GB2595356A - Baluster arrangement - Google Patents

Abstract

The baluster arrangement, for a support surface, comprises an anchor insert-moulded into the support surface and a baluster removably connected to the anchor. Also claimed is a method of manufacturing a baluster arrangement comprising moulding a support surface using a hardenable material; placing an anchor into the material before hardening such that the anchor is pre-moulded into the surface; and attaching a baluster to the anchor. A plurality of spaced anchors may be provided and held in position by a template during hardening. The baluster may comprise an aperture to receive a fastener to connect to the anchor; a fixing plate within a cavity in the baluster, the fastener extending into the fixing plate; wherein the aperture in the baluster is wider in two dimensions than the fastener such that the fastener is loosely retained. The support surface may comprise a prefabricated stairway or staircase. The support surface may comprise a cementitious material.

Description

Baluster arrangement The present disclosure comprises a baluster arrangement, particularly to a baluster arrangement for enabling a pre-fabricated staircase, mezzanine, balcony or the like.

Introduction

During construction of a building, stairways may be installed using a pre-fabricated arrangement. In such an arrangement, an individual concrete flight of stairs (i.e. a plurality of steps) is cast and solidified offsite according to a predetermined design. The pre-fabricated flight of stairs is transported to the building site and lifted into place using a crane or the like. The individual flights are installed into the building to provide the completed stairway.

Handrails, barrier walls and/or other fixtures are then fitted to the stairway after the stairway is installed. The handrails are supported above the stairway by a plurality of balusters (i.e. vertical posts). The plurality of balusters with the handrail are collectively referred to as a "balustrade". The balusters may also conventionally support barrier walls or screens fixed thereto.

The inventor has found that the installation of balustrades onto preinstalled stairways poses numerous problems. The dimensional arrangements of the stairways and the balustrades are typically defined in the building's engineering

specification before construction.

During installation of the stairway, manufacturing tolerances or installation errors may result in the stairway departing from the engineering specification. Similarly, during manufacture of balustrade components, tolerances may result in the balustrade assembly departing slightly from the engineering specification, which can compound the issues with the stairway. Therefore, when the balustrade is installed, difficulties may arise. The balustrade may have to be manually adjusted on site, or be removed from the site to be adjusted elsewhere to ensure correct fit.

This process is time consuming and ultimately leads to increased buildings costs, as well as additional man hours needed on site.

Secondly, as the balustrade is installed on the pre-constructed stairway, portions of the stairway may be inaccessible or difficult to reach. This increases the difficulty of installation and increases the risk of health and safety issues, as the installers may be required to use ladders or scaffolding etc. to reach the stairway. Even normal use of the stairway itself poses a safety risk prior to correct installation of the balustrade It is the aim of the present invention to overcome or ameliorate one or more of the above problems.

Statement of Invention

According to a first aspect if the invention, there is provided a baluster arrangement for mounting to a support surface of staircase or associated floor comprising: an anchor operatively attached to the support surface; a baluster comprising an aperture therein to receive a fastener to connect to the anchor; a fixing plate located within a cavity in the baluster, the fastener extending into the fixing plate; and where the aperture in the baluster is wider in at least two dimensions than the fastener passing therethrough such that the fastener is loosely retained in the aperture.

According to a second aspect of the invention, there is provided a method of installation as recited in appended claim 20.

According to a further aspect of the invention, there is provided a baluster arrangement and associated method of manufacture of claims 23 and 24.

Optional features are defined in the dependent claims. However it is to be understood that any optional features recited in the dependent claims may be applied to any aspect of the invention in addition to those explicitly claimed.

Detailed description

Practicable examples of the invention are disclosed in further detail below with reference to the accompanying figures, of which: Figures la and lb show plan views of opposing faces of a baluster; Figure 2 shows a cross-sectional view of the baluster; Figure 3 shows a close-up side view of an end of the baluster; Figure 4a shows a plan view of a fixing plate; Figure 4b shows a three-dimensional view of the fixing plate; Figure 5 shows a cross-sectional side view of a baluster arrangement mounted to a flight of stairs; Figure 6 shows a three-dimensional exploded view of the baluster arrangement; Figure 7 shows a three-dimensional cut-away view of the assembled baluster arrangement; Figure 8 shows a three-dimensional view of a balustrade arrangement mounted to the stairs; Figure 9 shows a three-dimensional exploded view of a second embodiment of the baluster arrangement; Figure 10 shows a three-dimensional cut-away view of the second embodiment of the baluster arrangement; Figure 11 shows a three-dimensional view of the second embodiment of the baluster arrangement.

