U.S. patent application number 13/274514 was filed with the patent office on 2012-02-09 for boardwalk, deck and platform system.
Invention is credited to Benjamin G. Stroyer.
Application Number | 20120031017 13/274514 |
Document ID | / |
Family ID | 37683817 |
Filed Date | 2012-02-09 |
United States Patent
Application |
20120031017 |
Kind Code |
A1 |
Stroyer; Benjamin G. |
February 9, 2012 |
BOARDWALK, DECK AND PLATFORM SYSTEM
Abstract
The invention provides a system, method, and components for
assembling and disassembling boardwalks, decks, and platforms. The
invention has a number of extruded and interlocking components. It
is installed by driving piles, preferably helical piles, into a
ground surface. The invention provides a comprehensive set of
assembly members, including and not limited to brackets that attach
to the piles, headers, joists, cross braces, decking, and decking
fasteners for holding the decking in place. In particular, a
multiple-way adjustable bracket connects the piles to the rest of
the structure.
Inventors: |
Stroyer; Benjamin G.;
(Rochester, NY) |
Family ID: |
37683817 |
Appl. No.: |
13/274514 |
Filed: |
October 17, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11490795 |
Jul 21, 2006 |
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13274514 |
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60701666 |
Jul 22, 2005 |
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Current U.S.
Class: |
52/157 ;
52/650.3; 52/655.1; 52/741.14; 52/745.21 |
Current CPC
Class: |
E01D 19/02 20130101;
E04C 2003/0465 20130101; E02B 3/068 20130101; E04C 2003/0439
20130101; E01D 19/005 20130101; E01D 2/00 20130101; E01D 15/133
20130101 |
Class at
Publication: |
52/157 ;
52/655.1; 52/650.3; 52/741.14; 52/745.21 |
International
Class: |
E04B 1/19 20060101
E04B001/19; E04H 12/00 20060101 E04H012/00; E02D 7/22 20060101
E02D007/22; E04B 1/38 20060101 E04B001/38; E02D 5/80 20060101
E02D005/80 |
Claims
1. A connector strip for affixing deck planks to a joist, the
connector strip comprising a top surface and a bottom surface; a
plurality of spacer posts projecting upward from the top surface;
and a plurality of pairs of clips projecting downward from the
bottom surface, wherein each pair of clips is configured for
engaging a pair of tabs associated with a joist.
2. The connector strip of claim 1, further comprising a first end
with a male connector and a second end with a female connector such
that the male connector connects to a female connector of another
connector strip.
3. The connector strip of claim 1, wherein no fasteners are
required to connect the connector strip to the joist.
4. A modular decking system comprising a deck frame segment
including a plurality of headers that define the width of the deck
frame segment and at least a first and second joist that define the
length of the deck frame segment, each joist having at least one
pair of first tabs on its upper surface; a plurality of piles
configured to be driven into a ground and support the deck frame
segment; a first and second connector strips respectively disposed
on the upper surface of the first and second joist and extending
parallel thereto, each connector strip having a top surface and a
bottom surface, the connector strips having spacer posts projecting
upward from their top surface and clips projecting downward from
their bottom surface wherein the clips are configured for engaging
the at least one pair of first tabs on the upper surface of the
joints; a plurality of deck planks extending perpendicular to the
first and second connector strips and attached to the spacer posts
of the connector strips such that the deck planks extend between
the first and second connector strips.
5. The modular decking system of claim 4, wherein deck planks
further include tabs on their undersides and the spacer posts of
the connector strip further include second clips configured to mate
with the tabs of the deck planks and thereby secure the deck planks
to the connector strips.
6. The modular decking system of claim 4, further comprising a
third connector strip, wherein the connector strips each further
comprise a first end with a male connector and a second end with a
female connector such that the male connector of the first
connector strip connects to a female connector of the third
connector strip.
7. The modular decking system of claim 4, wherein the piles are
helical piles.
