Patent Publication Number: US-8529157-B2

Title: Bracket system for building a deck or dock on a rock face

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority from U.S. provisional patent application No. 61/265,883 filed Dec. 2, 2009, the entirety of which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The invention relates generally to support brackets and pilings for decks. 
     BACKGROUND OF THE INVENTION 
     Building a deck or dock over a lake or other body of water generally requires the use of pilings driven into the bottom of the lake or other body of water adjacent the shore. After driving a sufficient number of pilings into the bottom, the deck could then be built onto the pilings. While this method does provide for a secure structure, driving pilings into the bottom adjacent the shore is often difficult. Furthermore, the pilings, being exposed to the water, can suffer damage as a result of the freezing of the water. Also, this method is particularly difficult to apply in areas where the shoreline consists of hard rock since it is difficult to drive pilings into hard rock. 
     An alternative approach to building a dock or deck over the water is to use a plurality of pedestal type pillars which rest on the water&#39;s bottom, as opposed to being driven into the bottom. While easier to construct, this is not a practical approach for building a permanent structure as the silt and mud on the bottom tends to cause the pillars to shift. 
     Yet another approach is to build a floating dock or deck which uses a plurality of floats or pontoons to support the decking Again, while convenient, this approach does not lend itself to building a permanent structure. An improved system for building a dock or deck which extends over water which overcomes the disadvantages of the prior art is therefore required. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect of the present invention, there is provided an improved bracket and method for constructing a dock or deck over water on a rocky shore line. The present invention includes a base bracket structure having opposite first and second ends, the base bracket being mountable to the rock by a plurality of anchor bolts. A boom having opposite first and second ends is pivotally connected to the base bracket structure adjacent the first end of the angle brackets such that the boom can be set at an angle relative to the base bracket structure, the boom being configured to mount the deck or dock thereon. The improved structure further includes a support rod having opposite first and second ends, the first end of the support rod being pivotally connected to the base bracket structure. The support rod is coupled to the boom by a connector joint located on the boom at a point on the boom between the booms opposite first and second ends. The connector joint is configured to selectively adjust the angle of the boom relative to the base bracket portion such that the boom is substantially horizontal. The connector joint is further configured to fix the boom in place relative to the base bracket portion. 
     In accordance with another aspect of the present invention, there is provided an improved support bracket for supporting a deck or dock over a hard rock shore which overcomes the disadvantages of the prior art. The improved support bracket includes a base bracket structure consisting of a pair of identical angle brackets each having a top web, a bottom web extending perpendicularly from the top web, and opposite first and second ends. The pair of angle brackets are arranged in parallel with the opposite first and second ends in alignment and with the top webs adjacent each other. The angle brackets are further oriented such that the bottom webs are coplanar and oriented away from each other. The pair of identical angle brackets are separated from each other by a gap. A plurality of apertures are formed on the bottom web of the angle brackets, said apertures dimensioned to receive anchor bolts for anchoring the base bracket structure to the rock forming the shore. The support bracket further includes a boom having opposite first and second ends, the first end of the boom being pivotally connected to the base bracket structure adjacent the first end of the angle brackets such that the boom can be set at an angle relative to the base bracket. The boom is configured to mount the deck or dock thereon. The mounting bracket further includes a long threaded rod having opposite first and second ends, the first end of the long threaded rod being pivotally connected to the base bracket structure by a pivoting anchor member extending between the angle brackets adjacent the second end of the angle brackets. The long threaded rod is coupled to the boom by a connector joint located on the boom at a point on the boom between the boom&#39;s opposite first and second ends. The connector joint is configured to selectively adjust the angle of the boom relative to the base bracket portion such that the boom is substantially horizontal. The connector joint is further configured to fix the boom in place relative to the base bracket portion. 
     In accordance with another aspect of the present invention, there is provided an improved method for constructing a dock on a rocky shore using a plurality of support brackets as described in the preceding paragraphs. The method includes the steps of drilling a plurality of anchor holes into the rock, the anchor holes each being dimensioned to receive one of the anchor bolts. Each anchor bolt is then secured in its respective hole with an adhesive. A plurality of base bracket structures are then secured to the anchor bolts. The angle of each of the booms is then adjusted such that the booms are all substantially horizontal and coplanar. Finally, the deck or dock is then constructed on top of the booms. 
