Abstract:
A guard rail system fabricated from standard-sized components, preferably extruded, comprises balusters fastened to a lower rail and to an upper retainer at fixed intervals. The balusters are provided with central bores for receiving fasteners such as screws through predrilled holes in the upper retainer and lower rail. A hand rail is slip-fitted over the upper retainer in locking relation, to provide integrated guard rail sections. Guard rail sections so assembled are fastened to end posts, preferably using mounting brackets having a flanged arm which nests in grooves or recesses in the upper retainer and lower rail to provide a safe, secure and aesthetically appealing guard rail.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a Continuation of application Ser. No. 10/753,423, filed Jan. 9, 2004, entitled GUARD RAIL SYSTEM, which is a Continuation-in-Part of application Ser. No. 09/994,736, filed Nov. 28, 2001, entitled GUARD RAIL SYSTEM, which are incorporated by reference herein. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to guard rail systems. In particular, this invention relates to a prefabricated guard rail system, components for a guard rail system and kits of components for a guard rail system, which is strong, inexpensive, easy to assemble and self-aligning, and meets the requirements of local building codes. 
     BACKGROUND OF THE INVENTION 
     Guard rails are used around decks, staircases and other elevated structures, to prevent injury and possible death from falling off of the edge of such structures. Most building codes have rigid requirements for guard rails, both in terms of when they are required and certain construction parameters, including for example the maximum spacing between balusters, length of span, height and load requirements. 
     The installation of guard rail systems can be a very labour intensive procedure. Balusters must be installed at precise intervals, and be substantially true to the vertical, both to comply with building code requirements and to be aesthetically acceptable. 
     Guard rails can be constructed from lumber, and frequently are in order to keep costs down. In a typical lumber guard rail construction balusters or pickets are nailed or screwed to top and bottom rails, which in turn are nailed to posts secured to or around the structure. A considerable amount of attention is required to ensure that the balusters are evenly spaced and vertical, and there is a limit to the aesthetic appeal which can be achieved. Moreover, the resulting guard rail is subject to separation, warping and other weathering effects over time, due to limits on the strength and degree of structural integration which can be achieved using nails and lumber. 
     The fabrication of components for guard rail systems can be facilitated by extruding components, for example out of a synthetic wood composition, plastic, aluminium or another suitable material. However, whether cut from lumber or extruded, the assembly and installation of the guard rail requires considerable skill, labour and time in order to construct a guard rail which is both structurally secure and appealing. 
     There is accordingly a need for a guard rail system which is easy to assemble, inexpensive, and produces a durable, structurally integrated guard rail which both meets building code requirements and is aesthetically appealing. 
     SUMMARY OF THE INVENTION 
     The present invention overcomes these disadvantages by providing a guard rail system fabricated from standard-sized components, which is strong enough to meet and exceed building code requirements. According to the invention, balusters which are preferably (but not necessarily) extruded are fastened to a lower rail and to an upper retainer at fixed intervals. The balusters are provided with central bores for receiving fasteners such as screws through predrilled holes in the upper retainer and lower rail. A hand rail is slip-fitted over the upper retainer in locking relation, to provide integrated guard rail sections. In the preferred embodiment guard rail sections so assembled are fastened by means of a special bracket system to end posts to provide a safe, secure and aesthetically appealing guard rail. 
     The invention provides a versatile, easy to assemble and structurally secure guard rail system which can be used in any application where conventional guard rails are used. 
     The present invention thus provides a guard rail system, comprising a top retainer and a bottom rail affixed between at least two posts, a plurality of hollow balusters extending between the top retainer and the bottom rail, each baluster comprising a plurality of inner webs affixed to a wall of the baluster and to a bore for a fastener disposed within the baluster wall, and a hand rail affixed to the top retainer, wherein the balusters are affixed between the top retainer and the bottom rail by fasteners disposed through the top retainer and the bottom rail and into the bore. 
     The present invention further provides a guard rail system, comprising a top retainer and a bottom rail affixed between at least two posts, a plurality of hollow balusters extending between the top retainer and the bottom rail, each baluster comprising a plurality of inner webs affixed to a wall of the baluster and to a bore for a fastener disposed within the baluster wall, and a hand rail affixed to the top retainer, the hand rail having a bearing plate supported by an upper surface of the upper retainer, wherein the upper retainer has an exterior surface having a pair of opposed channels and the hand rail has an internal surface having a pair of complementary projections, whereby the hand rail is affixed to the upper retainer by sliding engagement between the projections and the channels. 