8. The modular decking system of claim 4, further comprising an
inner joist disposed between, but parallel to, the first and second
joists.
9. The modular decking system of claim 8, further comprising a
third connector strip disposed on the inner joist, the plurality of
deck planks being attached to the third connector strip.
10. A method of installing a modular deck comprising the steps of:
driving a plurality of first helical piles into a ground surface;
affixing a first deck frame segment atop the first helical piles,
the first deck frame segment including a plurality of headers that
define the width of the first deck frame segment and at least a
first and second joist that define the length of the deck frame
segment, each joist having tabs on its upper surface; disposing,
respectively, a first and second connector strip on the upper
surface of the first and second joist such that the connector
strips extend parallel to the joists, each connector strip having a
top surface and a bottom surface, the connector strips having a
plurality of spacer posts projecting upward from their top surface
and a plurality of clips projecting downward from their bottom
surface wherein the clips are configured for engaging the tabs on
the upper surface of the joints thereby securing the bottom surface
of the connector strip to the upper surface of the respective
joist; placing a plurality of deck planks such that each deck plank
bridges the first and second joists and engages at least one spacer
post that projects upward from the top surface of the first
connector strip and at least one spacer post that projects upward
from the top surface of the second connector strip.
11. The method as recited in claim 10, wherein the connector strips
each further comprise a first end with a male connector and a
second end with a female connector, the method further including
the step of disposing a third connector strip with a female
connector on one end such that the male connector of the first
connector strip connects to the female connector of the third
connector strip.
12. The method as recited in claim 10, wherein deck planks further
include second tabs on their undersides and the spacer posts of the
connector strip further include second clips configured to mate
with the tabs of the deck planks and thereby secure the deck planks
to the connector strips, the method further including the step of
clipping the deck planks to the connector strips with the second
tabs and second clips.
13. The method as recited in claim 10 wherein no fasteners are
required to connect the connector strips to the joists.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. Ser. No.
11/490,795, filed Jul. 21, 2006 which claims priority from U.S.
Provisional Patent Application Ser. No. 60/701,666, filed Jul. 22,
2005. The content of these applications is hereby incorporated by
reference into this specification.
FIELD OF THE INVENTION
[0002] This invention relates to modular decking systems.
BACKGROUND OF THE INVENTION
[0003] It is a significant conventional construction project to
install a deck or a similar structure such as a dock, boardwalk, or
platform, whether it is a permanent installation or a temporary
one. The equipment needed to install the conventional deck can be
very disruptive to the ground surface affecting the appearance of a
lawn or a park or affecting the ecosystem in wetlands. Also, the
skill and care needed to precisely place and fasten together the
components of the deck is time consuming and costly--especially
when equipment must be submerged to reach a stable underground
surface. Further adding to the cost and skill required, the deck is
often custom built on site.
[0004] A modular deck system, such as the one described in U.S.
Patent Application, Publication No. 2005/0025465 by Osfolk, allows
the deck to be assembled in smaller portions. Pre-manufactured deck
modules have the advantage of requiring less on-site assembly.
However, such conventional modular or pre-manufactured decks
require precise placing of piers or piles and either require
significant fastening with screws or bolts, or are not
significantly sturdy. Further, pre-manufactured decks tend to be
quite heavy and cumbersome with regard to the shipping, handling,
and placement of the decks. Even further, the length of time it
takes to assemble conventional modules causes delays in the
advancement of the equipment along the modules.
[0005] Conventional decking systems tend to have relatively weak
connections between a wooden joist and a header. Such systems
utilize joist hangers that are fastened to the side of a header and
to the end of the joist. Such connections to the end of the joist
lack significant shear strength and the connection may be a weak
point in the system.
[0006] Therefore, a modular decking system that has a simple
assembly and a minimal impact on the ground surface while being
sturdy enough to support foot traffic and light vehicles is
desired. Further, a decking system with structurally superior
joints over conventional systems in critical areas is desired.
