AU1005602A - Deck construction - Google Patents

Description

Regulation 3.2

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

(ORIGINAL)

Name of Applicant: Actual Inventor(s): Address for Service: Invention Title: Bernard John Cummins of 29 Malmsbury Street, Hawthorn, Victoria 3122, Australia Bernard John CUMMINS DAVIES COLLISON CAVE, Patent Attorneys, 1 Little Collins Street, Melbourne 3000, Victoria, Australia "Deck construction" Details of Associated Provisional Application No(s): PR2480/01 The following statement is a full description of this invention, including the best method of performing it known to me: p:\OPER\GCPcunnis conplctc spe.,)3 doc4)4/)/02 l]A- DECK CONSTRUCTION This invention relates to deck construction.

More particularly, the invention relates to methods of deck construction of the type which can be used adjacent to buildings, verandahs, pathways or the like.

Conventionally, decks are made by first providing a support structure which includes joists to which decking planks are fastened. The joists are supported by a substructure which may include bearers and/or stumps which themselves need footings or the like.

The traditional methods of making a deck have a number of drawbacks. The S drawbacks include: 1. The construction time is relatively long because the traditional techniques require ~components of the supporting structure and deck to be cut to size, placed in the correct position and fastened.

2. They result in permanent fixtures which are not portable and cannot readily be moved. This makes them relatively inflexible and also has the disadvantage that tenants of a building who may install a deck cannot take it with them when their tenancy expires.

3. The supporting structure for the deck is difficult to make having a low height and therefore in some circumstances a traditional deck cannot be constructed where there is a maximum height available.

4. The appearance of the finished work will depend on the skill of the person constructing the deck and therefore the deck may have an untidy appearance if the deck is made by a handyman.

P:\OPER\GCPum-nins complete spe.tX)3.dc4 J/III2 -2- The object of the present invention is to at least partially overcome the disadvantages described above.

According to the present invention there is provided a method of constructing decking including the steps of preparing a deck site so as to have a generally flat support surface and placing a pre-constructed deck panel on the support surface.

Preferably, the pre-constructed deck panel includes a framework to which is affixed a plurality of timber decking boards.

*°".Preferably further, the pre-constructed deck panel includes at least some decking boards around the sides thereof.

In one arrangement, the support surface includes compacted particulate material such as sand and the method includes the steps of providing additional particulate material adjacent to the sides of the deck panel. In this way, the top of the deck can be made generally contiguous with the surrounding ground.

In an alternative arrangement, the generally flat support surface may include a concrete slurry and the method includes the step of forcing the deck panel at least partly into the slurry so that the lower parts thereof are embedded in the slurry and then permitting the slurry to cure.

The invention also provides a method of constructing decking including the steps of preparing a support structure having a number of support elements which are located in a generally horizontal plane, placing a pre-constructed deck panel on said support elements and then affixing the deck panel to the supporting structure.

In the above method, the supporting structure may include a number of posts or stumps or a number of stirrups.

PAOPERWGCPn,-n ,si -npldI spOJKA3.doc-4U/Ol2 The invention also provides a pre-constructed deck panel comprising a framework and a plurality of timber decking planks affixed to the framework.

Preferably further, the timber decking elements are parallel and extend substantially across the entire surface of the deck panel.

Preferably further, side deck planks are mounted on the sides of the framework.

The invention will now be further described with reference to the accompanying drawings, in which: Figure 1 is a plan view of a decking panel of the invention; Figure 2 is an underside view of the decking panel; Figure 3 is a side view of the decking panel; Figure 4 is a cross-sectional view along the lines 4-4; Figure 5 shows the decking panel mounted on a flat support structure; Figure 6 is a schematic cross-section showing the panel embedded in compacted *sand; Figure 7 is a schematic side view showing the panel embedded in a concrete slurry; Figure 8 is a fragmentary perspective view of a modified decking panel of the invention; and Figure 9 is a fragmentary view of part of the panel shown in Figure 8.

Figures 1 to 4 show a decking panel 2 constructed in accordance with the invention.

As best seen in Figures 2 and 4, the deck panel includes a framework 4 having side beams 6 and 8 between which extend side beams 10 and 11 and intermediate joists 12, 14 and 16.

The side beams 10 and 11 and the joists 12, 14, and 16 are connected to the beams 6 and 8 by means of nails and/or screws (not shown).

As best seen in Figure 4, the tops of the beams and joists lie in a plane 18, The panel 2 also includes a plurality of decking planks 20 which are affixed to the beams and joists in generally side by side relationship, transverse to the beams 10 and 11 and joists P:\OPER\GCP\lu-m Mnpld srpp0Xldm4J4A0l1A)21 -4- 12, 14 and 16, as shown in Figure 2. The planks 20 are affixed to the framework by means of nails or screws (not shown). Normally there is a 3mm gap between adjacent planks.

