Abstract:
An apparatus for use in forming a deck includes a platform having alternating elevated and depressed sections defining a plurality of troughs for receiving a hardenable fill material such as concrete, and at least one elongate cover segment positioned on a terminal edge of the platform. The cover segment includes a first side that covers the terminal edge of the platform, a second side angled in relation to the first side, and a plurality of outwardly extending flanges positioned on the first side such that the flanges contact the elevated sections. The flanges sit on top of the elevated sections, and the second side of the cover piece is positioned underneath the depressed sections. The cover segment is maintained on the platform by frictional engagement of the flanges and the elevated section and frictional engagement of the second side of the cover segment with the depressed sections.

Description:
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION 
   The invention relates to an elevated deck, and a method and apparatus for building a deck, particularly a concrete deck. The decking system of the present invention provides an efficient means for constructing a deck that requires minimal upkeep and maintenance. The decking system is particularly suited for residential applications, however, it can also be used in other environments such as commercial settings. 
   Most decks in residential settings are made of wood, which typically require regular maintenance as they are subject to decay and termite damage. Ultimately, a wooden deck must be totally replaced, requiring substantial labor to remove and discard the old structure and replace it with a new one. 
   In conventional deck construction, a recreational wooden deck is attached to the side of a house and typically involves a deck ledger being fastened to wall sheathing and flashed before finish siding is attached to the adjacent wall. A frame is then constructed out from the wall and supported by posts. Deck joists are connected to the deck ledger and the frame to underlay and support deck planking. In addition, existing raised decking systems require masonry support systems around the outer edges with a masonry “row lock” on the top of the supporting walls to retain a hardenable building fill material, which is typically concrete in such construction. A compacted fill is used to fill the void under the concrete or a metal pan system is used supported by and terminating at the masonry wall and “row lock” accordingly. 
   The present invention replaces the wooden deck system typically used in residential settings with a concrete deck. The present invention replaces the deck joists with metal pans which span from the house to a support beam, and provides a usable outdoor living area above while maintaining a relatively dry area below. 
   SUMMARY OF THE INVENTION 
   Therefore, it is an object of the present invention to provide a deck that can be attached to the outer band of a residence in a similar fashion as wooden decks are typically attached today. 
   It is another object of the invention to provide a concrete or similar deck that can be formed, poured and stamped with a decorative pattern. 
   It is yet another object of the invention to provide a deck that requires minimal maintenance, and is resistant to decay and termite infestation. 
   These and other objects of the present invention are achieved in the preferred embodiments disclosed below by providing an apparatus for use in forming a deck having a platform with alternating elevated and depressed sections that define at least one pan trough for receiving a hardenable fill material such as concrete, and an elongate cover segment positioned on a terminal edge of the platform. The cover segment includes a first side that covers the terminal edge of the platform, a second side angled in relation to the first side and positioned underneath the depressed section of the platform, and at least one outwardly extending flange positioned on the first side such that the flange contacts the elevated section of the platform. 
   According to a preferred embodiment of the invention, the flange sits on top of the elevated section, and the cover segment is maintained on the platform by frictional engagement of the flange and the elevated section and frictional engagement of the second side of the cover segment and the depressed section. 
   According to another preferred embodiment of the invention, the platform comprises a plurality of alternating elevated and depressed sections defining a plurality of troughs for receiving the hardenable fill material. 
   According to yet another preferred embodiment of the invention, the decking system includes a second elongate cover segment and a connector, and the first cover segment is positioned adjacent the second cover segment, the connector is positioned at a junction of the first and second cover segments, and the first and second cover segments are connected to each other by insertion a fastener in the connector and the first cover segment and a fastener in the connector and the second cover segment. 
   According to yet another preferred embodiment of the invention, the decking system includes a second elongate cover segment and a connector having first and second recessed portions for receiving an edge portion of a respective one of the first and second cover segments, in which the first and second cover segments are joined together by frictional engagement with the connector. 
   According to yet another preferred embodiment of the invention, the cover segment includes a plurality of outwardly extending flanges positioned on the first side such that each of the plurality of flanges contacts a respective one of the plurality of elevated sections of the platform, in which each of the plurality of flanges is attached to a respective one of the plurality of elevated sections. 
   According to yet another preferred embodiment of the invention, the plurality of flanges are formed by machine stamping a plurality of rectangular openings in the first side of the cover segment and bending a rectangular piece to an angle of about ninety degrees relative to the first side of the cover. 
   According to yet another preferred embodiment of the invention, each of the plurality of flanges sits on top of a respective one of the plurality of elevated sections of the platform. 
   According to yet another preferred embodiment of the invention, the plurality of flange members is attached to a respective one of the plurality of elevated sections by insertion of a fastening member through the flanges and the elevated sections. 