SUMMARY OF THE INVENTION
[0007] The invention comprises, in one form thereof, a system,
method and components for assembling and disassembling boardwalks,
decks, bridges, platforms and similar structures ("deck" will be
generally used to denote a boardwalk, deck, bridge, platform, or
similar structure hereinafter). The invention has a number of
extruded and interlocking components. It is installed by driving
piles, preferably helical piles, into a ground surface. The
invention provides a comprehensive set of assembly members,
including and not limited to brackets that attach to the piles,
headers, joists, cross braces, decking, and decking fasteners for
holding the decking in place. The components of the invention are
useful together with each other and also with conventional
structural members. In particular, a multiple-way adjustable
bracket connects the piles to the rest of the structure. Piles
often encounter subsurface impediments and cannot be set at their
precise desired locations. The pile bracket adjusts for off-set
piles.
[0008] More particularly, the invention includes a relatively
lightweight modular decking system, comprising a plurality of piles
(which may comprise aluminum) having a helical portion configured
to be driven into a ground surface; a pile bracket that engages a
top end of each of the piles; a plurality of headers, each attached
to two of the pile brackets; a plurality of joists each being
attached to two of the headers; and a plurality of deck planks that
are attached to a top portion of the joists or decking connectors.
The pile brackets are adjustable wherein each of the pile brackets
are rotatable about a center axis of the pile and translatable
along the center axis of the pile. Further, each of the pile
brackets include a saddle assembly that is translatable along a
slot in the pile bracket in a direction that is substantially
perpendicular to the center axis of the pile. The saddle assembly
is rotatable about a fastener and is capable of being leveled, such
as by a plurality of set screws or a partial ball joint. The deck
planks may be attached to the joists by an injection molded
connector strip having a plurality of spacer posts separating said
deck planks. The connector strip may further include a plurality of
clips provided in pairs, wherein the deck planks each include a
pair of tabs, and wherein each pair of clips is configured for
mating with the pair of tabs on one of the deck planks. The header
may include a plurality of joist holders, and the joists may be
placed in said joist holders to attach the joists to the
headers.
[0009] In another form, the invention includes a method for
installing a modular deck. The method comprises the steps of
driving a first set of helical piles and a second set of helical
piles (which may be aluminum) into a ground surface, wherein the
piles each have an adjustable pile bracket on a top end of the
pile; providing a plurality of headers having a plurality of header
brackets; affixing one of the headers to each of the first and
second sets of piles via the pile brackets such that the header
brackets of the header affixed to the first set of piles are
aligned with the header brackets of header affixed to the second
set of piles; inserting a joist into each of the aligned header
brackets; and placing a plurality of deck planks on the joists. The
method may further comprise the steps of driving a third set of
helical piles into the ground surface, wherein the piles of the
third set each have an adjustable pile bracket on a top end of the
piles; affixing a header to the third set of piles via the pile
brackets such that the header brackets of the header attached to
the third set of piles are aligned with the header brackets of the
header attached to the second set of piles; inserting an additional
joist into each of the aligned header brackets of the headers
attached to the second and third sets of piles; and placing a
plurality of additional deck planks on the additional joists. The
method may further include installing additional modules as needed.
In a temporary application of the decking system, the method
includes the further step of disassembling the deck planks from the
joists, the joists from the headers, and the headers from the
piles, and then removing the piles from the ground surface. A
further step of reinforcing the joists with cross-braces may also
be included. The step of placing the deck planks may comprise the
steps of connecting a plurality of connector strips to one or more
of the joists, the connector strips having a plurality of pairs of
clips; and, for each of the deck planks, snapping a pair of tabs
integral with the deck plank into one of the pairs of clips.
