Decking board drainage assembly

Abstract

A decking assembly is provided with a drainage solution providing ease of assembly and disassembly, further facilitating removal of a single panel. The assembly is formed from multiple like panels, 10

Description

09 06 25 Technical Field [0001 ] The present invention is concerned with a decking board drainage assembly. More specifically the present invention is concerned with a decking board drainage assembly and a decking board that facilitates ease of removal and replacement of individual decking members. Background Art

[0002] Decking assemblies are very common in the art of building and construction. Decking offers a fast, simple, and aesthetically pleasing way to construct raised floors, particularly externally. Wooden decking is very well known, but more recently alternative decking materials have been used such as fibre-reinforced composites and metals. Metal decking panels have the advantage that they are non-combustible and resistant to fires. This is highly advantageous to meet building regulations.

[0003] Decking systems typically comprise a support framework having plurality of spacedapart parallel beams, for example steel I-beams. Decking panels are attached to the upper surface of the beams, for example with mechanical fasteners such as screws. The decking panels are typically elongate (i.e. having a length to width ratio of at least 10:1)andarelaid perpendicular to the underlying beams to which they are attached.

[0004] One problem that external decking systems face is drainage. In orderto control the flow of rainwater from the upper surface of the decking there needs to be a drainage system. It is undesirable for water to collect on the surface of a decking system.

[0005] A prior art decking assembly 10 is shown in Figures 1a and 1b. Figure 1a is an exploded view, with Figure 1 b an assembled view. The assembly 10 comprises a firstand a second extruded aluminium decking board 12a, 12b, each having an infill panel 14a, 14b respectively. The assembly 10 further comprises a drainage channel 1 6.

[0006] The first and second boards 12a, 12b each comprise a top surface 18, a bottom surface 20, a top channel 22 and left and right side channels 24, 26.

[0007] The drainage channel 16 is shaped as an inverted "U". 09 06 25

[0008] In use, the first decking panel 12a is attached to an underlying structure 8 by a fastener 28 through the bottom surface 2. The fastener is attached through the top channel 22. The top channel 22 is then filled in by the infill panel 14a such that the decking board 12a is fastened in position. The drainage channel 16 is then inserted into the side channel 26 of the decking board 12a in a sideways direction SD (Figure 1a). The second decking board 12b can then be positioned such that the drainage channel 16 enters the side channel 24 of the panel 12b (i.e., it is also slid in sideways direction SD). This allows the two decking boards to encapsulate the drainage channel 16 with a drainage opening 30 provided between the top surfaces 18 of the panels, directly above the opening of the drainage channel 16. This allows water 6 to drain off the top surface 18 into the channel 16 which it can run along to the end of the decking (or some other point where it can be disposed of- e.g., guttering).

[0009] A problem with the assembly of Figures 1 a and 1 b is that it is difficultto remove and I or replace a single deck board 12a, 12b. In some circumstances, extraction of a single board is highly advantageous. For example, with pre-assembled balconies, the decking is typically installed in the balcony prior to delivery to the site. A crane can then be attached to anchor points on the balcony which is lifted into position. The anchor points are positioned under the deck boards, and as such removal and replacement of individual boards is desirable to allow the balcony to be easily lifted into position on the building.

[0010] A further reason to extract a single deck board may be e.g., to repair it if it has become damaged. Summary of Invention

[0011] According to a first aspect of the invention there is provided a decking assembly according to claim 1.

[0012] Preferably the overhanging formation comprises a downwardly depending retaining formation, which retaining formation retains the first decking panel relative to the second decking panel.

[0013] Preferably the first and second decking panels are assembled such that a drainage gap is formed between the respective decking surfaces, the drainage gap being positioned above the drainage channel. 09 06 25

[0014] Preferably the first decking panel comprises a leg extending downwardly with respect to the decking surface, and wherein the drainage channel extends from a position on the leg to the overhanging formation.

[0015] Preferably the drainage channel extends at a sloped angle from the leg to the overhanging formation.

[0016] Preferably the drainage channel extends at a sloped angle of between 30 and 60 degrees to the horizontal.

[0017] Preferably a gap is provided on an underside of the drainage channel to facilitate rotation of the first decking panel into engagement with the second decking panel.

[0018] Preferably the drainage channel comprises a curved portion at a free end, which curved portion engages the overhang. [001 9] Preferably the curved portion is dimensioned to elastically deform into engagement with the overhang.

