AU2005218061A1 - Fencing system - Google Patents

Description

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AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

Name of Applicant/s: Actual Inventor/s: James Hardie International Finance B.V.

Lindsay Gordon Hill Address for Service is: SHELSTON IP Margaret Street SYDNEY NSW 2000 CCN: 3710000352 Attorney Code: SW Telephone No: Facsimile No.

(02) 97771111 (02) 9241 4666 Invention Title: FENCING SYSTEM Details of Associated Provisional Application No. 2004905704 dated 01 Oct 2004 The following statement is a full description of this invention, including the best method of performing it known to me/us:- File: 43437AUP00 500700655 1.DOC/5844 -la- SField of the Invention The present invention relates to a fencing system. This new fencing system has been designed primarily for use with corrugated fibre reinforced cement panels and will be described herein with reference to this preferred form. However, it will be appreciated that the invention is clearly not limited to fencing systems using this 00 particular panel material or panel configuration.

Background of the Invention Corrugated fibre cement sheeting has been widely used as a versatile fencing material, particularly in Western Australian regions. To construct the fences, a narrow trench is dug and the vertically orientated sheets are partially buried into the ground.

The sheets are arranged to partially overlap along the longitudinal edges to form a continuous corrugate panel fence which provides maximum privacy for homeowners.

The trench is then backfilled to hold the sheets in place and optionally a finishing cap is installed to cover the top edges.

While this system has provided a simple, cost effective and durable fencing solution, this form of fencing structure can not be used on sloping blocks that have been levelled where the fence needs to be erected along a retaining wall where a trench can not be dug. Furthermore, the standing strength of the resulting fence is determined to a large extent by the integrity of the supporting groundwork which holds the fence in place.

The most popular general form of alternative fencing system is based on what is referred to as a post and rail system. In these systems selected forms of various screening materials are attached to horizontal rails, the rails having generally been preassembled to vertical support posts that are set into the ground. For metal systems the rails are usually attached to the vertical post members using bolts and/or specially made brackets which are often both costly and unsightly. Where the posts and rails are made of timber, these are usually assembled using bolts or other fasteners -2- The resulting structure usually has the posts extending outwardly from the general planar extent of the fence panels, thereby forming a prominent visual feature of the completed fencing system. Another potential limitation is that this kind of fencing system often has two visually very different appearances on opposing sides, with a facing side dominated by the fencing panels and a more structural reverse side that 0 includes the posts and rails. This can make systems of this kind less than ideal for use as boundary fences between residential properties.

SIn other systems where the panels are held captive within wide channel type posts, two such posts or a single wide post is often required between adjacent fence spans which increases the cost of the system. Furthermore, these large width posts still dominate the finished fence structure. There is also the added disadvantage when the posts are made of metal sections that the protruding edges may be dangerous and may form traps for spiders and dirt.

A further disadvantage of fence systems using metal posts that extend in any way beyond the fence panels and capping, is the need to separately seal the post ends to prevent water ingress and resulting corrosion. Furthermore, most post and rail systems are difficult to install, requiring skilled workers to accurately measure and position the posts.

It is an object of the present invention to provide a fencing system which overcomes or eliminates one or more of the above discussed disadvantages of the prior art or which at least offers a useful alternative.

Summary of the Invention According to a first aspect of the invention there is provided a bottom rail for a fencing system, the bottom rails including: a longitudinally extending channel member having a generally U-shaped crosssection including a base portion and two transversely extending parallel spaced apart side flanges; and at least one tab formation formed in said base portion, said tab or tabs being configured upon deployment to clear a passage for a fence post to pass there through O whereby said deployed tab or tabs can then be secured to said post to thereby support said rail.

Desirably, the bottom rail is formed from a resiliently deformable material such

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0as galvanised steel.

Preferably, some of the tabs are also configured such that on deployment they Sserve to connect and secure adjacent bottom rail sections together.