Figure 12 shows a three-dimensional exploded view of a third embodiment of the baluster arrangement; Figure 13 shows a three-dimensional cut-away view of the third embodiment of the baluster arrangement; Figures la and lb show a baluster 2. The baluster 2 is configured to support a vertically raised structural feature 4 above or adjacent a support surface 6 (see figure 8). The baluster thus provides a vertical support/post. In the present embodiment, the structural feature 4 comprises a handrail 7. Additionally, the baluster 2 supports a guard arrangement 8. However, it can be appreciated the baluster can support any number of structural features, for example, one or more of: a railing; fencing; paneling (e.g. glass panels); low wall; or other barrier type arrangements.

In the present embodiment, the support surface 6 comprises a flight of stairs 10. The stairs 10 are pre-fabricated. For example, the stairs comprise a pre-fabricated (i.e. pre-cast) concrete stairs. The stairs 10 may be moulded as a single. integral piece. Again, it can be appreciated this is merely exemplary, and the baluster 2 can be mounted to any suitable support surface, for example, one or more of: a balcony; mezzanine; gantry; or other elevated or outstanding platform or structure.

Referring back to figures la and lb, the baluster is elongate and extends in an axial direction 12. The axial direction 12 is typically vertical in use. However, it can be appreciated the axial direction 12 may extend in any direction, depending on the specific configuration of the balustrade. The baluster 2 is substantially linear/straight.

As shown in figure 3, the baluster 2 comprises a substantially tubular section (i.e. the baluster is hollow). Thus, a cavity 14 is provided within the baluster. Typically, the cavity 14 extends throughout the baluster, thus reducing the weight thereof. In alternative embodiments, the cavity 14 and may be intermittent some portions of the baluster 2 may be solid. The baluster 2 comprise a square cross-section.

Generally speaking, the exact shape or form of the baluster 2 is not pertinent to the invention at hand. The baluster 2 may be designed according to any specific engineering or aesthetic requirements. For example, the baluster may be curved, angular or polygonal. The cross-section may circular, rectangular, triangular, arcuate, helical or non-uniform. The baluster 2 may comprise aesthetic structures, adornments, embossing, branching or other shaping.

Typically, the balustrade 2 comprises a metallic material, preferably steel. In other embodiments, the balustrade 2 comprises plastics material. Again, the exact material configuration is not pertinent to the invention at hand. The balustrade 2 may be manufactured using extrusion.

Referring to figures 1-3, the balustrade 2 comprises a first plurality of apertures 16 therein. The apertures 16 are formed in a side wall 20a of the balustrade 2. The apertures therefore open into the cavity 14. The apertures 16 are provided proximal a lower end 22 of the balustrade 2 in use. The apertures 16 are axially spaced along the balustrade 2. The apertures 16 are provided in a lateral centre of the balustrade 2. The apertures 16 comprise a rectangular (e.g. square) shape. The apertures 16 are shown in closer detail in figure 3.

A second plurality of apertures 24 are provided on the baluster 2. The second apertures 24 are provided on an opposing side wall 20b of the baluster 2. The second apertures 24 are provided in corresponding positions to the first apertures 16. The apertures 24 comprise a circular shape. The second apertures 24 are thus differently shaped to the first apertures 16.

Further apertures 26 are provided on the baluster 2. The further apertures 26 provided a mounting point for the structural feature 4. As shown in figure 8, this provides mounting points for the guard 8. In other embodiments, the apertures 26 provides mounting points for corners of panels etc. In the present embodiment, the apertures 26 are provided proximal the ends of the baluster 2. However, the further apertures 26 may be provided in any suitable location, depending on the structural feature 4 being attached thereto. In some embodiments, the further apertures 26 may not be provided, and the apertures may be manually created during assembly of the balustrade.

Figures 4a and 4b, show a fixing plate 28 configured to be received within the cavity 14 in the baluster 2. The fixing plate 28 comprises an elongate rod/plate/beam. The fixing plate 28 comprises a first aperture 30 therein. The first aperture 30 is configured to overlie a first of first apertures 16 in the baluster 2.

