Deck spacer

An apparatus includes a predetermined size, shape, and thickness with a bolt hole adapted to receive a bolt therein and a method of attaching the apparatus to a ledger board sufficient to prevent rotation of the apparatus with respect to either the ledger board or the bolt hole. Modifications include securing the apparatus to the ledger board by the use of screws passing through a plurality of mounting holes provided in the apparatus or by the use of pointed protrusions that extend from the apparatus and which are pounded into the ledger board. Other modifications are described that include the use of intermediate shim spacers to vary the overall thickness of the spacer and of angled spacers for use with beveled types of siding.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention, in general, relates to building construction and, more particularly, to a spacer used to secure a ledger board distally with respect to a member of a structure that the deck is attached to.

When a deck is attached to a structure (i.e., a house), a supporting member (i.e., a ledger board) is attached to the house so that it is parallel with the structure. Joist hangers are typically attached to the ledger in spaced apart intervals, often at every sixteen or twenty-four inches. The joist hangers are used to hold one end each of a plurality of joists that extend away from the structure. The remaining opposite end of each joist is secured in any of a variety of well known ways. A decking material is then placed over the joists to provide a functional exterior deck surface.

The ledger is responsible for supporting the weight of one end of the deck and of securing that end to the structure.

The ledger cannot be attached directly to the structure because if it were so attached, water and debris would accumulate on top which would then hasten deterioration of the ledger board and also possibly damage the structure. Therefore, architects specify attaching the ledger board to the structure in ways that secure the ledger board away from the structure by an amount that typically is not less than one-quarter of an inch nor more than about one inch. This secures the deck to the structure, yet it prevents damage to the deck from the accumulation of water and debris.

As one of the most commonly specified ways of attaching the ledger to the structure is by the use of a plurality of bolts that pass through the ledger and the structure, most architects specify the use of a plurality of washers or shims that are disposed intermediate the ledger board and the structure through which each bolt then passes and is eventually tightened.

In actual use this is most difficult to accomplish. It is time consuming, even frustrating, to align the ledger board properly with respect to the structure, drill a plurality of holes at the proper locations along the ledger and through the structure, and then pass bolts through the outside of the ledger at each drilled location while also adding a specified number of washers (to obtain a desired spacing) over the end of each bolt intermediate the ledger and the structure.

The ends of the bolts are difficult to access to place the washers on and once this is accomplished the washers are apt to fall off the bolts before the bolts are aligned with and can enter into the drilled holes in the structure. The process of attaching a ledger to a structure in a spaced-apart configuration is a difficult and time consuming process. It also requires the presence of one or two helpers, therefore adding to the labor costs.

Also, beveled siding is often used on an exterior surface of a structure. The beveled siding provides an angle that is difficult to match. Depending on the location of the beveled siding that the ledger board is attached to, the distance varies from the beveled siding to a parallel and plumb ledger board. To date, there is no way to accommodate the angle of the beveled siding and no known way to accommodate the variation in depth other than by varying the number of washers that are used.

Accordingly, there exists today a need for an architectural deck spacer that helps overcome these problems and an accompanying method of attaching a ledger board to a structure.

Clearly, such an apparatus and method would be useful and desirable.

2. Description of Prior Art

While the structural arrangements of the above described devices, at first appearance, may have similarities with the present invention, they differ in material respects. These differences, which will be described in more detail hereinafter, are essential for the effective use of the invention and which admit of the advantages that are not available with the prior devices.

OBJECTS AND SUMMARY OF THE INVENTION

It is an object of the present invention to provide an architectural deck spacer that is useful in securing a ledger to a structure while maintaining the ledger a predetermined distance away from the structure.

It is also an important object of the invention to provide an architectural deck spacer that lessens the time required to properly secure a ledger to a structure.

Another object of the invention is to provide an architectural deck spacer that is economical to manufacture.

Still another object of the invention is to provide an architectural deck spacer that can be fabricated from a variety of materials.

Still yet another object of the invention is to provide an architectural deck spacer that is adapted to be attached to a ledger board.

Yet another important object of the invention is to provide an architectural deck spacer that is adapted to be attached to a ledger board and which includes a bolt hole therethrough.

Still yet another important object of the invention is to provide an architectural deck spacer that is adapted to be attached to a ledger board by at least two fasteners that are attached to and extend away from the spacer.

Still yet one other important object of the invention is to provide an architectural deck spacer that is adapted to be attached to a ledger board by at least two fasteners that pass through at least two openings in the spacer.

Still yet one remaining important object of the invention is to provide an architectural deck spacer that is adapted for use on beveled (i.e., angled siding).