In preferred forms, the bottom fence rail also includes a first male spigot formation formed at one end of said channel and a corresponding female socket formation formed at the opposing end, whereby end to end connection of adjacent lengths of bottom fence rail is achieved by insertion of the male spigot formation of a first length into the female socket formation in said adjacent length.

In other embodiments, not illustrated, end to end connection of adjacent lengths of bottom fence rail may be achieved by means of an appropriately shaped inserts or cover elements that extends within or over the respective channel members and bridges the join therebetween.

According to a second aspect of the invention there is provided a fencing system including: one or more generally corrugated fence panels each having a top edge; one or more posts each having a top end and being configured to be disposed on installation adjacent said fence panel or panels with each top end generally level with said fence panel top edge; and a generally channel shaped capping rail configured to sit over both said fence panel top edge and said top end of said adjacent posts.

Desirably, the posts and capping rails are formed from a metal material such as galvanised steel and in the preferred form of both aspects the fence panels are made from corrugated fibre cement sheet.

-4- I By the term generally corrugated it is meant that the fence panels are profiled in Sa third dimension generally transverse to the planar extent of the panel, whereby the posts may optionally be conveniently located within spaces formed within the overall C€3 maximum thickness of the panel.

D 5 In some preferred forms, the panels have a generally corrugated profile varying 00 from sine type wave forms to saw tooth, trapezoidal, rhombic or square type wave forms C or the like.

In one variation, the adjacent corrugated panel members are partially lapped synchronously so as to achieve a substantially continuous panel length and the posts are preferably disposed at or adjacent one of said joins so as to be visible from one side only.

In another variation, the adjacent corrugated panel members are partially lapped out of synchronisation, so as to define a cavity between the overlapping portions of adjacent panel members in which the post members can be concealed.

In a preferred form, the fencing system also includes a generally channel shaped bottom rail configured to allow the posts to extend therethrough and to support a lower edge of said corrugated fence panels.

In another form, a portion of the lower edge of the fence panel may be built in to the ground (where this is possible) to provide additional support to that provided by the posts.

According to a third aspect of the invention there is provided a method of installing a fencing system made in accordance with the second aspect of the invention, said method comprising the steps of: setting appropriately spaced posts into the ground; disposing one or more generally corrugated fence panels closely adjacent said spaced posts to bridge the span therebetween; attaching a generally channel shaped capping rail so as to sit over both a top edge of said fence panels and aligned top ends of said adjacent posts; and securing said capping rail to said posts.

1. Optionally, the panels may also be a supported and held in alignment at their Vlower edge by means of one or more clips set into the ground. Similarly, the panel or C panels may also optionally be secured to each other and/or to the adjacent posts.

According to a fourth aspect of the invention there is provided a method of installing a fencing system incorporating a bottom rail in accordance with the first aspect 00 of the invention, said method including steps of: selecting and if necessary connecting one or more lengths of bottom fence rail and deploying one or more of said tabs formed in the base portion thereof to clear r passages for respective fence posts to pass therethrough; using said deployed bottom rail as a template to mark the ground surface at the appropriate post spacings and then preparing post holes for same; assembling the posts through the passages in said bottom rail and setting the posts with the bottom rail slid up along the posts in a position well clear of the ground; lowering the bottom rail after the posts have been fully set in the ground; fixing the bottom rail to the posts by securing the tab or tabs to each adjacent post; inserting said panel members into the bottom rail to span between respective posts; securing a capping rail over the top edges of said panels and aligned top ends of said adjacent posts; and securing said capping rail to said posts.

Optionally, the fence panel or panels may also be clipped to the adjacent posts and/or to each other during assembly to hold in position prior to the capping rail being installed.

