Abstract:
The invention provides a system, method, and components for assembling and disassembling boardwalks, decks, and platforms. The invention has a number of extruded and interlocking components. It is installed by driving piles, preferably helical piles, into a ground surface. The invention provides a comprehensive set of assembly members, including and not limited to brackets that attach to the piles, headers, joists, cross braces, decking, and decking fasteners for holding the decking in place. In particular, a multiple-way adjustable bracket connects the piles to the rest of the structure.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims priority from U.S. Provisional Patent Application Ser. No. 60/701,666, filed Jul. 22, 2005. 
     
    
     FIELD OF THE INVENTION  
       [0002]     This invention relates to modular decking systems.  
       BACKGROUND OF THE INVENTION  
       [0003]     It is a significant conventional construction project to install a deck or a similar structure such as a dock, boardwalk, or platform, whether it is a permanent installation or a temporary one. The equipment needed to install the conventional deck can be very disruptive to the ground surface affecting the appearance of a lawn or a park or affecting the ecosystem in wetlands. Also, the skill and care needed to precisely place and fasten together the components of the deck is time consuming and costly—especially when equipment must be submerged to reach a stable underground surface. Further adding to the cost and skill required, the deck is often custom built on site.  
         [0004]     A modular deck system, such as the one described in U.S. Patent Application, Publication No. 2005/0025465 by Osfolk, allows the deck to be assembled in smaller portions. Pre-manufactured deck modules have the advantage of requiring less on-site assembly. However, such conventional modular or pre-manufactured decks require precise placing of piers or piles and either require significant fastening with screws or bolts, or are not significantly sturdy. Further, pre-manufactured decks tend to be quite heavy and cumbersome with regard to the shipping, handling, and placement of the decks. Even further, the length of time it takes to assemble conventional modules causes delays in the advancement of the equipment along the modules.  
         [0005]     Conventional decking systems tend to have relatively weak connections between a wooden joist and a header. Such systems utilize joist hangers that are fastened to the side of a header and to the end of the joist. Such connections to the end of the joist lack significant shear strength and the connection may be a weak point in the system.  
         [0006]     Therefore, a modular decking system that has a simple assembly and a minimal impact on the ground surface while being sturdy enough to support foot traffic and light vehicles is desired. Further, a decking system with structurally superior joints over conventional systems in critical areas is desired.  
       SUMMARY OF THE INVENTION  
       [0007]     The invention comprises, in one form thereof, a system, method and components for assembling and disassembling boardwalks, decks, bridges, platforms and similar structures (“deck” will be generally used to denote a boardwalk, deck, bridge, platform, or similar structure hereinafter). The invention has a number of extruded and interlocking components. It is installed by driving piles, preferably helical piles, into a ground surface. The invention provides a comprehensive set of assembly members, including and not limited to brackets that attach to the piles, headers, joists, cross braces, decking, and decking fasteners for holding the decking in place. The components of the invention are useful together with each other and also with conventional structural members. In particular, a multiple-way adjustable bracket connects the piles to the rest of the structure. Piles often encounter subsurface impediments and cannot be set at their precise desired locations. The pile bracket adjusts for off-set piles.  
         [0008]     More particularly, the invention includes a relatively lightweight modular decking system, comprising a plurality of piles (which may comprise aluminum) having a helical portion configured to be driven into a ground surface; a pile bracket that engages a top end of each of the piles; a plurality of headers, each attached to two of the pile brackets; a plurality of joists each being attached to two of the headers; and a plurality of deck planks that are attached to a top portion of the joists or decking connectors. The pile brackets are adjustable wherein each of the pile brackets are rotatable about a center axis of the pile and translatable along the center axis of the pile. Further, each of the pile brackets include a saddle assembly that is translatable along a slot in the pile bracket in a direction that is substantially perpendicular to the center axis of the pile. The saddle assembly is rotatable about a fastener and is capable of being leveled, such as by a plurality of set screws or a partial ball joint. The deck planks may be attached to the joists by an injection molded connector strip having a plurality of spacer posts separating said deck planks. The connector strip may further include a plurality of clips provided in pairs, wherein the deck planks each include a pair of tabs, and wherein each pair of clips is configured for mating with the pair of tabs on one of the deck planks. The header may include a plurality of joist holders, and the joists may be placed in said joist holders to attach the joists to the headers.  
