bracket can require manually maintaining the rail in
position or alignment while securely fastening the bracket to the
post. Additionally, since the synthetic rail may have to be secured
to the bracket at an angle other than perpendicular to a vertical
support structure upon which the bracket is mounted (e.g., when
providing railings for stairs between vertically positioned posts)
such manual alignment of the rail is made even more difficult.
[0004] Another difficulty in assembling synthetic fences and
railings results from the perception that such synthetic fences and
railings will not withstand the side impacts (or various other
loadings) as effectively as their counterpart wood or metal fences
or railings. Accordingly, various building regulations have been
put in place requiring such synthetic fences and railing to
withstand very high impacts and loads from various directions. In
many instances, the failure point of such synthetic fences and
railings has been at the railing mounting bracket and/or the
attachment of the railing thereto. For example, the railing may
detach from the bracket and/or the bracket may deform.
[0005] Additionally, since the bracket, and its various support
structure and railing fasteners (e.g., screws, clips, etc.), are
metal, it is very desirable esthetically to hide such hardware when
the synthetic fence or railing is fully assembled. Although
covering plates for hiding such hardware are available, such
covering plates may not easily attachable to their brackets, and
once attached cannot be detached without damaging at least the
covering plate.
[0006] Accordingly, it is desirable to have a synthetic rail
mounting bracket that addresses and substantially alleviates the
above-described difficulties with heretofore available synthetic
rail mounting brackets.
Description of Terms
[0007] Moldable materials: Materials that can be molded according
to molding techniques such as compression, transfer, and injection
molding, extrusion, and pultrusion.
[0008] Synthetic fencing, posts, rails and components thereof:
These terms, respectively, refer to fencing, posts, rails and
components thereof that provide at least some of the following
attributes: (a) such components are manufactured from a synthetic
or a non-naturally occurring material such as vinyl, PVC, plastic
or another polymer based compound(s), or composite including such a
synthetic material, (b) such components are manufactured using a
molding technique such as injection molding, extrusion, and
pultrusion, wherein a flowable material is shaped into a rigid
fencing components, generally having a hollow interior, and (c)
such components are assembled/constructed into fence posts and
rails by combining such components together with reinforcing
structural materials such as metal, wood, and concrete, wherein
such reinforcing structural materials are provided in a hollow
interior the components.
SUMMARY OF THE INVENTION
[0009] A rail mounting system is disclosed for mounting a rail
(e.g., a stair, walkway, or fence railing) to a support structure,
and a method for performing and using the same is also disclosed.
The rail mounting system includes a novel bracket that serves as an
intermediary apparatus between, e.g., a fence or banister rail, and
a support structure. Thus, a rail may attach to the bracket after
the bracket has been attached to a support structure (such a
support structure may be, e.g., the side of a building, a post, a
column, a beam, a wall or other rigid members to which a rail can
be fixedly attached). The bracket is particularly useful in that
once the bracket is secured to a support structure, a rail (more
precisely, a rail end) may be easily placed on the bracket for
supporting the rail in a desired position, wherein the rail can be
subsequently firmly secured to the bracket. In particular, a rail
end may be aligned on the bracket by placing the rail end within a
rail holding portion of the bracket that includes side supports,
and may include a support for the bottom edge of the rail. Thus,
the rail can be positioned in the rail holding portion wherein it
is supported on the bracket in a properly aligned position until
the rail can be firmly secured to the bracket.
[0010] Moreover, the rail may be attached to the bracket in any one
of a plurality of orientations, e.g., for a vertical support
structure surface having the bracket thereon, the rail may extend
substantially horizontally, extend downwardly (e.g., the
corresponding acute angle between vertical and the rail being
approximately 60 degrees or less), or extend upwardly (e.g., the
corresponding acute angle between vertical and the rail also being
approximately 60 degrees or less). To readily provide such
variation in rail orientations, the bracket may include a plurality
of rail supports for supporting the rail at at least two different
angular orientations. Thus, when the rail is oriented substantially
perpendicular to a planar face of the bracket, a first of the rail
supports may be used, and when the rail is angled either downwardly
or upwardly from the bracket face by, e.g., a deviation from a
perpendicular to the face of the bracket by an angle greater than
approximately a 30 degrees, a second rail support may be used.
[0011] The rail mounting system may also include a bracket cover
for covering the bracket and the end of a rail attached thereto.
The bracket cover provides an esthetically pleasing exterior that
hides the bracket, the rail end and the (any) fasteners used to
secure the bracket and the rail end together.
[0012] The rail mounting system may further include a bracket
attachment component, wherein this component can be secured in
place between the bracket and the support structure. Thus, such a
bracket attachment allows a bracket having a fixed contour for its
surface facing a support structure to be attached to a support
surface having a different surface contour. In particular, the
contour of a first side of the bracket attachment (facing the back
side of the bracket) mates with the bracket, and a second side of
the bracket attachment (facing the surface of the support
structure) conforms to the contour of the support structure
surface.
[0013] Further description of advantages, benefits and patentable
aspects of the present invention will become evident from the
accompanying drawings and description hereinbelow. All novel
aspects of the invention, whether mentioned explicitly in this
Summary section or not, are considered subject matter for patent
protection either singly or in combination with other aspects of
the invention. Accordingly, such novel aspects of the present
invention disclosed hereinbelow and/or in the drawings that may be
omitted from, or less than fully described in, this Summary section
are fully incorporated herein by reference into this Summary. In
particular, all claims of the Claims section hereinbelow are fully
incorporated herein by reference into this Summary section.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 shows a perspective view of one embodiment of the
rail mounting system 18, and in particular, shows an embodiment of
a bracket 20 to which the rail 26 is to be secured.
[0015] FIG. 2 shows the embodiment of the rail mounting system 18
of FIG. 1, wherein the bracket 20 is secured to a support structure
38 and a rail 26 is secured to the bracket.
[0016] FIG. 3 shows a face-on view of the bracket 20 together with
various embodiments of fasteners 52 for attaching the bracket to a
support structure and/or attaching a rail to the bracket 20.
[0017] FIG. 4 shows a side view of the bracket 20 together with a
dashed profile of the end of a rail 26, wherein the rail is
supported on the bracket at an angle (e.g., 45.degree.) to the
front face 34 of the bracket.
[0018] FIG. 5 is a perspective view showing the components of both
the bracket and the bracket cover 28 that mate together for
securing the bracket cover over both the bracket and the rail end
joined to the bracket.
[0019] FIG. 6 shows a more detailed view of the cover lock 112 of
the bracket 20.
[0020] FIG. 7 shows a top view of the cover lock 112.
[0021] FIG. 8 shows the internal structure of an embodiment of the
bracket cover 28.
[0022] FIG. 9 shows an exterior view of an embodiment of the
bracket cover (28a), wherein the bracket cover can be used for
covering the bracket 20 when a rail 26 attaches to the bracket at
an angle substantially different from orthogonal to the front face
of the bracket.
[0023] FIG. 10 shows a side view of the bracket cover 28a in place
for covering the bracket 20 and the end of a rail 26 which is
attached to the bracket so that the rail extends upwardly away from
the bracket.