Brief Description of the Drawings Preferred forms of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: Figure 1 is a side view of a first embodiment fencing system in accordance with the first aspect of the invention; I Figure 2 is a side view of a second embodiment fencing system incorporating a bottom rail in accordance with the second aspect of the invention;

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O Figure 3 is a perspective part view showing a connection between two adjacent lengths of bottom rail in accordance with the second aspect of the invention and 5 connection of the bottom rail with a post member; 0 0Figure 4 is a schematic sectional view of a first panel arrangement suitable for use in either embodiment with the posts disposed externally of synchronously aligned Spanels but within the capping rail; Figure 5 is a schematic sectional view of a second panel arrangement suitable for use in either embodiment with the posts concealed internally of non-synchronously overlapped panels again within the capping rail; Figure 6 is a perspective view of the second embodiment fencing system of Figure 2 illustrating a step-down arrangement; Figure 7 is a side view of a second embodiment .fencing system in accordance with the invention utilising planar panels or panel elements; Figure 8 is an end view of the system shown in Figure 7; Figure 9 is a sectional view showing interconnected male and female connecting spigot and socket formations; and Figure 10 is a side view of the male connecting spigot of Figure 9.

Preferred Embodiments of the Invention Referring to Figure 1, a first embodiment fencing system is shown generally at 1.

In the example illustrated, the fencing system includes three fence panels 2 each having a top edge (shown in dotted lines) 3 and a bottom edge 4. Supporting these panels 2 are two vertically extending posts 5 each having top ends 6 which in use are disposed generally level with the top edge 3 of the adjacent panels. Disposed over the upper ends of both the fence panels 2 and the posts 5 is a generally channel shaped capping rail 7.

In the preferred forms the fence posts and capping members are made of a metal I material such as galvanised steel. Finally, there is shown a plurality of metal clips 9 which are set into the ground which is represented in this instance by a retaining wall

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O In the preferred form of this embodiment, the fence panels 2 are each sheets of corrugated fibre reinforced cement, orientated with the corrugations extending vertically and with a small synchronous overlap between adjacent panels 2 provide a continuous

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0panel structure to maximise privacy. Further detail of this arrangement is shown in Ni Figure 4.

SDuring installation, the posts are first set into the ground at a predetermined spacing and optionally a plurality of the metal clips 9 are similarly set in at appropriate spacings therebetween. The post spacing is selected so that the posts can nest neatly into valleys formed in the panels. The fence panels are then placed into position to span the gap between the posts. The panels may be held in alignment using both the metal clips 9 which engage the bottom edges 4 of the panels 2, with or without additional clips that can be used over the top edges 3 of the panels which simply act to hold the panels in close engagement. Further clips may also be used at the ends of the panels adjacent posts to secure the panels to the posts. Installation of the system is then completed by securing a capping rail 7 over the assembled panels 2 and then securing the capping rail to the posts 5. This can be done using any suitable form of fastening means including metal screws and the like.

While the embodiment described has the bottom edges of the panel supported at ground level by metal clips 9, in alternative embodiments where the ground material allows, the bottom edges of the fence panel may be buried to provide support and/or act as a barrier as required.

A second embodiment representing a more preferred alternative form of the invention is shown at Figure 2 with further detail shown in Figure 3. This second embodiment has all the key features of the first embodiment and where possible like reference numerals have been used to denote corresponding features.

As will be clear from the drawings, the primary difference resides in the provision of a bottom rail 12 (which is also preferably formed in metal) which acts to I support the bottom edges 4 of the fence panels 2. As will be apparent from the description below, this facilitates easier installation and enables the bottom of the fence O to be spaced from the ground as may be required to provide bleed off in high wind applications.

