Abstract:
The present invention relates to a floor pier support and, in particular, to a pier support which allows for in-situ height adjustment of a floor frame mounted thereabove. In particular, the pier support includes a base adapted to be fixed to said surface, a connection member including a first and a second attachment means, the first attachment means used to fix the connection member to a frame element, and the second attachment means being connectable to the base in a configuration which facilitates height adjustment of the frame relative to the base. The pier support of the present invention provides for a strong, robust support for floor frames and is advantageous in that the height of the frame can be easily adjusted at regular intervals post-construction, for maintenance purposes, or for height re-adjustment where for example the ground has subsided over time.

Description:
[0001]    The present invention relates to a floor pier support and, in particular, to a pier support which allows for in-situ height adjustment of a floor frame. 
       BACKGROUND OF THE INVENTION 
       [0002]    A typical pre-assembled floor frame is square or rectangular in shape and comprises a plurality of floor bearers and floor joists. Floor bearers are usually the outer load bearing elements of the frame and floor joists are the inner elements which extend between bearers and intersect one another to provide a support for floor sheeting there above. Such floor frames are typically used in the construction of transportable housing, decking, walkways, multi-level construction, patios and the like. 
         [0003]    Floor frames for such structures are required to be positioned a predetermined distance above the ground, or in the case of multi-level construction, above the ceiling frame of the room below. This is typically achieved using a plurality of pier supports positioned at various points beneath the frame to provide the required structural support thereto. Typically, the pier supports are positioned beneath bearer-joist connections and are thereby arranged in a matrix-type formation beneath the floor frame. Not every bearer-joist connection necessarily requires a pier support, this being job specific and is something an engineer will determine depending on structural requirements, wind speeds in the area, earthquake risk, etc. 
         [0004]    The current method of erecting these supports is to pour concrete footings or piers deep into the ground where each support is to be located. The location of each support is typically determined by computer software whereby a printout of the pier support locations is sent to a footing contractor. Being able to adjust the height of the supports is essential when erecting floor frames in that the level of the footings across the entire frame are often not uniform and hence if the supports were all the same height, the resultant floor frame would be uneven. Laser levels are typically used as an indicator when adjusting the height of the frame, and so it can be appreciated that height adjustment of only a few millimetres at particular sections of the frame is sometimes required. 
         [0005]    Existing pier supports known to the present inventor include a vertical base beam adapted to be fixed to each concrete footing, and a frame connection member to which the floor frame is fixed, the connection member being threadably connected to the base beam for height adjustment. Such systems are unsuitable because they do not allow for in-situ levelling of floor frames. In particular, levelling must be performed prior to the floor frame being fixed to the base frames, and the height of the frame may not be easily adjusted thereafter. There is therefore a need for supports which allow a floor frame to be erected with more speed and accuracy than hitherto known supports. 
         [0006]    Another important issue is the structural integrity of existing pier supports, particularly in rough wind conditions and earthquake prone areas. The strength of the support is dependant upon its design and construction, and the way in which it is connected to the frame. Existing supports known to the applicant do not have a strong and robust means of connection between the base beams and floor frame. 
         [0007]    The present inventor is the owner of various patents and patent applications directed to the manufacture of floor frames, in particular, pre-assembled steel floor frames which include unique connection means in the form of tab-slot connections. Connection tabs are associated with one frame member and are insertable into slots associated with another frame member for connection thereto. There is therefore also a need for a floor pier support which is suitable for use in association with existing floor frame systems such as this one, but which is not limited to such systems. 
         [0008]    It is therefore an object of the present invention to overcome at least some of the aforementioned problems or to provide the public with a useful alternative. 
         [0009]    It is a further object of the present invention to provide floor pier supports which provide for more simplified and accurate erection of a floor frame there above, as well as a more strong and robust connection between support and frame. 
         [0010]    It is a still further object of the invention to provide a floor pier support which allows for the height of the associated floor frame to be easily raised or lowered in-situ. For example, in a situation where the ground has subsided in one area of a floor frame over time, the relevant pier support can be adjusted accordingly without having to remove the entire frame, or parts thereof. 
