Patent Publication Number: US-2006010790-A1

Title: Method and kit for supporting a foundation post

Description:
FIELD OF THE INVENTION  
      The present invention relates to a kit for supporting a foundation post on a footing block and more particularly relates to a method of lifting the foundation post relative to the footing block upon which it is supported in a static structure, for example a residential porch or deck.  
     BACKGROUND  
      In the construction of residential porches and decks, as well as many other similar static structures supported spaced above the ground, it is common to support the structure by plural foundation posts spaced along various beams of the structure. A footing block is typically provided on the ground upon which the post rests for supporting the static structure thereabove. Over time as the ground settles or heaves due to climate or other various conditions, it is commonly required to adjust the height of the foundation posts for levelling the structure. Adjusting the height of the posts conventionally involves insertion of shims between the post and structure or between the post and footing block. This is awkward and time consuming as the particular thickness of wedge or shim required for levelling the structure is determined by trial and error requiring the structure to be jacked up with each attempt. Other solutions involve replacing the post entirely with a height adjustable member or a new post cut to a different length.  
      U.S. Pat. No. 5,561,950 to Collins et al. and U.S. Patent Application Publication 2004/016334 to Carlson disclose examples of conventional height adjustable mechanisms for a foundation post and footing block structure. In each instance a specialized foundation block is required to be purchased for cooperation with the height extension mechanism. Neither is suited for attachment to existing commercially available post and footing block combinations which may already be installed on a particular structure requiring levelling. Accordingly the solutions described by Carlson and Collins, to avoid the problem of height adjustment of a foundation post, require costly and awkward replacement of the entire post and footing block combination.  
     SUMMARY OF THE INVENTION  
      According to one aspect of the invention there is provided a post support for use with a foundation post resting on a footing block which supports a static structure spaced above the ground thereon, the post support kit comprising: 
          at least one threaded member; and     a mounting bracket for supporting said at least one threaded member alongside the foundation post to extend in a longitudinal direction of the foundation post;     said at least one threaded member being movable relative to the bracket in the longitudinal direction of the foundation post between various mounting positions alongside the foundation post corresponding to different heights of the foundation post being supported relative to the footing block by said at least one threaded member.        

      By positioning a threaded member alongside the post rather than beneath the post, a height adjustable mechanism can be attached to an existing structure in a straight forward manner at minimal cost and effort. Simple rotation of the threaded member or the mechanism which attaches it to the post permits the effective length of the post to be extended thus raising the post relative to the footing block upon which it is supported. Accordingly levelling of a static structure of either new or existing construction can be readily accomplished using the post support according to the present invention.  
      The threaded member may comprise an elongate threaded rod which is moveable in longitudinal direction relative to the mounting bracket by relative rotation therebetween and which supports nuts threadably thereon which engage the mounting bracket.  
      Preferably two threaded members are supported on diametrically opposed sides of the post.  
      There may be provided a base member having a pair of sockets supported on opposing sides of the post between the post and the footing block for rotatably receiving the bottom end of a respective one of the threaded members therein.  
      The mounting bracket may comprise a mounting flange including fastener apertures therein for attachment to the post and a channel alongside the post for receiving the threaded rod therethrough. When the post comprises a wooden post of square cross section, the respective mounting brackets of the two opposed threaded rods are preferably fastened only to their respective side of the post using suitable wood screws.  
      Alternatively, the mounting bracket may comprise a clamping mechanism for clamping onto the post and a channel for receiving the threaded rod therethrough alongside the post. More particularly, the mounting bracket may comprise a clamping member including a channel for receiving the threaded rod therethrough alongside the post, the clamping member being shaped for clamping engagement with a clamping member of similar configuration on an opposing side of the post.  
      Preferably the clamping member is shaped to surround approximately half of periphery of the square post by spanning two adjacent sides of a square post Mounting flanges at opposing ends may couple to the mounting flanges of the opposing clamping member of similar configuration.  
      According to a further aspect of the present invention there is provided a method of lifting a foundation post of a static structure in relation to a footing block upon which the foundation post rests, the method comprising: 
          providing at least one threaded member;     supporting said at least one threaded member to extend alongside the foundation post in a longitudinal direction of the foundation post using a bracket; and     rotating said at least one threaded member relative to the bracket to displace the threaded member in the longitudinal direction of the post between various mounting positions alongside the post corresponding to different heights of the foundation post being supported above the footing block by the threaded member.        

      When the threaded member comprises a threaded rod and the bracket includes a nut threadably supported on the rod, the method preferably includes displacing the threaded member relative to the post in the longitudinal direction by rotation of either the threaded member or the nut.  
      Preferably a threaded member is provided on two opposing sides of the post, in which case the method includes inserting both threaded members in a respective socket in a common base member inserted between the post and the footing block.  
      Some embodiments of the invention will now be described in conjunction with the accompanying drawings in which: 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is a perspective view of the post support installed on a foundation post and footing block combination.  
       FIG. 2  and  FIG. 3  are respective front and side elevational views of the post support according to  FIG. 1 .  
       FIG. 4  is a top plan view of the post support according to  FIG. 1 .  
       FIG. 5  is an exploded perspective view of the components of the post support.  
       FIG. 6  is a perspective view of a second embodiment of the post support installed on a foundation post and footing block combination.  
       FIG. 7  is a plan view of the post support according to  FIG. 6 . 
    