         [0009]     In another form, the invention includes a method for installing a modular deck. The method comprises the steps of driving a first set of helical piles and a second set of helical piles (which may be aluminum) into a ground surface, wherein the piles each have an adjustable pile bracket on a top end of the pile; providing a plurality of headers having a plurality of header brackets; affixing one of the headers to each of the first and second sets of piles via the pile brackets such that the header brackets of the header affixed to the first set of piles are aligned with the header brackets of header affixed to the second set of piles; inserting a joist into each of the aligned header brackets; and placing a plurality of deck planks on the joists. The method may further comprise the steps of driving a third set of helical piles into the ground surface, wherein the piles of the third set each have an adjustable pile bracket on a top end of the piles; affixing a header to the third set of piles via the pile brackets such that the header brackets of the header attached to the third set of piles are aligned with the header brackets of the header attached to the second set of piles; inserting an additional joist into each of the aligned header brackets of the headers attached to the second and third sets of piles; and placing a plurality of additional deck planks on the additional joists. The method may further include installing additional modules as needed. In a temporary application of the decking system, the method includes the further step of disassembling the deck planks from the joists, the joists from the headers, and the headers from the piles, and then removing the piles from the ground surface. A further step of reinforcing the joists with cross-braces may also be included. The step of placing the deck planks may comprise the steps of connecting a plurality of connector strips to one or more of the joists, the connector strips having a plurality of pairs of clips; and, for each of the deck planks, snapping a pair of tabs integral with the deck plank into one of the pairs of clips.  
         [0010]     In another form, the invention includes an adjustable decking bracket having multiple degrees of freedom. The bracket comprises a base plate defining a slot; a collar affixed to a bottom surface of the base plate, which is rotatable about a center axis of the collar; a saddle assembly that has a protuberance connected to the base plate by a fastener through the slot; and a vertical adjustment fastener engaging the base plate and a support structure. The saddle assembly may include a plurality of set screws or a hub, such as a partial ball joint, in a saddle base for leveling the saddle assembly relative to the base plate. Further, the saddle assembly is translatable along the slot of the base plate and rotatable about the fastener connecting the protuberance to the slot of the base plate.  
         [0011]     In another form, the invention includes an end cap for a plurality of decking planks. The end cap comprises a tube providing a chase-way; a lens-receiving portion on a side of the tube; a connection portion on a bottom surface of the tube, the connection portion being configured to be attached to a frame element. The connection portion may be configured to snap into a groove in a joist. The end cap may include a plurality of lamps within said tube, and it may form an ADA-compliant curb.  
         [0012]     In another form, the invention includes a helical pile comprising an aluminum shaft and an inclined plane extending from a portion of the shaft in a helical shape. The inclined plane may be made of aluminum and may be welded to or integral with the shaft. The helical pile may also include a second inclined plane extending from a second portion of the shaft, extensions to add length, or both.  
         [0013]     In another form, the invention includes a header for a modular decking system. The header comprises a header beam having a first side and a second side; and a plurality of joist holders welded to or integral with the first side of said header beam. The header beam may be made of extruded metal or structural steel and the header beam and the joist holders may be made of aluminum. Alternatively, the header may be cast or molded material. A second plurality of joist holders may be welded to or integral with the second side of the header beam. The joist holders define a pair of aligned notches for engaging a fastener through an end of a joist to guide the placement of the joist.  
         [0014]     In another form, the invention includes a connector strip for affixing deck planks to a joist. The connector strip comprises a base configured for engaging a joist; a plurality of spacer posts projecting upward from the base; and a plurality of pairs of clips, wherein each pair of clips is configured for engaging a pair of tabs associated with a deck plank. The connector strip may further include a first end with a male connector and a second end with a female connector such that the male connector connects to a female connector of another connector strip. The base may be configured for sliding into a groove in an extruded joist. The connector strip may be configured such that no fasteners are required to connect the connector strip to the joist or to connect the deck plank to the connector strip. The connector strip may also be connected to conventional lumber.  