       SUMMARY OF THE INVENTION 
       [0011]    Therefore in one form of the invention there is proposed a pier support for maintaining a frame element above a surface, said pier support including:
   a base adapted to be fixed to said surface;   a connection member including a first and a second attachment means, said first attachment means used to fix the connection member to a frame element, and said second attachment means being connectable to the base in a configuration which facilitates height adjustment of the frame relative to the base.   
 
         [0014]    Preferably the pier support includes a means of locking the frame element at a desired height. 
         [0015]    Preferably said base includes two parallel surfaces having co-axially aligned apertures, said second attachment means of the connection member including a threaded shaft insertable through said co-axial apertures for engagement with two correspondingly threaded nuts located between the two parallel surfaces. 
         [0016]    In preference the first nut is used to adjust the height of the connection member and the second nut is used to lock the connection member at a desired height relative to said base. 
         [0017]    Preferably the first nut is adapted to bear against a first of said parallel surfaces, said first nut raising the height of the connection member by way of rotation in a first direction relative to the threaded shaft, and lowering the height of the connection member by way of rotation in the opposite direction. 
         [0018]    Preferably said first nut bears against said first surface by the weight of the frame element. The weight of the frame typically bears down against the connection member causing the lower levelling nut to bear against the first surface at all times. Preferably through adjustment of the levelling nut relative to the threaded rod, the level of the connection member and hence the frame element can be raised or lowered. 
         [0019]    Alternatively said first nut bears against said first surface by way of manual adjustment towards said first surface. For example, there may be circumstances where the frame does not cause the lower levelling nut to bear against the first surface. 
         [0020]    In preference the second nut is adapted to be tightened against the second of said parallel surfaces once the desired height is achieved, to thereby lock the connection member at said desired height. 
         [0021]    Preferably said base is in the form of an upright hollow beam and said surface to which the base is fixed is a concrete footing. 
         [0022]    Preferably said first and second parallel surfaces form part of a C-section bracket mounted above said upright beam in a configuration whereby said first and second surfaces extend substantially horizontally. 
         [0023]    In preference said frame element is a joist comprising two C-section members each having a central web and a pair of flanges extending outwardly therefrom, said C-section members being joined along their central webs to form said joist. 
         [0024]    Preferably said first attachment means of the connection member is in the form of a T-piece having a base plate and an upright tab. 
         [0025]    Preferably each joist includes at least one slot located in a lower flange of a C-section member adjacent the central web, said slot shaped to receive the connection member upright tab. 
         [0026]    Preferably after the upright tab is inserted into said slot, it is adapted to be fixed to the central webs of the two adjoining C-section members forming the joist. 
         [0027]    In preference said joist forms part of a floor frame having a plurality of connecting joists and bearers. 
         [0028]    In preference each slot is positioned proximate the joist-bearer connection. 
         [0029]    In a further form of the invention there is proposed a pier support for supporting at least one frame element of a horizontal frame, said pier support including:
   a base;   an elongate support member extending substantially vertically from the base and having a remote end opposed to the base with a cavity;   a bracket mounted above the vertical support member, said bracket having two parallel surfaces extending substantially horizontally and each surface including co-axially aligned apertures;   a frame connection member including a first attachment means so that said frame connection member can be fixed to said frame element and a second attachment means in the form of a threaded rod adapted to extend through said coaxially aligned apertures; and   at least one levelling nut which when rotated in a first direction whilst bearing against a first of said parallel surfaces, causes the rod and connection member to move vertically in a first direction, and when rotated in the opposite direction whilst bearing against the same parallel surface, causes the rod and connection member to move vertically in the opposite direction.   
 
         [0035]    Preferably said connection member includes a locking nut used to lock the connection member at the height set by the first levelling nut by being tightened against the second of said parallel surfaces. 