    
      In the drawings like characters of reference indicate corresponding parts in the different figures.  
     DETAILED DESCRIPTION  
      Referring to the accompanying drawings there is illustrated at post support kit generally indicated by reference numeral  10 . The kit  10  is particularly suited for adjusting height of a foundation post relative to a footing block  14  of a static structure, for example a residential deck or porch.  
      Residential decks typically include a frame including a plurality of horizontal beams supported on a plurality of foundation posts  12 . These posts are often formed of wood having a square cross section in the order of three and a half inches by three and a half inches. The footing block  14  is typically a concrete cast member having a square socket centered in a top side thereof for receiving the bottom end of the post. A slot  16  is formed in each of the four sides of the square socket which extends laterally through the block to the exterior side thereof such that the opposing pairs of slots  16  form two perpendicular channels for receiving a transverse beam therethrough in some applications.  
      The kit comprises two elongate treaded rods  18 , each having a hexagonal bolt head  20  fixed at a top end thereof. The bolt head is conventional having opposing flat sides for gripping with a wrench or other suitable tool for rotating the rod. The opposing bottom end of each rod  18  includes a flat engaging face  22  which substantially abuts the footing block in use.  
      Two mounting brackets  24  are provided for mounting the pair of rods  18  respectively on opposing sides of the foundation post  12 . Each bracket comprises a plate of sheet metal which is shaped to form an elongate U-shaped channel and two lateral mounting flanges  28  which are flat and coplanar with one another and which extend laterally outwardly an equal distance from opposing sides of the U-shaped channel  26 . Each of the mounting flanges includes plural fastener apertures  30  formed therein which are spaced apart in the direction of the longitudinal axis of the channel  26  of the bracket. The apertures are formed in both of the mounting flanges on opposite sides of the channel to ensure adequate securement of the bracket to the post. The bracket is typically secured to the post using conventional wood screws or any other suitable threaded fasteners.  
      The U-shaped channels  26  includes an internal dimension which is only slightly larger then the outer diameter of the rods  18  for receiving the rods therethrough when the brackets are mounted to the post. The opposing mounting flanges  28  of the bracket are suitably sized so that spacing between the opposing free edges of the bracket is near in width to that of the post. The brackets  24  therefore each mount to only one side of the post without interfering with mounting of the other bracket on the opposing side of the post.  
      The brackets  24  are mounted on the post so that the longitudinal axes of the channels  26  are parallel to the longitudinal direction of the post. In this manner the rods  18  received through the respective channels of the brackets extend vertically alongside the post with the longitudinal direction of the rods being parallel to the longitudinal direction of the post. The rods when received in the channels of the brackets  24 , are spaced laterally beside the post  12  sufficiently to accommodate tool access to the bolt head of each rod.  
      The brackets  24  each include a pair of threaded nuts  32  for securement about the respective rod  18  at opposing ends of the U-shaped channel  26 . Accordingly one of the threaded nuts  32  is secured about each rod  18  both above and below the respective mounting channel  26  in the assembled position of the kit. The nuts  32  engage opposing ends of the channel to effectively clamp the channel of the bracket therebetween. Suitable washers  34  are provided in cooperation with each of the nuts  32  in which both the washers  34  and the nuts  32  have an outer diameter which is greater than the inner diameter of the U-shaped channel  26 . By simply abutting the nuts  32  with the channel  26 , the nuts are free to rotate relative to the channel so that longitudinal position of the threaded rods relative to the brackets can be adjusted by either rotation of nuts  32  while the rod is fixed or by rotating the rod relative to the nuts which remain fixed.  
      An elongate base member  36  is provided in the form of a plate having a width and length which is substantially equal to one of the channels formed by opposing slots  16  in the footing blocks. The square edges of the base member  36  fit the square edges of the channel within which it is received in the footing block to resist any relative movement or rotation of the base member relative to the footing block.  
      A pair of sockets  38  are provided on the plate of the base member  36  at spaced apart positions thereon, greater than the width of the post so that the two sockets  38  are spaced laterally outwardly from opposing sides of the post  12  when the plate of the base member  36  is inserted in one of the channels of the footing between the post  12  and the footing block  14 . Due to the minimal thickness of the plate forming the base member, only minimal jacking of the post, in the order of less than an inch, relative to the footing block is required to install the base member between the post and footing block.  
      The sockets  38  each have an interior diameter which is near to the outer diameter of the threaded rod to receive the flat engaging face of the rods abutted against the plate therein. An annular rim is welded to the base plate to form each of the sockets  38  which effectively restrict lateral movement of the rods relative to the base plate while permitting free rotation therebetween. When the brackets  24  are mounted on opposing sides of the post  12 , which correspond to the sides locating the sockets  38  spaced laterally outward therefrom, the threaded rods  18  received through the bracket are aligned with the sockets in the base member  36 .  
