GB2582618A

GB2582618A - A decking assembly and decking support assembly

Info

Publication number: GB2582618A
Application number: GB1904312.4A
Authority: GB
Inventors: White Anton; White Caleb
Original assignee: Ryno Ltd
Current assignee: Ryno Ltd
Priority date: 2019-03-28
Filing date: 2019-03-28
Publication date: 2020-09-30
Anticipated expiration: 2039-03-28
Also published as: GB2582838A; GB201910218D0; GB201904312D0; GB201909689D0; GB2582618B; GB2582839A

Abstract

The decking support assembly 100 comprises a joist 104 with a retention member receiving channel and a retention member 136 defining a threaded bore for receiving a threaded support shaft, wherein the retention member is slidable in the channel and the movement of said retention member is constrained in a rotational degree of freedom. The retention member may be a nut. The joist may further define shaft-receiving and fastener-receiving channels. The support assembly may further comprise a pedestal comprising a support foot 106 and threaded support shaft 108, wherein the threaded support shaft engages with the threaded bore of the retention member. A portion of the support shaft may be receivable in the shaft-receiving channel. Also claimed is a decking assembly comprising two panels and a spacer; a decking support assembly comprising a joist with a slidable support bracket; and a decking assembly comprising a decking panel with a foot and an overhanging portion.

Description

A decking assembly and decking support assembly

Technical Field

This invention relates to a decking assembly and support assembly for decking, paving, or other, primarily exterior, flooring.

More particularly, the invention relates to an aluminium substructure for aluminium exterior decking.

Background of the Invention

Exterior ground surfaces, such as decking or paving, are popular in a variety of different settings. In general, a plurality of support joists, which may or may not be arranged in a lattice, are secured to pedestals, cradles, i-beams or other structures which directly contact the ground surface.

European fire classifications for building materials include Al and A2, which define non-combustible, plastic-free materials. Fire regulations for specific structures, such as prefabricated structures require that materials of these classes are used.

Decking and other exterior flooring systems for balconies and terraces are sometimes prefabricated for many reasons, e.g. cost, efficiency and speed of installation. However, there has been little development in the industry regarding such structures that adhere to the specific fire regulations mentioned above.

Known pedestals tend to be "clip-in" type, where the joist clips into a resilient plastic formation on a platform. Aside from the inherent unsuitability of plastics for fire resistant use, this type of system can be difficult to position accurately.

When implementing a metal decking system, it is desirable to try and eliminate any "rattling" in use.

Further, it is also desirable to prevent any loosening of fasteners.

Also, it is desirable to provide a system where individual deck panels can be removed and replaced in case of e.g. damage.

Finally, vertical adjustability for any such decking panels is desirable.

The present application aims to address some of the above-mentioned issues.

Summary of the Invention

According to a first aspect of the invention, there is provided a decking support assembly comprising: a joist having a cross-section profile, the cross-section profile defining a retention member receiving channel; a retention member received within the retention member receiving channel, the retention member defining a threaded bore for receiving a threaded support shaft, the threaded bore defining a support axis; in which the retention member is slideable in the channel along the length of the joist, and in which movement of the retention member is constrained in a rotational degree of freedom about the support axis.

Advantageously, this arrangement permits both horizontal (along the joist) and vertical adjustment of an associated pedestal or other support structure having a shaft. It is also particularly well-suited to construction from a metal material such as aluminium, which provides advantages in terms of fire and heat resistance.

Preferably the retention member is a nut.

Preferably wherein the retention member receiving channel has a width greater than the width across flats of the nut, but less than the width across corners of the nut. Thus the nut can slide, but cannot rotate in the channel.

Preferably the cross-section profile of the joist defines a pair of opposed walls extending from the retention member receiving channel, the pair of opposed walls defining a shaft-receiving channel.

Preferably wherein the cross-section profile defines an interior wall at the end of the shaft-receiving channel opposite the retention member receiving channel.

Preferably wherein the cross-section profile defines a fastener-receiving channel on an opposite side of the interior wall to the retention member receiving channel.