     In further aspects of the guard rail system of the invention: the top retainer and the bottom rail each have a series of pre-drilled holes for receiving the fastening members, to thereby align the balusters; a front of the bottom rail is provided with an upstanding lip spaced from the series of holes by a distance substantially corresponding to a distance between the bore and a front face of the baluster; the upper retainer has an exterior surface having a pair of opposed channels and the hand rail has an internal surface having a pair of complementary projections, whereby the hand rail is affixed to the upper retainer by sliding engagement between the projections and the channels; the hand rail is provided with a bearing plate supported by an upper surface of the upper retainer; a portion of the hand rail above the bearing plate is hollow; the balusters have a substantially square cross section and a substantially central bore; the webs extend from corners of the baluster wall to the bore; the posts are hollow and provided bosses disposed along an interior wall of the post, for abutting against a structural member disposed through each post; and/or the top retainer and bottom rail are affixed to the posts by a bracket comprising a flanged arm having depending flanges spaced apart so as to nest in grooves formed in the top retainer and bottom rail, to thereby interlock the bracket with the top retainer and bottom rail. 
     The present invention further provides a method of assembling a guard rail, comprising the steps of: a. pre-drilling a top retainer and a bottom rail for attachment to a plurality of hollow balusters, the top retainer having an exterior surface having a pair of opposed channels and each baluster comprising a plurality of inner webs affixed to a wall of the baluster and to a bore for a fastener disposed within the baluster wall, b. disposing fasteners through the holes into the bores to affix the balusters between the top retainer and bottom rail, c. sliding a hand rail having an internal surface having a pair of projections complementary to the channels over the upper retainer to engage the projections in the channels, and d. affixing the top retainer and the bottom rail to posts. 
     In further aspects of the method of the invention: the hand rail comprises a bearing plate supported by an upper surface of the upper retainer; the method includes, before step a., the step of extruding the top retainer, bottom rail, balusters and hand rail; each post is hollow and the method includes the steps of anchoring a structural member and disposing the post over a structural member; and/or the top retainer and bottom rail are affixed to the posts by a bracket comprising a flanged arm having depending flanges spaced apart so as to nest in grooves formed in the top retainer and bottom rail, to thereby interlock the bracket with the lower rail and upper retainer. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In drawings which illustrate by way of example only a preferred embodiment of the invention, 
         FIG. 1  is an elevation of a guard rail system according to the invention on a sun deck; 
         FIG. 2  is a cross sectional front elevation of the guard rail system of  FIG. 1 ; 
         FIG. 3  is a cross sectional end elevation of the guard rail system of  FIG. 1 ; 
         FIG. 4  is a cross section of a baluster of  FIG. 1 ; 
         FIG. 5  is a cross section of an end post of  FIG. 1 ; 
         FIG. 6  is a cross section of the upper retainer of  FIG. 1 ; 
         FIG. 7  is a cross section of the lower rail, baluster, upper retainer, and handrail of an embodiment of the invention; 
         FIG. 8  is a side elevational view of a bracket for fastening the guard rail sections to the end posts, according to one embodiment of the invention; 
         FIG. 9  is a plan view of a bracket, according to a further embodiment of the invention; and 
         FIG. 10  is an exploded perspective view of a bracket according to yet a further embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  illustrates a guard rail system  10  according to the present invention. The guard rail system  10  is illustrated in the environment of a sun deck for purposes of example only, however it will be appreciated that the guard rail system is adaptable to any environment in which a conventional guard rail system may be used. 
     In a preferred embodiment the components of the guard rail system are entirely extruded, for example in accordance with the technique described in U.S. Pat. No. 5,516,472 for an Extruded Synthetic Wood Composition and Method for Making Same issued May 14, 1996 to Strandex Corporation, and Canadian Patent No. 2153659 issued Feb. 23, 1999 to Strandex Corporation, which are incorporated herein by reference. However, the components of the invention may alternatively be milled from wood, molded or extruded from plastic or metal, or otherwise suitably formed. The particular material or materials from which the components of the guard rail are formed is limited only by the requirement for sufficient structural strength in the finished railing to comply with building code requirements.  FIGS. 2 and 3  illustrate the various components of the invention, comprising an end post  20 , a lower rail  30 , an upper retainer  40 , balusters  50  and a hand rail  60 . In the preferred embodiment the invention further includes a specially designed bracket  70  for fastening the guard rail sections to the end posts. 