   According to yet another preferred embodiment of the invention, the second side of the cover segment is positioned underneath the plurality of depressed sections of the platform. 
   According to yet another preferred embodiment of the invention, the elevated section of the platform is attached to the cover segment by insertion of a fastener into the flange of the cover segment and the elevated section. 
   According to yet another preferred embodiment of the invention, the depressed section of the platform is attached to the cover segment by insertion of a fastener into the second side of the cover segment and the depressed section. 
   According to yet another preferred embodiment of the invention, the first side of the cover segment is substantially perpendicular to the second side. 
   According to yet another preferred embodiment of the invention, the cover segment includes a third side angled in relation to the first side. The third side extends substantially perpendicularly from a top end of the first side, the second side extends substantially perpendicularly from a base end of the first side, and the flange extends substantially perpendicularly from a position on the first side intermediate the top and base ends. 
   According to yet another preferred embodiment of the invention, the first side of the cover segment is substantially perpendicular to the elevated and depressed sections of the platform. 
   According to yet another preferred embodiment of the invention, a removable strip is positioned on a top surface of the third side of the cover. As such, removal of the strip reduces the amount of hardenable fill material on the top surface. 
   According to yet another preferred embodiment of the invention, the platform is mounted on at least one support member so that the platform is elevated above the ground surface. 
   According to yet another preferred embodiment of the invention, an apparatus for use in forming a deck includes a platform having alternating elevated and depressed sections defining at least one trough for receiving a hardenable fill material, and a plurality of flanges, in which each of the plurality of flanges extend substantially perpendicularly from a terminal edge of one of the elevated and depressed sections. An elongate cover segment covers the terminal edge of the platform and is attached to the flanges of the platform. 
   According to yet another preferred embodiment of the invention, a fastener is inserted through each of the plurality of flanges and the cover segment to attach the cover segment to the platform. 
   According to yet another preferred embodiment of the invention, a method of making a deck includes the steps of providing a platform having alternating elevated and depressed sections defining at least one trough for receiving a hardenable fill material, and providing an elongate cover segment for positioning on a terminal edge of the platform. The cover includes a first side adapted for covering the terminal edge of the platform, a second side angled in relation to the first section and adapted for positioning underneath the depressed section of the platform, and at least one outwardly extending flange positioned on the first side such that the flange contacts the elevated section. The cover segment is positioned on the terminal edge of the platform, and the second side of the cover segment is positioned underneath the depressed section of the platform. The flange is attached to the elevated section of the platform. 
   According to yet another preferred embodiment of the invention, concrete is poured on the platform. 

   
     BRIEF DESCRIPTION OF THE FIGURES 
     Some of the objects of the invention have been set forth above. Other objects and advantages of the invention will appear as the invention proceeds when taken in conjunction with the following drawings, in which: 
       FIG. 1  is a partial perspective view of a decking system according to a preferred embodiment of the invention; 
       FIG. 2  is another partial perspective view of the decking system of  FIG. 1 ; 
       FIG. 3  is another partial perspective view of the decking system of  FIG. 1 ; 
       FIG. 4  is another partial perspective view of the decking system of  FIG. 1 ; 
       FIG. 5  is another partial perspective view of the decking system of  FIG. 1 ; 
       FIG. 6  is another partial perspective view of the decking system of  FIG. 1 ; 
       FIG. 7  is another partial perspective view of the decking system of  FIG. 1 ; 
       FIG. 8  is another partial perspective view of the decking system of  FIG. 1 ; 
       FIG. 9  is another partial perspective view of the decking system of  FIG. 1 ; 
       FIG. 10  is an environmental perspective view of the decking system of  FIG. 1 ; 
       FIG. 11  is another partial perspective view of the decking system of  FIG. 1 ; 
       FIG. 12  is another partial perspective view of the decking system of  FIG. 1 ; 
       FIG. 13  is another partial perspective view of the decking system of  FIG. 1 ; 
       FIG. 14  is a perspective view of a decking system according to another preferred embodiment of the invention; 
       FIG. 15  is a partial perspective view of the decking system of  FIG. 13 ; and 
       FIG. 16  is a perspective view of a component of the decking system of  FIG. 13 . 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Referring now specifically to the drawings, an apparatus for use in forming a deck according to a preferred embodiment of the invention is illustrated in  FIG. 1 , and shown generally at reference numeral  10 . The decking system  10  generally comprises a platform  12  and a cover piece  20 . The platform  12  is preferably rectangular, and the cover piece  20  is positioned on a longitudinal edge  14  of the platform  12 . The decking system  10  is particularly suited for building concrete decks, however, the decking system  10  can be used in conjunction with other suitable hardenable fill materials, such as grout, mortar, and various mixtures of water, sand, gravel crushed stones and/or other aggregates. 