The decking panel 2 also includes side decking planks 22, 24, 26 and 28 which are affixed to the sides of the beams 6, 8, 10 and 11 respectively, as best shown in Figures 3 and 4. The ends 30 of the side planks are mitred so as to form mitre joints at the corners of the deck panel as shown in Figures 1 and 2.

The panel 2 can be constructed in a factory so as to be robust and have a neat and accurate finish. It can be made in sizes which are convenient for manufacture, storage, transport and use. Suitable sizes are set out in the following table: 2400 x 1800 1800 x 1800 1200 x 1200 2400 x 900 1800 x 900 1200 x 900 2400 x 750 1800 x 750 1200 x 750 2400 x 400 1800 x 400 1200 x 400 .o Typically the beams and joists are made from timber such as kiln dried treated pine, typically 90 x 45 in cross-section. The decking planks 20 are preferably made from weather resistant timber such as treated pine, yellow balau, merbau or other weather resistant timbers. Typically, the cross-sectional .size would be 70 x 19. Preferably, the joists 12, 14 and 16 would be located at 450mm centres.

In an alternative construction, the framework 4 could be made from galvanised steel beams of C-section and otherwise having similar dimensions to the timber framework described above.

In an alternative arrangement, the decking planks 20 could be arranged in a herringbone, diagonal, or other pattern rather than the parallel arrangement shown in Figures 1 and 2.

P:\OPER\GCPiCninisc mnpltc spe.(X)3.dc-4An 1/02 Figure 5 illustrates one way in which the decking panel 2 can be used. In this arrangement the site for placement of the decking panel 2 includes an existing concrete slab 32 having a generally flat top surface 34. The method of the invention simply requires that the decking panel 2 be laid upon the top surface 34 of the slab. Packing can be used beneath the framework 4 in order to level the decking panel 2, if necessary. It would be appreciated that the construction technique in this case is particularly simple. It will also be appreciated that a number of panels can be laid side by side so as to cover a relatively large area. The adjacent decking panels could be connected together by means of Ushaped joining brackets (not shown). Conventionally, 90mm post support stirrups can be 10 used for this purpose. It will be further appreciated that the panels could be placed on -"different levels in order to follow a pre-existing shape of a site. Alternatively, the panels could be laid partially overlapping one another so as to form a stepped or tiered configuration.

Figure 6 diagrammatically illustrates an alternative method of mounting of the decking panel 2 of the invention. In this method, the decking panel 2 is laid upon a bed 36 of compacted particulate material such as sand having a flat top surface 38 as shown by the chain line. The decking panel 2 is simply placed upon the top surface 38 of the bed 36.

•The panel may then be pressed or agitated into the bed 36 so that at least the lower edges of the framework 4 are partly embedded in the bed 36. Additional sand can then be ~applied about the sides of the decking panel 2 and compacted so as to form side supporting bodies 40 and 42, as shown. The tops 44 and 46 of the bodies 40 and 42 can be made generally contiguous with the planks 20 so as to provide a neat appearance. The decking panel mounted in this way will also be quite stable and resistant to movement but can be readily removed if necessary.

Figure 7 shows a further alternative method of mounting of the decking panel 2 of the invention. In this arrangement, a body 50 of concrete slurry is provided at the site where the decking panel 2 is to be located and its top surface is levelled. The decking panel 2 is then placed on the top surface of the body of slurry and agitated or worked into the slurry so that at least the lower part of the framework 4 is embedded in the slurry. In P:\OPER\GCc cuiizls comlplete spc. 3.doc-41) I/I)2 -6the illustrated arrangement, the top surface 52 of the body of slurry is level with the decking planks 20 of the panel. The concrete slurry of the body is then permitted to cure.

In this way a very stable and permanent decking structure is simply and readily constructed.

Figures 8 and 9 show a modified decking panel 60. The same reference numerals have been used to denote parts which are the same as or correspond to those of the embodiment of Figures 1 to 4. In the embodiment of Figure 8, the side beams 6, 8, 10 and 12 as well as the intermediate joists 12, 14 and 16 are formed from a metal section. In the illustrated arrangement, a C-shaped section is used. Preferably, the section is made from :.:"-galvanised steel and having a web depth of 100 mm and side flanges of 50 mm. The thickness can be say 1.1 mm. The panel 60 has a modified framework 62 which can be S formed by using metal brackets 64 which connect the side beams to the intermediate joists, °.as shown. Similar brackets can be used to join the corners of the side beams. The brackets 64 may be held in place by means of bolts 66, the heads of brackets (not shown) of which are countersunk into the webs of the side beams. This enables the side decking planks 22, 24, 26 and 28 to be placed in direct contact with the webs of the side beams, and fixed thereto by means of fasteners 68. In the preferred arrangement, the fasteners 68 are selftapping screws the heads of which are located onthe inside of the framework 62 so that they are not visible on the exterior of the decking panel 60. The decking planks 20 can be fixed in a similar way to the side flanges of the intermediate joists 12, 14 and 16.

