Pedestal for ballast block decking

A deck system and pedestal for use in forming an elevated surface are provided. The pedestal for supports blocks, pavers, tiles, or panels a spaced distance above an underlying surface. The pedestal has a base, a reinforcement wall, a support, and a coupler with a flange. The base is at a lower end of the pedestal and has a plate extending outward from a post. The reinforcement wall extends between the plate and the post and has a first eyelet formed therein. The support is located at an upper end of the pedestal for supporting the blocks, pavers, tiles, or panels thereon. It is adjustably mounted relative to the base for altering an overall height of the pedestal. The coupler, having a flange is adjustably located between the support and the base for further altering the overall height of the pedestal. A plurality of spaced-apart second eyelets extend through the flange.

FIELD OF THE INVENTION

The present invention relates generally to a deck systems for use in constructing an elevated traffic-bearing surface, such as on the roof of a building, and more particularly, the present invention relates to a height-adjustable pedestal and deck system using same.

BACKGROUND

Roof structures of many buildings are capable of supporting a substantially horizontal surface, or deck, enabling the construction of roof terraces, pedestrian walkways, roof gardens, plaza decks, sun decks, balconies, patios or the like. Such roof surfaces are often formed at a slight slope relative to horizontal for drainage purposes. Typically, the roof surface itself is not constructed of a material that provides a suitable traffic bearing surface nor is it aesthetically pleasing.

Examples of deck systems utilizing roof pavers, or ballast blocks, are disclosed by U.S. Pat. Nos. 5,887,397; 5,377,468; 5,442,882; and 6,604,330 B2 issued to Repasky. Also see U.S. Pat. Nos. 4,570,397 issued to Creske; and 5,588,264 and 6,332,292 B1 issued to Buzon.

While the rooftop ballast block deck systems disclosed in the above referenced patents may be satisfactory for their intended purposes, there is a need for a stable, readily adjustable pedestal for use in such systems. The system should permit proper drainage, for instance to an underlying roof surface, and should enable ready installation of bracing between adjacent pedestals. In addition, the pedestals should be capable of efficient manufacture and installation.

SUMMARY

More specifically, the present invention is a pedestal for supporting blocks, pavers, tiles, or panels a spaced distance above an underlying surface. The pedestal has a base, a reinforcement wall, a support, and a coupler with a flange. The base is at a lower end of the pedestal and has a plate extending outward from a post. The reinforcement wall extends between the plate and the post and has a first eyelet formed therein. The support is located at an upper end of the pedestal for supporting the blocks, pavers, tiles, or panels thereon. It is adjustably mounted relative to the base for altering an overall height of the pedestal. The coupler, having a flange is adjustably located between the support and the base for further altering the overall height of the pedestal. A plurality of spaced-apart second eyelets extend through the flange.

According to some of the embodiments of the present invention, the support can include a support plate. The upper surface of the support plate can be provided with a surface that secures and stabilizes the block, paver, or panel on the pedestal. As an example, the surface can be provided by a rubber pad, coating, texture or the like applied to the upper surface. The pad, coating, texture or the like can be used to deaden noise, absorb shock, and increase friction between the pedestal and the block, paver, or panel. If a rubber pad is used, it can be mechanically snapped onto the support plate with cooperating bosses and recesses formed in engaging surfaces of the pad and support plate.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Referring now to the drawings, a deck10is constructed of a plurality of separate, substantially-rectangular pavers, ballast blocks, or panels12(hereinafter referred to as blocks) that are arranged in a grid layout, or pattern, and that are supported a spaced distance above a surface, such as an exterior roof surface14of a building. The deck10provides a substantially level traffic-bearing surface16for pedestrians and an aesthetic appearance. It can be used to convert an otherwise unusable rooftop or like space into a useful area.

Each block12can be made of concrete, marble, granite, wood, rubber, plastic, composite materials, or like weight-bearing substance and is typically square, rectangle, or some other shape that can be positioned in uniform patterns. Thus, each block12will typically have corner portions18, and the deck10will have intersection areas20in which corner portions18of adjacent blocks12extend. A separate pedestal22underlies each intersection area20and supports the corner portions18of the adjacent ballast blocks12. Thus, the entire deck10is elevated from an underlying structure, such as exterior roof surface14. The spacing provided between the blocks12and surface14and between the laterally positioned blocks12permits proper drainage of fluids, such as rain, through the deck10.