         [0015]     It is an advantage of the invention that the boardwalk, deck or platform provides a support for pile installation equipment. As one section of the platform is assembled, the installation machine may advance to the end of the platform to install piles for the next section. The decking system according to the present invention may be rapidly installed and the equipment may advance without stalling for significant periods of time to wait for a new module to be installed. The invention may also be used as a bridge.  
         [0016]     The structures made in accordance with the invention may be installed in protected environments, such as wetlands, nature preserves, swamps, marshes and beaches. The installation provides minimal disruption to the environment. The structures may also be installed as decks for home use. In another embodiment the structures may be installed temporarily at a location that needs a hardstand to support a number of people, such as a stage for a band in a park. After the event is over, the structure may be disassembled and removed.  
         [0017]     A further advantage of the invention is that the header comprises integral or pre-welded joist holders that have significantly higher shear strength than conventional joist hangers. Thus the header provides an improved long-range structural integrity over conventional systems, which may be compromised at this junction.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0018]     The present invention is disclosed with reference to the accompanying drawings, wherein:  
         [0019]      FIG. 1  is an isometric view of a deck module according to the present invention;  
         [0020]      FIGS. 2A-2D  are views of the helical pile and pile bracket of  FIG. 1 ;  
         [0021]      FIG. 3  is an isometric view of an alternative pile bracket;  
         [0022]      FIGS. 4A-4C  are views of the saddle assembly of  FIGS. 2A-2D ;  
         [0023]      FIGS. 5A-5D  are views of a header of  FIG. 1 ;  
         [0024]      FIGS. 6A and 6B  are views of a joist of  FIG. 1  with a connector strip attached to the top of the joist in  FIG. 6A ;  
         [0025]      FIGS. 7A-7   d  are views of a connector strip;  
         [0026]      FIG. 8  is an end view of a deck plank of  FIG. 1 ;  
         [0027]      FIG. 9  is a side view of a portion of the connector strip of  FIGS. 7A-7D  with a deck plank connected thereto;  
         [0028]      FIG. 10  is an end view of an end cap;  
         [0029]      FIG. 11  is an end view of a joining strip;  
         [0030]      FIG. 12  is an isometric view of a cross-brace assembly; and  
         [0031]      FIGS. 13A and 13B  are views of a brace of  FIG. 12 . 
     
    
       [0032]     Corresponding reference characters indicate corresponding parts throughout the several views. The examples set out herein illustrate several embodiments of the invention but should not be construed as limiting the scope of the invention in any manner.  
       DETAILED DESCRIPTION  
       [0033]     Referring to  FIG. 1 , there is shown the modular deck of the present invention. The deck module  10  includes a number of helical piles  12 , a pair of headers  14 , joists  16 , and a number of deck planks  18 .  
         [0034]      FIG. 1  shows the deck module  10  as having four piles  12 ; however, more or less piles  12  may be used as warranted by the application. For example, additional piles  12  may be required for additional support of the headers  14  or the joists  16 . The helical pile  12  is best shown in  FIGS. 2A-2D  and includes a shaft  19  and a helical portion  20  for driving the pile  12  into a ground surface and a top end  22  that engages a pile bracket  24 . The helical portion  20  includes an inclined plane  21  extending from the shaft  19  in a helical shape. The shaft  19  is cylindrical, as shown in  FIG. 2C ; however, the shaft  19  may alternatively be substantially any shape, such as a rectangular tube. The pile  12  may include multiple helical portions  20  each having an inclined plane  21 . Because the pile  12  is driven into the ground by providing a downward force to the shaft  19  and turning the pile to screw the inclined plane  21  into the ground rather than providing a high-impact vertical force to the pile, the pile  12  may be made of not only hardened steel or wood, but also of aluminum, aluminum alloys, and similar materials. In a particular embodiment, the piles  12  are hollow tubes that may be reinforced with concrete, steel, or both.  