[0010] In another form, the invention includes an adjustable
decking bracket having multiple degrees of freedom. The bracket
comprises a base plate defining a slot; a collar affixed to a
bottom surface of the base plate, which is rotatable about a center
axis of the collar; a saddle assembly that has a protuberance
connected to the base plate by a fastener through the slot; and a
vertical adjustment fastener engaging the base plate and a support
structure. The saddle assembly may include a plurality of set
screws or a hub, such as a partial ball joint, in a saddle base for
leveling the saddle assembly relative to the base plate. Further,
the saddle assembly is translatable along the slot of the base
plate and rotatable about the fastener connecting the protuberance
to the slot of the base plate.
[0011] In another form, the invention includes an end cap for a
plurality of decking planks. The end cap comprises a tube providing
a chase-way; a lens-receiving portion on a side of the tube; a
connection portion on a bottom surface of the tube, the connection
portion being configured to be attached to a frame element. The
connection portion may be configured to snap into a groove in a
joist. The end cap may include a plurality of lamps within said
tube, and it may form an ADA-compliant curb.
[0012] In another form, the invention includes a helical pile
comprising an aluminum shaft and an inclined plane extending from a
portion of the shaft in a helical shape. The inclined plane may be
made of aluminum and may be welded to or integral with the shaft.
The helical pile may also include a second inclined plane extending
from a second portion of the shaft, extensions to add length, or
both.
[0013] In another form, the invention includes a header for a
modular decking system. The header comprises a header beam having a
first side and a second side; and a plurality of joist holders
welded to or integral with the first side of said header beam. The
header beam may be made of extruded metal or structural steel and
the header beam and the joist holders may be made of aluminum.
Alternatively, the header may be cast or molded material. A second
plurality of joist holders may be welded to or integral with the
second side of the header beam. The joist holders define a pair of
aligned notches for engaging a fastener through an end of a joist
to guide the placement of the joist.
[0014] In another form, the invention includes a connector strip
for affixing deck planks to a joist. The connector strip comprises
a base configured for engaging a joist; a plurality of spacer posts
projecting upward from the base; and a plurality of pairs of clips,
wherein each pair of clips is configured for engaging a pair of
tabs associated with a deck plank. The connector strip may further
include a first end with a male connector and a second end with a
female connector such that the male connector connects to a female
connector of another connector strip. The base may be configured
for sliding into a groove in an extruded joist. The connector strip
may be configured such that no fasteners are required to connect
the connector strip to the joist or to connect the deck plank to
the connector strip. The connector strip may also be connected to
conventional lumber.
[0015] It is an advantage of the invention that the boardwalk, deck
or platform provides a support for pile installation equipment. As
one section of the platform is assembled, the installation machine
may advance to the end of the platform to install piles for the
next section. The decking system according to the present invention
may be rapidly installed and the equipment may advance without
stalling for significant periods of time to wait for a new module
to be installed. The invention may also be used as a bridge.
[0016] The structures made in accordance with the invention may be
installed in protected environments, such as wetlands, nature
preserves, swamps, marshes and beaches. The installation provides
minimal disruption to the environment. The structures may also be
installed as decks for home use. In another embodiment the
structures may be installed temporarily at a location that needs a
hardstand to support a number of people, such as a stage for a band
in a park. After the event is over, the structure may be
disassembled and removed.
[0017] A further advantage of the invention is that the header
comprises integral or pre-welded joist holders that have
significantly higher shear strength than conventional joist
hangers. Thus the header provides an improved long-range structural
integrity over conventional systems, which may be compromised at
this junction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The present invention is disclosed with reference to the
accompanying drawings, wherein:
[0019] FIG. 1 is an isometric view of a deck module according to
the present invention;
[0020] FIGS. 2A-2D are views of the helical pile and pile bracket
of FIG. 1;
[0021] FIG. 3 is an isometric view of an alternative pile
bracket;
[0022] FIGS. 4A-4C are views of the saddle assembly of FIGS.