Still yet one remaining especially important object of the invention is to provide an architectural deck spacer that is adapted for use on structures that include an uneven exterior surface (stucco, ship lap, etc.) when a variable distance from the surface to a ledger board results in a need to provide a variable thickness of a spacer in order to maintain a plumb orientation for the ledger board.

Briefly, a spacer that is constructed in accordance with the principles of the present invention has a predetermined three dimensional shape. A bolt hole is provided for a bolt to pass through. At least two fasteners that are distally located with respect to the bolt hole are used to secure the deck spacer to a ledger board. The fasteners include screws that pass through countersunk mounting holes in the deck spacer or they may extend away from the deck spacer and be adapted for forced entry (i.e., hammered) into the ledger board. A plurality of the deck spacers are then attached to the ledger board. The bolts holes provide a guide (i.e., a pilot) as to where to drill the holes through the ledger board and then through an exterior portion of a structure. The deck spacers cannot move or rotate once they have been attached to the ledger board. For beveled siding, an angled type of spacer is provided. A plurality of shim spacers are placed intermediate the spacer and the ledger board to accommodate uneven surfaces. According to a modification, a thread is provided in a modified threaded spacer to which threads of the bolt are adapted to cooperate. The threaded spacer can be secured to the inside of the structure (after drilling the holes). The bolts are then passed from the outside of the structure, through the ledger board, and tightened.

DETAILED DESCRIPTION OF THE INVENTION

Referring on occasion to all of the figure drawings and in particular now toFIG. 1, is shown a spacer, identified in general by the reference numeral10.

The spacer10, as shown, includes a predetermined size and shape. The preferred shape is circular with a predetermined thickness. For example, a diameter of at least two inches with a thickness of at least one-eight of an inch is required for the spacer10. However, a diameter of two and one-half inches and a thickness of one-half of an inch is preferred most applications of the spacer10. The smaller thickness (one-eight of an inch) is used for a special shimming purpose and is described in greater detail hereinafter.

Referring momentarily now also toFIG. 4, the spacer10includes a center bolt hole12. A preferred diameter for the center bolt hole12is sufficient to allow a one-half inch diameter bolt15to pass freely through the spacer10. The bolt15is used to secure a ledger board20to a structure16and its use is also described in greater detail hereinafter.

The spacer10includes a plurality of mounting holes14that are used to secure the spacer to the ledger board20(or the structure16). The mounting holes14are counter sunk and accept wood screws or other types of screws or fasteners (not shown).

In use, a plurality of the spacers10are attached to one side of the ledger board20along its longitudinal length at predetermined desired intervals (as are commonly known or which are specified by an architect). The spacers10are preferably staggered above and below a longitudinal centerline as well as on the centerline of the ledger board20, as desired.

Wood screws, nails, or other fasteners, are placed in the mounting holes14and are used to attach the spacers10to the ledger board20where desired. At least two mounting holes14are provided through the spacer10. The mounting holes14are located away from the center bolt hole12and at least two fasteners are used that pass through each of the mounting holes14. Two mounting holes14with fasteners are minimally required to secure each of the spacers10to the ledger board20sufficient to prevent rotation or other movement of the spacers10with respect to the ledger board20.

Once the required number of spacers10have been attached to the ledger board20, a drill (not shown) is used to drill a bolt hole through the ledger board20at each location that aligns with the bolt hole12of each of the attached spacers10. This is easily and rapidly accomplished by using each of the bolt holes12as a pilot hole to place a drill bit (not shown) and drill the holes through the ledger board20.

The ledger board20is then placed adjacent to the structure16and is adjusted and moved until properly located so that it is at the correct height and is level. A couple of nails are used to lightly secure the ledger board20(i.e., to tack the ledger board20) in place. If help is available, the ledger board20is temporarily held in place adjacent the structure16. In either case, the previously drilled holes through the ledger board20and the bolt holes12in the spacers10are now used as pilot holes to drill mounting holes into and through an exterior wall of the structure16.

If help is available and the interior of the structure16is readily accessible, one each of the bolts15is passed through each of the holes through the ledger board20and into the structure16. A nut17is threaded on the end of each bolt15inside of the structure. Each bolt15is tightened to a desired range of torque sufficient to properly retain the ledger board20to an exterior wall (surface) of the structure16. This is repeated at each spacer10location.

A first end of a plurality of joists22are each attached to the ledger board20, either by nails or screws or by the use of joist hangers, any of which are well known in the deck building arts and not shown. An opposite second end of each of the joists22are supported by any of a variety of well known methods as well. A plurality of deck boards24are attached to the tops of the joists22to provide a completed surface for the deck18.