         [0036]    In a still further form of the invention there is proposed a steel floor frame having a plurality of interconnected floor joists and floor bearers, said steel floor frame including a plurality of pier supports as defined above located proximate the joist-bearer connections. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0037]    The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an implementation of the invention and, together with the description, serve to explain the advantages and principles of the invention. In the drawings: 
           [0038]      FIG. 1  illustrates a perspective view of a floor frame supported above a plurality of floor pier supports in accordance with the present invention, and an enlarged perspective view of the connection between a single floor pier support and a floor joist; 
           [0039]      FIG. 2  illustrates a partially exploded view of the connecting pier support and floor joist of  FIG. 1 ; 
           [0040]      FIG. 3  illustrates a cross-sectional view of the connecting pier support and floor joist of  FIG. 1 ; 
           [0041]      FIG. 4   a  illustrates a side view of the frame connection member forming part of the floor pier support of the present invention; 
           [0042]      FIG. 4   b  illustrates a front view of the frame connection member of  FIG. 4   a;    
           [0043]      FIG. 5   a  illustrates a side view of the C-section support bracket forming part of the floor pier support of the present invention; and 
           [0044]      FIG. 5   b  illustrates a front view of the C-section support bracket of  FIG. 5   a.    
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0045]    The following detailed description of the invention refers to the accompanying drawings. Although the description includes exemplary embodiments, other embodiments are possible, and changes may be made to the embodiments described without departing from the spirit and scope of the invention. Wherever possible, the same reference numbers will be used throughout the drawings and the following description to refer to the same and like parts. 
         [0046]    The present invention relates to a floor pier support  10  and floor frame  12  incorporating such floor pier supports, as shown in  FIGS. 1-3 . In  FIG. 1 , a pre-assembled floor frame  12  is shown which comprises floor joists  14  and floor bearers  16 , each of which is formed from C-section structural members rolled from light-gauge strip steel. The frame  12  is typically covered by floor sheeting (not shown) and is supported above a plurality of pier supports  10  positioned adjacent the connections between floor joist  14  and floor bearers  16 . 
         [0047]    It is to be understood that the present invention is not to be limited to use in supporting floor frames only but may equally well be used in the support of any structure which may require in-situ height adjustment. 
         [0048]    Each floor pier support  10  is fixed at its base to a concrete footing  18  which is poured a predetermined depth within the ground to support the structure to be built above, whether it be a transportable house, a walkway, a patio, or the like. The position of each footing  18  is determined off-site, for example, using computer software which calculates the required spaced apart footing distances in accordance with the dimensions of the floor frame  12  which, in the embodiment shown, is also assembled off-site. 
         [0049]    Turning now to the floor frame  12  in more detail, the floor joists  14  and floor bearers  16  are each made up of C-section members and for the purpose of brevity, each similar feature of the joist  14  and bearer  16  will be referenced using like numbers. Each C-section member comprises a central web  20  and a pair of flanges  22  extending outwardly therefrom. Each flange  22  terminates with a flange return  24 . The floor joists  14 , which comprise two opposed C-section members joined along their central webs  22 , are adapted to be inserted into the bearer  16  as shown in the enlarged view of  FIG. 1 , and the flange return  24  of the bearer  16  is removed at these parts of the bearer in order to enable receipt of the joist  14 . 
         [0050]    The ends of the central webs  20  of each C-section member in joist  14  is folded over at approximately 90 degrees in order to form an end portion  26 , forming a box-shape at the end of the C-section member in joist  14 . The end portions  26  include a number of dimples  28 , each of which is centrally punched to receive a fixing member such as a rivet or screw (not shown). The web  20  of the bearer  16  is likewise dimpled or punched to assist in aligning the floor joist  14  relative to the bearer  16  during assembly, and additionally provide resistance against shearing when secured together via a rivet or the like. The joist  14  includes a slot  30  extending through the lower flange  22  of one of its C-section members, the purpose of which is described below. 
         [0051]    As mentioned in the preamble of the invention, the floor frame  12  is adapted to be mounted a predetermined distance above the ground and is typically levelled using a laser level (not shown). The present invention provides for in-situ height adjustment of the floor frame using the adjustment means now described. 
         [0052]    The floor pier support  10  essentially comprises two parts, a hollow base member  32  of square cross-section having a C-section support bracket  34  fixed there above, and a frame connection member  36 . The hollow base member  32  could equally well have a different cross-sectional shape such as circular for example. The frame connection member  36  is shown as a separate component in  FIGS. 4   a - 4   b,  and the C-section support bracket  34  is shown as a separate component in  FIGS. 5   a - 5   b.    