As best illustrated inFIG. 2, each pedestal22includes a support24at an upper end thereof and a base26at a lower end thereof. The presence of an intermediate coupler50, as shown inFIG. 2, is optional. In its simplest form, the pedestal22can consist solely of the support24and base26without an intermediate coupler50. The support24and base26are preferably manufactured separately and are molded of plastic. The support24and base26interconnect in a manner permitting an overall height “H” of the pedestal22to be adjusted. More specifically, the action of rotating the support24relative to the base26causes the height “H” of the pedestal22to be altered. Thus, the height “H” of each pedestal22in the deck10can be readily adjusted, as required, during installation of the deck10and/or during maintenance thereof.

In the illustrated embodiment, the support24includes a plate28with a substantially cylindrical post30depending therefrom. In use, the plate28is disposed in a substantially horizontal position thereby providing a surface on which the corner portions18of the blocks12can be supported. Preferably, a plurality of upstanding walls32project from the plate28and define separate quadrants34on the plate28. Each quadrant34receives one corner portion18of a block12. The walls32align the corner portions18on the pedestal22and define lateral spacing between adjacent blocks12to permit rain water and other fluids to drain through the deck10and around the outside of plate28.

The upper surface of the plate28is provided with a surface that secures and stabilizes the block, paver, or panel on the pedestal22. This surface functions to prevent and/or deaden noise that may otherwise be created when pedestrians walk on the blocks, pavers, or panels. In addition, the surface can provide a shock absorbing function and can increase friction between the block, paver, or panel and the pedestal22. As an example, the surface can be provided by a pad36or by a coating, texture, or the like applied to an upper surface of the plate28.

If a separately manufactured pad36is used, it can be made of rubber, an elastomeric material, or like material and secured on the upper surface of the plate28. The rubber pad36deadens any noise that may otherwise be generated due to any slight movement between the contacting surfaces of the pedestal22and block12such as when pedestrians walk on the block. The pad36also increases friction between the block12and the pedestal22and can prevent damage to the upper surface of the pedestal22from placement of the block12thereon. The pad36can be provided as single pad or as multiple separate strips or sections.

The pad36can be mechanically and/or adhesively secured to the plate28. For example, the engaging surfaces of the pad36and plate28can include a plurality of bosses38and recesses40that cooperate to provide a snap-fit connection. An adhesive can be applied between the surfaces before snap fitting the pad36to the plate28.

In the illustrated embodiment, the base26includes a plate42with a substantially cylindrical, hollow post44projecting therefrom. In use, the plate42is disposed in a substantially horizontal position and the post30of the support24is received therein. Preferably, spiral threads46are located on an external surface of the post30of the support24and cooperating spiral threads48are located on the internal surface of the hollow post44of the base26. The cooperating threads,46and48, are sized to engage each other and permit the support24to be screwed into the base26. The threads,46and48, can be continuous or discontinuous. Rotation of the support24relative to the base26enables the overall height “H” of the pedestal22to be continuously adjustable. As an alternative arrangement, the post of the support can receive the post of the base, and the positioning of the threads can be reversed such that the support has internal threads and the base has external threads.

One or more couplers50can be assembled between the support24and base26to add further height to the pedestal22. For example,FIGS. 1-3show the use of a single coupler50, whereasFIG. 4shows the use of multiple couplers50. Each coupler50is identical and separately manufactured from preferably the same plastic material as the support24and base26.

Each coupler50includes a flange, or collar52, from which a substantially cylindrical, hollow post54projects and a substantially cylindrical post56depends. In this configuration, the flange52extends circumferentially about a mid-section of the coupler50and extends laterally therefrom. Continuous or discontinuous spiral threads58are provided on an inner surface of the hollow post54and are capable of cooperatively engaging the threads46on post30of the support24. In addition, continuous or discontinuous spiral threads60are provided on an outer surface of the hollow post56and are capable of cooperatively engaging the threads48on post44of the base26. Accordingly, the coupler50can be used to interconnect the support24to the base26. Further, the couplers50are designed to interconnect to each other so that multiple couplers50can be interconnected between the support24and the base26. Rotation of the couplers50, support24, and base26relative to each other can be used to adjust the overall height “H” of the pedestal22.