The invention also provides a decking support assembly according to the first aspect, comprising: a pedestal comprising a support foot and a threaded support shaft; wherein the threaded support shaft is engaged with the threaded bore of the retention member.

Preferably a portion of the support shaft is receivable in the shaft-receiving channel.

Preferably the shaft-receiving channel is smaller in width than the retention member receiving channel so as to provide lateral support for the threaded shaft.

Preferably the shaft-receiving channel is between 1mm and 5mm wider than the threaded shaft outer diameter.

Preferably there is provided: a locking member having a threaded bore; wherein the locking member is engaged with the threaded shaft exterior to the joist such that it can be tightened against an outer surface of the joist in use.

According to a second aspect of the invention there is provided a decking assembly comprising: a first decking panel having a first decking panel profile in cross-section; a second decking panel having a second decking panel profile in cross-section; a spacer positioned between the first and second decking panels, the spacer providing a predetermined gap between the decking panels when both decking panels abut the spacer, wherein the spacer defines an opening to receiving a fastener to secure the decking panels to an underlying structure.

Advantageously, the spacer provides a dual function of both spacing the panels apart, and also clamping them to the underlying structure.

Preferably the first and second decking panel profiles are identical.

Preferably wherein the first and second decking panel profiles each define a shoulder on which the spacer rests in use.

Preferably a downwardly depending toe is provided on each shoulder, the toe configured to contact an underlying surface to react a securing force of the fastener.

Preferably the toe is configured to contact underlying surface directly vertically below the fastener in use.

Preferably each decking panel comprises a deck portion, and wherein the predetermined gap between the deck portions is vertically above the opening in use so as to admit access of a tool to adjust the fastener.

According to a third aspect there is provided a decking support assembly comprising: a joist having an opposed pair of sidewalls; a support bracket comprising a base portion, two spaced-apart upright portions and a mounting portion for attaching the support bracket to an underlying structure; wherein the joist is received between the upright portions and is vertically slidable therein so as to be attachable to the support bracket across a range of vertical positions.

Advantageously, this permits variable vertical positioning of the joist to suit the application.

Preferably the upright portions each define at least one outwardly facing vertical channel for receiving a fastener.

Preferably there is provided a first fastener attaching one of the upright portions to one sidewall, and a second fastener attaching the other of the upright portions to the other sidewall.

According to a fourth aspect there is provided a decking assembly comprising: a first decking panel having a first decking panel profile in cross-section, the first decking panel profile having a foot and an overhanging portion; an edge profile component comprising a foot and a fixing portion; wherein the overhanging portion of the first decking panel profile is assembled with the fixing portion of the edge profile component such that vertical loads on the overhanging portion are reacted through the edge profile component to the foot thereof.

The fourth aspect is configured for use with the first and / or second aspects.

Preferably the fixing portion of the edge profile component comprises a formation receiving the overhanging portion of the first decking panel profile.

Preferably the edge profile component comprises a wall, wherein the foot and the fixing portion extend from the wall, and wherein the foot extends further from the wall than the fixing portion to facilitate fixing of the foot to an underlying structure.

Brief description of the drawings

Figure 1 is an end view of a first support apparatus according to the present invention; Figure 2 is a perspective view of the support apparatus of Figure 1; Figure 3 is a perspective view of a first decking subassembly in accordance with the present invention; Figure 4 is an end view of part of the subassembly of Figure 3; Figure 5 is a detail view of a part of the subassembly of Figure 3; Figure 6 is a detail end view of a part of the subassembly of Figure 3; Figure 7 is a perspective view of a second support apparatus in accordance with the invention in a first configuration; Figure 8 is a perspective view of the support apparatus of Figure 7 in a second configuration; Figure 9 is a perspective end view of a part of the support apparatus of Figure 1, having an end profile in accordance with the invention; and, Figure 10 is an end view of the assembly of Figure 9.

Detailed description

First support assembly Referring to Figure la, a decking support apparatus 100 comprises a pedestal 102 and a joist 104.