The first aperture 30 is elongate. The elongate length of the first aperture 30 may correspond to the axial height of the first aperture 16 in the baluster 2. The lateral width of the first aperture 30 is therefore less than the width of the first aperture 16 in the baluster 2.

The fixing plate 28 comprises a second aperture 32 therein. The second aperture 32 is configured to overlie the second of first apertures 16 in the baluster 2. The second aperture 32 is non-elongate (i.e. circular).

The fixing plate 28 comprises a separate, discrete piece from the baluster (i.e. the fixing plate is freely movable within the cavity 14 and/or freely removable from therein.

Attachment of the baluster 2 to the support surface 6 is shown in figures 5-8. The baluster 2 is attached to the support surface 6 via an anchor 34. The anchor 34 is embedded within the support surface 6. In the present embodiment, the anchor 34 is placed into the support surface 6 during manufacture thereof. For example, the anchor 34 is placed into the concrete whilst the concrete is still in a fluid (i.e. pre-hardened) form. The anchor 34 is then held within the concrete as the concrete dries/hardens, thus embedding the anchor 34 therein. Similar arrangements can be envisaged where the support surface 6 comprises a plastics, or other hardenable/curable materials. The anchor 34 is thus insert-moulded into the support surface 6.

Embedding the anchor 34 into the support surface 6 mitigates the need to manually drill holes or like the into the concrete to mount the anchor 34 thereinto. Thus provides numerous benefits: This reduces the chance of the concrete cracking or otherwise being damaged Reduces the time, expensive or difficulty in drilling the holes The anchors can be predictably placed in a fixed position ensuring correct positioning and alignment (i.e. the system does not rely on a human measuring out the position of each anchor during installation).

As best seen in figure 5, the anchor 34 comprises a plurality of sockets 36. The sockets 36 comprises a recess/cavity 38 therein configured to receive respective fasteners 40. The sockets 36 comprise threads or the like to secure the fastener 40 therein. The anchor 34 is positioned within the support surface 6 such that he ends 42 of the sockets 36 are flush or recessed with the outer surface 44 of the support surface 6. As seen in figure 6, the anchor 34 appears as a plurality of spaced recesses 38 from an external viewpoint. The recesses 38 are spaced to correspond to the spacing of the first apertures 16 and the second apertures 24 in the baluster 2. The sockets 36 extend substantially perpendicularly to the outer surface 44.

The sockets 36 are connected via an intermediate connector 41. The connector 41 is displaced from the ends 42 of the sockets 36, such that the connector 41 is spaced from the outer surface 44 of the support surface 6. The anchor 34 is thus H-shaped or U-shaped. The connector 41 helps to retain the anchor 4 within the support surface 6.

A spacer 46 is interposed the baluster 2 and the support surface 6. The spacer 46 spacers the baluster from the support surface, preventing damage thereto. The spacer 46 comprises a flat plate or the like. The spacer 46 comprises a plurality of apertures 48 therein. The apertures 48 correspond in position to the sockets 36 and first apertures 16 on the baluster. The apertures 48 correspond in shape/size to the first apertures 16.

As best seen in figure 5, the respective fasteners 40 pass through/into: - the apertures 30,32 in the fixing plate 28 -the first apertures 16 in the baluster 2 - the apertures 48 in the spacer -the sockets 36 in the anchor 34.

A head portion 50 of the fasteners 40 engages the fixing plate 28 as the fasteners are fixed into the sockets 36 (best seen in figure 7), thus retaining the baluster 2 onto the support surface 6. The fixing plate 28 acts to clamp the baluster 2 against the support surface 6/spacer 46.

The second apertures 24 on the baluster 2 allow insertion of the fasteners 40 into the baluster 2. Additionally, this allows insertion of a tool (e.g. a screwdriver or Allen key) to tighten or untighten the fasteners 40.

As best shown in figure 6, the head portion 50 may comprise a washer or flange 52 configured to engage the fixing plate 28. The head portion 50 may comprise a standoff 54 to allow easier access to the fastener 40.

In the present embodiment, two axially spaced fasteners 40 are used. However, any number of fasteners 40 (and corresponding socket/apertures) may be used depending on the load requirements of the baluster 2.