[0020] Preferably the assembly comprises: an underlying structure; a plurality of decking panel mounting brackets attached to the underlying structure; wherein each of the first and second decking panels are attached to a respective decking panel mounting bracket.

[0021] Preferably the decking panels and the mounting brackets are attached by a mechanical snap-fit.

[0022] According to a second aspect of the invention there is provided a method according to claim 1 9. Brief Description of Drawings

[0023] An embodiment of the present invention will now be described with reference to the following figure in which: FIGURE 1a is an exploded section view of a first prior art decking assembly; 09 06 25 FIGURE 1 b is a section view of the prior art decking assembly of Figure 1 a; FIGURE 2 is a section view of a first decking assembly according to the present invention; FIGURE 3 is a detailed view of a component of the first decking assembly of Figure 2; FIGURE 4 is a detail view of region IV of Figure 3; FIGURES 5 and 6 are detailed views of components of the first decking assembly of Figure 2; FIGURES 7 and 8 are detail views of regions VII and VIII of Figure 2; FIGURE 9 is a view of two components of the assembly of Figure 2 being assembled; FIGURE 10 a section view of a second decking assembly according to the present invention; FIGURE 11 is detail view of a component of the first decking assembly of Figure 10; FIGURE 12 is a detail view of region XII of Figure 10; FIGURE 13 is a view of two components of the assembly of Figure 10 being assembled; and, FIGURES 14 and 15 are detail views of regions XIV and XV of Figure 10 respectively. Description of the first embodiment

[0024] The first embodiment is shown in Figures 2 to 9. Configuration

[0025] Referring to Figure 2, there is shown a decking assembly 100 according to the present invention. The assembly 100 comprises a first decking panel 102a, a second decking panel 102b, a drainage channel 104, and a plurality of mounting brackets 106a, 106b, 106c, 106d.

[0026] The assembly 100 is supported on a sub-structure comprising a plurality of parallel, offset beams (one beam 108 is shown). Decking panel 102a

[0027] Referring to Figures 3 &4, the first decking panel 102a is shown. It will be noted that the second decking panel 102b is identical to the first. The decking panel 102a is an 09 06 25 elongate, unitary member in this embodiment constructed asan aluminium extrusion (other materials are possible). The section shown is in the YZ plane, with the main axis of the extrusion being along the X axis.

[0028] The panel 102a comprises a generally planar upper member 110, the top surface of which forms the top surface 112 of the decking panel 102a. The upper member 110 has a plurality of longitudinally extending recesses 114 to provide grip. At either end of the member 110 there are provided downwardly depending end flanges 128, 130.

[0029] At either transverse end of the member 110 there are provided a first and a second downwardly depending edge legs 116, 118. Each edge leg 116, 118 has a respective inwardly facing foot 120, 122. The feet 120, 122 are defined at the free end of each edge leg opposite the member 110. Each edge leg also defines an outwardly facing flange 124, 126 which is disposed partway up the leg between the foot 120, 122 and the member 110. Each flange 124, 126 defines a respective downwardly depending tab 132, 134.

[0030] Equally spaced between the edge legs there are provided a first and a second downwardly depending intermediate leg 136, 138. Each intermediate leg 136, 138 has respective oppositely facing feet 140, 142; 144,146 at its free end, opposite to the member 110. All of the feet 120, 122, 140, 142, 144, 146 are generally co-planar defining a lower surface plane 148 of the decking panel 102a. [0031 ] Channels 150, 152, 154 are defined as follows: • Channel 150 has a mouth 151 defined between the feet 120, 140 of width CMW; • Channel 152 has a mouth 153 defined between the feet 142, 144 of width CMW; • Channel 154 has a mouth 155 defined between the feet 146, 122 of width CMW.

[0032] Because the feet are directed inwardly with respect to each channel, each provides an upwardly facing shoulder which will be referred to below. Drainage channel 104 The drainage channel 104 is shown in more detail in section in Figure 5. It is generally U-shaped in section, having a base region 156, joined to respective sidewalls 162, 164 by curved regions 158, 160. The sidewalls 162, 164 are joined to respective inwardly projecting tabs 166, 168 by curved regions 170, 172. A channel inlet 169 is defined 09 06 25 between the tabs 166, 168. This gives each end of the channel section a curved or "C" shape. Mounting bracket 106a

[0033] The mounting bracket 106a (which is identical to the brackets 106b, 106c, 106d) is shown in more detail in section in Figure 6. It is generally U-shaped in section, having a base region 174. The base region 174 defines a screw pilot groove 175 therein. Two sidewalls 1 76, 178 project both inwardly and upwardly, being angled with respectto the base region 174.