   As shown in  FIG. 1 , the platform  12  is fluted such that it has alternating depressed sections  16  and elevated sections  18 , thereby creating a pan with a series of troughs  17  that can receive concrete or other suitable hardening fill material. The platform  12  is preferably made of metal. The platform  12  is supported above the ground surface “G” by a support structure. The support structure can include beams (not shown) directly underneath the platform  12  supported by posts  50 . The beams can be treated Parallam beams, treated wood two-by-tens or two-by-twelves, steel beams or other suitable structure. The posts can be metal tubes, treated wood four-by-fours or six-by-sixes, or other suitable structure. 
   The cover piece  20  is preferably made of metal, and has first, second and third sides  21 ,  22 ,  23 , respectively. The first side  21  is sized to cover the longitudinal end  14  of the platform  12 . The second side  22  extends outwardly from a base end  25  of the first side  21 , and the third side  23  extends outwardly from the top end  26  of the first side  21 . The second and third sides  22 ,  23 , are preferably perpendicular to the first side  21 , but can extend at other angles relative to the first side  21 . Between the base end  25  and top end  26  of the first side  21 , a plurality of flanges  28  extend outwardly from the first side  21 . The flanges  28  are preferably perpendicular to the first side  21 , but can be at other angles as well. The flanges  28  are shown in  FIG. 1  to be positioned on the first side  21  about mid-way between the base end  25  and top end  26 , however, the position of the flanges  28  on the first side  21  can vary depending on the depth of the troughs  17 . The second side  22 , third side  23  and flanges  28  all extend outwardly from the first side in the same direction. 
   The flanges  28  are positioned at a height on the first side  21  of the cover piece such that when the cover piece  20  is positioned on the longitudinal edge  14  of the platform  12 , the second side  22  of the cover piece  20  is underneath and adjacent to the depressed sections  16  of the platform  12 , and the flanges  28  are above and adjacent to the elevated sections  18  of the platform  12 . As shown in  FIG. 2 , the cover piece  20  is placed onto the longitudinal edge  14  of the platform  12 , and can be lightly hammered into position. Once in position, the cover piece  20  can be held in place on the longitudinal edge  14  of the platform  12  by the frictional engagement of the flanges  28  on the elevated sections  18  of the platform  12 , and the second side  22  of the cover piece  20  with the depressed sections  16  of the platform  12 , as shown in  FIG. 3 . The cover piece  20  is a self-bracing form that stays in place without outside bracing. 
   The flanges  18  are preferably formed by machine stamping rectangular openings  27 ,  27 ′ in the first side  21  of the cover piece  20 , shown in  FIG. 5 , and bending the stamped out portion to an angle of approximately ninety degrees relative to the rest of the first side  21 . Holes  29  can be formed in the flanges  28  to facilitate insertion of fasteners  39 , such as screws, nails, pins or other fasteners, through the flanges  28  and into the elevated sections  18  of the platform  12  to securely attach the cover piece  20  to the platform  12 , as shown in  FIG. 4 . 
   Depending on the total length of the longitudinal end  14  of the platform  12 , additional cover pieces can be utilized. For example,  FIG. 5  illustrates a second cover piece  20 ′ being positioned on the longitudinal end  14  of the platform  12  after the first cover piece  20 . The second cover piece  20 ′ is identical in structure to the first cover piece  20 , and therefore is not described in further detail. The first and second cover pieces  20 ,  20 ′ are joined together by a connector  30 . The connector  30 , which is similarly shaped as the cover pieces  20 ,  20 ′, is inserted between the first cover piece  20  and the platform  12 , such that a part of the connector  30  is between the first cover piece  20  and the platform  12 , as shown in  FIGS. 6 and 7 . The second cover piece  20 ′ is then positioned on the longitudinal end  14  of the platform  12  adjacent to the first cover piece  20 , such that the second cover piece  20 ′ contacts the exposed portion of the connector  30 . As such, the connector  30  resides between the junction of the first and second cover pieces  20 ,  20 ′ on one side, and the platform  12  on the other side, as shown in  FIG. 8 . The cover pieces  20 ,  20 ′ can then be securely connected by inserting fasteners  39  through the cover pieces  20 ,  20 ′ and into the connector  30 , as shown in  FIG. 9 . 
