GB2310223A - Constructing an area of hard standing; piles and slabs therefor - Google Patents

Description

Title: Components for and method of construction of an area of hard standing.

Description of Invention The invention relates to the components for and the method of construction of an area of hard standing, and in particular although not exclusively, for an area of hard standing such as a domestic garden patios and pathways.

Traditionally, areas of hard standing, such as domestic garden patios, comprise an area of paving. The construction of such patios is generally undertaken as follows.

Assume that an area of 20 metres squared is being constructed in a typical garden environment onto a lawned or flowerbed area. First, turf and soil is removed to a depth of at least 150 mm, resulting in the need to dispose of 4.8 tonnes of material. Then, a sub-base of stone chippings is brought to the site, spread in the excavated area and compacted to a depth of 85 mm. This uses approximately 2.9 tonnes of stone. Next, sand and cement is imported to the site, mixed together with water added to create mortar, and spread appropriately on the stone sub-base. This involves a further 0.6 tonnes material. Paving slabs are then positioned on the mortar, and comprise a further 2 tonnes of material.

Finally, the joints between the paving slabs are grouted, or similar. The total process involves the transport of approximately 10.3 tonnes of material to or from the site, with not only the cost of the transport, but also the cost of disposing of the waste removed from the site. Also, this process involves considerable labour, over a relatively lengthy period of time, involving further costs.

Once such an area of hard standing has been completed, it also suffers from a number of disadvantages. Principally, there are a large number of joints between the paving slabs used as the upper surface. If settlement occurs, these deflect, resulting in an uneven surface. In addition, there is considerable maintenance required to prevent weed growth through the joints.

It is an object of the invention to provide alternative components for and a method of constructing such an area of hard standing.

According to a first aspect of the invention there is provided a kit of components for construction of an area of hard standing comprising a plurality of piles and one or more decking slabs.

Preferably the upper surface of the piles comprise formations which co-operate with formations on the under surface of the decking slab(s).

Formations on the heads of the piles may comprise indentations in the form of a cross, whilst the formations on the undersides of the slabs may comprise ribs.

Preferably, the upper surface of the decking slab(s) is patterned to have the effect of an area of conventional paving, comprising areas mimicking paving slabs, with portions therebetween mimicking grouted joints.

The ribs provided on the undersurface of the decking slabs may be located at the same positions as the grouted joints are mimicked on the upper surface, and around the periphery of the slab.

Preferably the kit of components further comprises a membrane, for suppression of plant growth, and on which the necessary pile positions are premarked.

The kit of components may further comprise packing elements adapted to engage in formations on the head of piles, and to compensate for inaccurate pile positioning.

The kit may also comprise jointing means which co-operate with ribs at the periphery of abutting slabs to join the slabs together.

The kit may also comprise sub-frame elements, which co-operate with formations on the upper surface of the piles at both ends to form a surface providing additional support to the decking slabs.

Preferably the decking slab(s) are manufactured of glass fibre reinforced concrete. This provides the advantage that it is strong and relatively light. This enables the decking slabs to be manufactured thinner than conventional paving reducing the weight of materials required still further, and enabling the slabs to be manufactured larger whilst still being handleable by one or two people.

According to a second aspect of the invention, there is provided a method of constructing an area of hard standing comprising driving a plurality of piles into the ground and positioning one or more decking slabs on the upper surfaces of the piles.

Preferably, a membrane is laid on the ground prior to driving in of the piles, the membrane having marked on it the required pile positions.

Preferably, a bedding material is laid on the upper surfaces of the piles before the decking slabs are positioned. Packing elements may also be placed on the upper surface of one or more piles, prior to the positioning of the decking slabs, in order to level the supports for the slabs.

The method may further comprise the step of attaching the slabs together where they abut by use of jointing means.

An additional step, prior to the positioning of the slabs, may be the attachment between piles of sub-frame elements to provide additional support to the decking slabs.

According to a third aspect of the invention, there is provided an area of hard standing constructed using a kit of components according to the first aspect of the invention and/or according to the method of the second aspect of the invention.

One embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: FIGURE 1 shows a plan view of a typical 4 metre by 5 metre area of hard standing according to the present invention; FIGURE 2 shows a cross section through part of the area of hard standing of Figure 1; FIGURE 3 shows a plan view of a pre-marked membrane showing the pile positions; FIGURE 4 shows the marking of the pile positions through the membrane on (a) uneven ground, and (b) flat ground; FIGURE 5 shows the installation of a pile in relatively soft ground; FIGURE 6 shows the installation of a pile in relatively hard ground; FIGURE 7 shows one form of pile for use in the invention; FIGURE 8 shows an alternative form of pile for use in the invention; FIGURE 9 shows two forms of packing elements for use in the invention; FIGURE 10 shows a clip joining decking slabs together in the invention; FIGURE 11 shows detail at the edge of the area of hard standing according to the invention, and, FIGURE 12 shows the use of a sub-frame in an area of hard standing according to the invention.