The pedestal 102 comprises a foot 106 and a shaft 108 extending therefrom. The foot is a flat, plate-like component having a generally shape about a primary, vertical support axis Z. The shaft 108 extends from the geometric centre of the foot 106 along the axis Z to a free end 110. The shaft 108 is threaded along its length in this embodiment (although it will be understood that a partially threaded shaft is also possible). The shaft 108 is welded to the foot 106 in this embodiment, although in another embodiment there may be a mechanical attachment such as a boss with a female thread on the foot 106 which is engaged by a male threaded formation on the end of the shaft 108.

The joist 104 is an elongate, prismatic component which is shown from the end in Figure 1 (its longitudinal direction extends into the page). The longitudinal axis of the joist 104 is identified as X in Figure 2. The joist 104 has a constant cross-sectional profile visible in Figure 1. The profile comprises a generally rectangular outer surface defined by two parallel sidewalls 112, 114, a top wall 116 and a bottom wall 118 parallel to the top wall.

The joist 104 defines two interior walls 120, 122, parallel to the sidewalls 112, 114 and extending between the top and bottom walls 116, 118. The interior walls 120, 122 define a channel 124 therebetween, extending along the joist 104.

An interior sub-wall 126 is provided being parallel to the top and bottom walls 116, 118 and extending between the interior walls 120, 122 proximate the top wall 116. The interior sub-wall 126 splits the channel 124 into a shaft receiving portion 128 and a fastener receiving portion 130.

Both interior walls 120, 122 define opposing recesses 121, 123 therein adjacent the bottom wall 118.

The recesses provide a retaining member receiving channel portion 125 which is wider than the shaft receiving channel portion 128.

The top wall 116 defines a longitudinally extending recess 132 at its centre, which extends between the interior walls 120, 122.

The bottom wall 118 defines an elongate slot 134 in communication with the channel 124, and more specifically the retaining member receiving channel portion 125. The slot 134 runs in the longitudinal direction of the joist 104 and is the same width as the shaft receiving portion 128 (i.e. narrower than the retaining member receiving channel portion 125).

A first retaining member 136 is provided disposed within the retaining member receiving channel portion 125. In this embodiment, the retaining member 136 is an M12 nut having a plurality of flats 138 and an internal threaded bore 140 as is known in the art. The retaining member 136 is rotationally captured in the channel portion 125. This is achieved by selection of the distance between the opposing recesses 121, 123 to be slightly greater than the width across flats on the nut 136, but less than the width across corners. This prevents rotation of the nut 136 but permits sliding movement along the length of the joist 104. It will be further noted that the height of the channel portion is approximately the same as (or slightly greater than) the height / thickness of the nut preventing movement in a vertical sense (i.e. along the axis of Figure 1). In summary, the retaining member is constrained from movement in all degrees of freedom with the exception of the longitudinal direction of the joist 104.

The external thread of the pedestal shaft 108 is engaged with the internal thread of the retaining member 136 such that it can be rotated to adjust the distance D1 between the base of the foot 106 and the top of the joist 104. Once rotated into position, the pedestal 102 can transfer vertical loads to a surface 10.

Referring to Figure 2, a second retaining member 142 is provided. The second retaining member 142 is also an M12 nut in this embodiment and is engaged with the thread of the pedestal shaft 108. To prevent any rotation and associated axial movement of the pedestal 102 relative to the joist 104 due to movement or vibration, the second retaining member 142 is tightened to clamp the bottom wall 118 of the joist 104 between it and the first retaining member 136. The friction created by tightening resists rotational movement of the pedestal 102 relative to the joist 104. It also inhibits further linear movement along the joist 104.

In use, the pedestal 102 can be engaged with the joist 104 via the retaining member 136. It can be positioned by sliding the pedestal along the length of the joist 104 and rotating the pedestal 102 to select the appropriate distance Dl. Once the position and height are determined, the second retaining member 142 (which is pre-threaded onto the pedestal-note that this is not shown in Figure 1) is tightened against the underside of the joist 104 to secure the pedestal in place.

It will be noted that the second retaining member 142 is optional.