The bottom rail 12 comprises a channel member having a generally U-shaped 00 cross-section including a base portion 13 from which extend two parallel spaced apart side flanges 14. Formed within the base portion 13 are one or more tab formations Sshown generally at 15. These tabs are in the form of flaps that can be bent upward along ,I a fold line 16 so that the tab extends in a direction generally transverse to the base portion of the rail simultaneously defining a through passage 17 in the bottom rail which is sized to receive a fence post In preferred forms of the invention, the bottom rail 12 also includes a male spigot formation 18 formed at one end and a corresponding female socket 19 at the opposing end, whereby end to end connection of adjacent lengths of the bottom rail is achieved by insertion of the male spigot formation of a first length into the female socket opening in said adjacent length. Further details of a preferred form are shown in Figures 9 and As can be seen, the bottom rail side flanges 14 are formed from folded sheet material that defines a gap therebetween. The spigot is formed by deforming and compressing the sheet material so that it fits within the gap formed in the opposite end of an adjacent rail. The spigot end may also be tapered as shown in Figure 10 to enable better lead in and alignment during connection. It will be appreciated that this spigot and socket arrangement can be achieved in the metal bottom rails in numerous ways using techniques such as cutting, swaging and forging etc. In alternative embodiments, an inner or outer connecting sleeve member may be used to join adjacent lengths of bottom rail.

In the embodiment illustrated, the tab formations 15 are formed in the ends of the bottom rail 12 that include the spigot and socket formations (18, 19). In this manner, two tabs are formed with one either side of each post, the tabs also advantageously acting to secure adjacent bottom rail sections together. However, it will be appreciated that in other embodiments the tabs can be formed at continuous spaced intervals along the length of the bottom rail matching valleys formed in the panels. In those embodiments single tabs may be replaced with double paired opposed tabs which open 0 to define the post passage therebetween.

The bottom rail and tab arrangement enables easy and accurate installation of the fence. In this regard, the tabs can be deployed at the locations in which the posts are to

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0 be set and the bottom rail then used a template to mark out the post holes in the ground therebelow. Once the holes have been prepared, the posts can be inserted through the Spassages in the assembled bottom rails and set into the ground with the bottom rails

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,Ie positioned at a convenient location away from the ground so as to hold the posts in a vertical and parallel orientation. Once the posts have then been set, the bottom rail can be lowered into its final position and secured to the posts at a predetermined height setting by securing the tabs to the posts using simple metal screws or the like.

The fence panels 2 can then be inserted into the bottom rails with whatever lapping formations are required and the fence panels optionally clipped together and/or to the posts along their top edges 3. At this stage it is ensured that the top ends of the posts 5 are cut generally level with the top edges 3 of the fence panel 2. Completion of the assembly is then achieved by simply attaching the generally channel shaped capping rail 7 over the fence panels 2 and the posts 5 and securing the capping to the posts. The ends of the fence lengths can then be finished by any suitable means which may include a further length of a capping rail 7 disposed in a vertical orientation as an end cap.

It is envisaged that preferred forms of the invention are most likely to use corrugated fibre cement sheeting as the fence panels 2. As will be seen by reference to Figures 4 and 5, these corrugated sheets can be arranged either to form a continuous panel on one side of the fence posts 5, or alternatively, by overlapping the panels out of synchronisation as shown in Figure 5, the posts can be fully concealed. Similar results can be achieved with panels having alternative profiles but which also include valleys in which the posts can be located. Furthermore, the panels can be made of any suitable material and the invention is not limited to the use of fibre reinforced cement panels.

It will also be appreciated that the system can readily be adapted for use with substantially planar fence panels and/or panels comprised of a plurality of individual S.panel elements such as planks or the like as is discussed in more detail in relation to Figures 7 and 8.

Figure 6 shows a perspective view of the second embodiment fencing system of Figure 2 incorporating the bottom rail illustrating one form of step-down arrangement.

In this arrangement, appropriately cut lengths of capping rail or bottom rail can 00 be used to frame the vertical edge drops 20, which can then be joined with a mitre cut or N square cut to the adjacent bottom rail sections 13 as shown. Interconnection of the Svertical drops to the bottom rails can be by any means including the use of tabs 15 of the ,I same kind as are used to attach the rail to the post. Such tabs can be readily cut on site as required. The vertical drops 20 can be further supported by direct attachment to the substrate using rawl plugs and screws 21 or the like where this is possible. Finally, the vertical ends of the completed fence can be finished off using lengths of capping rail or other suitable cover means.