         [0035]     Though any bracket may be used to connect the pile  12  to the header  14  (or joists  16 ), the pile bracket  24  of the present embodiment is adjustable by rotation about the axis of the pile  12 , elevation relative to the pile  12 , distance from the axis of the pile  12 , and rotation about an axis offset from the axis of the pile  12 . The bracket  24  includes a collar  26 , a base plate  28 , and a saddle assembly  30 . The base plate  28  is supported by the collar  26  and supports  32  that are welded or otherwise affixed to the collar  26  and the base plate  28 . A fastener  34  engages a tapped hole in the base plate  28  and is substantially aligned with the axis of the collar  26 . A disk  36  having a tapped hole for mating with the fastener  34  is welded or otherwise affixed to the top end  22  of the pile  12 . When assembled to the pile  12 , the collar  26  and base plate  28  may be rotated about the axis of the pile  12 . The collar  26  and base plate  28  also may be raised and lowered in relation to the pile  12  by turning the fastener  34 . In alternative embodiments, the collar may be other shapes, such as the square collar shown in  FIG. 3 .  
         [0036]     The saddle assembly  30  is best shown in  FIGS. 4A-4C  and includes a saddle base  38  and vertical plates  40  welded or otherwise affixed to the top of the saddle base  38 . Slots  41  in the vertical plates  40  allow the header  14  to be attached to the pile bracket  24  by fasteners. The saddle base  38  includes several set screws  42  and a downward-directed protuberance  44  with a clearance hole for a fastener. The set screws  42  allow fine adjustment of the elevation of the saddle assembly  30  as well as leveling of the saddle assembly  30 . A fastener is inserted through the clearance hole in the protuberance  44  and through a slot  46  in the base plate  28 , as shown by  FIG. 2D . Until the fastener is tightened, the saddle assembly  30  may slide along the slot  46  as well as rotate about the fastener. Thus, the pile bracket  24  is highly adjustable to allow the header  14  to be placed substantially parallel and level with the previously placed header by compensating for variation in the placement of the pile  12 .  
         [0037]     It should be noted that multiple pile extensions may be coupled together with the piles to allow deeper penetration into the ground surface as may be required by the application.  
         [0038]     The header  14  is best shown in  FIGS. 5A-5D  and includes an welded or cast header beam  48  and several joist holders  50 . In the illustrated embodiment, the header beam  48  is extruded with grooves on the top and bottom. The end of the header beam  48  is shown as open in the figures to illustrate its shape; however, it is preferred that the end be covered by a cap or a plate after the header beam  48  is cut to length in pre-manufacturing. The header beam  48  is placed between the vertical plates  40  of two or more brackets  24  and aligned substantially perpendicular to the intended direction of travel of the deck by adjusting the brackets  24 . Fasteners inserted through the slots  52  in the vertical plates  40  and a through hole in the header beam  48  to secure the header  14  to the pile bracket  30 . The joist holders  50  are welded or cast in place on the header beam  48  to provide a strong support for the joists  16 . In alternative embodiments, the joist holders  50  may be fastened in place, such as by rivets, bolts, or screws. The joist holders  50  are aligned such that a joist  16  may be run between two joist holders of two headers  14  and be oriented substantially parallel to the direction of travel of the deck.  
         [0039]     In the case that the joist holders  50  are welded onto the header beam  48 , they may be cut from a flat piece of material and bent into the U-shape shown in the figures with a bending break or other machine. An angled notch  54  in each side of the joist holder  50  guides a fastener through the end of the joist  16  to provide proper placement of the joist within the joist holder  50 . The fastener is tightened to secure the joist  16  to the header  14  and no other fasteners are required, though additional fasteners may be used.  
         [0040]     The joist  16  is a tubular beam similar to the header beam  48 , though the joist  16  may have a different length. The cross-section and the end of the joist  16  are shown in  FIGS. 6A and 6B , respectively. The groove features on the top and bottom of the joist  16  provide for snap-connections with cooperating components, such as the connector strip  60 , which is described in more detail below. Alternatively, cooperating components slide into the grooves from an end of the joist  16 . The outermost joists in the deck module  10  may include railing supports  56  ( FIG. 1 ) that are welded, fastened, or otherwise affixed to the outer side of the joist. These supports  56  may be as simple as boxes for receiving the legs of a railing  58  as shown in  FIG. 1 .  