Referring to Figure 2, a decking panel 144 is installed on the joist 104. The decking panel 144 may be according to either of the decking subassemblies described below or may be conventional decking panel.

First decking subassembly Referring to Figures 3 to 6 a decking subassembly 200 according to the invention is shown. The subassembly may be used with either of the support assemblies described herein.

The decking subassembly 200 comprises a plurality of decking panels 202. Two such panels are identified as 202a and 202b in Figures 3 and 4. The panels are supported on the joist 104 per the first support subassembly 100. The panels 202 run perpendicular to the joist 104.

Each panel 202 is constructed from extruded aluminium and is prismatic in shape having a longitudinal axis Y. The cross-sectional profile of the panel 202 is shown in Figure 4. Each panel has a flat, substantially planar deck 204. The deck 204 has a plurality of longitudinally extending grooves 206 defined therein to enhance grip and drainage.

The panel profile defines four legs 208, 210, 212, 214 extending downwardly from the deck 204. Legs 208, 214 are defines at either end of the profile. Legs 210, 212 are defined between the legs 208, 214.

The legs 208, 214 are mirror images of each other, and at the free end (opposite the deck 204) define an inwardly projecting first foot portion 216, 218 respectively. Each foot portion 216, 218 is a flange extending from the free end of the respective leg. Extending outwardly from each leg 208, 214, partway up the leg, there is provided a respective flange 220, 222 forming a shoulder, which terminates in a downwardly depending respective toe portion 224,226.

Each of the middle legs 210, 212 define a first respective foot portion 228, 230 and second respective foot portion 232, 234 forming T-shaped legs.

At each end of the deck, a downwardly depending end flange 236, 238 is provided. The end flanges 236, 238 are aligned with (i.e. vertically above) the toe portions 224, 226.

The decking subassembly 200 further comprises a spacer 240 shown in Figure 4. The spacer 240 is substantially flat comprising a peripheral edge 242 and a through-bore 244. In this embodiment, the spacer 240 is annular in shape, having a circular peripheral edge and concentric through bore. The spacer has an edge-to-edge width (i.e. diameter) W. In use, the panels 202a, 202b are positioned on top of the joist 104 and perpendicular thereto.

Between the panels 202a, 202b a plurality of spacers 240 are provided, which rest on the shoulders formed by the flanges 220, 222. The panels 202a, 202b can be moved together such that each panel leg 208, 214 abuts the spacer 240. The spacer is dimensioned such that W is more than twice the horizontal width of the flanges 220, 222. As such, an inter-panel gap 246 of width G is provided.

This allows a fastener in the form of a self-tapping screw 248 to be inserted from above the panels 202a, 202b through the gap 246, through the bore 244 and into the top surface of the joist 104. A tool 250 can be inserted through the gap 246. If the joist 104 is used, the fastener engages the top wall 116 and penetrates therethrough into the fastener receiving portion 130. Further tightening provides a downward clamping force on the spacer 240 which in turn secures the panels 202a, 202b to the joist 104.

This arrangement provides consistent spacing between adjacent panels 202 which adds to the aesthetic appeal of the decking system. Further, the predetermined gaps between the panels provide access for tools to be inserted meaning that individual panels can easily be replaced if required.

This arrangement provides consistent spacing between adjacent panels 302 which adds to the aesthetic appeal of the decking system. Further, the predetermined gaps between the panels provide access for tools to be inserted meaning that individual panels can easily be replaced if required.

Second support assembly Referring to Figures 11 and 12, a support assembly 400 according to the present invention is shown. The support assembly 400 comprises a support bracket 402 and a joist 404. The support bracket 402 is attached to an I-beam 12 or similar structural element.

The support bracket 402 comprises a base portion 406 which is flat and generally rectangular. The base portion 406 defines to end regions 408, 410 and a central region 412. The end regions 408, 410 each have a respective opening 414, 416 defined therein.

