GB2386620A

GB2386620A - Modular decking system providing access for fixing

Info

Publication number: GB2386620A
Application number: GB0306062A
Authority: GB
Inventors: Brian Studholme
Original assignee: Jewson Ltd
Current assignee: Jewson Ltd
Priority date: 2002-03-18
Filing date: 2003-03-17
Publication date: 2003-09-24
Also published as: GB0206385D0; GB0306062D0

Abstract

A module (10) for a modular decking system that includes a support frame (20) constructed from a number of frame members (21, 22) and a decking surface (30) constructed from a number of decking members (31). The decking surface (30) includes a group of decking members (32) that are fixed (permanently) to the support frame (20) and a group of removable decking members (33). In this way it is possible to remove a decking member (33) and gain access to the support frame, thereby enabling adjacent modules to be adjoined together easily (from a position above the deck, rather than below).

Description

Modular lecl;in System The present invention relates to a modular decking

system which may be used to construct an area of decking.

Decking, usually made from wood, is often employed in gardens and other exterior locations to provide an aesthetically-pleasing and structurallystable area which is suitable for siting chairs, tables, barbeques, etc. or for providing a is alkvv-ay. Decking normally comprises strips or planks of wood which forte the walking surface and which are mounted 10 on a supporting framework of joists. The joists may be supported on a layer of concrete or on paving slabs to improve stability and prevent the structure becoming uneven over time.

The wood is normally treated if the decking is to be located outside.

The simplest type of decking system which exists in the art is one in which the decking 15 structure is constructed from individual planks of wood in situ. Such a system is relatively time-consuming during construction for obvious reasons, and is also not entirely suitable for the DIY market as the customer's carpentry skills might not be adequate to build such a structure from scratch.

20 In more recent times, another decking system has become available which comprises a plurality of;tiles" of pre-assembled decking squares. Each tile comprises strips of wood forming the decking surface pre- mounted onto a frame. In construction, the tiles are laid adjacent one another until the decking area is built up. By virtue of the fact that the tiles are simply laid adjacent one another, the resulting decking area has no structural integrity 25 and thus the tiles are prone to movement, creating an uneven and potentially dangerous decking area This type of decking is often laid down on top of an existing surface, such as . a patio for example, which has not been specifically prepared by levelling. etc., and therefore in such circumstances is even more susceptible to movement.

30 Thus, there is a need for a simple, easy to use decking system hich is straightforward to construct and which overcomes the above disadvantages with known construction systems.

-2 In accordance with a first aspect. the present invention provides a modular decking system for providing a decking surface each module comprising a support frame and a plurality of decking members attached lo the frame to form the decking surface, wherein the support frame comprises a plurality of frame members, and wherein the decking members comprise 5 a first group of members pennaulently attached to the support frame and a second group of members removably attached to the support frame such that, when removed, access to the support frame members is provided.

Thus, the present invention provides a modular decking system in which, during assembly 10 of the decking surface, the support frame can be accessed so as to facilitate attachment of adjacent modules to one another. Thus, the resultant decking surface will be maintained in a stable configuration and the modules will not tend to separate or move relative to one another over time.

15 The manner in which the attachment is effected is also straightforward, by simple removal of the appropriate decking member to obtain access to the support frame. The attachment of one support frame to another may typically be effected by clamping, nailing or screwing the adjacent frame members of adjacent modules together. Preferably, the attachment is achieved by means of bolts. The frame members may be pre-drilled with holes at spaced 20 intervals to accommodate such bolts or screws. In order that the support frame members of adjacent attached modules abut one another, it is preferable that the frame members form at least a portion of the periphery of the module. After attachment, the removed decking members are simply replaced in position.

25 By means of "permanent" attachment of the decking members to the support frame, it is meant that the attachment is such that it is not easy for the end user to separate the components. For example. methods of attachment such as gluing or nailing are considered to be "permanent' in this context. If it is not possible to separate the components without causing damage to one or both of the decking members and support frame members, then 30 this attachment is also considered to be permanent.