2A-2D;
[0023] FIGS. 5A-5D are views of a header of FIG. 1;
[0024] FIGS. 6A and 6B are views of a joist of FIG. 1 with a
connector strip attached to the top of the joist in FIG. 6A;
[0025] FIGS. 7A-7d are views of a connector strip;
[0026] FIG. 8 is an end view of a deck plank of FIG. 1;
[0027] FIG. 9 is a side view of a portion of the connector strip of
FIGS. 7A-7D with a deck plank connected thereto;
[0028] FIG. 10 is an end view of an end cap;
[0029] FIG. 11 is an end view of a joining strip;
[0030] FIG. 12 is an isometric view of a cross-brace assembly;
and
[0031] FIGS. 13A and 13B are views of a brace of FIG. 12.
[0032] Corresponding reference characters indicate corresponding
parts throughout the several views. The examples set out herein
illustrate several embodiments of the invention but should not be
construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION
[0033] Referring to FIG. 1, there is shown the modular deck of the
present invention. The deck module 10 includes a number of helical
piles 12, a pair of headers 14, joists 16, and a number of deck
planks 18.
[0034] FIG. 1 shows the deck module 10 as having four piles 12;
however, more or less piles 12 may be used as warranted by the
application. For example, additional piles 12 may be required for
additional support of the headers 14 or the joists 16. The helical
pile 12 is best shown in FIGS. 2A-2D and includes a shaft 19 and a
helical portion 20 for driving the pile 12 into a ground surface
and a top end 22 that engages a pile bracket 24. The helical
portion 20 includes an inclined plane 21 extending from the shaft
19 in a helical shape. The shaft 19 is cylindrical, as shown in
FIG. 2C; however, the shaft 19 may alternatively be substantially
any shape, such as a rectangular tube. The pile 12 may include
multiple helical portions 20 each having an inclined plane 21.
Because the pile 12 is driven into the ground by providing a
downward force to the shaft 19 and turning the pile to screw the
inclined plane 21 into the ground rather than providing a
high-impact vertical force to the pile, the pile 12 may be made of
not only hardened steel or wood, but also of aluminum, aluminum
alloys, and similar materials. In a particular embodiment, the
piles 12 are hollow tubes that may be reinforced with concrete,
steel, or both.
[0035] Though any bracket may be used to connect the pile 12 to the
header 14 (or joists 16), the pile bracket 24 of the present
embodiment is adjustable by rotation about the axis of the pile 12,
elevation relative to the pile 12, distance from the axis of the
pile 12, and rotation about an axis offset from the axis of the
pile 12. The pile bracket 24 includes a collar 26, a base plate 28,
and a saddle assembly 30. The base plate 28 is supported by the
collar 26 and supports 32 that are welded or otherwise affixed to
the collar 26 and the base plate 28. A fastener 34 engages a tapped
hole in the base plate 28 and is substantially aligned with the
axis of the collar 26. A disk 36 having a tapped hole for mating
with the fastener 34 is welded or otherwise affixed to the top end
22 of the pile 12. When assembled to the pile 12, the collar 26 and
base plate 28 may be rotated about the axis of the pile 12. The
collar 26 and base plate 28 also may be raised and lowered in
relation to the pile 12 by turning the fastener 34. In alternative
embodiments, the collar may be other shapes, such as the square
collar shown in FIG. 3.
[0036] The saddle assembly 30 is best shown in FIGS. 4A-4C and
includes a saddle base 38 and vertical plates 40 welded or
otherwise affixed to the top of the saddle base 38. Slots 52 in the
vertical plates 40 allow the header 14 to be attached to the pile
bracket 24 by fasteners. The saddle base 38 includes several set
screws 42 and a downward-directed protuberance 44 with a clearance
hole for a fastener. The set screws 42 allow fine adjustment of the
elevation of the saddle assembly 30 as well as leveling of the
saddle assembly 30. A fastener is inserted through the clearance
hole in the protuberance 44 and through a slot 46 in the base plate
28, as shown by FIG. 2D. Until the fastener is tightened, the
saddle assembly 30 may slide along the slot 46 as well as rotate
about the fastener. Thus, the pile bracket 24 is highly adjustable
to allow the header 14 to be placed substantially parallel and
level with the previously placed header by compensating for
variation in the placement of the pile 12. Saddle base 38, shown in
detail in FIGS. 4A-4C, is adjustable with six degrees of freedom
including controlling its yaw, pitch and roll. The yaw of saddle
base 38 is adjustable by rotating the base about its point of
attachment to the elongated slot 46. Saddle base 38 has a downward
protuberance 44 which has a partially spherical convex shape to
facilitate control of the yaw, pitch and roll. The magnitude of the
pitch and roll can be controlled by adjusting fastners 42.