[0024] FIG. 11 shows a perspective view of an embodiment of a
bracket attachment 59 which serves as an intermediary component
between embodiments of the bracket, and a support structure 38. In
particular, such a bracket attachment 59 (and variations thereof)
allow a bracket having a fixed contour of its surface for facing a
support structure (e.g., back face 36, FIGS. 1 and 4) to be
attached to a support surface having a different surface contour
(e.g., including a corner).
[0025] FIG. 12 shows an internal structure of the bracket
attachment 59 shown in FIG. 11.
[0026] FIG. 13 shows an alternative embodiment of the bracket
attachment 59, wherein the raised portion 61a assists an installer
in properly mounting a bracket thereto.
[0027] FIG. 14 shows another embodiment of a bracket attachment 59
for attaching to a curved support structure 38.
[0028] FIG. 15 shows another embodiment of a bracket attachment 59,
wherein the raised bracket alignment portions 61 are positioned
across the width of the bracket attachment rather than lengthwise
as shown in FIGS. 13 and 14. Additionally, this figure illustrates
that bracket attachments can be fitted to a support structure
surface so that a rail 26 extending therefrom at substantially any
angle by adjusting the bracket attachment profile 69.
[0029] FIG. 16 shows a face-on view of a guardrail assembly 204
constructed using the rail mounting system 18 for securing the
rails 26a and 26b to the posts 208.
[0030] FIG. 17 shows a guardrail assembly 204 specimen undergoing
horizontal load testing to determine, in particular, the
performance of the brackets 20.
[0031] FIG. 18 shows a guardrail assembly 204 specimen undergoing
inclined load testing to determine, in particular, the performance
of the brackets 20.
[0032] FIG. 19 shows another embodiment for the bracket (20a) of
the rail mounting system 18 together with a "T" shaped rail 26T for
attaching to the bracket 20a.
[0033] FIGS. 20 through 22 show side views of the bracket 20a with
a rail 26T supported thereon at various angular orientations.
Additionally, these figures show the cross sections of various
embodiments of bracket covers 28b-28d attached to the bracket
20a.
[0034] FIG. 23 shows another embodiment of both the bracket (20b),
and a corresponding bracket attachment (59b).
DETAILED DESCRIPTION
[0035] FIG. 1 shows an embodiment of the rail mounting system 18.
The rail mounting system 18 includes a bracket 20 for mounting an
end 24 of a rail 26 thereto (e.g., a synthetic rail, or
alternatively, a wood, or metal rail). The rail 26 may be, e.g., up
to ten feet in length (FIG. 1 does not show such a length of the
rail 26 according to scale), and may have cross sectional
dimensions of, e.g., less than eight inches by eight inches. The
bracket 20 is correspondingly dimensioned to appropriately mate
with the rail end 24. Additionally, the rail mounting system 18
includes a bracket cover 28 (e.g., FIGS. 1 and 8) for covering the
bracket 20 once the rail end 24 is secured to the bracket 20 (as
shown in FIG. 2). The bracket cover 28 may be manufactured from a
moldable material(s) such as, e.g., vinyl, PVC, plastic, and the
like. The bracket cover 28 includes a central channel 30 extending
through the thickness 31 of the bracket cover, wherein a front end
opening 29 of the central channel (furthest from the rail end 24)
tightly, but slidably, follows the outer shape of the rail 26, and
when traversing through the thickness 31 toward the rail end 24,
the bracket covering expands outwardly about the rail 26 until the
opposite or attachment end 32 of the bracket cover is of sufficient
size to entirely enclose the bracket 20 and any fasteners required
to secure: (a) the bracket and rail end together, and (b) the
bracket to a support structure (e.g., support structure 38, FIG.
2). In particular, the bracket cover 28 can be slid on the rail 26
toward the joined bracket 20 and rail end 24 for attaching to the
bracket (as is described hereinbelow). Thus, when the bracket cover
28 is secured to the bracket 20, the bracket cover entirely covers
the joined bracket and rail end 24, such as the joined bracket and
rail end of FIG. 2.
[0036] Referring now to the bracket 20, the bracket includes a
plate 33 having a front face 34 and an opposing back face 36
(occluded in FIG. 1). These faces have dimensions that are, e.g.,
one to three centimeters larger, in both their length and width,
than the cross section of the rail end 24 for joining to the
bracket 20. In at least some embodiments, the bracket is a die-cast
#3 zinc part having thickness 40 (FIG. 1) in a range of 0.25 cm to
0.7 cm. However, in other embodiments, the bracket 20 may be
manufactured from a zinc alloy, stainless steel, a high strength
plastic (e.g., polyvinyl chloride (PVC), thermoplastics;
polyurethane, polyethylene (and/or high density variations
thereof), polypropylene, nylon, polycarbonate, butyrate, PETG,
propionate, ABS plastic, polystyrene, styrene (e.g., ASA and
similar variations thereof), a polyacetal resin such as Delrin),
high strength resins (e.g., epoxy resins), aluminum (or an alloy
thereof). When the bracket 20 is secured to a support structure 38
(FIG. 2), e.g., a post or the side of a building, it is preferred
that the back face 36 entirely contact the support structure.
Ignoring for the moment the dashed lines 44 of FIG. 1, since a
typical support structure 38 will likely have a vertical planar
surface, the back face 36 may be substantially flat or planar with
the exception of the holes and extrusions that indent toward the
front face 32 and/or pierce the thickness 40 of the bracket 20.
However, the back face 36 may be curved, as illustrated by the
dashed lines 44, so that the back face follows a surface contour of
a non-planar support structure 38 upon which the back face seats
(e.g., the support structure may be a column or cylindrical
post).
[0037] The bracket 20 includes a number holes therethrough for
securing the bracket to a support structure 38. Referring to FIG.
3, there are three attachment holes 48 along each bracket side 50
for providing fasteners 52 (e.g., screws 52a, threaded bolts 52b,
rivets 52c, expandable shaft fasteners 52d, nails (not shown), and
the like) therein to attach the bracket 20 to the support structure
38. Additionally, there are two inner columns of holes, each having
three holes 54 for securing the bracket 20 to the support structure
38 with fasteners 52. Note that the holes 54 are tapered so that
the heads of fasteners 52 secured in these holes can be
substantially flush with the front face 34. As will become evident
from the description hereinbelow, the reduction (or complete
exclusion) of any protrusion of such fastener heads out from the
front face 34 is desirable in that the end 24 of a rail 26 covers
an area of the front face containing the holes 56, and preferably
abuts against this area.
[0038] The bracket 20 also has two large holes 56 vertically
oriented relative to one another. These holes 56 provide a
reduction in the bracket material needed to manufacture the bracket
20. Additionally, the holes 56 may be helpful to a person mounting
a rail 26 to a bracket 20. In particular, for a synthetic rail 26,
such as the rail shown in FIG. 1, the person mounting the rail may
wish to fit the bracket 20 onto a rail end 24 prior to the bracket
being attached to the support structure 38, e.g., so that he/she
can view where various fasteners 52 (screws, etc.) will contact
rail interior reinforcements (e.g., reinforcements 58, FIG. 1).