Figures 7 and 8 shows an alternative embodiment set into normal ground material 24 and which has been configured for use with substantially planar panels As can be seen the basic structure is the same and the dimensions of the bottom and top rails can be varied according to the form and thickness of the panels and the preferred orientation of the panels with respect to the posts.

For example, and as shown in the accompanying drawings, the planar panels can be set into a space 26 provided in the rail bottom between the posts 5 and an outer edge of the rail 27, whereby the posts are usually disposed to one side of the panels at or adjacent vertical joins in the fence panels. However, in alternative forms, the width of the bottom rail may be configured to be a close fit on the posts and the panels arranged to butt up against the side of the posts.

As to the form of the generally planar panels, the options are numerous, ranging for example from singular planar panels to panels made up of individual plank elements that may be aligned horizontally or vertically, and/or may butt jointed or configured to interlock or overlap. Similarly, the panel or panel elements may be made from a wide range of material types and structures including, but not being limited to, various solid, lightweight or composite materials having a variety of external finishes.

-11 I In use, this embodiment is installed in a similar manner to that shown in Figures 1 and 6, the panel installation details depending on the type of panel selected.

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O It will be appreciated that in all embodiments of the invention, the housing of the posts 5 fully within the capping rail 7 provides a neat narrow width fencing solution D 5 which also has the added advantage of eliminating the need to separately seal the upper 00 ends of the fence posts. This is particularly relevant where hollow metal tube fence posts are used and sealing is essential to prevent or at least minimise water ingress and Sresulting corrosion.

Furthermore, the use of posts facilitates the use of the fence systems of the invention on top of retaining wall formations as well as with normal ground formations.

The preferred and enhanced embodiments of Figures 2, 6, 7 and 8 also have the added advantages conferred by the innovative bottom rail 12 which makes the system extremely flexible, strong and easy to accurately install. Furthermore, the system provides for neat and complete framing of the upper and lower edges of the panel thereby also eliminating sharp edges.

Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention can be embodied in many other forms.

Claims (15)