By contrast,;;removable7 is intended to mean that the decking member is configured to be removable from the support theme by the end user without causing damage to the decking members or frame. A removable' attachment would be provided be; means of screws or like fixings, for example, which may be easily undone and redone by the end user.

5 Preferably, the same means of attachment/fixings can be re-used when the decking member is reattached to the support frame.

Preferably, the support frame is rectangular or square in configuration and the support frame members preferably include four peripheral members which form the square or 10 rectangular periphery of the frame. Additional support frame members may be included to strengthen the frame, such as diagonal cross-bracing members or strengthening members which connect two opposing parallel peripheral members for example.

Brackets are preferably provided to connect the various support frame members together, 15 the brackets being secured to the support frame members by means of glue, nails, screws or the like. The brackets themselves are preferably formed from metal, such as steel for example. The peripheral members are preferably connected together at the corners of the support frame by means of comer brackets. These corner brackets may take a novel form which, as well as connecting members of the support frame together, provides a sleeve 20 suitable for retaining a newel post or a deck levelling leg, as will be explained below.

Thus, the corner brackets have a dual function. The sleeve preferably has a square or rectangular cross-section.

In a preferred fomm, the corner bracket comprises a right-angled plate having flanges 25 extending at right-angles from the outer edge of each face of the plate, away from the central angle, such that the bracket appears W-shaped when viewed in plan. The sleeve is thus formed when the corner bracket is mounted inside the comer fommed by the two peripheral support frame members, between the right-angled plate and the right-angle fowled by the two peripheral support frame members. Of course, it will be apparent that 30 the sleeve can be formed in other ways. For example, the comer bracket may comprise a square-section tube provided with a mounting flange at one or more edge thereof.

Preferably. the decking members are elongate and are arranged in parallel configuration when attached to the support frame. In preferred embodiments the second group of removably-attached decking members comprises the two outermost decking members of the parallel configuration. the remaining decking members in between being permanently 5 fixed. Thus. in the case where the support frame is rectangular or square, by removing only these two outermost members, it will be possible to access the two peripheral support frame members underneath as well as all four corner brackets. Thus. adjoining modules can be attached together (for example. by means of bolts through pre-drilled holes as previously discussed) and also deck-levelling legs can be inserted and/or adjusted in the 10 sleeves formed by the corner brackets.

It may be desirable in some instances to fit a handrail to the decking platform. In the present invention, this can be easily done by supplying a handrail ready-mounted on a section of decking (i.e. a decking member). To fit the handrail, all that is necessary is for 15 the appropriate removable decking member to be removed from the support frame and the new decking member plus handrail to be installed in its place. The same fixings (such as screws) and fixing locations as for the removable decking member are preferably used.

The handrail decking member (or decking rail) may also be pre-drilled \wth holes to accept the fixings.

This is a new- departure. and therefore in accordance with a second aspect, the present invention provides a modular decking system comprising: a decking module comprising a support frame and a plurality of decking members attached to the frame to forth the decking surface, one of the decking members being 25 removably attached to the support frame; and a handrail module comprising a handrail mounted on a decking rail, the decking rail having similar dimensions to the removable decking member such that the handrail module can be attached to the decking module in place of the removable decking member.

3 0 As will be understood. this aspect of the invention provides a straightforward modular decking system which can be easily supplemented to provide a handrail.

-5 If it is desired to pros ide greater rigidity to the handrail. newel posts may be provided at the ends of each handrail section which can extend from or through the decking member and below it to engage with the coiner sleeves provided by the corner brackets.