Moreover, such holes 56 may be used for aligning the bracket 20 on
a support structure 38. For example, a bracket attachment 59 is
shown in FIG. 11, wherein this attachment is positioned on a corner
of a support structure 38. The bracket 20 can be aligned onto the
front surface 57 of the bracket attachment 59 by inserting the
cylindrical raised portions 61 into the holes 56 of the bracket.
Accordingly, once the bracket 20 is positioned on the bracket
attachment 59, the bracket and the bracket attachment 59 can be
secured to the support structure 38 by appropriate fasteners 52
(e.g., 52a, 52b, 52c, or 52d) that extend through the holes 48 and
54 of the bracket, and respectively through the holes 62 and 63 of
the bracket attachment. Note that the holes 62 and/or the holes 63
may be asymmetrically offset from an axis 65 of points equally
spaced from each of the raised portions 61. In a similar manner,
the holes 48 and 54 may be correspondingly asymmetrically offset
from an axis (not shown) of points on the bracket front face 34
that are equally spaced from each of the holes 56. Such asymmetric
alignment of holes can assist in securing the bracket 20 with the
bracket attachment 59 since the corresponding holes in the bracket
and the bracket attachment will only align when the bracket is in a
desired orientation to the bracket attachment. Thus, by requiring a
person to position the bracket 20 correctly on the bracket
attachment 59, he/she is more likely align the bracket 20 as shown
in FIG. 1 (instead of upside down). FIG. 12 shows the side of the
bracket attachment 59 that faces the support structure 38. Note
that each of the holes 62 and 63 are provided within reinforced
tubes 67 that extend from the front surface 57 to the surface of
the support structure 38.
[0039] In the embodiment of the bracket attachment shown in FIG.
13, the lower cylindrical raised portion 61 has been replaced by a
triangular raised portion 61a. When this embodiment is used with an
embodiment of the bracket 20 having correspondingly shaped holes 56
(e.g., the lower hole 56 being triangularly shaped rather than
circular), there can be only one way to align the bracket 20 on the
bracket attachment 59 (e.g., the triangular raised portion may have
a side that extends beyond the perimeter of the upper cylindrical
portion 61). Moreover, for the person installing the bracket 20 and
the attachment bracket 59, the triangular raised portion 61a can
assist the person with orienting the bracket attachment properly on
the support structure 38 in that the raised portion 61a appears to
point to the end of the bracket attachment that should be the
uppermost.
[0040] FIG. 14 shows another embodiment of the bracket attachment
59, wherein this embodiment is used as an intermediary component
between a support structure 38 having a curved surface and the
bracket 20.
[0041] FIG. 15 shows yet another embodiment of the bracket
attachment 59, wherein this embodiment is for securing the bracket
20 to a corner of a support structure 38 such that the front
surface 57 is tilted approximately 22 degrees from one of two
adjacent support structure sides (not shown) that meet at a support
structure corner (also not shown), wherein a contour of these
adjacent sides and their mutual corner mates with the contour 69.
Note that in this embodiment, the raised portions 61 are aligned
across the width of the bracket attachment 59 instead being aligned
across the length of the bracket attachments (as in the previous
embodiments). Moreover, instead of mating with the holes 56 of the
bracket 20, the raised portions 61 here mate with the holes 54 that
are nearest to the center of the front face 34 (FIG. 3). Note that
raised portions 61 here are also offset so that the remaining
bracket holes 48 and 54 only align with the holes 62 and 63 when
the bracket 20 is properly positioned on this bracket attachment
59.
[0042] Returning now to the description of the bracket 20, FIGS.
1-7 show various protrusions extending outwardly from the front
face 32 of the bracket 20. Upper pair of rail supports 60 (FIGS. 1
and 4) are provided as such protrusions upon which the bottom side
64 of a rail end 24 rests when it is mounted on the bracket 20 so
that the rail 26 extends outwardly from the bracket in a direction
approximately perpendicular to the front face 32 (e.g., the rail
extends at an angle within a range of +30 degrees of being
perpendicular to the front face). In one embodiment, each of the
upper rail supports 60 extends approximately one centimeter from
the front face 32 for supporting on its upper surface 66 a rail end
24. Each of the upper rail supports 60 may have a corresponding
opening 68 adjacent to it (and above it in the operable position of
FIG. 1). Only a lower portion of the thickness 72 (FIG. 4) of each
upper rail support 60 attaches to the bracket 20 with a remaining
upper portion of the thickness occluding the corresponding opening
68 through the front face 32. The reduced amount of bracket
material attaching each upper rail support 60 to the remainder of
the bracket 20 is sufficient for supporting a rail 26 while it is
being further secured to the bracket. However, this reduced amount
of bracket material also allows the upper rail supports to be
easily broken off or detached from the remainder of the bracket 20
with pliers or other gripping tool.
[0043] The upper rail supports 60 can be broken off in the event
that the lower rail support 76 is to be used in supporting the rail
end 24, at least during the process of firmly securing the rail end
24 and the bracket 20 together. The lower rail support 76 may
extend outwardly from the front face approximately 0.5 centimeters.
The lower rail support 76 is used for supporting a rail end 24 when
the rail 26 is pitched at an angle of more than, e.g., 30 degrees
from being perpendicular to the front face 32. FIG. 4 shows a
dashed outline of a side view of a rail end 24 supported by the
lower rail support 76 (it is assumed that the upper rail supports
66 were previously broken off). Note that the lower rail support 76
can also be used for supporting a rail end 24 cut for fitting flush
with the front face 32, wherein the rail 26 extends upwardly from
the bracket instead of downwardly as shown in FIG. 4. In fact as
shown in FIG. 10, the outline of the rail end 24 shown in FIG. 4
need only be flipped bottom to top so that the upper most portion
of the rail outline is positioned on top surface 80 of the lower
rail support 76.
[0044] Additionally projecting outwardly from the front face 32 is
a pair of rail side supports 84 and 88 (FIGS. 1-6). In the
embodiment of FIG. 1, each of the rail side supports 84 and 88 are
mirror images of one another, and each extends perpendicularly from
the front face 32 approximately two centimeters (at their furthest
points). Additionally, each of the rail side supports 84 and 88 has
a thickness 90 of approximately 0.4 centimeters. However, such
dimensions are illustrative since alternatives to such dimensions
are possible. Each rail side support has an inner surface 92 (FIG.
3), and an outer surface 94 on the opposite side to the inner
surface. The inner surfaces 92 face one another. The rail side
supports 84 and 88 are substantially parallel to one another and
are spaced apart by a distance that is substantially the width "w"
(FIG. 1) of the rail end 24 so that when the rail end 24 is
positioned between the rail side supports, the rail end
simultaneously (and slidably) contacts both inner surfaces 92.
Thus, when a rail end 24 is positioned on the bracket 20 (e.g., one
of the upper or lower rail supports), the rail end is prevented
from shifting or moving laterally by the rail side supports 84 and
88. Accordingly, the rail end 24 can be maintained in a desired
alignment with the bracket 20 during the process of securing the
rail end to the bracket. In particular, there are rail securing
holes 98a and 98b on each of the rail side supports 84 and 88 (FIG.