[0037] It should be noted that multiple pile extensions may be
coupled together with the piles to allow deeper penetration into
the ground surface as may be required by the application.
[0038] The header 14 is best shown in FIGS. 5A-5D and includes an
welded or cast header beam 48 and several joist holders 50. In the
illustrated embodiment, the header beam 48 is extruded with grooves
on the top and bottom. The end of the header beam 48 is shown as
open in the figures to illustrate its shape; however, it is
preferred that the end be covered by a cap or a plate after the
header beam 48 is cut to length in pre-manufacturing. The header
beam 48 is placed between the vertical plates 40 of two or more
pile brackets 24 and aligned substantially perpendicular to the
intended direction of travel of the deck by adjusting the pile
brackets 24. Fasteners inserted through the slots 52 in the
vertical plates 40 and a through hole in the header beam 48 to
secure the header 14 to the pile bracket 30. The joist holders 50
are welded or cast in place on the header beam 48 to provide a
strong support for the joists 16. In alternative embodiments, the
joist holders 50 may be fastened in place, such as by rivets,
bolts, or screws. The joist holders 50 are aligned such that a
joist 16 may be run between two joist holders of two headers 14 and
be oriented substantially parallel to the direction of travel of
the deck.
[0039] In the case that the joist holders 50 are welded onto the
header beam 48, they may be cut from a flat piece of material and
bent into the U-shape shown in the figures with a bending break or
other machine. An angled notch 54 in each side of the joist holder
50 guides a fastener through the end of the joist 16 to provide
proper placement of the joist within the joist holder 50. The
fastener is tightened to secure the joist 16 to the header 14 and
no other fasteners are required, though additional fasteners may be
used.
[0040] The joist 16 is a tubular beam similar to the header beam
48, though the joist 16 may have a different length. The
cross-section and the end of the joist 16 are shown in FIGS. 6A and
6B, respectively. The groove features on the top and bottom of the
joist 16 provide for snap-connections with cooperating components,
such as the connector strip 60, which is described in more detail
below. Alternatively, cooperating components slide into the grooves
from an end of the joist 16. The outermost joists in the deck
module 10 may include railing supports 56 (FIG. 1) that are welded,
fastened, or otherwise affixed to the outer side of the joist.
These supports 56 may be as simple as boxes for receiving the legs
of a railing 58 as shown in FIG. 1.
[0041] The deck planks 18 are affixed to the joists 16 via a
connector strip 60 shown in FIGS. 7A-7D. The connector strips 60
each have a pair of walls 62 that go into the slots in the top of
the joists 16 and include clips 64 that retain the connector strip
60 in connection with the joist 16 (see FIG. 6A). The connector
strips 60 may be included on the outermost joists 16 only or on
some or all of the inner joists 16. The connector strips 60 may be
connected in series along the length of the joist 16 by coupling a
male connector end 66 to a female connector end 68.