Referring first to Figures 1 and 2, an area of hard standing 10 comprises four decking slabs 11. Each decking slab 11 has an upper decorative surface 12 giving the effect of an area of traditional paving. The upper decorative surface 12 therefore comprises areas mimicking paving slabs 12 and areas mimicking grout joints 12b. Each decking slab 11 also comprises an under surface 13 as will be discussed later. The four decking slabs 11 are constructed such that they tessellate to provide the required area of hard standing, in this case a rectangle 4 metres by 5 metres.

The under surface 13 of each decking slab 11 bears formations in the form of ribs 14, which in this case coincide with the provision on the upper decorative surface 12 of the areas representing grouted joints 12b. In addition, around the periphery of the decking slabs 11, where they do not adjoint another decking slab 11, there is provided a rib in the form of downturned edge 15 giving the impression that the decking slab 11 is of greater thickness than it is in reality.

The area of hard standing 10 also comprises a plurality of piles 16 which are driven into the ground and on which the decking slabs 11 are supported. The piles 16 are arranged such that the ribs 14, and downturned edges 15, rest on the upper surfaces of the piles 16. In general, as shown in Figure 2, a bedding material 17, such as grout or glue is provided on the upper surface of the piles 16 where the ribs 14 and downturned edges 15 contact them. The bedding material 17 provides scope for final levelling of the decking slabs 11 during construction of the area 10, and assists in retention of the slabs 11 in their correct locations.

The area of hard standing 10 further comprises a membrane 18 which is laid on the prepared ground prior to construction of the area, and serves a primary purpose of inhibiting weed growth. The membrane 18 also provides a second purpose, in that it is pre-marked with the appropriate positions of the piles as discussed below.

Referring now also to the remaining figures, the method of construction of the area of hard standing 10 will be described. First, the site is prepared. This may involve the removal of turf although this is not strictly necessary. However, ideally the ground is levelled to a tolerance of 150 mm. The membrane 18 is then spread over the desired position of the area of hard standing as shown in Figure 3. If the ground is uneven, the membrane 18 is pulled taught over clearance pegs 19 as shown in Figure 4a. As can be seen from Figure 3, the membrane 18 is pre-marked with the required positions of the piles 16.

Preferably, the pre-marked positions comprise holes 20 made in the membrane 18. The required pile positions may then be marked, using for example spray marker paint, as shown in Figures 4a and 4b, through the holes 20. The membrane 18 is then allowed to fall to the natural ground profile.

Next, the piles are positioned. Appropriate piles are chosen for the type of ground, only short piles being required for a hard sub-base whilst a softer sub-base will require piles of greater diameter and/or length. Where the ground is relatively soft, the piles may simply be driven in over the pre-marked spot using a support dolly 21, driver 22, and an appropriate tool 23, as shown in Figure 5.

The tool may be, a hand tool such as a sledgehammer or a pneumatic implement.

For harder ground, for example old concrete or tarmac, holes must be pre-drilled as shown in Figure 6g. The piles 16 may then be driven in as previously described.

The piles are now ready for the laying of the decking slabs 11. Ideally, the upper surfaces of all the piles 16 will lie in the desired plane, and small amounts of bedding material may simply be placed on the upper surfaces of the piles 16 and the decking slabs 11 laid thereon. However, in general, there will be inaccuracies in the positioning of the piles 16. These may be due to inclusions such as rocks in the ground which have caused deflection of the piles during their insertion. Therefore, tolerance in the positioning of the slabs 11 is required and means are provided to make the necessary adjustment. For small inaccuracies, larger quantities of bedding material 17 may be sufficient to achieve levelling.

Preferably, the upper surface of each pile 16 bears a formation 16a with which the ribs 14 on the lower surfaces of the slabs 11 co-operate, with a relatively large tolerance. The formation 16a will in general comprise a cross shaped indentation, thus allowing for use of the piles at points where the ribs 14 cross. When such piles 16 are used, the bedding material 17 is placed within the formation 16a.

Where inaccuracies in the pile insertion are greater, packing elements 24 may be required, as shown in Figure 9. The packing elements 24 are bedded on bedding material 17 on the upper surface of the pile 16 with additional bedding material placed on the upper surface of the packing element 24 on which to locate the rib 14. The packing elements 24 may themselves comprise ribs on their lower surface or may be smooth. They may also comprise formations on their upper surface as for the upper surfaces of the piles 16. The use of packing elements 24 may be used to compensate for piles which have been driven into the ground at an angle and on which the formations 16a are left out of alignment with the appropriate ribs 14.

