Abstract:
A corrosion resistant railing insert including a stainless steel upper body for insertion into a railing post and including channels for liquid drainage from the railing post, an elongated stainless steel mounting arm protruding from the upper body. The mounting arm has a smaller cross-sectional area than the upper body, which are integrally associated as a unitary device. The upper body is secured within a railing post while the mounting aim is inserted into a complimentary aperture or sleeve formed in a concrete substrate and secured therein with an adhesive.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to handrails and more specifically to corrosion resistant handrails to be installed in concrete balconies. 
     2. Description of Related Art 
     The aluminum handrail industry suffers from a serious problem. Hundreds of millions of dollars are spent each year on repairing concrete balcony edges and replacing railings due to the corrosion that occurs when aluminum is embedded in concrete in a harsh (beach or salty) environment. The problem arises because the concrete balcony edges are reinforced with steel reinforcement bars. These reinforcement bars are located between 1.5″-2″ from the edge of the concrete slab. Typically, when installing an aluminum handrail, a post must be embedded into the concrete. Thus, it is necessary to drill a large hole, which oftentimes cuts or contacts the steel reinforcements. Consequently, when the aluminum posts are installed, they are in contact with the steel reinforcement bars and cause electrolysis, in which the aluminum becomes the sacrifice metal and expands. When the aluminum expands, it begins to disintegrate and the surrounding concrete spalls. 
     Most bases around the aluminum post are composed of gypsum, which deteriorates over time. When the posts are used in a coastal setting, the deterioration produces a pocket and allows for saltwater intrusion. When this occurs, the surrounding concrete becomes less alkaline and causes the reinforcement to expand and form hairline fractures in the concrete. When moisture seeps into the pocket around the post, the aluminum oxidizes and expands. The combination of these effects creates a safety issue because the concrete loses strength and structure. 
     Several attempts to create further stability in the handrail business have been presented. For example, U.S. Patent Application number 2004/0177586 published by McLean on Sep. 16, 2004 is entitled BALUSTER RETAINING MEMBER. This patent discloses a baluster retaining member for connecting the end of a baluster to an opening in a rail of a railing system. The rail and baluster sections are oriented with respect to one another at an angle so that when the baluster is connected to the rail by the member and the rail is positioned for use adjacent a stairway at an angle from the horizontal, the baluster is oriented vertically. 
     U.S. Pat. No. 6,484,471 issued to Steed on Nov. 26, 2002 is entitled ADHESIVE FIXED ANCHORS. An anchoring member is disclosed for anchoring an object to a supporting surface having a bore for receiving the anchoring member. The anchoring member comprises an elongate cylindrical body having a penetrating end arranged to be embedded in the bore and an exposed end opposite the penetrating end. An adhesive compound arranged to be coated about the penetrating end of the body secures the body within the bore. 
     U.S. Pat. No. 6,311,957 issued to Driscoll et al. on Nov. 6, 2001 is entitled DEVICE AND METHOD FOR ATTACHING BALUSTERS. This patent related to a device for attaching a polygonal baluster end to a handrail or base. This device includes a connector which is generally cylindrical. This connector also defines an internal axial channel having a polygonal cross-section. The axial channel is adapted to receive the polygonal baluster end. 
     U.S. Pat. No. 5,888,334 issued to Abraham on Mar. 30, 1999 is entitled METHOD OF INDICATING THE LOCATION AND DEPTH OF AN ANCHOR IN A HOLE IN A SUBSTRATE AND DRILLING THROUGH FILL MATERIAL TO THE ANCHOR. The invention is a fixture that can be readily mounted to a surface by embedding and adhering an internally threaded anchoring element in a hole in the surface. The fixture can then be removed and replaced or the fixture can be removed and the hole covered. The end of the fixture is also threaded so that it firmly attaches to the anchor. 
     U.S. Pat. No. 5,807,051 issued to Heminger on Sep. 15, 1998 is entitled DIELECTRIC ADHESIVE INSERT ANCHOR, and discloses a dielectric adhesive insert anchor including an anchor body and a screw member for insertion into a drilled hole in a substrate containing an adhesive. A friction segment includes an internally threaded cavity in which to receive a screw member. An adhesion segment includes a cylindrical section and a plurality of saucer-shaped buttons positioned along its length ending with a terminal button. Both the anchor member and screw members are preferably constructed of carbon steel or stainless steel. 
     U.S. Pat. No. 4,930,284 issued to Falco on Jun. 5, 1990 is entitled MASONRY ANCHOR. This patent teaches a masonry fastening system in which a porous sleeve filled with a hardenable adhesive mass is inserted in a hole interconnecting two or more masonry elements with an anchoring pin having a tapered or conical shape, the anchoring pin being insertable into the sleeve, through the hardenable mass. 