1) for receiving rail fasteners 96 (e.g., screws, expandable shaft
fasteners, threaded bolts or the like, such as the fasteners 52 of
FIG. 3) used for securing the rail end 24 (and the reinforcements
58 therein) to the bracket 20 as shown in FIG. 2. Note that if a
threaded bolt is used mating nuts may be fastened to the end of the
bolt in the interior of the rail 26, or if the bolt extends from a
first hole of one of the hole pairs 98a or 98b through the other or
second hole of the pair, then the nut can be attached to the
portion of the bolt extending from second hole. Additionally, note
that once the rail end 24 is secured to the rail side supports 84
and 88, these side supports (with their fasteners 96) provide the
primary attachments that secure the bracket and the rail 26
together.
[0045] Each of the rail side supports 84 and 88 further includes a
central recessed portion 100 (FIG. 2) of reduced height from the
front face 32. This recessed portion of each rail side support is
beneficial in securing a fastener 52 (e.g., a screw, threaded bolt,
rivet, or the like) in the middle hole 48 adjacent to the side
support's the recessed portion 100. In particular, the recessed
portion 100 allows a person securing the bracket 20 to a support
structure 38 to more easily tighten a fastener 52 in this adjacent
hole 48 using any appropriate tool (screw driver, bolt tighter,
rivet gun, hammer, etc.). Moreover, each middle hole 48 has, on the
outer surface 94 adjacent thereto, a cylindrical recess 104 that
provides greater clearance for tightening (or untightening) a
fastener 52 in such a middle hole.
[0046] Furthermore, the recessed portion 100 is useful in
combination with the alignment tabs 106 (FIGS. 5 and 8) of the
bracket cover 28 for aligning the bracket cover on the bracket 20
so that bracket cover is properly secured thereto as is described
hereinbelow. In particular, when the bracket cover 28 is properly
positioned for covering the bracket 20, each of the alignment tabs
106 fits within one of the recessed portions 100.
[0047] Additionally, each of the rail side supports 84 and 88 is
reinforced on its outer surface 94 by reinforcements 108 for
further strengthening the rail side supports from deforming when an
attached rail 26 sustains a lateral impact.
[0048] Adjacent to each end of each of the rail side supports 84
and 88 is a cover lock 112 (e.g., FIGS. 1, 5 and 6) for attaching
the bracket cover 28 (e.g., FIGS. 1 and 5) over both the bracket 20
and the rail end 24 mounted thereto. As described above, the front
end of the bracket cover 28 includes a front end opening 29 that
follows the outer shape of the rail 26 so that once the rail end 24
is securely attached to the bracket 20 (as in FIG. 2), the bracket
cover then can be slid on the rail toward the joined bracket and
rail end. The embodiment of the bracket cover 28 shown in FIGS. 5
and 8 includes four cover locking projections 120 for inserting
into the four cover locks 112, one such projection 120 per cover
lock. Each of the cover locks 112 may be identical. Accordingly,
only one such cover lock 112 is provided with detailed labeling in
the figures (e.g., FIGS. 6 and 7). Each cover lock 112 includes an
outer wall 124 connected to the adjacent outer surface 94 by a
connecting wall 128 (FIGS. 1 and 7). An interior 132 (FIGS. 6 and
7) is provided that is bounded by the two walls 124, 128, and a
portion of the outer surface 94. The interior surface 136 (FIG. 7)
of the outer wall 124 and the opposing portion of the outer surface
94 each include a barb 140 that is angled toward the front face 32
(FIG. 6). The edges 144 (FIG. 7) of the barbs 140 are spaced apart
a slightly smaller distance than the thickness 148 (FIG. 5) of the
corresponding projection 120 so that for securing the bracket cover
28 to the bracket 20, the corresponding projection enters the
interior 132 by forcing the barbs 144 further apart. Accordingly,
when an attempt is made to remove the bracket cover 28, the barb
edges 144 are biased to bite into the bracket cover material of the
projections 120 thereby resisting removal of the bracket cover from
the bracket 20. In at least some embodiments, for a rail 26 having
a cross sectional size of less than, e.g., 400 sq. cm, a force of
approximately between five and twenty-five pounds is required to
disengage the projections 120 from their corresponding cover locks
112. Note that in one embodiment, the cover lock insertion end of
each projection 120 can be roughened on the sides that contact the
edges 144, and/or each projection 120 may have a greater thickness
148 than the thickness of the projection closer to its attachment
to the rest of the bracket cover 28. Thus, when such an enhanced
surface roughness and/or enhanced thickness 148 enters the interior
132, the bond between the projection 120 and its corresponding
cover lock 112 can be substantially strengthened.
[0049] Moreover, there are various ways to permanently attach the
bracket cover 28 to the bracket 20 such as by providing glue on the
projections 120 prior to inserting them into their corresponding
cover locks 112. Alternatively and/or optionally, an oppositely
oriented barb may also be provided on the cover lock insertion end
of each projection 120 so that each such projection barb couples or
mates with one of the barbs 140. In such permanently attached
bracket cover 28 embodiments, the bracket cover may only be removed
by rendering the bracket cover incapable of being reattached to a
bracket 20.
[0050] In FIGS. 4 and 10, the bracket 20 is shown in use with a
rail 26 that is sufficiently angled relative to the plane of the
front face 34 (as, e.g., may be required for stair railings) so
that the lower rail support 76 supports the rail end 24. In such
circumstances, the embodiment of the bracket cover 28 shown in
FIGS. 1 and 8 is unlikely to fit onto the bracket 20. Accordingly,
an alternative embodiment of the bracket cover (labeled 28a) is
shown in FIGS. 9 and 10, wherein this alternative embodiment can be
used to effectively to attach to a bracket 20 as described
hereinabove, and also cover the bracket 20 and the rail end 24 when
the rail 26 is angled more than, e.g., 30 degrees from being
perpendicular to the front face 34 of the bracket. The cover
bracket 28a may be substantially identical to a cover bracket 28
with the exception that: [0051] (a) the end 152 (FIGS. 9 and 10) of
the bracket cover 28a has a cutout 154 to accommodate the more
acute angle between the rail 26, and the front face 34; and [0052]
(b) in order to provide a close fit between the rail 26 and the
edge 156 of the front end opening 29, the edge 156 is shifted
toward the end 152, and the slope of the surface 160 (FIG. 10) of
the material of the bracket cover 28a (adjacent to the edge 156) is
angled at least 60 degrees from the front face 34.
[0053] It is important to note that the cover bracket 28a can be
used both for a rail 26 that extends downwardly from the bracket 20
(e.g., FIG. 4), and for a rail 26 that extends upwardly from the
bracket (e.g., FIG. 10). Thus, to use the bracket cover 28a for a
downwardly extending rail 26, the bracket cover is flipped so that
the cutout 154 is above the rail rather than below it.