[0034] At either end of the base region 174, at the outer corners where the sidewalls 1 76, 1 78 meet the base region 1 74 there are provided outwardly facing undercut grooves 180, 1 82. Each groove defines an upper shoulder 1 84, 1 86. Assembly

[0035] Referring to Figure 2, a mounting bracket 106b is positioned on the beam 108 and secured thereto with a screw engaging the groove 175. The panel 102a can then be lowered overthe bracket 106b such that he mounting bracket 106b enters the channel 152 through the channel mouth 153. As the panel 102b is lowered, it is positioned along the Y axis (transversely) by engagement with the sidewalls 176, 178 which taper outwardly towards the base region 174. To secure the panel 102a in position, it is pushed onto the bracket 106b such that the legs 136, 138 elastically deform outwardly and snap back into position as the feet 142, 146 enter the grooves 180, 182. The engagement between the shoulders 184, 186 and the feet 142, 146 retains the panel 102a in position. This is shown in Figure 8.

[0036] It will be noted that although three brackets 106a, 106b, 106c are shown in Figure 2, in reality only one (106b) or two (106a, 106c) are likely to be used to allow deformation of the feet. It should also be noted that the mounting brackets 106a - 106d are identical and can fit into any of the channels 150, 152, 154 as their mouths 151, 153,155 are identical in width (CMW).

[0037] The drainage channel 104 is installed by rotating and hooking it under the flange 126. The channel 104 can be rotated into position on account of the curved regions 158, 1 70. As it is rotated into position, the free end of the tab 166 bears against the tab 134 of the flange 126 holding the channel 104 in place in the position shown in Figure 8. 09 06 25

[0038] A further bracket 106d is fixed into position on the beam 108 with a screw engaging the groove 175. The second panel 102b is then fixed to the bracket 106d in the same way as the first panel 102a. As the second panel 102b is put into position, the flange 124 receives the tab 1 68 of the drainage channel. Use

[0039] Further panels 102 can be installed in this manner. When liquid falls onto the panels 102, it can run between them and passes into the channels 104 where it flows towards an appropriate drainage point (e.g. the end of the decking, guttering or a drainage hole).

[0040] It will be noted that removal ofa single panel 102 is facilitated bythe present design. Each panel 102a, 102b can be lifted up to deform the mounting bracket(s) inwardly and release the panels. Because the drainage channels 104 are positioned entirely below any part of the panels 102a, 102b, they do not need to be disturbed as this happens. [0041 ] It will also be noted thatthe "snap fit" between the mounting brackets and the panels means that if a panel needs to be removed and replaced, no new holes need to be made, nor does a screw need to be removed and replaced in the underlying beam 108 (which would potentially enlarge the hole and loosen the screw). Description of the second embodiment

[0042] The second embodiment of the invention is shown in Figures 10 to 15. Configuration

[0043] Referring to Figure 10, there is shown a decking assembly 200 according to the present invention. The assembly 200 comprises a first decking panel 202a, a second decking panel 202b, and a third decking panel 202c. A plurality of mounting brackets 106a, 106b are provided, as well as a plurality of infill pieces 204a, 204b, 204c and an edge profile 206.

[0044] The assembly 200 is supported on a sub-structure comprising a beam (not shown). Decking panel 202a

[0045] Referring to Figures 11 and 12, the first decking panel 202a is shown. It will be noted that the second decking panel 202b is identical to the first. The third decking panel 202c is 09 06 25 identical, although it has been cut as will be discussed below. The decking panel 202a is an elongate, unitary memberinthisembodiment constructed asan aluminium extrusion (other materials are possible). The section shown is in the YZ plane, with the main axis of the extrusion being along the X axis.

[0046] The panel 202a comprises two spaced-apart generally planar upper members 210, 211 with an opening 212 therebetween. The upper member 210 has a plurality of longitudinally extending recesses 214 to provide grip. At the outer ends of the respective members 210, 211 there are provided downwardly depending end flanges 228, 230.