     U.S. Pat. No. 3,893,271 issued to Kotlarz on Jul. 8, 1975 is entitled BASIC BEAM STRUCTURAL MEMBER AND STRUCTURES BUILT THEREFROM. The &#39;271 patent relates to a high-strength, lightweight, basic beam of a single shape which can serve as a column, truss, girder, jamb or other structural member whereby an entire structure can be built using the same basic beam for all of the structural members. The basic structure comprises a unitary, elongated rigid beam having a pair of parallel, opposed channel-shaped portions connected by a pair of spaced walls positioned inwardly from the sides of the channels to define a longitudinally extending slot therebetween and a pair of opposed recesses. 
     U.S. Pat. No. 3,835,615 issued to King, Jr. on Sep. 17, 1974 is entitled FASTENER JOINT CONSTRUCTION. This reference illustrates a joint assembly including work pieces with aligned holes of a prescribed diameter therethrough, a fastener in the holes and having a shank portion a prescribed amount less in diameter than the holes, and a metal sleeve member positioned between the shank portion of the fastener and the work pieces within the holes and in bearing contact with both the shank portion and the work pieces. 
     Finally, U.S. Pat. No. 3,810,339 issued to Russo on May 14, 1974 is entitled METHOD AND APPARATUS FOR FORMING CONSTRUCTION ELEMENT LOCATING AND MOUNTING VOIDS IN A POURED CONCRETE STRUCTURE, and illustrates an assembly comprised of desirably spaced sleeves interconnected to a framework within a concrete form by means of noncorrosive studs protruding from the base of each sleeve. The sleeves provide receptacles for mounting guardrails. 
     However, none of the prior art references, either alone or in combination with one another, teach or suggest the particular solutions to the problems addressed by the instant invention. 
     Accordingly, what is needed in the guardrail and handrail industry is an improved embed system that removes the possibility of corrosion and concrete spalling, thus increasing the length of the life and safety of the balcony and guardrail. It is, therefore, to the effective resolution of the aforementioned problems and shortcomings of the prior art that the present invention is directed. However, in view of the guardrail and handrail systems in existence at the time of the present invention, it was not obvious to those persons of ordinary skill in the pertinent art as to how the identified needs could be fulfilled in an advantageous manner. 
     SUMMARY OF THE INVENTION 
     The present invention contemplates an improved and modified railing system which is corrosion resistant, as well as a method for the installation. The system designs are applicable to both new construction and the repair of existing rail systems. The invention is a stainless steel insert that is placed inside a rail post and then is secured to the post for structural rigidity. The stainless steel insert has an enlarged head or upper body, and lower arm which exits the bottom of the railing post when installed. This lower arm can constitute a rod, pin, stud or shaft of varying shapes, for example cylindrical, rectangular, hexagonal, oblong or other shape as desired. In a primary embodiment, the lower arm is a cylindrical rod having a smaller radial dimension and cross-sectional area than the upper body. 
     The lower arm, and relatively narrow end, may be serrated, notched or may be smooth. A discontinuous surface assists with stability, bonding with concrete, and permanent mounting. The stainless steel insert has the aforementioned upper body, being a larger section that has a similar shape complementing the railing post and is sized to be friction fit within the railing post. The larger upper section also is equipped with channel means which allow any moisture or liquid to exit the railing post. The upper section may have any applicable shape depending on the rail posts used in design of the system, for example, square, cylindrical, hexagonal, or the like. The stainless steel insert are preferably composed of either 304 or 316 stainless steel, as they are alloys highly compatible with both aluminum and concrete. 304 and 316 stainless steel can handle alkaline and acidic conditions in the most corrosive conditions because they have a low carbon content. As an alternative design, the insert may be constructed of aluminum. The upper section and the lower arm may be cast aluminum to be one piece. The use of aluminum and either 304 or 316 type stainless steel prevents electrolysis and corrosion of the aluminum and eventual spalling of the concrete. 
     The method of installing the stainless steel insert is also an improvement. A hole is drilled into a concrete balcony. The hole is between one and one and a half inches in diameter and a depth of between 2 and 3 and one half inches depending on the load requirement of the post. Drilling a hole with such a small diameter prevents unwanted contact with the reinforcement bars. 