5 Embodiments of the invention will now be described by wax- of example only and with reference to the accompanying drawings, in which: Figs. 1 A and 1B show a square embodiment of a decking module in accordance with the invention, in perspective view and with the decking members spaced from the support 10 frame respectively; Figs. 2A and 2B show a rectangular embodiment of a decking module in accordance with it; the invention, also in perspective view and with the decking members spaced from the support frame respectively; Figs. 3A and 3B show in perspective view one embodiment for the corner bracket suitable for use in the decking module of the invention; Figs. 4A, 4B and 4C show in plan view alternative configurations for the corner bracket, 20 including the embodiment of Fig. 3; Fig. 5 shows a railing section suitable for attaching to the decking module of the present invention; and 25 Fig. 6 illustrates how the railing section of Fig. 5 may be attached to the decking module by means of newel posts.

With reference to Figs. 1 and 2, decking modules in accordance with the invention are shown generally as 10. The module of Figs. 1A and 1B is square. for example lm x lm.

30 The module of Figs. 2A and 2B is rectangular, for example lm x 2m.

-6 Each decking module 'I O comprises a support frame 20 and a pluralir of decking members shown collectively as 30. Support frame 20 comprises parallel opposing pairs ot' peripheral support members 21 and 22 to form the square or rectangular periphery- of the support frame, together with internal strengthening members 23. In the preferred embodiments, 5 strengthening members 23 orthogonally connect one support member lo the opposing parallel support member. as can be seen in the drawings.

In order to secure the peripheral support members together in a rightangle. comer brackets 40 are provided which are fastened to each support member by means of screws. nails, glue 10 or the like. Corner brackets 40 also function to retain decl; levelling legs, an example of which is shown as 60 in Figs. 1 B and 2B, or newel posts of a handrail ( discussed in more detail below). In Figs. lB and 2B. corner brackets 40 are generally P-shaped when viewed in plan, and provide a square-section sleeve into which may be inserted a square-section levelling leg or newel post. Various types of comer bracket 40 are discussed in more detail 15 below. The ends of each support member 21 and 22 are cut at a 45 degree angle so that they form a mitre joint when brought together.

Strengthening members 23 are secured to each peripheral support member 22 by means of simple right-angled brackets 24, which may also be secured by means of screws. nails, glue 20 or the like.

Decking section 30 comprises a plurality of elongate decking members 31. Each decking member 31 may be provided with a grooved upper surface so as to provide increased grip in use. The central section of decking members, shown as 32, are permanently'' attached 25 to the support frame by being nailed to support members 21 and to strengthening members 23. The two external decking members, shown as 33, are removably attached to the support frame 20. These members are attached to the support frame by means of screws at their 30 ends into support members 21 and along one edge into support member 22.

-7 Holes 26 are provided in support members 21 and 22 such that bolts may be inserted therethrough and through corresponding support members of adjacent modules such that the modules may be secured together to provide a stable decking area.

5 Fig. 3A shows one embodiment of corner bracket 40 in snore detail. This particular configuration comprises two plates 41 and 42 at right-angles to one another and two flanges 43 and 44 which extend from each plate 41 and 49 also at right-angles, but away from the central angle. so as to form a W-shaped plan. The plan vied; can be seen in Fig. 4A. Fixing holes 45 are also provided in the bracket 40 for attaching the bracket to the 10 frame support members and fixing holes 46 are provided for securing the levelling leg 60 or handrail newel post (not shown) in position as shown in Fig. 3B.

Fig. 3B shows bracket 40 in use, secured to support frame members 21 and 22, with coach screws 47 securing the levelling leg 60 to bracket 40.

Further possible configurations of corner bracket 40 are shown in plan view in Figs. 4B and 4C. Attachment locations are shown as dashed lines. Fig 4B shows a generally P shaped bracket (as discussed in relation to Figs. 1 and 2 above), having a square-section sleeve 48 and a single projecting flange 49. Fig. 4C shows a bracket having two flanges 5 20 which project from square-section sleeve 51.

Fig. 5 shows an embodiment of a railing section 70 which can be employed with the decking module of the present invention. Railing section 70 comprises a handrail 71 and a plurality of spindles 72. Spindles 72 are mounted on base rail 73.