The spacers10maintain the ledger board20a predetermined distance away from the structure (i.e., the thickness of the spacers10). This prevents water from accumulated on the ledger board adjacent to the structure16. Instead, water as well as small debris falls down around the spacers10through the space provided to a location that is beneath the ledger board20. If water were to accumulate, over time it would cause damage to the ledger board20, the structure16, or both. The ledger board20is essential to the design, function, and safety of a deck, the deck being identified in general by reference numeral18.

The spacers10not only provide the required spacing, but they also serve as a pilot to quickly drill the bolt holes through the ledger board20at the proper location and also through the structure16.

The spacers10can be modified to include any preferred shape other than circular, for example square, rectangular, triangular, or other polygonal shape.

The size or diameter affects the bearing area on each opposite planar side of the spacer10and therefore the pressure in pounds per square inch that the surface (side) of each spacer10experiences. A larger diameter (or surface area) for the spacer10allows it to withstand a greater pressure without excessively embedding into either the ledger board20or the structure16.

Accordingly, the surface area of the spacer10is chosen to correspond ideally with the materials used for the ledger board20and the structure16. A soft wood, for example, requires a greater surface area for the spacer10than does a hardwood. Of course, the spacer10can be designed so as to include a surface area sufficient for most applications that are likely to occur thereby providing one size of the spacer10that is suitable for most applications. If desired, the surface area of one side can be less or more than the surface area of the opposite side.

Referring now also toFIG. 3, a first modified spacer50is used. The first modified spacer50includes the center bolt hole12of the spacer. A plurality (at least two) pointed protrusions52are attached to and extend from one planar side of the first modified spacer50. As shown, three pointed protrusions52are radially spaced equidistant from each other and also from the center bolt hole12.

The first modified spacer50is attached to the ledger board20by placing the pointed protrusions52against the ledger board20and then pounding the first modified spacer50with a hammer so that the pointed protrusions52enter into the ledger board20and secure the first modified spacer50to the ledger board20. This process is repeated for all of the first modified spacers50that are to be used. Once the first modified spacers50are attached to the ledger board20, the holes in the ledger board20and into the structure are drilled as was previously described.

Having at least two pointed protrusions52, and preferably three, prevents rotation or other movement of the first modified spacer50on the ledger board20. It is important that such rotation not occur, otherwise the center bolt hole12would move relative to the ledger board20. This would make it difficult to impossible to pass bolts through the spacer10or first modified spacer50from the outside of the ledger board20(on an opposite side where the spacer10,50is not accessible).

While any suitable material including metals can be used for any of the spacers10,50(or others as later described), plastic is preferred. For the first modified spacer50, the pointed protrusions52are either formed (i.e., molded) as an integral part of the first modified spacer50or they are molded into the first modified spacer50.

For example, the pointed protrusions52can be formed of a metal and molded part way into a plastic type of the first modified spacer50sufficient to retain them in position while allowing the pointed ends to extend therefrom. Alternatively, the first modified spacer50and the pointed protrusions52can all be formed of a metal.

Referring now also toFIG. 5, if the outside of the structure16includes beveled siding or an uneven surface (for example, a stucco finish), then both the angle and the thickness of the spacer10may need to be varied. To accomplish this, a second modified spacer100is provided that is similar to the spacer10except a cross section reveals that it includes an angle with respect to a first and a second opposite planar side thereof. The angle is selected to match the taper angle of most common types of beveled sidings (not shown).

Accordingly, the thickness of the second modified spacer100is greater at one end than at an opposite end. The second modified spacer100is attached to an upper portion of the ledger board20so that the thicker end is up (toward the deck boards24) and the thinner end is down (away from the deck boards24). This ensures that the thicker portion of the second modified spacer100aligns with a thinner portion of the beveled siding thereby compensating for the thinner portion of the beveled siding and providing a plumb surface to properly secure the ledger board20.

The second modified spacers100are also attached at various places along the ledger board20, some higher and some lower. The higher ones must overcome a greater disparity in thickness as the beveled siding tapers to greater extend than at a lower location of the beveled siding. Accordingly, the second modified spacers100require a different overall thickness, depending upon where they are attached to the ledger board20and how they align with the beveled siding underneath.

To accommodate this, a plurality of intermediate shim spacers102(only one is shown) are used and are placed in atop the second modified spacer100and between the structure16as needed sufficient to retain the ledger board20plumb. The second modified spacer100is used where the beveled siding is thickest. The intermediate shim spacers102are added (as many as required) wherever the beveled siding is thinner (and therefore further away from the ledger board20).

The intermediate shim spacers102include the center bolt hole12and the mounting holes14and therefore align properly with the second modified spacer100. The screws used to retain the second modified spacer100also retain the intermediate shim spacers102in position. Longer screws may, of course, be needed.