     The stainless steel insert is then inserted into the drilled hole and is secured with an epoxy or an acrylic adhesive which does not deteriorate over time as does concrete. Further, the epoxy or acrylic is impervious to water. The epoxy or acrylic will not expand or contract with the concrete. The epoxy or acrylic bonds with both the concrete and the stainless steel insert and this property prevents saltwater intrusion. 
     In accordance with the instant invention, it is an object thereof to provide an improved corrosion resistant railing and method for installation. 
     It is a further object to provide a corrosion resistant railing that allows water or moisture to escape. 
     It is a further object to provide corrosion resistant railing that will not cause the rust stains usually present with traditional drilling methods. 
     It is a further object to provide corrosion resistant railing that will not cause electrolysis and spall the concrete. 
     It is a further object to provide a corrosion resistant rail system that is cost effective and operationally efficient. 
     Finally, it is an object to provide a corrosion resistant rail system that provides all of the above mentioned features and objectives. 
     In accordance with these and other objects which will become apparent hereinafter, the instant invention will now be described with particular reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a cross sectional view of a railing as found in the prior art. 
         FIG. 2  shows a cross sectional view of the present invention corrosion resistant railing insert. 
         FIG. 3  shows a top plan view of a particular shape of the corrosion resistant railing insert and the railing post into which it is inserted. 
         FIG. 4  shows a top plan view of a second particular shape of the corrosion resistant railing insert and the railing post into which it is inserted. 
         FIG. 5  shows a top plan view of a third particular shape of the corrosion resistant railing insert and the railing post into which it is inserted. 
         FIG. 6  shows an exploded perspective view of the corrosion resistant railing insert and the railing post into which it is inserted. 
         FIG. 7  shows an underneath perspective view of the corrosion resistant railing insert inserted into the railing post. 
     
    
    
     DETAILED DESCRIPTION 
     The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious modifications will occur to a person skilled in the art. 
       FIG. 1  shows a cross sectional view of a railing  18  as found in the prior art. The railing  18  is inserted into a concrete balcony slab  10 . The railing  18  is most likely composed of aluminum. A hole  14  is drilled into the concrete slab  10  in order to insert the railing  18 . The drilled hole  14  should be around four inches in diameter and three and a half inches in depth and must be drilled as close to the edge of the concrete slab  10  as possible. The railing  18  is secured within the hole  14  through the use of an hydraulic or gypsum based cement  16 . When drilling the hole  14 , steel reinforcement bars  12  often obstruct the path of the drill and the bars  12  may be accidentally cut. Each time the reinforcement bars  12  are cut, electrolysis occurs. When this occurs, the aluminum post  18  becomes the “sacrifice metal” and causes it to expand. When the aluminum post  18  expands, the surrounding concrete  16  begins to spall and causes the aluminum post  18  to disintegrate. The type of aluminum used in composing the hand railing varies, however it is always an alloy. For structural extrusions such as posts, the type of aluminum used shall be 6061-T6 or 6005-T5 Alloy/Temper. For all other extrusions such as caps, pickets, mid and bottom rails, the aluminum used shall be at least 6063-T5. For castings, the aluminum used must be high quality prime material or materials remelted from a prime extrusion. The grout typically used is nonshrink, nonmetallic grout or erosion resistant anchoring cement. 
     Posts may be anchored into concrete by means of preset sleeves into concrete. After the posts have been inserted into sleeves, fill the space between the post and sleeve solid with anchoring material. First anchor posts into concrete by core drilling holes not less than 3″ deep and 1″ greater than the outside diameter of the post. Clean the holes of all loose material, insert the posts, and fill the space between the post and concrete with anchoring material. The anchoring material used can be either nonshrink, nonmetallic grout or anchoring cement. Leave the anchoring material down approximately ½″ to allow for the final topping with a waterproof material matching the surrounding areas. Whenever possible, fill the holes with waterproof topping slightly higher than the adjacent surfaces and taper and taperaway from the post. 
     Over time, the gypsum based material or cementitious grouts  16  around the aluminum post  18  deteriorates. When the gypsum based material  16  deteriorates, it forms a vacant pocket around the aluminum post  18  and thus allows moisture or liquid to enter. Oftentimes, these types of railings are used in coastal settings and are thus subject to infiltration by saltwater. When saltwater invades, the surrounding concrete slab  10  becomes less alkaline in nature. When the concrete slab  10  becomes less alkaline, the reinforcement bars  12  expand due to corrosion. When the reinforcement bars  12  expand, the concrete  10  begins to form hairline cracks which allow the intrusion of further saltwater causing further spall. This reaction spreads and reduces the structural integrity of the concrete slab  10 , causing damage to a balcony and may cause the aluminum railing  18  to become loose and fall off. 