[0042] The connector strips 60 guide the evenly spaced placement of
the deck planks 18 along the joists 16 with spacer posts 70. Each
connector strip 60 accommodates several deck planks 18. The deck
planks 18 may be any substantially rigid material, such as hard
plastic, wood, plastic molded with wood, aluminum, or other
materials. In one embodiment, the deck planks 18 have a
cross-section as shown in FIG. 8, and each includes a pair of tabs
72 configured for mating with clips 74 on the connector strip 60,
as shown in FIG. 9. This mating relationship allows the deck planks
18 to be placed without requiring fasteners, though fasteners may
be used for further securing the planks. The joint between two
connector strips 60 provides space for a deck plank 18 so that the
plank may be affixed to the connector strips over the joint. In an
alternative embodiment, the deck planks 18 are conventional planks
and are fastened to the connector strips 60. In a further
alternative embodiment, the deck planks 18 are affixed directly to
the joists 16 by fasteners, adhesives, or another suitable method.
It should be noted that the connector strips 60 may be configured
to be attached to any frame element by a snap-connection,
fasteners, or adhesives.
[0043] In an alternative embodiment, the connector strips 60 are
fastened to conventional lumber and the deck planks 18 may be
affixed atop.
[0044] An end cap 76, shown in FIG. 10, may be included running
parallel to the joists 16 and covering the ends of the deck planks
18. The end cap 76 may act as a bumper for wheel chairs as required
by the Americans with Disabilities Act or for light vehicles. The
end cap 76 may also be tubular, as shown in the current embodiment,
to provide a chase-way 78 for electrical wiring, water, etc. A lens
receiving portion 80 is included on the side of the end cap 76
facing the deck planks 18 so that light from lamps inside the
chase-way 78 may be directed onto the top of the planks. The end
cap 76 includes a connection portion 82 with a clasp 84 that
engages a groove in the top of the outer joists 16.
[0045] A joining strip 86, shown in cross-section in FIG. 11, may
be included to compensate for elevation changes or turns from one
deck module 10 to another. The joining strip 86 includes a top
platform 88 that may be angled as required and a pair of tabs 90
that engage grooves in the top of a header 14.
[0046] The joists 16 may be reinforced by cross-brace assemblies
92, shown in FIG. 12, having two braces 94 adjoined at a fulcrum 96
by a fastener. Each brace 94 includes a vertical member 98 welded
to the bottom surface of a top member 100. The top member 100
includes a protrusion 102 at each end for hooking into a groove in
the top or bottom of a joist. The cross-brace assembly 92 is
assembled by hooking the protrusions 102 of a first brace 94 into
the grooves in the tops of adjacent joists 16. A second, inverted
brace 94 is brought up underneath the first brace such that the
protrusions 102 of the second brace 94 engage grooves in the
bottoms of the adjacent joists 16 and the fulcrum halves meet to
form the fulcrum 96. A fastener is inserted into the fulcrum 96 to
secure the cross-brace assembly 92. Several cross-brace assemblies
installed between each set of adjacent joists 16 will significantly
strengthen the deck module 10 without adding substantial weight to
the structure.
[0047] The structural elements of the deck module 10, such as the
piles 12, the headers 14, the joists 16, and the cross-brace
assemblies 92, are made of aluminum, aluminum alloy, or a similarly
strong, lightweight material according to the present embodiment.
Further, these components are generally tubular as shown in the
figures, to keep the weight of the components down. Other elements
of the module are made of lightweight materials such as lightweight
plastics and wood. Therefore the components of the module 10 may be
easily transported by a person or a light vehicle.
[0048] In use, the modular deck system may be assembled in a
variety of locations, such as in a field, in wetlands, or in a body
of water, without significantly affecting the location. In an
example, the deck system is installed as a dock in a body of water
or a boardwalk through wetlands and the deck modules 10 are
installed with the personnel and equipment situated on a previously
installed deck module. No equipment is required to be submerged or
driven though the wetlands to install the modules. Thus, the only
impact on the ground surface by the deck system is the driving of
the piles 12 into the ground surface. However, as the application
warrants and allows, the system may also be installed at ground
level.