[0054] Utilization of the bracket 20 and its corresponding bracket
cover 28 (28a) has been generally described above. However, for
further clarity, the rail mounting system 18 may be used according
to the following steps: [0055] Step 1: Orient and secure a first
bracket 20 to a first support structure 38 by placing fasteners 52
within the holes 48 and causing the fasteners to enter or otherwise
attach to the first support structure 38. Alternatively, the
bracket 20 may be secured to the first support structure 38 by
gluing, welding, banding, or securing the bracket 20 onto
projections (not shown) extending from the first support structure
38, wherein such projections enter at least one of the holes 48,
and/or one of the large holes 56 (e.g., such projections may have a
threaded central bore into which a threaded bolt 52b may be secured
to hold the bracket 20 on the first support structure 38). Note, as
a substep, if a bracket attachment 59 is to be used, the bracket
attachment and the bracket 20 are mated together in the proper
orientation and jointly attached to the support structure 38.
However, in some embodiments of the bracket attachment 59, there
may be holes in addition to the holes 62 and 63 that align with
corresponding holes of the bracket 20, wherein such additional
holes may be used to first secure the bracket attachment to a
support structure so that subsequently the bracket 20 can be
aligned on the bracket attachment and attached to both the bracket
attachment and the support structure as described hereinabove.
Additionally, note that embodiments of posts (or other support
structures) may be manufactured with features corresponding to the
bracket attachments being integral with each such post.
Accordingly, such posts (or other support structures) may reduce
the amount of measuring an installer must perform since the
positions for attaching the brackets 20 is predetermined on the
posts. [0056] Step 2: For a second support structure 38 that is
secured in a stationary position the distance of a desired rail
length away from the first support structure, orient and secure a
second bracket 20 to the second support structure 38 by placing
fasteners 52 within the holes 48 and causing the fasteners to enter
or otherwise attach to the first support structure 38. Note that
the various substeps and embodiments described in Step 1 also apply
here as well. In typical embodiments, the first and second brackets
will be at the same vertical offset from an end of their
corresponding support structures. However, in alternative
embodiments, the first and second brackets 20 may be vertically
offset different amounts on their corresponding support structures
so that when the rail 26 is provided therebetween, the rail extends
from a relatively high position on one of the support structures to
a relatively low position on the other support structure. [0057]
Step 3: If either of end of the desired rail is to form a vertical
angle that is, e.g., greater than or equal to approximately 30
degrees from an orthogonal alignment with a front face 34 of the
corresponding one of the first and second brackets for supporting
the rail end, then detach the rail supports 60 from this
corresponding bracket using pliers or another gripping tool. [0058]
Step 4: Obtain the desired rail 26 of the desired rail length and
having rail ends 24 that are of a desired angle so that each of the
rail ends can be supported on a corresponding one of the first and
second brackets 20. If necessary, such a rail 26 may be obtained by
cutting a rail that is too long and/or by cutting one or both rail
ends 24 at an angle that is appropriate for mounting the cut rail
on the first and second brackets. [0059] Step 5: Slide two bracket
covers 28 onto the rail 26 obtained from Step 3, wherein the
bracket covers are oriented so that their front end openings 29
face on another on the rail 26. If the rail 26 is to be oriented at
an angle less than approximately 30 degrees from the front face 34
of one of the first and second brackets, then the corresponding one
of the bracket covers for covering this bracket may be
substantially functionally similar to the bracket cover 28 shown,
e.g., in FIGS. 1 and 8. Alternatively, if the rail 26 is to be
oriented at an angle greater than approximately 30 degrees from the
front face 34 of one of the first and second brackets (as in FIGS.
4 and 10), then the corresponding one of the bracket covers for
covering this bracket may be substantially functionally similar to
the bracket cover 28a shown, e.g., in FIG. 9. [0060] Step 6: Place
each of the rail ends 24 between the rail side supports 84 and 88
of a corresponding one of the first and second brackets 20 to which
the rail end is to be secured, wherein the rail end is supported on
the rail supports 60, if they are still attached, and the lower
rail supports otherwise. [0061] Step 7: With the rail 26 supported
on the first and second brackets, secure the rail 26 to each of the
first and second brackets using, e.g., fasteners 52 as described
hereinabove. [0062] Step 8: Subsequently, slide the two bracket
covers 28 (28a) away from one another and toward a corresponding
one of the first and second brackets 20. Attach each bracket cover
28 (28a) to its corresponding (nearest) bracket 20 by mating each
of the alignment tabs 106 and the cover locking projections 120,
respectively, with a corresponding recessed portion 100 and cover
lock 112 as described hereinabove. Load Tests of the Rail Mounting
System 18 Tests were conducted to determine the structural
performance of guardrail assemblies 204 (FIGS. 16-18) having the
rail mounting system 18 for connecting upper and lower rails 26
(denoted 26a and 26b, respectively) to posts 208. The tests were
performed using 2 inch by 31/2 inch die-cast #3 zinc brackets 20
substantially as shown in FIGS. 1-3, wherein the plate 33 (FIG. 1)
had a thickness 40 of approximately 0.160''. Each bracket 20 was
attached to their corresponding posts 208 and rails using screws
52a as shown in FIG. 3. More specifically, each bracket 20 was
attached to: (a) a support post 208 with six (6) #10.times.1-1/2''
Phillips panhead wood screws, and (b) attached to one of the rails
26a and 26b with four (4) #12.times.1'' Phillips panhead wood
screws. All screw locations for attachment to the support(s) and
rail(s) were pre-drilled. The posts were common 4.times.4 treated
Southern Pine with PVC covers. The rails 26a and 26b were synthetic
rails as described in the Description of Terms above having a
length of 10 feet. In particular, each of the rails 26a and 26b
included a hollow PVC extruded exterior frame having an aluminum
reinforced interior, e.g., as shown in FIG. 1. Each of the
guardrail assemblies 204 incorporated a midspan support leg 210
located beneath and supporting the bottom rail 26b.
[0063] Each of the guardrail assemblies 208 also included a
plurality of vertical pickets 212 attached between each of the
rails 26a and 26b. Each of the pickets 212 was a synthetic fencing
component having a PVC extruded exterior frame with a hollow
interior in which an aluminum reinforcing component (not shown) was
provided. Each of the pickets 212 was attached to each of the rails
26a and 26b via insertion of the aluminum reinforcing component
within each picket into connector holes (not shown) providing
access to the interior of each of the rails 26a and 26b.
[0064] The brackets 20 were evaluated using the load requirements
identified in the following building codes: [0065] (a)
IBC-2000/ICC--International Code Council, published by
International Code Council, 900 Montclair Road, Birmingham, Ala.
35213-1206 USA; URL: www.iccsafe.org; [0066] (b)
BOCA-1999--Building Officials and Code Administrators (Reference
ASCE 7-95) published by Published by Building Officials and Code
Administrators International, Inc. 4051 West Flossmoor Road,
Country Club Hills, Ill. 60478-5795; [0067] (c)
SBC-1999/SBCCI--Southern Building Code Conference International
published by International Code Council 900 Montclair Road,
Birmingham, Ala. 35213-1206 USA; URL: www.iccsafe.org. In
particular, the brackets 20 were tested for determining whether
they satisfied the load requirements for guardrails as specified by
the above identified building codes.