       FIG. 2  shows a cross sectional view of the present invention corrosion resistant railing insert  22 . The railing insert  22  is inserted into a concrete slab  10  having reinforcement bars  12 . A hole  32  is drilled into the concrete slab  10  with a relatively small diameter of between one inch and one and one half inches. Further, the hole  32  will have an embed of between two inches and three and one half inches. The depth of the embed depends upon the load requirement of the railing  20 . With such a small hole  32  drilled, the reinforcement bars  12  are not at risk of being cut and causing electrolysis. 
     The railing insert  22  is comprised of a narrow diameter lower arm  26  and an upper body with larger surface area  24 . The upper body  24  inserts into the railing post  20  and the lower arm  26  inserts into the hole drilled into the concrete slab  10 . The lower arm  26  is secured within the drilled hole  32  with an epoxy or acrylic adhesive  28  that is impervious to water. This adhesive  28  will not expand or contract as does the gypsum based concrete  16 . Further, the adhesive  28  bonds with both the concrete  10  and the railing insert  22  and thus prevents any intrusion of water. It is further contemplated that an escutcheon  30  may be inserted between the upper body  24  of the railing insert  22  and the concrete balcony  10 . 
     It is important to note that in the preferred embodiment, the upper body  24  does not contact the cement slab. Air gaps and spaces  29  assist with drainage, as described hereinafter. An escutcheon  30  is largely cosmetic, and can be discontinuous to avoid interference with drainage. The railing insert  22  may be comprised of aluminum, it may also be comprised of either type 304 or type 316 stainless steel because 304 and 316 stainless steel are the only alloys that are compatible with aluminum and concrete. 304 and 316 stainless steel do not react to alkaline and acidic conditions in the most corrosive environments due to their low carbon content. It is also contemplated that the railing insert may be constructed of aluminum.  FIG. 3  shows a top plan view of a particular shape of the corrosion resistant railing insert  22  and a particular shape of the railing post  20  into which it is inserted. The particular railing insert  22  in  FIG. 3  has a square shaped upper body  34 , the body further containing a plurality of channel means  35 , which provide for drainage of deleterious liquid. In one embodiment, the mounting arm or lower arm  26  of the instant invention can be a cylindrical rod which extends through the upper body  24 , and is integral thereto. In alternative embodiments, the upper body  24  and mounting arm  26  constitute a unitary device. It is contemplated that the upper body  24  and the mounting lower arm  26  can be cast together and composed of aluminum. The channel means  35  allows any liquid to exit the railing post  20 . The channel means  35  can be rectangular or curved grooves of different geometries, or recesses within the upper body  24  which allow liquid outflow from the rail post. 
     The upper body  24  is also significant, in that it strengthens the rail post itself. The upper body  24  is a substantial metal support for the base of the aluminum rail, is mounted internally, and is a much stronger metal. 
       FIG. 4  shows a top plan view of a second particular shape of the corrosion resistant railing insert  22  and the railing post  20  into which it is inserted. At the center of the insert  22  can be a cylindrical rod  26  which extends through the upper body  24  to become the lower arm  26 . The second embodiment for the particular railing insert  22  in  FIG. 4  has a circular cylindrical body  36  and four channel means or fins  37  which protrude from the body  36 . The fins  37  allow any liquid to exit the railing post  20 , through the vacant spaces between any two adjacent fins. 
       FIG. 5  shows a top plan view of a third particular shape of the corrosion resistant railing insert  22  and the rounded railing post  38  into which it is inserted. At the center of the insert  22  is a cylindrical rod  26  which extends through the upper portion  24  to become the lower arm  26 . The third particular railing insert  22  in  FIG. 5  has a circular cylindrical body  40  and four short channel means or fins  41  which protrude from the body  41 . The railing post  38  into which the railing insert  22  is inserted is also circular. The fins  41  allow any liquid to exit the railing post  38 . 
       FIG. 6  shows an exploded perspective view of the corrosion resistant railing insert  22  and the railing post  20  into which it is inserted. The figure shows that a handrail  42  is connected to the railing post  20 . The upper body  24  of the railing insert  22  is inserted into the bottom of the railing post  20 . The lower arm  26  remains outside of the railing post  20  when installed. 
       FIG. 7  shows an underneath perspective view of the upper body  24  of the corrosion resistant railing insert inserted into the railing post  20 . As shown, once the upper body  24  is inserted, it is secured in place through a variety of methods  44 . It is contemplated that the upper body  24  may be secured with welding, hydraulic press fitting, glue, pinch pressing, or able to be set with a stainless steel screw.