     The end post  20 , illustrated in  FIG. 5 , is preferably hollow and has an interior dimension which allows the end post  20  to be slip-fitted over a structural member  2  (shown in phantom in  FIG. 5 ) such as a 4×4 pressure treated post, 2×4 pressure treated lumber or a 3½ inch steel pipe (for example of the type used in chain link fencing), which is anchored into the ground, deck substructure or other foundation for the guard rail  10 . In the preferred embodiment the end post  20  comprises vertical ridges  22  which snugly abut the four by four post  2  in order to fix the end post  20  in a stable, vertical position. 
     Rail sections are formed by a series of balusters  50  fastened to the lower rail  30  and the upper retainer  40 . The lower rail  30  and upper retainer  40  are preferably predrilled at the desired positions for the balusters, for example 4 inches on-center (OC). 
     The lower rail  30 , shown in  FIG. 7 , preferably comprises a hollow body  32  having decorative flanges  34  depending therefrom, serves to impart aesthetic appeal to the lower rail  30  and to hide the hardware such as screws  4  which secure the balusters  50  and brackets  70  (shown in  FIG. 9 ) which secure the lower rail  30  to the end post  20 . In a preferred embodiment, an alignment lip (not shown) serves the purposes of both aligning the balusters  50  along the lower rail  30  and concealing any small gap between the balusters  50  and the body  32  of the lower rail  30  after the balusters  50  have been fastened thereto. 
     The upper retainer  40 , shown in  FIG. 6 , comprises an abutment plate  42  extending axially along the upper retainer  40  which abuts the top ends of the balusters  50 , and a pair of wings  44  which are preferably dimensioned to overlap the sides of the balusters  50 , holding the balusters  50  in place and keeping them from rotating, as shown in  FIG. 3 . Preferably the row of drill holes  8  is contained within a longitudinal recess  46 , so that the heads of fasteners such as screws  6  or recessed relative to, or at least are flush with, the top face  43  of the upper retainer  40 , thereby avoiding the need to countersink screws  6  when the balusters  50  are fastened to the upper retainer  40 . 
     The hand rail  60 , shown in  FIG. 7 , has an exterior surface  61  configured in any desired shape or pattern for usability and aesthetic appeal. The interior surface  63  of the hand rail  60  is configured to slip-fit over the upper retainer  40 . The hand rail  60  is slip-fit over the upper retainer  40 . Preferably the interior surface  63  has a bearing plate  64  having ridges or bosses  66  which bear on the top surface  43  of the upper retainer  40 , to snugly secure the handrail  60  in position. Preferably there is a hollow between the bearing plate  64  and the upper surface of the hand rail  60 , which increases strength, and reduces the cost and weight of the hand rail  60 . Also, a slight flexibility in the bearing plate  64  and the wings  62  allows the hand rail  60  to grip the upper retainer  40  when slip-fitted thereto. 
     The balusters  50 , shown in  FIG. 4 , may be formed in any desired decorative shape, and may be symmetrical in cross section. Each baluster  50  is hollow and provided with inner webs  52  affixed to the wall of the baluster  50  and supporting a bore  54 , which preferably extends along the entire length of the baluster  50 . In the embodiment shown the balusters  50  each have a square cross section and the webs  52  extend from the corners of the baluster wall toward a central bore  54 . 
     The spacing between the bore  54  and the front outer face  56  of the baluster  50  corresponds to the spacing between the predrilled holes  8  and the wings  44  of the upper retainer  40 , and to the spacing between the predrilled holes  9  and the lip  36  of the lower rail  30 . Thus, when assembled in the manner described below, the balusters  50  will self align against the wings  44  and the lip  36  to align the balusters relative to one another, and to square the balusters relative to the rail section when the upper retainer  40  and lower rail  30  are affixed to the end post  20 . 