[0068] Rail assembly 204 specimens were tested in a self-contained
rigid steel test frame 220 (FIGS. 17 and 18) designed to anchor one
of the rail assemblies 204 during the application of test loads to
be applied. An electric winch (not shown) mounted to the rigid
steel test frame was used to induce loads on the rail assemblies
for determining, e.g., maximum deflection, load at rail assembly
failure, and/or extent of permanent bending. Chains, cables, nylon
lifting straps, and load distribution beams 224 were used to impose
the test loads on each specimen of the rail assemblies 204. Each
applied load was measured using an electronic load cell located
in-line between the specimen and the electric winch. Deflections
are measured to the nearest 0.01'' using electronic linear
transducers (not shown).
[0069] Each rail assembly 204 was tested by securing its posts 208
into the rigid steel test frame. The rigid test frame 220 rigidly
restrained the posts 208 from deflecting. The linear transducers
were mounted to an independent reference frame to record movement
of reference points on various components of the specimen being
tested (e.g., end points and mid-point of the rails 26a and 26b) to
determine net component deflections. Uniform distributed loads with
simple end supports were simulated with 1/4-point loading (i.e., a
load distributed evenly over two or four locations equally spaced
across the horizontal length of the specimen). Uniform distributed
loading conditions with interior support (e.g., FIG. 18), as per
SBC top rail loading requirements, were simulated by distributing a
load across four equal load points.
Test Procedure:
[0070] Each rail assembly 208 specimen was preloaded up to a level
not exceeding design load (e.g., the load which the rail assembly
is designed to withstand). After pre-loading, all load was released
and any necessary fixture adjustments were made. An initial load,
not exceeding 20% of design load, was applied and initial
deflections recorded. Loads were then applied at a steady uniform
rate in step loading increments. Each load increment was reached in
approximately one minute and deflections were recorded. The
load/deflection procedure continued until reaching 2.0 times design
load. At 2.0 times the design load, the load was released. After
allowing a minimum period of one minute for stabilization, load is
reapplied to the initial load used at the start of the
load/deflection procedure and deflections were again recorded and
used to analyze recovery. For tests that require ultimate loads
greater than 2.0 times design load, loading is reapplied and
increased at a steady uniform rate until failure occurred or the
required ultimate load is reached. The testing time was continually
recorded from the application of initial test load until the
maximum test load is reached.
[0071] The tables hereinbelow are representative of results from
the test procedure.
[0072] Tables 1 through 3 are the test results from a test of a
first specimen of the rail assemblies 204, wherein a uniform
horizontal design load on the top rail 26a of the specimen was
approximately 50 pounds per linear foot (lpf) of the top rail 26a.
The tests performed simulated various uniform horizontal loads both
above and below the design load. Each simulation applied equal
loads at two or four points equally distributed across the rail 26a
of the specimen as shown in FIGS. 17 and 18.
[0073] For the first table (TABLE 1) following, the columns can be
described as follows: [0074] Load Level: The multiplicative factor
indicative of the relative amount of the design load to which the
specimen was subjected (e.g., a load level of 0.2 represents a load
that is 20% of the design load). [0075] Test Load: The actual load
(in pounds) to which the specimen was subjected.
[0076] Test Data Top Rail Deflection (Inches) [0077] End-1:
Identification of one of the ends of the top rail 26a. Each number
of this column is a measurement (in inches) of the deflection of
the rail 26a end represented by End-1 when the load in the same row
was applied to the specimen. [0078] Mid: Each number of this column
is a measurement of the deflections of the rail 26a midway between
the posts 208. [0079] End-2 Identification of the end of the top
rail 26a opposite from End-1.
[0080] Net This is an abbreviation for "Net Deflection". Each "Net"
value was computed as follows: average the deflection values for
the "End-1" and "End-2" columns in the same row as the Net entry to
be computed, then subtract the "Mid" value for the same row from
this average.
[0081] Deflection Analysis [0082] y=mx The values in this column
are obtained from a linear regression of the values in the
"Deflection" column. Thus, for a linear equation of the form y=mx,
"x" can be interpreted as the test load applied to a specimen of
the rail assemblies 204, and "y" can be interpreted as the
corresponding deflection of the specimen.
[0083] Deflection The maximum displacement from initial
configuration of a specimen of the rail assemblies 204.
TABLE-US-00001 TABLE 1 IBC and BOCA Design Load: 50 plf Uniform
Load on Top Rail.sup.2 Test Test Data Load Load Top Rail Deflection
(inches) Deflection Analysis Level.sup.1 (lbs) End-1 Mid End-2 Net
y = mx Deflection 0.0 0 -- -- -- -- 0.00 0.00 0.2 105 0.000 0.000
0.000 0.00 0.50 0.51 0.4 203 0.069 0.536 0.068 0.47 0.97 0.98 0.6
301 0.141 1.031 0.128 0.90 1.44 1.41 0.8 400 0.225 1.605 0.204 1.39
1.91 1.90 1.0 507 0.308 2.229 0.287 1.93 2.43 2.44 1.2 605 0.388
2.784 0.367 2.41 2.89 2.92 1.4 701 0.464 3.365 0.447 2.91 3.35 3.42
1.6 805 0.550 4.017 0.527 3.48 3.85 3.99 1.8 903 0.640 4.717 0.610
4.09 4.32 4.61 2.0 1001 0.726 5.446 0.698 4.73 4.79 5.25 0.2 107
0.068 0.645 0.045 0.59 88% Recovery 2.5 1267 Maximum Test Load -
Sustained without failure.
[0084] For the second table (TABLE 2) following, the columns can be
described as follows:
[0085] Load Level: Same as for TABLE 1.
[0086] Test Load: Same as for TABLE 1.
[0087] Test Data Top Rail Deflection (inches) [0088] Post: Each
number of this column is a measurement of the deflections of the
post 208 at the rail 26a end identified as End-1. [0089] Rail: Each
number of this column is a measurement of the displacement of the
rail 26a end identified as End-1. Note, this column is identical to
the End-1 column of TABLE 1. [0090] Net: Each number of this column
is a measurement of the net displacement of the rail 26a relative
to the post 208 to which the rail end End-1 is attached. Note that
the net displacement is determined by subtracting the corresponding
rail deflection value (in the same row) from the post deflection
value (in the same row).
[0091] Displacement Analysis [0092] y=mx Same as for Table 1
above.
[0093] Displacement Same as for Table 1 above. TABLE-US-00002 TABLE
2 IBC and BOCA Design Load: 50 plf Uniform Load on Top Rail.sup.2
Test Data Test Displacement (inches) Load Load At Rail End-1
Displacement Analysis Level.sup.1 (lbs) Post Rail Net.sup.3 y = mx
Displacement 0.0 0 -- -- -- 0.00 0.00 0.2 105 0.000 0.000 0.000
0.03 0.04 0.4 203 0.043 0.069 0.026 0.07 0.06 0.6 301 0.082 0.141
0.059 0.10 0.10 0.8 400 0.129 0.225 0.096 0.13 0.13 1.0 507 0.175
0.308 0.133 0.17 0.17 1.2 605 0.211 0.388 0.177 0.20 0.21 1.4 701
0.249 0.464 0.215 0.23 0.25 1.6 805 0.290 0.550 0.260 0.26 0.30 1.8
903 0.329 0.640 0.311 0.29 0.35 2.0 1001 0.366 0.726 0.360 0.33
0.40 0.2 107 0.033 0.068 0.035 90% Recovery 2.5 1267 Maximum Test
Load - Sustained without failure.