1. 2. A bottom fence rail according to claim 1 wherein the rail is made from a deformable material.
2. 3. A bottom fence rail according to claim 1 or claim 2, wherein one or more of the tabs adjacent ends of the rail are configured such that on deployment they optionally provide a means to connect and secure adjacent bottom rail sections together.
3. 4. A bottom fence rail according to any one of the preceding claims, including a first male spigot formation formed at one end of said channel and a corresponding female socket formation formed at the opposed end, whereby end-to-end connection of adjacent lengths of bottom fence rail is achieved by insertion of the male spigot formation of a first length into the female socket formation in said adjacent length.
4. 5. A bottom fence rail according to claim 4, wherein the side flanges of channel member are formed from folded sheet spaced to define a gap therebetween the male spigot being formed by compression of these layers.
5. 6. A bottom fence rail according to any one claims 1 to 3, wherein end-to-end connection of adjacent length of bottom fence rail may be achieved by means of an appropriately shaped insert or cover element that extends within or over the respective channel members and bridges the join therebetween.
6. 13- 1 7. A bottom fence rail according to any one of the preceding claims, wherein at least some of the tab formations are provided as opposing pairs. 8. A fencing system including: a bottom rail according to any one of the preceding claims: D 5 one or more fence panels having a bottom edge for location within the bottom 0 00 fence rail and a top edge; one or more posts each having a top end and being configured to be disposed on installation adjacent said fence panel or panels with each top end generally level with said fence panel top edge, and a bottom end that extends through the passage provided in the bottom rail when said tab or tabs are deployed; and a generally channel-shaped capping rail configured to sit over both said fence panel top edge and said top end of said adjacent posts. 9. A fencing system according to claim 8, wherein the posts and capping rails are formed from a metal material. 10. A fencing system according to claims 8 or 9, wherein the fence panel or panels are made profiled in a third dimension generally transverse to the planar extent of the panel, whereby the posts may be located within spaced formed within the overall maximum thickness of the panel. 11. A fencing system according to claim 10, wherein the panels have a generally corrugated profile varying from sine type wave forms to sawtooth, trapezoidal, rhombic or square type wave forms. 12. A fencing system according to any one of claims 8 to 11, wherein the fence panels are made from fibre cement. 13. A fence system according to any one of claims 10 to 12, wherein adjacent profiled panel members are partially lapped synchronously so as to achieve a substantially continuous panel length and the posts are disposed so as to be visible from one side only. -14- S14. A fence system according to any one of claims 10 to 12, wherein the profiled panel members are partially lapped out of synchronization so as to define a cavity between the overlapping portions of adjacent panel members in which the post members can be concealed. D 5 15. A fence system according to any one of claims 10 to 14, wherein each panel is 00oO formed from a plurality of discrete panel elements.
7. 16. A method of installing a fencing system according to claim 8, said method including the steps of: selecting and if necessary connecting one or more lengths of bottom fence rail and deploying one or more of said tabs formed in the base portion thereof to clear passages for respective fence posts to pass therethrough; using said deployed bottom rail as a template to mark the ground surface at the appropriate post spacings and then preparing post holes for same; assembling the posts through the passages in said bottom rail and setting the posts with the bottom rail slid up along the posts in a position well clear of the ground; lowering the bottom rail after the posts have been fully set in the ground; fixing the bottom rail to the posts by securing the tab or tabs to each adjacent post; inserting panel members into the bottom rail to span between respective posts; securing a capping rail over the top edges of said panels and aligned top ends of said adjacent posts; and securing said capping rail to said posts.
8. 17. A method of installing a fence according to claim 16, wherein the fence panels have a generally corrugated profile and are partially lapped out of synchronisation so as to define a cavity in which the post members are concealed.
9. 18. A method of installing a fencing system according to claim 16 or claim 17, including the step of clipping the panels to the adjacent posts and/or to each other to hold in position prior to the capping rail being installed. 1 19. A fencing system including: one or more generally corrugated fence panels each having a top edge; one or more posts each having a top end and being configured to be disposed on e¢3 installation adjacent fence panel or panels with each top end generally level with said fence panel top edge; and 0a generally channel-shaped capping rail configured to sit over both said fence 00 0panel top edge and said top end of said adjacent posts. A fencing system according to claim 19, wherein the posts and capping rails are formed from a metal material.
10. 21. A fencing system according to claim 19 or 20, wherein the fence panels are made from corrugated fibre cement sheets.
11. 22. A fencing system according to any one of claims 19 to 21, wherein adjacent corrugated panel members are partially lapped synchronously so as to achieve a substantially continuous panel length and the posts are disposed so as to be visible from one side only.
12. 23. A fencing system according to any one of claims 19 to 21, wherein adjacent corrugated panel members are partially lapped out of synchronisation, so as to define a cavity between the overlapping portions of adjacent panel members in which the post members can be concealed.
13. 24. A fencing system according to any one of claims 19 to 23, wherein a portion of the lower edge of the fence panel may be buried into the ground to provide additional support to that provided by the posts. A fencing system according to any one of claims 19 to 23, including a generally channel-shaped bottom rail configured to allow the posts to extend therethrough.
14. 26. A method of installing a fencing system made in accordance with claim 19, said method comprising the steps of -16- I setting appropriately spaced posts into the ground; Sdisposing one or more generally corrugated fence panels closely adjacent said spaced posts to bridge the span therebetween; attaching a generally channel-shaped capping rail so as to sit over both the top edge of said fence panels and aligned top ends of said adjacent posts; and INO 0securing said capping rail to said posts. 00 S27. A method of installing fencing system according to claim 26, wherein the panels Smay also be supported and held in alignment at their lower edge by means of one or more clips set into the ground.
15. 28. A method of installing a fencing system according to claim 26 or 27, including the step of arranging the panels so they are partially lapped out of synchronisation so as to define a cavity in which the post members are concealed. DATED this 30 t h Day of September, 2005 Shelston IP Attorneys for: JAMES HARDIE INTERNATIONAL FINANCE B.V.