Figure 9 shows an end 70 of one of the side intermediate joists 12. Parts 72 of the side flanges, as indicated in broken lines in Figure 9, have been removed in order to enable the ends of the intermediate joists to abut the webs of the side beams to facilitate coupling thereto.

In the preferred form of the invention, the side beams and intermediate joists are cut to size and drilled then hot-dip galvanised. This would enable the framework 62 to be corrosion-resistant so that it could be placed directly on the ground or in a concrete support as in Figure 7.

PAOPER\GCPM-innins coiplote spc.(X)3doc4WN)IA)2 -7- It will be appreciated that the decking panel and its methods of installation have a number of advantages.

Many modifications will be apparent to those skilled in the art without departing from the spirit and scope of the invention.

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Claims (23)

1. A method of constructing decking including the steps of preparing a deck site so as to have a generally flat support surface and placing a pre-constructed deck panel on the support.

2. A method as claimed in claim 1 wherein the pre-constructed deck panel includes a framework to which is affixed a plurality of timber decking boards.

3. A method as claimed in claim 1 or 2 wherein the pre-constructed deck panel includes at least some decking boards around the sides thereof.

4. A method as claimed in claims 1, 2 or 3 wherein the step of preparing the deck site includes placing particulate material on a substrate and then compacting the particulate material.

A method as claimed in claim 4 including the step of placing additional particulate material adjacent to the sides of the deck panel. o#0oo

6. A method as claimed in claim 5 wherein the additional particulate material is placed adjacent to the sides of the deck panel so that the top of the panel is generally contiguous with the upper surface of said additional particulate material.

7. A method as claimed in any one of claims 4 to 6 wherein said particulate material is sand.

8. A method as claimed in any one of claims 1 to 3 wherein the generally flat support surface may include a concrete slurry and the method includes the step of forcing the deck panel at least partly into the slurry so that the lower parts thereof are embedded in the slurry and then permitting the slurry to cure. P:\OPERGCK unl, c npkt. sp.(X3.doc4)4IAlA)2 -9-

9. A method of constructing decking including the steps of preparing a support structure having a number of support elements which are located in a generally horizontal plane, placing a pre-constructed deck panel on said support elements and then affixing the deck panel to the supporting structure.

A method as claimed in claim 10 wherein the support elements include a number of posts or stumps or a number of stirrups.

11. A pre-constructed deck panel comprising a framework and a plurality of timber 10 decking planks affixed to the framework.

12. A deck panel as claimed in claim 11, wherein the timber decking elements are parallel and extend substantially across the entire surface of the deck panel. .oo••i

13. A deck panel as claimed in claim 11 or 12, wherein side deck planks are mounted S. on the sides of the framework. °0

14. A deck panel as claimed in any one of claims 11 to 13 wherein the framework includes peripheral side beams and a plurality of intermediate joists connected thereto.

A deck panel as claimed in claim 14 wherein the side beams define a square or *rectangle.

16. A deck panel as claimed in any one of claims 11 to 15 wherein the side beams and joists are timber beams and joists.

17. A deck panel as claimed in any one of claims 11 to 15 wherein the side beams and joists are metal sections.

18. A deck panel as claimed in claim 17 wherein the metal sections are C-shaped in cross-section. P:\OPER\GCP\M mmlns comnlplce spCx.N)l.doc--I/)1)2 oooo ooo o a. a .o o *o oooo

19. A deck panel as claimed in claim 18 wherein the side beams and joists are connected together using brackets.

20. A deck panel as claimed in claim 18 or 19 wherein the timber decking planks are affixed to side flanges of the C-shaped sections.

21. A deck panel as claimed in claim 20 wherein screws are used to affix the timber decking planks to the C-shaped sections and the heads of the screws are internal to the 10 deck panel.

22. A method of constructing decking substantially as hereinbefore described with reference to the accompanying drawings. 15

23. A pre-constructed deck panel substantially as hereinbefore described with reference to the accompanying drawings. DATED this 4 th day of January, 2002 BERNARD JOHN CUMMINS By his Patent Attorneys DAVIES COLLISON CAVE