         [0041]     The deck planks  18  are affixed to the joists  16  via a connector strip  60  shown in  FIGS. 7A-7D . The connector strips  60  each have a pair of walls  62  that go into the slots in the top of the joists  16  and include clips  64  that retain the connector strip  60  in connection with the joist  16  (see  FIG. 6A ). The connector strips  60  may be included on the outermost joists  16  only or on some or all of the inner joists  16 . The connector strips  60  may be connected in series along the length of the joist  16  by coupling a male connector end  66  to a female connector end  68 .  
         [0042]     The connector strips  60  guide the evenly spaced placement of the deck planks  18  along the joists  16  with spacer posts  70 . Each connector strip  60  accommodates several deck planks  18 . The deck planks  18  may be any substantially rigid material, such as hard plastic, wood, plastic molded with wood, aluminum, or other materials. In one embodiment, the deck planks  18  have a cross-section as shown in  FIG. 8 , and each includes a pair of tabs  72  configured for mating with clips  74  on the connector strip  60 , as shown in  FIG. 9 . This mating relationship allows the deck planks  18  to be placed without requiring fasteners, though fasteners may be used for further securing the planks. The joint between two connector strips  60  provides space for a deck plank  18  so that the plank may be affixed to the connector strips over the joint. In an alternative embodiment, the deck planks  18  are conventional planks and are fastened to the connector strips  60 . In a further alternative embodiment, the deck planks  18  are affixed directly to the joists  16  by fasteners, adhesives, or another suitable method. It should be noted that the connector strips  60  may be configured to be attached to any frame element by a snap-connection, fasteners, or adhesives.  
         [0043]     In an alternative embodiment, the connector strips  60  are fastened to conventional lumber and the deck planks  18  may be affixed atop.  
         [0044]     An end cap  76 , shown in  FIG. 10 , may be included running parallel to the joists  16  and covering the ends of the deck planks  18 . The end cap  76  may act as a bumper for wheel chairs as required by the Americans with Disabilities Act or for light vehicles. The end cap  76  may also be tubular, as shown in the current embodiment, to provide a chase-way  78  for electrical wiring, water, etc. A lens receiving portion  80  is included on the side of the end cap  76  facing the deck planks  18  so that light from lamps inside the chase-way  78  may be directed onto the top of the planks. The end cap  76  includes a connection portion  82  with a clasp  84  that engages a groove in the top of the outer joists  16 .  
         [0045]     A joining strip  86 , shown in cross-section in  FIG. 11 , may be included to compensate for elevation changes or turns from one deck module  10  to another. The joining strip  86  includes a top platform  88  that may be angled as required and a pair of tabs  90  that engage grooves in the top of a header  14 .  
         [0046]     The joists  16  may be reinforced by cross-brace assemblies  92 , shown in  FIG. 12 , having two braces  94  adjoined at a fulcrum  96  by a fastener. Each brace  94  includes a vertical member  98  welded to the bottom surface of a top member  100 . The top member  100  includes a protrusion  102  at each end for hooking into a groove in the top or bottom of a joist. The cross-brace assembly  92  is assembled by hooking the protrusions  102  of a first brace  94  into the grooves in the tops of adjacent joists  16 . A second, inverted brace  94  is brought up underneath the first brace such that the protrusions  102  of the second brace  94  engage grooves in the bottoms of the adjacent joists  16  and the fulcrum halves meet to form the fulcrum  96 . A fastener is inserted into the fulcrum  96  to secure the cross-brace assembly  92 . Several cross-brace assemblies installed between each set of adjacent joists  16  will significantly strengthen the deck module  10  without adding substantial weight to the structure.  
         [0047]     The structural elements of the deck module  10 , such as the piles  12 , the headers  14 , the joists  16 , and the cross-brace assemblies  92 , are made of aluminum, aluminum alloy, or a similarly strong, lightweight material according to the present embodiment. Further, these components are generally tubular as shown in the figures, to keep the weight of the components down. Other elements of the module are made of lightweight materials such as lightweight plastics and wood. Therefore the components of the module  10  may be easily transported by a person or a light vehicle.  