[0047] At either transverse end of the member 210 there are provided a first and a second downwardly depending edge legs 216, 218. The legs are inboard of the edges of the members 210 which creates respective overhanging portions 217, 21 9. Each edge leg 21 6, 218 has a respective inwardly facing foot 220, 222. The feet 220, 222 are defined atthe free end of each edge leg opposite the members 210, 211. The second edge leg 218 also defines an outwardly facing drainage channel 224. The drainage channel 224 comprises an angled portion 225 extending at a 45 degree angle, which creates a triangular gap 223 underneath. The portion 225 terminates in a vertical portion 226 which defines a C-shaped engagement formation 227 at a free end. The opening of the C-shaped engagement formation faces the member 211.

[0048] Equally spaced between the edge legs there are provided a first and a second downwardly depending intermediate leg 236, 238. Each intermediate leg comprises two spaced apart, inwardly facing ridges 237, 239, 241,243. Each intermediate leg 236, 238 has respective outwardly facing feet 240, 242 at its free end, opposite to the members 210, 211. A lower member 244 extends between the legs 236, 238 forming a base opposite the opening 212.

[0049] Channels 250, 252, 254 are defined as follows: • Channel 250 has a mouth 251 defined between the feet 220, 240 of width CMW; • Channel 252 faces upwardly towards the opening 212; • Channel 254 has a mouth 255 defined between the feet 242, 222 of width CMW.

[0050] Because the feet are directed inwardly with respect to each channel 250, 254, each provides an upwardly facing shoulder. 09 06 25 Mounting bracket 106a [0051 ] The mounting bracket 106a is described with respect to the first embodiment. Infill piece 204a The infill pieces are identical. The piece 204a, referring to Figure 14 is an inverted "U" shape, comprising a generally planar upper member 258 having two downwardly depending legs 260, 262 at either transverse end. An outwardly projecting upper tab 264, 266 is provided at either end of the upper member 258, and an outwardly projecting lower tab 268, 270 extending outwardly from the free ends of the legs 260, 262. Edge profile 206

[0052] The edge profile 206 is similar to that described in the applicant's patent GB 2 582 618, which is incorporated herein where permitted. The edge profile 206 is generally elongate and prismatic, comprising a wall 264 with a mounting portion 266 in the form of a flange disposed at a first, lower end, and a fixing portion 268 provide at a second, upper end. The fixing portion 268 comprises an upper flange 270 and a lower flange 272 defining a deck receiving channel 274 therebetween.

[0053] The mounting portion 266 and fixing portion 268 extend in the same direction from the wall 264, making the edge profile component 206 U-shaped. The mounting portion 266 extends further from the wall 264 than the fixing portion 268 such that a fastener 274 can be used to secure the edge profile component 206 to the underlying beam. Assembly

[0054] The panels 202a, 202b, 202c can be mounted in two different ways. The first manner of mounting the panels is shown in Figure 10 with respect to panels 202b and 202c. A first panel (e.g. panel 202c is attached to an underlying structure with a fastener 2 passing through the opening 212 and secured to lower member 244. A further, adjacent panel 202b can be assembled by hooking the engagement formation 227 under the flange 228 (adjacent to the leg 216). Once rotated into position, the panel 206b can be screwed into position. 09 06 25

[0055] The panels 202b, 202c can be finished by pressing the infill pieces 204a, 204b into the channels 252. As this occurs, the legs 260, 262 deform inwardly as the tabs 268, 270 pass the lower ridges 239, 243. The legs resile once the tabs 268, 270 are on the lower side of the ridges 239, 243, securing the infill piece in position. The upper tabs 264, 266 rest on the upper ridges 237, 239 to support the infill piece in position and to react any loads on the member 258. The member 258 is flush with the members 210, 211 to provide the decking surface.

[0056] Individual panels can be removed by pulling the infill piece 204a out to expose the fastener. The fastener can be undone, and the panel 202b rotated in a clockwise direction to unhook the engagement formation 227 from the flange 228.

[0057] The second way in which the panels can be mounted to the beam is shown with respect to panel 202a (Figure 10), also referring to Figure 13. The panel 202b is fixed in position. The mounting brackets 106a, 106b are secured to the underlying beam with screws 4, 6. Referring to Figure 13, the panel 202a can then be rotated into position in an anti-clockwise direction ACW where the engagement formation 227 engages the flange 228, and atthe same time the panel 202a receives the mounting brackets 106a, 106b in the channels 250, 254 in the same manner as the first embodiment to secure it in place.

[0058] In terms of the edge profile 268, at the edge of the decking, the final panel 202c is cut to leave an overhanging portion 275. The edge profile is installed using a fastener 274 and the portion 274 inserted into the fixing portion 268. This terminates the decking at either side.