Preferably, the flange52of each coupler50extends in a plane that is substantially parallel to the support plate28and base plate42. SeeFIG. 3. In the illustrated embodiments, the flange52is annular; however, it could be of any shape in plan. In addition, preferably, the support plate28is of a similar size, in plan, to that of the base plate42. For example, both plates28and42can be provided in a circular shape, in plan, having substantially identical diameters. Alternatively, the plates,28and42, and the flange52can be of different shapes and sizes.

The flange52preferably has a series of eyelets62extending therethrough. For instance, the eyelets62can be provided as apertures that are circumferentially spaced-apart about the mid-section of the coupler50. In the illustrated embodiment, sixteen separate eyelets62are equally spaced-apart about the coupler50. Fewer or more eyelets62can be provided on the annular flange52. The eyelets62are used for securing the ends of bracing wires to the pedestal22. The uniform distribution of closely-spaced eyelets62about the coupler ensures that an eyelet62will always be opposed to an eyelet62in an adjacent pedestal22thereby enabling ease of installation of the bracing. Thus, eyelets62should be readily available at most or substantially all locations about the coupler for ready coupling of bracing wires between pedestals. The bracing should not be required to be bent or the like due to the unavailability of eyelets and should not generate forces that may cause undesired rotation of any components of the pedestals22.

The base26can also be provided with brace securement eyelets. For example, each base26can have a plurality of reinforcement walls66that extend radially-from an exterior68of the post44. The walls66can be spaced-apart circumferentially about the post44and can extend integrally from both the plate42and post44of the base26. Brace securement eyelets64can be provided in the walls66. In the illustrated embodiment, the eyelets64are provided adjacent an area on the base26where the post44interconnects with the plate42. As shown inFIG. 3, a plurality of drainage openings are formed in the plate42and extend into an inside of the hollow post44. Each drainage opening is in communication with the eyelets64.

The deck system according to the present invention can include cross bracing that ties adjacent pedestals22together and restrains their movement relative to one another. SeeFIG. 4. The bracing can include elongate wires, or rods,70that are secured to adjacent pedestals22. The bracing70can extend substantially horizontal or can extend at angles to the horizontal. For instance, X-bracing patterns can be utilized. The ends of the bracing wires70can be crimped and secured to the eyelets,62and64, of the pedestals22, and the wires70can extend coupler-to-coupler using eyelets62or base-to-coupler using eyelets62and64.

As stated above, a possible location of the deck10is on a sloped underlying surface, such as the sloped roof14of a building. Of course, the deck10can also be formed as a terrace, pedestrian walkway, plaza, sun deck, balcony, patio or any type of elevated flooring. Some surfaces, such as the roof surface14, are provided at a slope for drainage or other purposes. In this case, levelers72(shown in phantom inFIG. 3) are used between the roof surface14and base plate42to ensure that the pedestal22projects substantially parallel to a vertical direction. As an example, the levelers72can be those disclosed in U.S. Pat. No. 5,442,882 issued to Repasky, the disclosure of which is herein incorporated by reference. Accordingly, each base plate42of each pedestal22is seated within a recess of a level72that compensates for the slope angle of the roof so that the pedestals22can extend substantially parallel to a vertical direction thereby providing for ready formation of a horizontal deck surface16.

It may be desired in some installations that the blocks12be mechanically tied to the pedestals22. In this case, a corner cap74(shown in phantom inFIG. 3) can extend over the corner portions18of the blocks12within an intersection area20and be mechanically tied to the pedestal22with a fastener or the like. As an example, the caps74can be those disclosed in U.S. Pat. No. 6,604,330 B2 issued to Repasky, the disclosure of which is herein incorporated by reference.

The above-described deck system and pedestal assembly according to the present invention provides a stable elevated traffic bearing surface for pedestrians and the like on an existing structure, such as rooftop. The deck is easy to install and inexpensive to manufacture. The height of each pedestal can be adjusted by rotating the support relative to the base or by adding or subtracting couplers. Cross bracing can be installed coupler-to-coupler and base-to-coupler in a manner preventing unwanted rotation of various components of the pedestal assembly.

While a preferred ballast block deck system and pedestal assembly have been described in detail, various modifications, alterations, and changes may be made without departing from the spirit and scope of the ballast block deck system and pedestal assembly according to the present invention as defined in the appended claims.