         [0053]    The hollow base member  32  includes a base plate (not shown) adapted to be bolted down to the footing  18  at a predetermined position also calculated by the computer software. The C-section support bracket  34  is fixed, preferably by a weld, to the top of the hollow base member  32  in a configuration whereby one of the C-section bracket parallel walls covers the open top of the base member  32 , and the opposed parallel wall extends a short distance there above. Each parallel wall includes a vertically extending aperture  38  and  40  which are co-axially aligned. 
         [0054]    The frame connection member  36  is in the shape of an inverted T-piece, that is, it includes an elongate bottom plate  42  and a transverse connection tab  44  extending upwardly from the bottom plate  42 . A threaded rod  46  extends downwardly from the opposite side of the plate  42 . 
         [0055]    During assembly, the threaded rod  46  is firstly adapted to be inserted through the upper aperture  38  of the C-section support bracket  34 . Then, two levelling nuts  48  and  50  are screwed onto the threaded rod  46 , and the free end of the rod is then inserted into the second aperture  40  so that the nuts  48  and  50  are located between the two parallel walls of the C-section support bracket  34 . The free end of the threaded rod  46  therefore extends into the hollow base member  32  and the lower levelling nut  48  will typically bear against the lower wall of the bracket  34  due to the weight of the frame  12  thereabove. Although this will not always be the case, as is described further below. 
         [0056]    As mentioned above, the joist  14  includes a slot  30  which extends through a lower flange  22  of one of its C-section members adjacent the central web  20 . The transverse connection tab  44  includes two vertically spaced apart apertures  52  and  54 . Therefore, once the connection tab  44  is inserted all the way into slot  30 , so that the bottom plate  42  abuts with the joist  14 , the spaced apart apertures  52  and  54  become co-axially aligned with respective spaced apart apertures  56  and  58  extending through the central webs  20  of the two opposed C-section members which form the joist  14 . A bolt  60  is adapted to extend through co-axially aligned apertures  52  and  56 , as is bolt  62  through apertures  54  and  58 . Both are secured by respective nuts  64  and  66  as known in the art. Once the nuts are tightened, the frame connection member  34  is thereby securely fixed to the joist  14 . 
         [0057]    It is to be understood that the connection means between the pier support and frame may well vary in accordance with the type of frame and other conditions. For example, in the case of timber frames having timber joists, the frame connection member would be U-shaped in order to accommodate a typically square cross-sectioned timber beam joist. 
         [0058]    Also, in the case of steel frames, the frame connection means is not to be limited to only the tab-slot connection means embodied herein, but to any connection means of suitable strength. The tab-slot connection is used in preference to maintain consistency with the present inventor&#39;s unique roof and floor frame system which both incorporate a similar tab-slot connection between frame elements. Such a connection means is preferred because it maintains superior stiffness in steel frame joints. 
         [0059]    The hollow base member  32  and the frame connection member  36  are now both fixed which means that the height of the frame  12  is ready to be finely adjusted. This may be achieved using an appropriate level such as a laser level (not shown) as mentioned earlier, while manipulating the nuts  48  and  50  of each pier support  10  as described below. 
         [0060]    It is to be understood that when the following description refers to screwing of the nuts, this is intended to mean rotation thereof in a clockwise motion when viewing the apparatus from above, and likewise, unscrewing of the nuts is intended to mean rotation thereof in an anticlockwise motion when viewing the apparatus from above. 
         [0061]    It is to be further understood that each component could be configured differently, for example, they could be oppositely threaded requiring unscrewing as opposed to screwing, and vice versa. Provided the means by which the height is adjusted is the same, then other components can equally well be used without deviating from the scope of the invention. 
         [0062]    In the embodiment shown, in order to increase the height of the frame  12  the lower nut  48  is required to be screwed. The threaded rod  46  will be forced to move upwardly thereby raising the level of the frame  12 . Of course, during this process, the upper nut  50  will gradually move closer to the upper flange of the support bracket  34 , and so one needs to also unscrew the upper nut  50  in the meantime if/when required in order to maintain it in a floating state. 