     With the foregoing in view, and other advantages as will become apparent to those skilled in the art to which this invention relates as this specification proceeds, the invention is herein described by reference to the accompanying drawings forming a part hereof, which includes a description of the preferred typical embodiment of the principles of the present invention. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a dock constructed using the support bracket and method of the present invention showing the support bracket supporting a deck on a relatively shallow rock face. 
         FIG. 2  is a perspective view of a dock constructed using the support bracket and method of the present invention showing the support bracket supporting a deck on a relatively steep rock face. 
         FIG. 3  is a top view of the base bracket portion of the support bracket of the present invention. 
         FIG. 4  is a side view of the base bracket portion of the support bracket of the present invention. 
         FIG. 5  is a top view of the boom portion of the present invention. 
         FIG. 6  is a side view of the boom portion of the present invention. 
         FIG. 7  is a side view of the support rod portion of the present invention. 
         FIG. 8  is a front view of the base bracket portion of the support bracket of the present invention. 
         FIG. 9  is a front view of the boom portion of the present invention. 
         FIG. 10  is a side view of the pivoting anchor member of the present invention. 
         FIG. 11  is a side view of the connector joint portion of the present invention. 
     
    
    
     In the drawings like characters of reference indicate corresponding parts in the different figures. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring firstly to  FIG. 1 , a deck or dock constructed over a hard rock shore in accordance with one aspect of the present invention is shown generally as item  10  and includes a deck  11  supported on hard rock surface  9  by support bracket assembly  12 . Deck  11  is a standard deck preferably made of pressure treated lumber or the like. Hard rock surface  9  is any hard rock as is often found in places such as the Canadian shield. Preferably, hard rock surface  9  is a continuous mass of rock such as granite or basalt or other similar solid hard rock. Support bracket assembly  12  includes base bracket portion  14 , a boom portion  16  and an elongated support rod  18 . Base bracket portion  14  is bolted to hard rock surface  9  by means of a plurality of anchor bolts  20  and nuts  21 . Bottom web portion  24  of the base bracket is provided with a plurality of apertures dimensioned to receive the anchor bolts. Each bolt is secured to the bottom web portion by nuts  21  which are threaded onto each of the bolts both below and above web portion  24  so as to secure the web portion between two nuts. Each bolt  20  is secured in a hole  22  which is drilled several inches into the hard rock surface and then held in place by rock adhesive or cement. To ensure ease of installation, bolts  20  are sufficiently long so as to ensure that base bracket portion  14  is at least an inch or so away from the surface of hard rock surface  9 ; however, if the hard rock surface is particularly uniform and flat it is possible to mount the base bracket so that the base bracket contacts the hard rock surface. 
     Referring now to  FIGS. 3 ,  4  and  8 , base bracket  14  is formed from a pair of steel angle brackets  25  each having a top web portion  34  and a bottom web portion  26  and opposite ends  30  and  32 . The pair of angle brackets are held in parallel with their bottom web portions in coplanar arrangement and secured by support members  36  which are welded to each of the angle brackets. A plurality of apertures  38  are formed on the bottom web portions  26  of each angle bracket, the apertures being dimensioned to receive anchor bolts  20  (see  FIG. 1 ). Apertures  40  and  42  are provided on the top web portions  34  of angle brackets  25  adjacent ends  30  and  32 , respectively. As will be explained below, aperture  40  is formed to permit the pivotal connection of boom  16  to base bracket  14  while aperture  42  permits pivotal connection of support rod  18  to the base bracket. 
     Preferably angle brackets  25  and support members  36  are made of galvanized steel to inhibit the corrosion of the brackets. Alternatively, the entire bracket  14  could be galvanized after assembly. It is also possible to build support bracket  14  from some other metal which is not prone to rusting, such as stainless steel or even aluminum; however, galvanized steel provides a good balance of strength, corrosion resistance and cost. 
     Referring now to  FIGS. 5 ,  6 , and  9 , boom  16  is pivotally coupled to bracket  14 . Boom  16  has opposite ends  44  and  46  and preferably consists of an elongated steel bracket having a U shaped profile with a top web  54  and side webs  56 . Apertures  50  and  52  are formed on side webs  56  adjacent end  44  and mid way between ends  44  and  46 , respectively. Boom  16  is pivotally connected to base bracket  14  by placing end  44  of the boom between angle brackets  25 , coaxially aligning apertures  40  of the base bracket with apertures  50  of the boom and then passing a bolt (not shown) or other similar structure through the aligned apertures. Boom  16  further includes flanges  58  having apertures  60  formed thereon. Flanges  58  assist in mounting a deck structure onto boom  16 . Boom  16  may be made of galvanized steel or some other preferably corrosion resistant strong metal. 