Fig. 6 shows how railing section 70 is attached to decking module 10. First, one of the removable decking members 33 is removed from the support France to gain access to corner brackets 40. Two newel posts 74 are then inserted into the exposed corner brackets 40 and secured with coach screws. in a similar manner to the decking levelling legs discussed 30 above. Next, two cut-outs are made at each end of the removed decking member 33 so as to accommodate newel posts 74, and the member is reattached to the support frame.

Finally, railing section 70 is secured to the decking module between the two newel posts

-- (as shown in outline) b securin the base rail 73 to declin member 33 and handrail 71 to each newel post 74. Base rail 73 may be pre-drilled with holes to accept the securing fixings, such as screws

Claims

What we claim is:

A modular decking system for providing a decking surface, each module comprising a support frame and a plurality of decking members attached to the frame to form the decking surface, wherein the support frame comprises a plurality of frame members, and wherein the decking members comprise a first group of members permanently attached to the support frame and a second group of members removably attached to the support frame such that, when removed, access to the support framem-e-mbers-- isprovided.
2. The modular decking system of Claim 1 wherein the second group of decking members is a decking member at a peripheral edge of the decking surface.
3. The modular decking system of Claim 2 wherein the decking members are elongate and arranged in parallel configuration, the second group of decking members comprising the two outermost decking members of the parallel configuration.
4. The modular decking system of Claim 1, 2 or 3 wherein a module is attached to an adjacent module by clamping, nailing or screwing frame members of the separate modules placed adjacent thereto.
5. The modular decking system of Claim 1, 2 or 3 wherein frame members include holes therethrough to receive bolts to attach frame members of separate modules placed adjacent thereto.
6. The modular decking system of any one of the preceding claims wherein the frame members form at least a portion of the periphery of the module.

-10
7. The modular decking system of any one of the preceding claims wherein peripheral members of the support frame form a substantially square or rectangular configuration.
8. The modular decking system of Claim 7 wherein additional cross bracing members are provided between peripheral members of the support frame.
9. The modular decking system of any one of the preceding claims wherein brackets are provided to connect the frame members.
10. The modular decking system of Claim 9 wherein the brackets are secured to the frame members by glue, nails or screws.
The modular decking system of any one of the preceding claims wherein the support frame has attached thereto at least one receiving bracket for retaining e.g. a newel post or deck levelling leg.
12. The modular decking system of Claim 11 wherein the receiving bracket is located substantially at an inside corner of the support frame.
The modular decking system of Claim 11 or 12 wherein the receiving bracket forms a sleeve for receiving the newel post or levelling leg.
14. The modular decking system of any one of Claims 11 to 13 wherein the receiving bracket has a substantially P or W appearance in plan.
15. A modular decking system comprising a decking module comprising a support frame and a plurality of decking

-11 members atached to the frame to form the decking surface, one of the decking members being removably attached to the support frame; and a handrail module comprising a handrail mounted on a decking rail, the decking rail having a similar dimension to the removable decking member such that the handrail module can be attached to the decking module in place of the removable decking member.
16. A method of constructing a deck by adjoining a plurality of modules, each module having a support frame and a plurality of decking members attached thereto to form a deck surface, wherein the deck surface includes a first group of decking members to be permanently attached to the support frame and a second group of decking members removably attached to the support frame such that, when removed, access to the support frame (thereunder) is provided and hence the support frames of adjacent modules maybe connected by suitable fastening means.
17. A module for a modular deck comprising a support frame and a deck surface comprised of a first group of decking members permanently attached to the support frame and a second group of members removably attached to the support frame such that, when removed, access to the support frame is provided (therethrough the deck surface).
18. A modular decking system substantially as herein described with reference to the accompanying drawings.
19. A module for a modular deck substantially as herein described with reference to the accompanying drawings.