As shown in figure 6 and 7, caps 56 may be used to seal the second apertures 24. A cap 58 may be used to seal one or both of the ends of the baluster 2. The caps 56,58 may be snap fit/interference fit with the respective apertures. Additionally, or alternatively, latches may be provided to prevent removal of the caps 56,58.

The fastener 40 comprises a width less than width of the first apertures 16 in the baluster 2 (best seen in figure 5). The baluster 2 is thus free to move relative to the support surface 6 despite the fasteners 40 passing through the baluster 2 and engaging the support surface 6. The degree of free movement will be determined by the difference in the width of the fastener 40 and the first apertures 16. For example, if the first apertures 16 are 25mm wide and the fastener is lOmm wide, then the baluster 2 will have 15mm of free movement. This difference in width/height may be anywhere between 5mm and 25mm, e.g. between lOmm and 20mm.

The width of the fastener 40 for a given configuration is typically fixed by the width (i.e. the bore) of the socket 36. Similarly, the fastener 40 is limited in width by the apertures 30,32 in the fixing plate 28. The socket 36 and the fixing plate apertures 30,32 provide an upper bound for the width of the fastener 40. The ratio in width of the socket 36 and/or the fixing plate apertures 30,32 to the first apertures 16 in the baluster 2 thus determines the degree of free movement of the baluster 2.

The width of the fastener 40/socket 36/fixing plates apertures 30,32 may be less than or equal to 90%; preferably, less than or equal to 80%; preferably, less than or equal to 70%; preferably, less than or equal to 60%; preferably, less than or equal to 55% of the width of the baluster first apertures 16. For example, the width of the fastener 40 may be approximately half the width of the baluster first apertures 16.

The free movement of the baluster 2 allows fine adjustment of the position of the baluster 2 whilst at least partially secured to the support surface 6. This allows the installer to ensure correct positioning of the balusters 2 to allow connection of the handrails etc. whilst mitigating the effects of any manufacturing tolerance in the support surface 6 and/or the balustrade arrangement. The installer is therefore not required to make adjustments to the size balustrade and/or the position of anchor 34 as the free movement accommodates any deviation from specification.

The rectangular shape of the first apertures 16 are greater than the width of the fastener 40 in two dimensions. Thus, the baluster 2 is movable about a plane. This allows both horizontal and vertical position adjustment in use. It can be appreciated that free movement in two dimensions could potentially be provided by any suitable oversized shape, for example, circular, hexagonal, X-shaped etc. However the square/rectangular opening has been found to be particularly well-suited to offering the desired freedom of movement in the longitudinal and lateral directions of the baluster, as well as in the diagonal direction. In this regard it can be appreciated that a staircase extends in a diagonal direction relative to the longitudinal direction of the baluster and so the shape of aperture 16 allows adjustment of the balusters 2 by translation in the direction of the staircase.

In alternative embodiments, the first apertures 16 are greater than the width of the fastener 40 in only a single dimension (i.e. they are elongate).

The fixing plate 28 provides a reinforcement of the baluster 2 due to the over-sized first apertures 16 therein. Additionally, this provides an engagement surface for the head portion 50 of the fasteners 40 (i.e. due to the fact that the first apertures 16 may be too large to retain the head portion 50).

Similarly, the elongate first aperture 30 in the fixing plate 28 accommodates free movement of the baluster 2 and/or any tolerance in the spacing/alignment of the sockets 36. Vertical free movement is provided by the vertical elongation of the aperture 30, whilst horizontal free movement is accommodated by rotation of the fixing member.

The oversize apertures 48 in the spacer 46 accommodate tolerance in the spacing of the sockets 36.

Assembly of the invention A mould is used to provide a prefabricated flight of stairs 10. The mould is filled with a cementitious material, such as concrete and hardened. Before the material hardens, the anchor 34 is embedded therein and held in place. Once hardened, the stairs 10 are removed from the mould. The moulding process is otherwise conventional.

A template may be provided to align/hold the anchor 34 in place before or during the hardening of the concrete. The template thus ensures correct spacing and/or positioning of the anchors 34.