         [0063]    In order to decrease the height of the frame  12 , the lower nut  48  needs to be unscrewed. The threaded rod  46  will be forced to move downwards thereby lowering the level of the frame  12 . During this process, the upper nut  50  will gradually move closer to nut  48 , and so one needs to also unscrew the upper nut  50  if/when required in order to maintain it in a floating state. 
         [0064]    Once a desired level is reached through adjustment of the lower nut  48 , the upper nut  50  can be tightened against the upper flange of the support bracket  34  (by unscrewing it), thereby locking the pier support in place. It is important during tightening of the upper nut  50 , that the lower nut  48  be maintained in the position it was moved to earlier using a level, so that the height of the frame is not affected during the locking process. Because of the weight of the frame bearing down on the nut  48 , it is likely that a spanner or other rotating tool will be required to rotate nut  48 , and also to maintain nut  48  in position during tightening of nut  50 . 
         [0065]    There may be circumstances in which the frame may not cause nut  48  to bear against the lower flange of the C-section support bracket, for example, where the frame is lightweight, where the bearers/joists are not exactly straight, or where the supports at one end of the frame have been level adjusted and tightened but at the other end still requires adjustment. In such circumstances, both the nut  48  and nut  50  may be floating. The pier support  10  of the present invention is also suitable in these circumstances. 
         [0066]    Raising of the frame is achieved using the same method described above whereby the lower nut  48  is screwed until it bears against the lower flange of the C-section support bracket  34 . The threaded rod  46  will eventually be forced to move upwardly thereby raising the level of the frame  12 , or at least reaching the level of the other pier supports which have been adjusted already. Tightening of nut  50  will then secure the pier support in place, as above. 
         [0067]    However, lowering the frame is achieved slightly differently because the weight of the frame can no longer be relied upon. Because the lower nut  48  does not bear down against the lower flange of the support bracket  34 , unscrewing of the nut  48  alone will not cause the threaded rod to move downwardly. Therefore, alternatively, the upper nut  50  needs to be unscrewed so that it bears against the upper flange of the C-section support bracket  34 . The threaded rod  46  will eventually be forced to move downwardly thereby lowering the level of the frame  12 . Nut  48  can then be tightened against the lower flange (by unscrewing it) in order to secure the support in the desired position. Effectively, nut  50  becomes the adjusting nut, and nut  48  becomes the locking nut. 
         [0068]    The skilled addressee should now realise the benefits provided by the present invention. Various adjustable pier support systems exist, however, none that are known to the present inventor can be assembled as quickly and efficiently as the pier support  10  of the present invention. One of the improvements resides in the use of the C-section support bracket  34  which exposes two nuts  48  and  50  used to raise, lower and lock the frame  12  at a desired level. This configuration enables height adjustment without the need for moving any of the supporting structures such as the base beam or the frame connection member, allowing these components to be assembled prior to adjusting the height of the floor. The entire floor frame  12  can therefore be levelled in-situ. 
         [0069]    In using the floor pier support  10  of the present invention, the strength and integrity of the support provided to the frame  12  is also not compromised. Once the desired level is achieved and the bolts secured, each base beam provides an extremely strong and robust support. When using the tab-slot frame connection embodied herein, the floor frame as a whole also has superior strength characteristics over existing systems. Once again, because the nuts are both exposed, they can be easily tightened at regular intervals post-construction, for maintenance purposes, or for height re-adjustment. 
         [0070]    The present invention is designed to be used in combination with unique pre-assembled floor frames which have been developed by the present inventor. However, it is to be understood that the present invention could equally well be used in combination with any type of floor frame, whether pre-assembled or assembled on-site. Existing or newly manufactured floor frames could be modified slightly in order to accommodate the connection tabs  44  associated with the frame connection members  36 . For example, slots could be machined into the frame at appropriate positions. 
         [0071]    Further advantages and improvements may very well be made to the present invention without deviating from its scope. Although the invention has been shown and described in what is conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom within the scope and spirit of the invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent devices and apparatus. 
         [0072]    In any claims that follow and in the summary of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprising” is used in the sense of “including”, i.e. the features specified may be associated with further features in various embodiments of the invention.