The support bracket further comprises two upright portions 418, 420 each of which project normal to the base portion 406. The upright portions 418, 420 are spaced apart and parallel, each being generally flat and rectangular. The support bracket 402 therefore defines an inverted n (pi) shape. Each upright portion defines two linear channels 422, 444 (upright portion 418) 446, 448 (upright portion 420) on its outwardly facing surface extending from the base portion to the respective free end. The upright portions 418, 420 are a distance B apart.

The joist 404 is an elongate, prismatic component. The longitudinal axis of the joist 404 is identified as X in Figure 12. The joist 404 has a constant cross-sectional profile. The profile comprises a generally rectangular outer surface defined by two parallel sidewalls 450, 452, a top wall 454 and a bottom wall 456 parallel to the top wall.

The joist 404 defines two interior walls 458, 460, each angled at C degrees to the closest sidewall and thus forming an inverted "V" shape extending between the top and bottom walls 454, 456.

The top wall 454 defines a longitudinally extending channel or recess 462 at its centre, on the exterior of the profile, and parallel to the axis X. In use, the support bracket 402 is secured to the I-beam 12 using mechanical fasteners (e.g. a nut and bolt arrangement). Once installed, the joist 404 can be lowered between the upright portions 418, 420. It will be noted that the width of the joist 404 is only slightly less than the dimension B. When the desired vertical position of the joist 404 is reached, fasteners in the form of screws 464 are used to screw through the uprights 418, 420 at the channels 422, 444, 446, 448 in order to penetrate the side walls 450, 452.

It will be noted that the joist can be secured in any vertical position in which the uprights 418, 420 and side walls 450, 452 overlap.

The second support assembly can be used with either of the decking subassemblies defined herein. End profile Referring to Figures 9 and 10, the decking support apparatus 100 is shown again, with the pedestal 102 and joist 104. The first decking subassembly 200 is mounted onto the joist 104. A panel 202c at the end of the decking subassembly is shown mounted to the joist 104.

The end panel 202c is constructed from extruded aluminium per the panels 202a, b. The cross-sectional profile of the panel 202 is shown in Figure 10. The panel has a flat, substantially planar deck 204. The deck 204 has a plurality of longitudinally extending grooves 206 defined therein to enhance grip and drainage.

The panel profile defines a leg 252 extending downwardly from the deck 204. The leg 252 is at the outermost edge of the panel 202c and the decking structure. The leg is positioned inboard of the edge of the deck 204, and defines a first respective foot portion 254 and second respective foot portion 256 forming an inverted T-shape.

Evidently a downward force F on the edge of the deck 204 would result a high bending stress where the deck edge is cantilevered from the leg 252. To alleviate this problem, an end profile component 258 is provided. The end profile component 258 is generally elongate and prismatic, comprising a wall 260 with a mounting portion 262 in the form of a flange disposed at a first, lower end, and a fixing portion 264 provide at a second, upper end. The fixing portion 264 comprises an upper flange 266 and a lower flange 268 defining a deck receiving channel 270 therebetween.

The mounting portion 262 and fixing portion 264 extend in the same direction from the wall 260, making the end profile component 258 U-shaped.

The mounting portion 262 extends further from the wall 260 than the fixing portion 264 such that a fastener 272 can be used to secure the end profile component 258 to the joist 104. The end panel 202c can be positioned on top of the joist 104 such that the end of the deck 204 can be inserted into the deck receiving channel 270 of the fixing portion 264. The panel 202c is then fixed in the manner described above.

Not only does this provide horizontal stability preventing the panel 202c from moving off the joist), the force F can be reacted vertically through the wall 260 into the joist 104, reducing or eliminating the aforementioned bending stress and reducing potential damage to the deck 204.