     Referring now to  FIGS. 3 ,  5 ,  7 ,  10  and  11 , support rod  18  consists of an elongated rod having opposite ends  62  and  64 . Preferably, rod  18  is cylindrical with end  64  of rod  18  being threaded. Preferably, the entire rod is threaded. First end  62  of rod  18  is pivotally connected to base bracket  14  by means of a pivoting anchor member  66 . Anchor member  66  consists of a steel tube  69  having a threaded receiver  67  welded thereon. Anchor member  66  is mounted between angle brackets  25  by aligning tube  69  with apertures  42  formed in the angle bracket and then passing a bolt (not shown) or other member through the tube and the apertures. End  62  can then be screwed into threaded receiver  67 , although it is also possible to secure the rod to the receiver by other means such as welding. Rod  18  is further coupled to boom  16  by means of connector joint  68  which consists of a strong tubular member having passage  70 ,  71  and  72 . Passage  70  passes completely through connector joint  68 . End  64  is passed through passage  72  and connector joint  68  is secured to boom  16  by coaxially aligning passages  71  and  72  with apertures  52  in the boom and then securing the connector joint by bolts (not shown). Aperture  48  formed in boom  16  permits end  64  of rod  18  to pass through the boom. 
     Referring back to  FIG. 1 , when fully assembled, boom  16  of bracket  14  can be tilted relative to bracket base  14 . Support rod  18  is used to adjust the angle of boom  16  relative to base bracket  14  and to secure the boom in place. After base bracket  14  is secured to hard rock face  9 , boom  16  can be adjusted by simply passing rod  18  through the connector joint  68  until boom  16  is horizontal. The boom is secured by means of nuts  74  positioned above and below connector joint  68  which act to lock the support rod and the boom in position. Any portion of rod  18  projecting past the top of boom  16  can simply be cut off. Deck  11  can then be built on top of boom  16  and secured thereto by flanges  58 . As can be seen from  FIG. 2 , since boom  16  is pivotally connected to base bracket  14 , boom  16  can be maintained at a horizontal angle even if hard rock surface  9  is nearly vertical. This greatly increases the flexibility of bracket  14  allowing it to be used to construct a dock or deck even where the rock surface is uneven. 
     Referring back to  FIG. 1 , to construct a deck or dock structure over a hard rock surface  9 , a plurality of apertures  22  are first drilled into the hard rock. The depth of the apertures depends on the structural load to be supported on the deck (or dock) and the composition of the rock forming surface  9 . The larger the load, the deeper apertures  22  have to be. Preferably, apertures  22  are several inches to a foot or more in depth. After the apertures are formed, bolts  20  are inserted into the apertures  22  and held in place by rock adhesive or cement. Suitable adhesives and cements are readily available in the market. Bolts  20  are several inches longer than the depth of apertures  22  so that the bolts project from the rock face by several inches. After the adhesive/cement has set, base bracket  14  is then secured to bolts  20  by nuts  21 . Nuts  21  are threaded onto bolts  20  both below and above bottom web  24  with sufficient torque to rigidly secure base bracket  14  to rock face  9 . Boom  16  may then be mounted to base bracket  14  assuming it was not already attached to the base bracket when the base bracket was mounted to the rock face. Boom  16  is then pivoted until it is substantially horizontal and then locked in place by securing nuts  74  to rod  18  both above and below connector joint  68 . Sufficient torque is applied to nuts  74  to firmly lock the rod and boom together. Any length of support rod  18  which projects above boom  16  may then be cut off. This procedure will have to be repeated several times so that a plurality of support brackets  12  are secured to rock face  9  each with its boom in a horizontal orientation. Deck  11  can then be assembled on top of booms  16  as required. 
     The present invention has several advantages over the prior art. In particular, the support brackets, having pivotally adjustable booms are capable of securing a deck to a hard rock surface which is at an angle from the horizontal and or which is uneven. The brackets can adjust to any angle as required to provide a firm foundation upon which a deck can be built. 
     A specific embodiment of the present invention has been disclosed; however, several variations of the disclosed embodiment could be envisioned as within the scope of this invention. It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.