[0059] Importantly, the engagement of the drainage channels 224 with the overhangs 217 creates an engagement between adjacent panels that enable each panel to be individually removed. Referring to Figure 13 after unfastening the panel, it can be rotated by lifting the end that overhangs over the adjacent channel (i.e. the rightmost ends in Figure 10). This causes a rotation about the drainage channel, which due to the angle of the channel itself forming the gap 223 allows the end (engagement formation 227) to drop from the overhang 217 of the adjacent panel. This rotation (for removal) is opposite to the direction ACW in Figure 13. Use

[0060] In both cases described above, the panels are fixed into position with the engagement formation 227 of the drainage channel 224 entering a receiving portion of the adjacent panel. The shape of the engagement formation 227 is such that it is able to be compressed and deformed elastically, which provides an outward "gripping" force on the adjacent panel to hold it in place. It also will be noted that the overhanging flange 228 means that any liquid on the upper surface of the deck runs into the channel 224. Variations

[0061] It is envisaged that the embodiments may be combined. For example, the fixing method of the second embodiment (using the infill pieces) may be utilised with the drainage channel of the first embodiment. 09 06 25

Claims

09 06 251. A decking assembly comprising:a first decking panel having a decking surface, and a drainage channel formed at a first edge;a second decking panel having a decking surface, and an overhanging formation formed at a second edge;wherein the first and second decking panels are configured such that the drainage channel is received under the overhanging formation;wherein the first decking panel comprises a leg extending downwardly with respect to the decking surface, and wherein the drainage channel extends at a sloped angle from a position on the leg to the overhanging formation; and,wherein a gap is provided on an underside of the drainage channel to facilitate rotation of the first decking panel into engagement with the second decking panel.

2. A decking assembly according to claim 1, wherein the overhanging formation comprises a downwardly depending retaining formation, which retaining formation retains the first decking panel relative to the second decking panel.

3. A decking assembly according to claim 2, wherein the first and second decking panels are assembled such that a drainage gap is formed between the respective decking surfaces, the drainage gap being positioned above the drainage channel.

4. A decking assembly according to any of claims 1 to 3, wherein the drainage channel extends at a sloped angle of between 30 and 60 degrees to the horizontal.

5. A decking assembly according to any of claims 1 to 4, wherein the drainage channel comprises a curved portion at a free end, which curved portion engages the overhang.

6. A decking assembly according to claim 5, wherein the curved portion is dimensioned to elastically deform into engagement with the overhang.

7. A decking assembly according to any of claims 1 to 6, comprising:an underlying structure;a plurality of decking panel mounting brackets attached to the underlying structure;09 06 25wherein each of the first and second decking panels are attached to a respective decking panel mounting bracket.

8. A decking assembly according to claim 7, wherein the decking panels and the mounting brackets are attached by a mechanical snap-fit.

9. A method of installing a decking assembly comprising the steps of:providing:a first decking panel having a decking surface, and a drainage channel formed at a first edge;a second decking panel having a decking surface, and an overhanging formation formed at a second edge;assembling the first and second panels such that the drainage channel is received underthe overhanging formation;wherein the first decking panel comprises a leg extending downwardly with respect to the decking surface, and wherein the drainage channel extends at a sloped angle from a position on the leg to the overhanging formation; and,wherein a gap is provided on an underside of the drainage channel to facilitate rotation of the first decking panel into engagement with the second decking panel.

10. A method according to claim 9, wherein the overhanging formation comprises a downwardly depending retaining formation, which retaining formation retains the first decking panel relative to the second decking panel.

11. A method according to claim 10, wherein the first and second decking panels are assembled such that a drainage gap is formed between the respective decking surfaces, the drainage gap being positioned above the drainage channel.

12. A method according to any of claims 9 to 11, wherein the drainage channel extends at a sloped angle of between 30 and 60 degrees to the horizontal.

13. A method according to any of claims 9 to 12, wherein the drainage channel comprises a curved portion at a free end, which curved portion engages the overhang.

14. A method according to claim 13, wherein the curved portion is dimensioned to elastically deform into engagement with the overhang.

15. A method according to any of claims 9 to 14, comprising:an underlying structure;a plurality of decking panel mounting brackets attached to the underlying structure;wherein each of the first and second decking panels are attached to a respective decking panel mounting bracket.

16. A method according to claim 15, wherein the decking panels and the mounting brackets are attached by a mechanical snap-fit.09 06 25

Images