The baluster 2 is then attached to the support surface 6 via the anchor 34. The fasteners 40 are inserted into the second apertures 26 on the baluster 2, through the fixing plate 28, the first apertures 16 and the spacer 46. The fasteners 40 are then screwed into the anchor sockets 36. The fasteners 40 are tightened, such that the support surface 6, spacer 46, baluster 2 and fixing plate 28 are brought into engagement. The fasteners 40 may be tightened such that baluster 2 is fixed in position under its own weight but still movable with manual manipulation. The installer can then make fine adjustments to ensure the baluster 2 is in the correct alignment. Once correctly in position, the fasteners 40 are fully tightened to hold the baluster 2 firmly in place.

The balustrade and/or hand rails etc. may be pre-assembled onto the stairs 10 before installation of the stairs 10 into the building. The stairs 10 and the balustrade can therefore be supplied as a single unit (i.e. as shown in figure 8). This mitigates the need to install the balustrade during construction, which may be difficult or pose safety issues. The single unit is then transported to the construction site and installed as the single unit.

In some embodiments, the balustrade may be attached to the stairs onsite (i.e. at the construction site) but spaced from the stairwell in which the straircase is to be installed. The balustrade and stair unit may then be lifted into place and installed.

Alternatively, the balustrade may be disassembled and transported with the stairs 10. However, due to the pre-assembly, correct alignment of the balustrade components has been ensured, thus allowing a quick and easy installation thereof.

A protective layer may be provided on balustrade, e.g. on the balusters and/or handrail, to protect the balustrade during transport of installation of the stairs 10. The protective layer may be removed once the stairs 10 have been installed, e.g. after construction work and/or decoration of the building has been completed. The protective layer may comprise a coating and/or a removable layer. For example, the protective layer may comprise a peelable polymer layer. Regardless of whether or not a protective layer is used, the balustrade may be painted onsite after installation, e.g. to match a desired colour/finish.

In the present embodiment, the anchor 34 is mounted to the side of the stairs 10.

The balustrade arrangement is thus provided on the side of the side stairs 10. In other embodiments, the anchor 34 is provided on a top, bottom or other location on the support surface 6. The baluster 2 may be modified accordingly to accommodate free movement in the desired planar direction.

A second embodiment of the invention is shown in figures 9-11.

In this embodiment, the anchor 34 is fixed to an outside surface of the support surface 6. The anchor 34 comprises a base/flange 60 configured to abut the surface of the support surface 6. The base 60 lies flat/flush with the support surface 6. The base 60 comprises a plurality of apertures 62 to permit fasteners 64 to pass through. The fasteners 64 are fixed into the support surface to fix the base 60 thereto. Such an arrangement allows retrofitting of the balustrade to a constructed/installed stairway.

In alternative embodiments, the anchor 34 is fixed to an embedded anchor 34 as described in the first embodiment. Each of the fasteners 64 therefore connects to a respective socket 36. The sockets 36 may be arranged in a triangular arrangement in corresponding positions to the fasteners 64.

An upstanding beam 66 is fixed to the base 60. The beam 66 is configured to be received within the baluster 2.

The baluster 2 comprises an elongate aperture 68 therein. The aperture 68 extends along the axial length of the baluster 2 (e.g. in a vertical direction in use).

A corresponding aperture (not shown) is provided on an opposing side of the baluster 2.

An aperture 70 is provided on the beam 66. The aperture 70 is aligned with the apertures 68 on the baluster 2. A second aperture (not shown) may be provided on the opposing side of the beam 66. The apertures 70 may be linked to provide a single through-hole. This allows respective fasteners 72 to pass through the respective apertures 68 and engage the apertures 70 to secure the baluster 2 to the anchor 34 (see figure 10). Alternatively, a single fastener may extend through both baluster apertures 68 and the beam aperture 70.

In the present embodiment, the axial length of the aperture 68 is greater than the width of the fastener 72. The aperture 68 thus allows vertical adjustment of the baluster 2, in a similar fashion as to previously described The transverse width of the aperture, however, is only marginally greater in width than the fastener. The aperture 68 is thus elongate. This allows a greater degree of movement in a first dimension than the second dimension In alternative embodiments, it can be appreciated that he aperture 68 is similar to the aperture 16 in the first embodiment of the invention (e.g. the aperture 68 may square/rectangular).

The width of the fastener 72 is typically limited by the width of the beam aperture 70. The width of the fastener 72/beam aperture 70 may less than or equal to 80%; preferably, less than or equal to 60%; preferably, less than or equal to 50%; preferably, less than or equal to 40%; preferably, less than or equal to 30% of the width of the baluster aperture 68.