Claims

Claims 1. A decking support assembly comprising: a joist having a cross-section profile, the cross-section profile defining a retention member receiving channel; a retention member received within the retention member receiving channel, the retention member defining a threaded bore for receiving a threaded support shaft, the threaded bore defining a support axis; in which the retention member is slideable in the channel along the length of the joist, and in which movement of the retention member is constrained in a rotational degree of freedom about the support axis.
2. A decking support assembly according to claim 1, wherein the retention member is a nut.
3. A decking support assembly according to claim 2, wherein the retention member receiving channel has a width greater than the width across flats of the nut, but less than the width across corners of the nut.
4. A decking support assembly according to any preceding claim, wherein the cross-section profile of the joist defines a pair of opposed walls extending from the retention member receiving channel, the pair of opposed walls defining a shaft-receiving channel.
S. A decking support assembly according to claim 4, wherein the cross-section profile defines an interior wall at the end of the shaft-receiving channel opposite the retention member receiving channel.
6. A decking support assembly according to claim 5, wherein the cross-section profile defines a fastener-receiving channel on an opposite side of the interior wall to the retention member receiving channel.
7. A decking support assembly according to any preceding claim, comprising: a pedestal comprising a support foot and a threaded support shaft; wherein the threaded support shaft is engaged with the threaded bore of the retention member.
8. A decking support assembly according to claim 7 when dependent upon any of claims 4 to 6, wherein a portion of the support shaft is receivable in the shaft-receiving channel.
9. A decking support assembly according to claim 8, wherein the shaft-receiving channel is smaller in width than the retention member receiving channel so as to provide lateral support for the threaded shaft.
10. A decking support assembly according to claim 9, wherein the shaft-receiving channel is between 1mm and 5mm wider than the threaded shaft outer diameter.
11. A decking support assembly according to any of claims 7 to 10, comprising: a locking member having a threaded bore; wherein the locking member is engaged with the threaded shaft exterior to the joist such that it can be tightened against an outer surface of the joist in use.
12. A decking assembly comprising: a first decking panel having a first decking panel profile in cross-section; a second decking panel having a second decking panel profile in cross-section; a spacer positioned between the first and second decking panels, the spacer providing a predetermined gap between the decking panels when both decking panels abut the spacer, wherein the spacer defines an opening to receiving a fastener to secure the decking panels to an underlying structure.
13. A decking assembly according to claim 12, wherein the first and second decking panel profiles are identical.
14. A decking assembly according to claim 12 or 13, wherein the first and second decking panel profiles each define a shoulder on which the spacer rests in use.
15. A decking assembly according to claim 14, wherein a downwardly depending toe is provided on each shoulder, the toe configured to contact an underlying surface to react a securing force of the fastener.
16. A decking assembly according to claim 15, wherein the toe is configured to contact underlying surface directly vertically below the fastener in use.
17. A decking assembly according to any of claims 12 to 16, wherein each decking panel comprises a deck portion, and wherein the predetermined gap between the deck portions is vertically above the opening in use so as to admit access of a tool to adjust the fastener.
18. A decking assembly according to any of claims 12 to 17, wherein the spacer has a circular outer periphery.
19. A decking support assembly comprising: a joist having an opposed pair of sidewalls; a support bracket comprising a base portion, two spaced-apart upright portions and a mounting portion for attaching the support bracket to an underlying structure; wherein the joist is received between the upright portions and is vertically slidable therein so as to be attachable to the support bracket across a range of vertical positions.
20. A decking support assembly according to claim 19, wherein the upright portions each define at least one outwardly facing vertical channel for receiving a fastener.
21. A decking support assembly according to claim 19 or 20, comprising a first fastener attaching one of the upright portions to one sidewall, and a second fastener attaching the other of the upright portions to the other sidewall.
22. A decking assembly comprising: a first decking panel having a first decking panel profile in cross-section, the first decking panel profile having a foot and an overhanging portion; an edge profile component comprising a foot and a fixing portion; wherein the overhanging portion of the first decking panel profile is assembled with the fixing portion of the edge profile component such that vertical loads on the overhanging portion are reacted through the edge profile component to the foot thereof.
23. A decking assembly according to 22, wherein the fixing portion of the edge profile component comprises a formation receiving the overhanging portion of the first decking panel profile.
24. A decking assembly according to 22 or 23, wherein the edge profile component comprises a wall, wherein the foot and the fixing portion extend from the wall, and wherein the foot extends further from the wall than the fixing portion to facilitate fixing of the foot to an underlying structure.