[0049] The deck module 10 is assembled by driving a first set of
piles 12 and a second set of piles 12 into a ground surface. In the
current embodiment, each set of piles includes two piles 12;
however, additional piles 12 may be used to further support the
headers 14, the joists 16, or both. The helical piles 12 are
installed by applying vertical force and rotating the pile 12 to
screw it into the ground or wetland floor. A pile bracket 24 is
assembled onto the top of each pile 12 and adjusted so that the
saddle assembly 30 is level and the headers 14 may be aligned
substantially parallel to each other. One header 14 is fastened to
the saddle assemblies 30 of the first set of piles 12 and the
second header 14 is fastened to the saddle assemblies 30 of the
second set of piles 12. The pile brackets 24 are finely adjusted
such that the headers 14 are level and aligned and the joist
holders 50 of one header 14 are each aligned with a joist holder 50
of the opposite header 14. A bolt or other fastener is inserted
through a hole near each end of each joist 16 such that the bolt
extends through both sides of the joist. Each joist is then placed
into two aligned joist holders 50 with the bolts engaging the
notches 54. The bolts are mated with nuts and tightened to secure
the joist 16. Four joists 16 are used in the illustrated
embodiment, though more or less may be required in specific
applications. Several of the cross-brace assemblies 92 are
assembled between each pair of adjacent joists 16 as needed.
[0050] The walls 62 of the connector strips 60 are inserted into
grooves in the tops two or more of the joists 16 and connected in
series by the connector ends 66, 68. The connector strips 60 may be
secured to the joists 16 by fasteners. The deck planks 18 are
placed between the spacer posts 70 and connected to the connector
strips 60 by a snap connection, fasteners, or both. The end caps 76
are connected to the outermost joists 16 and over the edges of the
deck planks 18. The railings 58 may then be inserted into the
railing supports 56.
[0051] A subsequent module is assembled from the first module by
driving a third set of piles 12 into the ground surface relatively
aligned with the first and second sets of piles 12. Imprecise
placement of the piles 12 is compensated by the adjustable pile
brackets 24. A third header 14 is attached to the pile brackets 24
of the third set of piles and the brackets are adjusted such that
the header is level and aligned with the second header 14. Several
joists 16 are placed into the joist holders 50 of the second and
third headers 14. The remaining components are assembled as
described with the first module 10 above. Additional modules are
likewise added as required. Because interlocking, preformed
components are used in the construction of the deck module 10 and
few fasteners are required, disassembly of the deck module 10 is
made simple.
[0052] In an alternative embodiment, the components of the deck
module are made of a stronger, heavier materials, such as steel.
The system retains its advantages of rapid installation and strong
joints, though heavier equipment may be required to transport the
heavier materials. This alternative embodiment would be useful, for
example, for a temporary, high-strength bridge for heavy equipment
in a military setting.
[0053] It should be particularly noted that certain deck modules 10
may have angled planks and curved joists for turning corners. In
this case, the headers 14 are aligned such that the curved joists
may be placed in the joist holders 50. Further, the headers 14 may
be aligned for gradual changes in elevation. In this case, the
joist holders 50 may be slanted to accommodate the angled joists
16.
[0054] It should be further noted that several of the components of
the deck module 10 of the present invention may be used separate
from the other components of the module. The header 14 with the
integral or welded-on joist holders 50 may be used to support
conventional wooden joists or the header may be supported by
structural elements other than piles. The connector strip 60 may be
configured to engage dimensional lumber or other materials instead
of the extruded joists 16. The pile bracket 24 may be used in any
application that may benefit from a wide range saddle bracket. The
aluminum helical piles 12 may be used in any situation requiring a
lightweight or corrosive resistant pile.
[0055] While the invention has been described with reference to
preferred 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 to adapt to particular situations
without departing from the scope of the invention. Therefore, it is
intended that the invention not be limited to the particular
embodiments disclosed as the best mode contemplated for carrying
out this invention, but that the invention will include all
embodiments falling within the scope and spirit of the appended
claims.
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