A third embodiment of the invention is shown in figures 12 and 13.

The third embodiment of the invention is similar to that of the first embodiment of the invention and like features will not be described.

In this embodiment, the spacer 46 comprises a single aperture 48. Thus, a discrete spacer 46 is provided for each respective fastener 40. The spacers 46 comprise cylindrical members (e.g. puck or plug like).

The anchor 34 is countersunk/recessed from the outer surface 44 of the support surface 6. The width of the countersunk area 74 is greater than the width of the sockets 36. The width of the countersunk area 74 is typically greater than the 30 width of the spacers 46 such that they may be accommodated therein.

The intermediate portion 41 of the anchor 34 is only partially provided. Thus, the sockets 36 for each respective fastener 40 are provided as discrete portions (i.e. they are unconnected). The anchors are substantially T-shaped.

In alternative embodiments, the anchor 34 comprises the intermediate portion 41 as provided in the first embodiment.

It can be appreciated that any of the spacer 46/anchor 34 arrangements of the third embodiment may be used in first embodiment.

The present invention provides a prefabricated stairway with a balustrade arrangement pre-assembled thereonto. This allows quick, safe and convenient construction of a stairway into a building. The balustrade can be installed in a more optimal environment with convenient access to any tools or parts which may not be easily accessible on the construction site. No welding or cutting of the balustrade components is required onsite, thus increasing the safety of the installation thereof.

The present arrangement allows adjustment of the position of the baluster, thus accommodating manufacturing/installation defects or tolerances. This removes the need to move anchors (which may reduce the support surface integrity) to cut or otherwise adjust the length of the baluster/handrails etc. to ensure correct alignment thereof.

Claims (17)

1. Claims: 1. A baluster arrangement for a support surface comprising: an anchor, the anchor insert-moulded into the support surface; and a baluster removably connected to the anchor.
2. 2. A method of manufacturing a baluster arrangement for a support surface comprising: moulding a support surface using a hardenable material; placing an anchor into the hardenable material before hardening thereof such that the anchor is premoulded into the support surface; and attaching the baluster to the anchor.
3. 3. A method according to claim 2, where a plurality of spaced anchors are provided and the anchors are held in position by a template during hardening of the hardenable material.
4. 4. A baluster according to claim 1 or method according to claim 2, where the support surface is a support surface of a staircase or associated floor. 20
5. 5. A baluster or method according to any preceding claim, the baluster comprising: an aperture therein to receive a fastener to connect to the anchor; a fixing plate located within a cavity in the baluster, the fastener extending into the fixing plate; and where the aperture in the baluster is wider in two dimensions than the fastener passing therethrough such that the fastener is loosely retained in the aperture.
6. 6. A baluster or method according to claim 5, where the aperture in the baluster is quadrilateral in plan.
7. 7. A baluster or method according to any preceding claim, where the anchor comprises a plurality of connectors anchored into the support surface, and the plurality of connectors are connected via an intermediate connector extending through the support structure.
8. 8. A baluster or method according to any preceding claim, where the anchor is countersunk from a surface of the support surface
9. 9. A baluster or method according to any preceding claim, where a portion of the baluster adjacent the anchor is substantially flat.
10. 10. A baluster or method according to any preceding claim, where the baluster is spaced from the support surface via a spacer.
11. 11. A baluster or method according to any preceding claim, where the support surface comprises a pre-fabricated stairway or staircase.
12. 12. A baluster or method according to any preceding claim, where the support surface comprises a cementitious material. 20
13. 13. A baluster or method according to claim 5, where the fixing plate is freely removable from within the baluster.
14. 14. A baluster or method according to claim 5, where the width of the fastener in either one or both of said two dimensions is less than or equal to 70%, preferably, less than or equal to 50% of the width of the baluster aperture.
15. 15. A method of installing a pre-fabricated stairway according to claim 11 further comprising: installing the stairway in/on a building with the baluster arrangement assembled thereon.
16. 16. A method according to claim 15, comprising adjusting the position of baluster on the stairway whilst mounted thereon before installation of the stairway.
17. 17. A method according to claim 15 or 16, wherein the baluster arrangement is assembled on the stairway remotely of the building and/or transported to the building site in an assembled condition.