Where two decking slabs 11 abut each other, each slab 11 comprises a rib in the form of a downturned and out-turned edge 25. The edges 25 are held together by a jointing means in the form of a clip 26, under the slabs 11, as shown in Figure 10. The joint is then disguised by the insertion of grout 27 to match the areas 12b on the upper decorative surfaces of the slab 11. The whole upper surface of the area of hard standing 10 therefore has a uniform appearance.

Around the periphery of the area of hard standing 10, it is the downturned edges 15 which are supported on bedding material 17 on the upper surface of the piles 16. The ground surrounding the area of hard standing 10, may then butt up to the downturned edges 15 in order to completely obscure the piles 16.

The form of the piles 16 illustrated herein is by way of example only.

Any appropriate form of pile may be employed in accordance with the invention.

Likewise any appropriate form of decking slab may be employed. Hence, the cooperating formations 16a and 14,15,25 may take appropriate forms also, as may the packing elements 24 and jointing means 26.

The piles 16 may be constructed from any appropriate material, for example concrete, metals appropriately coated to prevent corrosion, or moulded plastic which may be recycled material. The decking slabs 11 are preferably produced from a material which is strong and relatively light and ideally are produced from glass fibre reinforced concrete. When produced from this material, significant reduction in material weight is achieved, reducing transport costs and enabling large slabs to be produced which may still be handled by one or two people. However, other materials may be used as required. If the material from which the decking slabs are constructed is not sufficiently strong, sub-frame elements 28 may be used as shown in Figure 12. Each end of an element 28 bears a formation adapted to co-operate with a formation on the upper surface of a pile 16, for attachment thereto.

Clearly, the number of decking slabs 11 incorporated in an area of hard standing 10 according to the invention will be determined by the area to be covered and what weights and sizes are manageable. Typically, a number of standard kits will be available providing different areas and shapes of hard standing 10 with different upper decorative surfaces.

The features disclosed in the foregoing description the following claims or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, or a class or group of substances or compositions, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

Claims (20)

1. A kit of components for construction of an area of hard standing comprising a plurality of piles and one or more decking slabs.

2. A kit according to claim 1 wherein the upper surface of the decking slab(s) is patterned to have the effect of an area of conventional paving, comprising areas mimicking paving slabs, with portions therebetween mimicking grouted joints.

3. A kit according to claim 1 or 2 wherein the upper surface of the piles comprise formations which co-operate with formations on the under surface of the decking slab(s).

4. A kit according to claim 3 wherein the formations on the upper surface of the piles comprise indentations in the forms of a cross, whilst the formations on the underside of the slab(s) comprise co-operating ribs.

5. A kit according to claim 4 as dependant from claim 2 wherein the ribs provided on the under surface of the decking slab(s) are located at the same positions as the grouted joints are mimicked on the upper surface, and around the periphery of the slab(s).

6. A kit according to any preceding claim wherein the kit further comprises a membrane, for suppression of plant growth, and on which the necessary pile positions are pre-marked.

7. A kit according to any preceding claim wherein it further comprises packing elements adapted to engage in formations on the upper surface of piles, and to compensate for inaccurate pile positioning.

8. A kit according to claim 5 or any claim dependant thereon, wherein it further comprises jointing means which co-operate with ribs at the periphery of abutting slabs to join the slabs together.

9. A kit according to any preceding claim wherein it further comprises sub-frame elements, which co-operate with formations on the upper surface of the piles at both ends to form a surface providing additional support to the decking slab(s).

10. A kit according to any preceding claim wherein the decking slab(s) are manufactured of glass fibre reinforced concrete.

11. A kit substantially as hereinbefore described with reference to the accompanying drawings.

12. A method of constructing an area of hard standing comprising driving a plurality of piles into the ground and positioning one or more decking slabs on the upper surfaces of the piles.

13. A method according to claim 12 wherein a membrane is laid on the ground prior to driving in of the piles, the membrane having marked on it the required pile positions.

14. A method according to claim 12 or 13 wherein a bedding material is laid on the upper surface of the piles before the decking slabs are positioned.

15. A method according to any one of claims 12 to 14 wherein packing elements are placed on the upper surface of one or more piles, prior to the positioning of the decking slabs, in order to level the supports for the slabs.

16. A method according to any one of claims 12 to 15 wherein the method further comprises the step of attaching the slabs together where they abut by means of jointing means.

17. A method according to any one of claims 12 to 16 wherein the method further comprises the step of, prior to the positioning of the slabs, the attachment between piles of sub-frame elements to provide additional support to the decking slabs.

18. A method of constructing an area of hard standing substantially as hereinbefore described with reference to the accompanying drawings.

19. An area of hard standing constructed using a kit of components according to any one of claims 1 to 11 and/or according to the method of any one of claims 12 to 18.

20. Any novel feature or novel combination of features as herein defined and/or shown in the accompanying drawings.