     Preferably, the upper retainer  40  and lower rail  30  are affixed to the end post  20  by a bracket  70 , illustrated in  FIG. 8 , comprising a flat arm  72  having screw holes  78 , extending generally perpendicular to an arm  74  having screw holes  78 . The bracket  70  may be stamped or otherwise suitably formed from metal. In a preferred embodiment, depending flanges  76  are provided on the arm  74 , and are spaced apart so as to nest in grooves or recesses  31  and  41  respectively formed in the underside of lower rail  30  and upper retainer  40 , as can be seen in  FIGS. 9 and 10 , thus interlocking with the lower rail  30  and upper retainer  40  for increased strength and stability. In a preferred embodiment, the bracket  70  is configured to permit the upper retainer  40  and the lower rail  30  to be affixed to the end post  20  at an angle. As shown in  FIG. 10 , the bracket  70  may comprise a flat arm  72  having screw holes  78  for affixing to an end post  20 . The bracket  70  further comprises a generally perpendicular flanged arm  74  rotatably mounted on the flat arm  72  by means of a fastener  90 , such as a rivet or another suitable fastening means. The perpendicular flanged arm  74  is provided with screw holes  78  and depending flanges  76 , which are spaced apart so as to nest in the grooves or recesses  31  and  41  formed in the underside of lower rail  30 , and upper rail  40 . The flat arm  72  and the flanged arm  74  may likewise be stamped or otherwise formed from metal. While the fastener  90  in the rotating bracket  70  shown in  FIG. 10  provides rotational movement over a full 360°, when the bracket  70  is mounted in a guard rail assembly, full rotation may be restricted to a range of less than 360°, since full rotation will be hampered by the interference of the upper retainer  40 , lower rail  30 , and the end post  20 . However, with the rotating bracket  70 , the guard rail assembly may be configured to surround an irregularly (non-rectangular) shaped area. 
     In a further embodiment, the bracket  70  is shaped to fit around a vertex of an end post  20 . Referring to  FIG. 9 , the bracket  70  is provided with an angled arm  92 , which is shaped to fit around the corner of an end post  20 , preferably at a 90° angle. The angled arm  92  is provided with screw holes  78  for mounting to the end post  20 . A generally perpendicular flanged arm  74  extends from the angled arm  92 . and is provided with screw holes  78  and depending flanges  76 , which are spaced apart so as to nest in the grooves or recesses  31  and  41  formed in the underside of lower rail  30  and upper rail  40 . In the preferred embodiment, the vertex  93  of the angled bracket  70  shown in  FIG. 12  truncated to provide an edge for the join  95  between the angled arm  92  and the flanged arm  74 . If the angled bracket  70  is integrally formed, for example by metal stamping or another suitable method, when formed the bracket  70  may be bent along the join  95 . Alternatively, if the bracket  70  is formed from a separate flanged arm  74  and an angled arm  92 , the join  95  may be formed by spot welding or other means. 
     To assemble the guard rail of the invention, the end posts  20  are fitted over suitably dimensioned structural posts  2  such as four-by-four treated lumber, and positioned to rest on the deck, floor, stair or other elevated structure. The rail sections are assembled by driving fasteners such as screws  6  through the predrilled holes  8  in the upper retainer  40  into the bores  54  in the balusters  50 . The lower rail  30  is similarly fastened to the bottom ends of the balusters  50  by driving fasteners such as screws  6  through the predrilled holes  9  into the bores  54 . The rail section so constructed is integrated and structurally secure. The rail sections may be constructed to any suitable length, and can be assembled to a single length of lower rail  30  and upper retainer  40 , depending upon the material from which the rail section is formed. 
     A length of hand rail  60  is cut to match the length of the assembled rail section, and slip-fitted over the upper retainer  40  by aligning ridges or bosses  62  with channels  48  and sliding the hand rail  60  along the upper retainer  40  until the upper retainer  40  is fully concealed. The rail section is then mounted between end posts  20  by brackets  70  affixed to the upper retainer  40  and lower rail  30  using suitable fastening members, in the case of a wood composite or synthetic wood composite, preferably bolts with wood or other suitable inserts (not shown), and preferably screws  6  extending through the wall of the end post  20  into the structural member  2  for strength. 
     It will be appreciate by those skilled in the art that the particular configurations of the components of the guard rail system of the invention may be altered to suit specific installation parameters and/or aesthetic or decorative requirements. For example, the embodiment illustrated shows plain-faced, square-shaped balusters  50 , however the balusters  50  can be formed in any other desired configuration as long as the bore  54  is spaced from the front face  56  of each baluster in a manner which allows the front face  56  to align with the lip  36  of the lower rail  30 . In the embodiment shown the side faces  58  of the balusters  50  are equidistant from the bore  54 , however this is not essential and a precise on-center spacing between balusters  50  can be obtained even if the baluster  50  is not laterally symmetrical relative to the bore  54 . 
     Various embodiments of the present invention having been thus described in detail by way of example, it will be apparent to those skilled in the art that variations and modifications may be made without departing from the invention. The invention includes all such variations and modifications as fall within the scope of the appended claims.