[0094] For the third table (TABLE 3) following, the columns can be
described as follows:
[0095] Load Level: Same as for TABLE 1.
[0096] Test Load: Same as for TABLE 1.
[0097] Test Data Top Rail Deflection (inches) [0098] Post: Each
number of this column is a measurement of the deflections of the
post 208 at the rail 26a end identified as End-2. [0099] Rail: Each
number of this column is a measurement of the deflections of the
rail 26a end identified as End-2. Note, this column is identical to
the End-2 column of TABLE 1. [0100] Net: Same as for TABLE 2
above.
[0101] Displacement Analysis [0102] y=mx Same as for TABLE 1
above.
[0103] Displacement Same as for TABLE 1 above. TABLE-US-00003 TABLE
3 IBC and BOCA Design Load: 50 plf Uniform Load on Top Rail.sup.2
Test Data Test Displacement (inches) Load Load At Rail End-2
Displacement Analysis Level.sup.1 (lbs) Post Rail Net.sup.3 y = mx
Displacement 0.0 0 -- -- -- 0.00 0.00 0.2 105 0.000 0.000 0.000
0.03 0.03 0.4 203 0.034 0.068 0.034 0.07 0.07 0.6 301 0.065 0.128
0.063 0.10 0.10 0.8 400 0.108 0.204 0.096 0.13 0.13 1.0 507 0.154
0.287 0.133 0.16 0.17 1.2 605 0.189 0.367 0.178 0.20 0.21 1.4 701
0.236 0.447 0.211 0.23 0.24 1.6 805 0.268 0.527 0.259 0.26 0.29 1.8
903 0.305 0.610 0.305 0.29 0.34 2.0 1001 0.336 0.698 0.362 0.32
0.40 0.2 107 0.009 0.045 0.036 90% Recovery 2.5 1267 Maximum Test
Load - Sustained without failure.
[0104] Tables 4 through 6 are the test results from a test of a
second specimen of the rail assemblies 204, wherein a uniform
downward sloping design load on the top rail 26a of the specimen
was approximately 112 pounds per linear foot (plf) of the rail 26a
at approximately a 63.4 degree downward direction from horizontal
as shown in FIG. 18. The tests performed simulated various uniform
downward sloping loads both above and below the design load. Each
simulation applied equal loads at four points equally distributed
across the rail 26a. Note that the columns for each of the tables 4
through 6 have the same interpretations as described above for
Tables 1 through 3. TABLE-US-00004 TABLE 4 SBC Design Load: (50
Horizontal + 100 Vertical) plf Uniform Load.sup.1 on Top Rail Test
Test Data Load Load Top Rail Deflection (inches) Deflection
Analysis Level.sup.2 (lbs) End-1 Mid End-2 Net y = mx Deflection
0.0 0 -- -- -- -- 0.00 0.00 0.2 226 0.000 0.000 0.000 0.00 0.38
0.44 0.4 453 0.046 0.348 0.049 0.30 0.76 0.74 0.6 678 0.097 0.728
0.101 0.63 1.14 1.07 0.8 903 0.162 1.205 0.167 1.04 1.51 1.48 1.0
1126 0.246 1.758 0.235 1.52 1.89 1.96 1.2 1345 0.342 2.424 0.315
2.10 2.26 2.53 1.4 1583 0.408 2.876 0.373 2.49 2.66 2.92 1.6 1815
0.499 3.534 0.457 3.06 3.04 3.49 1.8 2016 0.547 3.959 0.504 3.43
3.38 3.87 2.0 2250 0.610 4.518 0.564 3.93 3.77 4.37 0.2 228 0.061
0.535 0.053 0.48 88% Recovery
[0105] TABLE-US-00005 TABLE 5 SBC Design Load: (50 Horizontal + 100
Vertical) plf Uniform Load.sup.1 on Top Rail Test Data Test
Displacement (inches) Load Load At Rail End-1 Displacement Analysis
Level.sup.2 (lbs) Post Rail Net.sup.3 y = mx Displacement 0.0 0 --
-- -- 0.00 0.00 0.2 226 0.000 0.000 0.000 0.02 0.02 0.4 453 0.028
0.046 0.018 0.04 0.04 0.6 678 0.058 0.097 0.039 0.06 0.06 0.8 903
0.098 0.162 0.064 0.09 0.08 1.0 1126 0.149 0.246 0.097 0.11 0.12
1.2 1345 0.202 0.342 0.140 0.13 0.16 1.4 1583 0.236 0.408 0.172
0.15 0.19 1.6 1815 0.271 0.499 0.228 0.17 0.25 1.8 2016 0.294 0.547
0.253 0.19 0.27 2.0 2250 0.320 0.610 0.290 0.21 0.31 0.2 228 0.030
0.061 0.031 89% Recovery
[0106] TABLE-US-00006 TABLE 6 SBC Design Load: (50 Horizontal + 100
Vertical) plf Uniform Load.sup.1 on Top Rail Test Data Test
Displacement (inches) Load Load At Rail End-2 Displacement Analysis
Level.sup.2 (lbs) Post Rail Net.sup.3 y = mx Displacement 0.0 0 --
-- -- 0.00 0.00 0.2 226 0.000 0.000 0.000 0.02 0.02 0.4 453 0.028
0.049 0.021 0.05 0.04 0.6 678 0.057 0.101 0.044 0.07 0.07 0.8 903
0.094 0.167 0.073 0.10 0.10 1.0 1126 0.125 0.235 0.110 0.12 0.13
1.2 1345 0.163 0.315 0.152 0.14 0.17 1.4 1583 0.188 0.373 0.185
0.17 0.21 1.6 1815 0.230 0.457 0.227 0.19 0.25 1.8 2016 0.245 0.504
0.259 0.22 0.28 2.0 2250 0.275 0.564 0.289 0.24 0.31 0.2 228 0.029
0.053 0.024 92% Recovery
[0107] Satisfactory performance for the above tests is specified in
the above-identified building codes. In particular, the performance
requirements in these building codes are satisfied when there is a
75% recovery from a load of 2.0 times the design load in both the
horizontal and downward sloping application of a uniform top rail
load, and additionally, for the horizontal uniform load simulation,
an ultimate load of not less than 2.5 times the design load can be
sustained without the specimen failing. From the above Tables 1-6
it is apparent that the rail mounting system 18 meets these
performance requirements.
ADDITIONAL EMBODIMENTS
[0108] FIGS. 19 through 22 show an embodiment of the bracket 20a.
Additionally, FIGS. 20 through 22 show cross sections of three
alternative bracket covers 28b, 28c and 28d attached to the bracket
20a (wherein the cross sectioning plane is normal to the front face
34 of the bracket 20a, and includes the axis 300 in FIG. 1).
[0109] The bracket 20a has many features that are substantially the
same as those of bracket 20. Accordingly, such substantially
identical features are labeled with the same numerical labels used
hereinabove for features of bracket 20, and such features will not
be further described in the context of bracket 20a.