      By using the post supporting kit  10  as described herein, a static structure, for example a residential deck, can be levelled by lifting foundation posts of the structure relative to the respective footing blocks. This is accomplished by first selecting which posts of the structure require lifting to level the deck. A base member  36  is then inserted between the selected posts and there respective footing blocks by lifting the selected posts from their footing blocks. Rods  18  are inserted into the channels  26  of a respective pair of brackets  24  for attachment to opposing sides of the selected posts with the rods being aligned with the sockets  38  in the base member. Once the brackets are mounted on the posts, the threaded rods  18  lie parallel and spaced laterally beside the respective posts rather than replacing the posts entirely. Position of the rods relative to the respective brackets and posts upon which they are mounted is accomplished by relative rotation between the threaded rods and the nuts of the brackets  24  until the rod projects beyond the bottom end of the post to a degree which corresponds to a desired height elevation of the post relative to its respective footing block. The two rods  18  of each post are extended beyond the post a similar dimension for purposes of substantially evenly distributing the weight applied by the structure onto the post between the two rods. Each position of the threaded rod relative to the bracket and post corresponds to a different height of the post relative to the footing block when the bottom end of the rods are engaged within the respective sockets of the base member  36 .  
      The two brackets and rods  18  of each kit are identical to one another but are mounted in opposite directions from one another. In its mounted position, the bottom end of each rod extends into a respective socket of a common base member  36  which acts as a stabilizing brace. Two adjustable threaded nuts are provided on each rod on opposing sides of the channel formed in the brackets to ensure the position of the rod relative to the bracket is well secured. Weight is primarily carried by the bracket resting on the lowermost nut on each rod while the uppermost nut primarily acts to ensure a snug engagement between the bracket and the lowermost nut.  
      As described above, the brackets are designed to allow them to be attached to the existing foundation posts of a deck by the use of threaded fasteners without replacing existing posts or footing blocks. While one particular example of a foundation post and footing block is shown in the accompanying figures, the simplicity of the design of the components of the post support kit permit similar application on much larger dimensions of posts or posts formed of other materials even if the post is merely supported on a flat supporting surface or other form of footing block. The base member  36  acts to distribute the weight applied to the ends of the two threaded rods  18  for evenly supporting the post on a somewhat irregular surfaced footing as well.  
      In further embodiments, a threaded sleeve may instead be provided as the adjustment member which is displaced relative to the brackets when the brackets include a threaded rod fixed thereon in engagement with the threaded sleeve. Any relative rotation, either by the rod or some form of threaded sleeve which permits longitudinal displacement of one member relative to another mounted on the post would be effective to jack the post relative to a respective footing block for levelling of a deck as described herein.  
      Turning now to  FIGS. 6 and 7 , a further embodiment of the post support is illustrated in which a pair of mounting brackets  24  are similarly provided for supporting a foundation post  12  on a footing block  14 . Each bracket  24  similarly includes a channel  26  formed integrally therein for receiving the threaded rods  18  respectively. A similar arrangement of threaded nuts permits height of the rods to be adjusted relative to the brackets for adjusting height of the post relative to the footing blocks. The two brackets  24  are configured identical to one another for being coupled to each other on opposing sides of the post in which the rods are vertically oriented alongside the post on opposing sides thereof for engaging the base plate  36  therebelow are described above with regard to the previous embodiment.  
      In the second illustrated embodiment of  FIGS. 6 and 7 , the two mounting brackets  24  each comprise a clamping member  50  for clamping the post between the two members. Each clamping member comprises a pair of plates  52  suitably sized for substantially spanning one side of the conventional foundation post  12 . The plates  52  are joined perpendicularly to one another with one of the plates integrally forming the channel  26  therein centered along one side of the post. Each clamping member thus extends around approximately half of the outer periphery of the foundation post. The plates  52  are slightly less than the overall width of the post such that when two opposing clamping members  50  are coupled about opposing diagonal corners of the post, a slight gap is formed between the two clamping members at each intermediate corner of the post.  
      Mounting flanges  54  are coupled to the free edges of each of the plates  52  to span outwardly at an inclination of approximately 135 degrees from the respective plate  52  from which it spans at an outer side thereof. When two clamping members  50  are mounted on opposing diagonal corners of a square foundation post, the mounting flanges  54  of each member lie in a common plane with each other, parallel and adjacent to the mounting flanges of the opposing member so that all of the mounting flanges are substantially coplanar with a central axis of the post when the mounting members are clamped together. The mounting flanges  54  include cooperating apertures  56  formed therein for receiving bolts to clamp the members together. By providing a slight gap between the opposing clamping members  50 , a compression force can be applied to the post for frictionally gripping the post as the bolts received through the cooperating apertures  56  are tightened to bring the two clamping members  50  together.  
      In further embodiments the plates  52  may include an internal gripping surface formed thereon for improving frictional engagement of the clamping members with the post. Perforations may be provided in the plates  52  which form toothed projections projecting inwardly towards the opposing clamping member for being embedded into the post upon assembly.  
      In yet further embodiments, the base plate  36  may be formed from a single piece of material which has been moulded or machined to result in the desired shape of sockets for receiving the rods to distribute load onto the footing block.  
      Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without department from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.