If desired, the intermediate shim spacers102also align with and therefore can also be used with the spacers10(that include parallel opposite surfaces) to provide a variable thickness (i.e., depth) for surfaces that are parallel and plumb but which include variations in depth. This can occur for any number of reasons, for example, trim material (not shown) may be added to the outside of the structure16that protrudes from the normal surface. The use of the intermediate shim spacers102and the spacers10eliminate the need to remove the trim material. This also facilitates the speed of installation.

Many modifications are also possible. For example, recesses can be provided in one or both sides of any of the spacers10,50,100. The recesses can serve a variety of purposes. They save material during formation of the spacers10,50,100and are useful in increasing the pressure (in pounds per square inch) by which the spacers10,50,100attach to the ledger board20or the structure16. This helps set them better in position, lessening the chances of settling. This is important because it decreases the chances that over time, the deck18will loosen or creak when a person walks on the deck boards24. Accordingly, the finished deck will appear to have more quality over a longer period of time than if other attachment means were utilized. If the recesses extend across the width of any of the spacers10,50,100, they also act as a channel to allow water to pass.

Referring now also toFIG. 6, a third modified spacer150is shown. When the inside of the structure16is difficult to access or if help is not available to prevent the nut17(FIG. 4) from rotating when the bolt15head is tightened from the outside of the structure16, the third modified spacer150is preferred.

The third modified spacer150also includes the pointed protrusions52, as previously described. The third modified spacer150however, does not include the standard bolt hole12. Rather, a smaller opening is provided in the center and is tapped with a thread pattern that matches and cooperates with the thread pattern of an end of the bolt15.

In use, after the holes are drilled through the ledger board20and the structure16, the third modified spacer150is pounded into an interior member152of the structure16over each of the holes that have been drilled through the ledger board20and into the structure.

The third modified spacer150covers each hole on an inside of the structure16. When the bolts15are then inserted from the outside of the structure16through the ledger board20and into the structure16, the threaded bolt15ends contact each of the third modified spacers150on an inside of the structure.

The bolts15are then turned (i.e., rotated) from the outside so as to engage the threads in each of the third modified spacers150. The bolts15are tightened from the outside sufficient to properly secure the ledger board20to the structure16. The pointed protrusions52prevent the third modified spacer150from rotating and allow tightening of the bolts15from the outside. Only one person is required to accomplish the entire process.

The third modified spacer150functions in one capacity as a special type of a nut that cannot rotate. The third modified spacer150serves a dual purpose in that it can also be used with smaller diameter bolts (not shown) that do not engage with the center threads but rather pass through them. Therefore the third modified spacer150can be used in the same manner as the first modified spacer50, but with the smaller diameter bolt to secure the ledger board20a predetermined distance away from the structure16.

Accordingly, the third modified spacer150, if used, can function both as a non-rotating type of a nut for use with the larger diameter bolt15or as variation of the first modified spacer50for attachment directly to the ledger board20when used with the smaller diameter bolt.

Referring now toFIG. 7is shown a cross-section of a fourth modified spacer200that includes a threaded interior202that is similar to that of the third modified spacer150and is adapted to cooperate with the threads of the bolt15.

The fourth modified spacer200includes a larger diameter bottom plane204and an opposite smaller plane206. The opposite plane206preferably includes hex shape, identified in general by the reference numeral208, which is provided for ease of tightening.

A plurality of modified mounting holes210are provided for attachment to the ledger board20or to the interior member152of the structure16by the use of screws (not shown).

Accordingly, the fourth modified spacer200can be used in virtually all applications. It can be used in identical fashion to that of the third modified spacer150. If the screws are not used, it can be tightened by using the hex shape208on the opposite plane206. After tightening, the screws can be passed through the modified mounting holes210to ensure that it can never loosen.

Similarly, the screws can be used to prevent the fourth modified spacer200from rotating and then, as was previously described for the third modified spacer150, the bolts15can be passed through the ledger board20and rotated so as to engage with the fourth modified spacer200and secure the ledger board20to the structure16.

If desired, the bolt15can be passed in from the inside of the structure16, out through the ledger board20where the fourth modified spacer200is used to engage with its threads. If a helper is available on the inside of the structure16to prevent rotation of the bolt15, then the fourth modified spacer200can be tightened from the outside using the hex shape208.

The fourth modified spacer200can be used exactly the same as the spacer10if the smaller diameter bolt is used that does not engage with the threads202of the fourth modified spacer200but instead passes through the threads202. In this instance, the hex shape208provides a smaller bearing area that can be used to provide the proper spacing in between the ledger board20and the structure16providing the smaller diameter bolt is not excessively tightened.

The invention has been shown, described, and illustrated in substantial detail with reference to the presently preferred embodiment. It will be understood by those skilled in this art that other and further changes and modifications may be made without departing from the spirit and scope of the invention which is defined by the claims appended hereto.