         [0048]     In use, the modular deck system may be assembled in a variety of locations, such as in a field, in wetlands, or in a body of water, without significantly affecting the location. In an example, the deck system is installed as a dock in a body of water or a boardwalk through wetlands and the deck modules  10  are installed with the personnel and equipment situated on a previously installed deck module. No equipment is required to be submerged or driven though the wetlands to install the modules. Thus, the only impact on the ground surface by the deck system is the driving of the piles  12  into the ground surface. However, as the application warrants and allows, the system may also be installed at ground level.  
         [0049]     The deck module  10  is assembled by driving a first set of piles  12  and a second set of piles  12  into a ground surface. In the current embodiment, each set of piles includes two piles  12 ; however, additional piles  12  may be used to further support the headers  14 , the joists  16 , or both. The helical piles  12  are installed by applying vertical force and rotating the pile  12  to screw it into the ground or wetland floor. A pile bracket  24  is assembled onto the top of each pile  12  and adjusted so that the saddle assembly  30  is level and the headers  14  may be aligned substantially parallel to each other. One header  14  is fastened to the saddle assemblies  30  of the first set of piles  12  and the second header  14  is fastened to the saddle assemblies  30  of the second set of piles  12 . The pile brackets  24  are finely adjusted such that the headers  14  are level and aligned and the joist holders  50  of one header  14  are each aligned with a joist holder  50  of the opposite header  14 . A bolt or other fastener is inserted through a hole near each end of each joist  16  such that the bolt extends through both sides of the joist. Each joist is then placed into two aligned joist holders  50  with the bolts engaging the notches  54 . The bolts are mated with nuts and tightened to secure the joist  16 . Four joists  16  are used in the illustrated embodiment, though more or less may be required in specific applications. Several of the cross-brace assemblies  92  are assembled between each pair of adjacent joists  16  as needed.  
         [0050]     The walls  62  of the connector strips  60  are inserted into grooves in the tops two or more of the joists  16  and connected in series by the connector ends  66 ,  68 . The connector strips  60  may be secured to the joists  16  by fasteners. The deck planks  18  are placed between the spacer posts  70  and connected to the connector strips  60  by a snap connection, fasteners, or both. The end caps  76  are connected to the outermost joists  16  and over the edges of the deck planks  18 . The railings  58  may then be inserted into the railing supports  56 .  
         [0051]     A subsequent module is assembled from the first module by driving a third set of piles  12  into the ground surface relatively aligned with the first and second sets of piles  12 . Imprecise placement of the piles  12  is compensated by the adjustable pile brackets  24 . A third header  14  is attached to the pile brackets  24  of the third set of piles and the brackets are adjusted such that the header is level and aligned with the second header  14 . Several joists  16  are placed into the joist holders  50  of the second and third headers  14 . The remaining components are assembled as described with the first module  10  above. Additional modules are likewise added as required. Because interlocking, preformed components are used in the construction of the deck module  10  and few fasteners are required, disassembly of the deck module  10  is made simple.  
         [0052]     In an alternative embodiment, the components of the deck module are made of a stronger, heavier materials, such as steel. The system retains its advantages of rapid installation and strong joints, though heavier equipment may be required to transport the heavier materials. This alternative embodiment would be useful, for example, for a temporary, high-strength bridge for heavy equipment in a military setting.  
         [0053]     It should be particularly noted that certain deck modules  10  may have angled planks and curved joists for turning corners. In this case, the headers  14  are aligned such that the curved joists may be placed in the joist holders  50 . Further, the headers  14  may be aligned for gradual changes in elevation. In this case, the joist holders  50  may be slanted to accommodate the angled joists  16 .  
         [0054]     It should be further noted that several of the components of the deck module  10  of the present invention may be used separate from the other components of the module. The header  14  with the integral or welded-on joist holders  50  may be used to support conventional wooden joists or the header may be supported by structural elements other than piles. The connector strip  60  may be configured to engage dimensional lumber or other materials instead of the extruded joists  16 . The pile bracket  24  may be used in any application that may benefit from a wide range saddle bracket. The aluminum helical piles  12  may be used in any situation requiring a lightweight or corrosive resistant pile.  
         [0055]     While the invention has been described with reference to preferred embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof to adapt to particular situations without departing from the scope of the invention. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope and spirit of the appended claims.