   As shown in  FIG. 10 , side pieces  40 ,  40 ′ are mounted on the lateral edges  15 ,  15 ′, respectively, of the platform  12 . The side pieces  40 ,  40 ′ are similar in structure to the cover pieces  20 ,  20 ′, except that they do not have flanges  28 . As shown in  FIG. 11 , side piece  40  is positioned on lateral edge  15  of the platform  12 , and mounted thereon with L-brackets  42 . The other side piece  40 ′ is mounted on the other lateral edge  15 ′ of the platform  12  in similar fashion, and therefore is not shown in further detail. Side piece  40  is connected to the cover pieces  20  using corner brackets  44 , as shown in  FIGS. 3 and 12 . Side piece  40 ′ is attached in a similar fashion, and therefore is not shown in further detail. 
   Maintaining the connectors  30 , L-brackets  42  and corner brackets  44  inside of the cover pieces  20 ,  20 ′ and side pieces  40 ,  40 ′ provides an aesthetically pleasing appearance. In addition, a decorative piece (not shown) can be mounted on the cover pieces  20 ,  20 ′ and side pieces  40 ,  40 ′, and can be powder coated to allow for a black coating or other colors. 
   As shown in  FIG. 10 , the decking system  10  is preferably used in conjunction with an adjoining building structure, such as house “H”. The platform  12  includes a second longitudinal end  14 ′ opposite the first longitudinal end  14  and proximate the house “H”. As shown in  FIG. 13 , a plurality of threaded rods  19  are mounted at spaced apart intervals to the house “H” and extend approximately four to six inches onto the platform  12 . As such, the exposed portions of the rods  19  are buried in the concrete when it is poured on the platform  12 , thereby securely connecting the concrete to the house “H”. This secure connection is particularly important in the event of an earthquake or other similar natural disaster. 
   Once assembled, concrete or other hardening fill material can be poured onto the platform  12  and allowed to harden. Once the concrete has hardened, a variety of flooring materials can be laid on the concrete to provide a functional and aesthetically pleasing floor surface for the deck. A variety of flooring imprints, such as brick, stone or wooden imprints can be utilized. 
   An alternative embodiment of a decking system according to a preferred embodiment of the invention is illustrated in  FIG. 14 , and shown generally at reference numeral  100 . The decking system  100  generally comprises a platform  112  and a cover piece  120 , both of which are preferably metal. The platform  112  is fluted such that it has alternating depressed sections  116  and elevated sections  118 , thereby creating a series of troughs  117  that can receive concrete, or other suitable fill material. Flanges  108  extend upwardly from the depressed and elevated sections  116 ,  118  of the platform  112 , at an angle of approximately  90  degrees relative to the depressed and elevated sections  116 ,  118 . 
   The cover piece  120  has first, second and third sides  121 , 122 , 123 , respectively. The first side  121  is sized to cover the longitudinal end of the platform  112 . The second side  122  extends perpendicularly from a base end  125  of the first side  121 , and the third side  123  extends perpendicularly from the top end  126  of the first side  121 . 
   The cover piece  120  is attached to the platform  112  by insertion of a fastener through holes  109  in the flanges  108  of the platform  112  and into the first side  121  of the cover piece  120 . A removable strip  128  can be placed on the top surface of the third side  123  of the cover piece  120 . The strip  128  protects the cover piece  120  from concrete while pouring. After the concrete has been poured, stamped and has been set up, the strip  128  is removed and discarded and a decorative “C” channel piece can be installed to the cover piece  120 . Another benefit of the strip  125  is to create a recessed area for the decorative piece to fit. This allows for cleaning of the deck  100  without debris collecting on the edge of the deck  100  under the top edge of the recessed area. In addition, it provides a finished edge to the concrete and may be powder coated to match railings used on the deck  100 . 
   In order to accommodate various sizes of platform  112 , additional cover pieces can be utilized by use of a connector  130 . As shown in  FIG. 14 , a second cover piece  120 ′ can be connected to the first cover piece  120  via connector  130 . The connector  130  has the same general U-shape of the cover pieces  120 ,  120 ′. As shown in  FIG. 15 , the connector  130  has two C-channels  132 ,  132 ′ recessed in opposite sides of the connector  130  for receiving longitudinal edge portions of the cover pieces  120 ,  120 ′, respectively. A median section  134  of the connector  130  divides the C-channels  132 ,  132 ′. The C-channels  132 ,  132 ′ are shaped and sized such that the connector  130  frictionally engages the cover pieces  120 ,  120 ′. As such, the cover pieces  120 ,  120 ′ can be joined together by the connector  130 , as shown in  FIG. 14 , and is held in place without the need for fasteners such as bolts or pins. In addition, the connector  130  hides the edges of the cover pieces  120 ,  120 ′. 
   A decking system and method of using same are described above. Various details of the invention may be changed without departing from its scope. Furthermore, the foregoing description of the preferred embodiments of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation—the invention being defined by the claims.