[0110] The bracket 20a is designed to be used with a rail 26 whose
cross sectional profile is generally in the shape of a "T". One
such "T" rail 26 is shown in FIGS. 19 through 22, this rail being
labeled 26T. The bracket 20a includes side supports 84a and 88a of
reduced length, wherein each of the side supports has a shelf 304
at its upper end. The shelves 304 function as a support for the
rail 26T in a similar manner to the function of the upper pair of
rail supports 60 in the bracket 20. That is, the rail 26T can be
placed on the pair of shelves 304 for supporting the rail in
position until the rail can be secured to the bracket 20a with
fasteners 52 as described hereinabove. In particular as shown in
FIG. 20, the overhangs 308 contact the shelves 304 for supporting
the rail until rail fasteners 96 (e.g., as shown in FIG. 2) can be
provided in the holes 98b and through both: (a) the sides 312 of
the rail 26T, and (b) the reinforcement(s) 58 (for simplicity, not
shown in FIG. 19) provided in the interior 316 (FIG. 19) of the
rail. Accordingly, the bracket 20a does not need the upper rail
supports 60 shown in FIG. 1.
[0111] For rails 26T that extend at a downward incline from the
bracket 20a (as shown in FIG. 21), each of the side supports 84a
and 88a also include an inclined support 320 for supporting the
rail on its overhangs 308. Thus, the bracket 20a does not need the
lower rail support 76 shown in FIG. 1. Note, however, that for
rails 26T extending upwardly from the bracket 20a, the overhangs
308 contact the shelves 304 for initial support (as shown in FIG.
22), and in particular, the end edge of the each of the overhangs
308 may seat into a corresponding one of the corners 324 formed
between the front face 34 and one of the shelves 308.
[0112] The bracket covers 28b, 28c, and 28d shown FIGS. 20 through
22, attach to the bracket 20a as described above for bracket cover
28 and bracket 20. However, due to the reduced length of the side
supports 84a and 88a, each such side support has a single adjacent
cover lock 112.
[0113] Note that since various embodiments of the bracket 20a can
have the same hole patterns for the holes 48, 54 and 56 as shown in
FIGS. 1 and 3 for bracket 20, the bracket attachments 59 described
hereinabove can be used to attach the bracket 20a to a support
structure 38.
[0114] FIG. 23 shows another embodiment of the bracket (20b)
together with an embodiment of a bracket attachment 59b for mating
with the bracket 20b. The bracket 20b can be used in a
substantially similar manner to the bracket 20a for attaching a
railing thereto. However, bracket 20b is particularly useful for
"T" rails having sides 312 (FIG. 19) of reduced height, wherein it
may be difficult or impossible to secure two spaced apart fasters
52 in each of the rail sides 312 via the rail securing holes 98a
and 98b of FIG. 19-21.
[0115] As shown in FIG. 23, the bracket 20b can be aligned onto the
front surface 57 of the bracket attachment 59b by aligning the
holes 62 with the holes 48 of the bracket, and aligning the holes
63 with the holes 54 of the bracket so that fasteners 52 can be
placed through the aligned holes for securing the bracket and
bracket attachment to a support structure. In at least one
embodiment, note that these corresponding holes in the bracket 20b
and bracket attachment 59b will not completely align with one
another unless the bracket 20b and the bracket attachment 59b are
placed together as indicated by the dashed arrows 328; i.e., if the
bracket is rotated 90.degree. (keeping the front face 34 in the
plane) the holes in the bracket and the bracket attachment will not
align. In other embodiments, the bracket 20b and the bracket
attachment 59b can mate together via, e.g., additional holes in the
bracket and mating raised portions on the front surface 57 of the
bracket attachment as, for example, are shown in FIGS. 11 and
13-15.
[0116] Several of the above-described methods, techniques, and/or
components may have additional alternative embodiments. For
example, the cover locks 112 may be provided within the bracket
cover channel 30, and the mating locking projections 120 may be
provided as part of the bracket 20. Additionally, various types of
resilient locking tabs or protrusions and mating catches may be
provided (e.g., such as the protrusions 36 and passages 32 of U.S.
Pat. No. 6,460,829, filed Jan. 15, 1999 and fully incorporated
herein by reference) as a replacement for the cover locks 112 and
projections 120.
[0117] Further embodiments of the rail mounting system 18 can be
provided by utilizing various alternative methods, techniques
and/or components (e.g., components that are substantially
functionally equivalent to the components described herein) such
as: [0118] (a) alternative fasteners 52 (e.g., clips providing
corresponding functionality, shafts having a locking lever, or the
locking pin of disclosed in U.S. Patent Application 20040261243,
filed Apr. 5, 2994, fully incorporated herein by reference); [0119]
(b) alternative types of rails 26 (e.g., non-synthetic rails, metal
or wood rails, and/or non-hollow rails); [0120] (c) alternative
techniques for mounting a bracket cover 28 (or 28a-d) to a bracket
20 (or 20b) such as a snap on bracket cover as shown in FIGS. 3,
3A, and 3B of U.S. Pat. No. 5,873,671, filed Feb. 19, 1997 and
fully incorporated herein by reference, or the disclosure of U.S.
Patent Application 20040261243; [0121] (d) alternative rail 26
orientations relative to the bracket 20, e.g., embodiments of the
bracket 20 wherein the side supports 84 and 88 are parallel to one
another, but each are at an angle such as 45.degree. to the front
face 34 thereby allowing a rail 26 to fitted between the side
supports when the rail approaches the front face 34 from a
non-orthogonal angle such as 45.degree.; and/or [0122] (e)
alternative support structures 38 (e.g., composite posts of various
composition, and walls of various composition, such as concrete,
wood, metal, stone, brick, etc.).
[0123] Additionally, the alternative fence constructing techniques
described in the following list of references that are fully
incorporated herein by reference: [0124] U.S. Patent Application
having publication number US 2003/0030048 filed Jun. 6, 2002;
[0125] U.S. Patent Application having publication number US
2003/0101673 filed Jun. 5, 2003; [0126] U.S. Pat. No. 6,682,056
filed Oct. 30, 2000; [0127] U.S. Pat. No. 6,460,829 filed Jan. 15,
1999; [0128] U.S. Pat. No. 6,314,699 filed Jan. 15, 1999; [0129]
U.S. Pat. No. 6,202,987 filed Nov. 8, 1999; [0130] U.S. Pat. No.
6,041,486 filed Jan. 28, 1999; [0131] U.S. Pat. No. 5,988,599 filed
Feb. 19, 1997; [0132] U.S. Pat. No. 5,873,671 filed Feb. 19, 1997;
[0133] U.S. Pat. No. 5,853,167 filed Feb. 19, 1997;
[0134] The foregoing discussion of the invention has been presented
for purposes of illustration and description. Further, the
description is not intended to limit the invention to the form
disclosed herein. Consequently, variation and modification
commensurate with the above teachings, within the skill and
knowledge of the relevant art, are within the scope of the present
invention. The embodiment described hereinabove is further intended
to explain the best mode presently known of practicing the
invention and to enable others skilled in the art to utilize the
invention as such, or in other embodiments, and with the various
modifications required by their particular application or uses of
the invention.
* * * * *
References