Fascia rail mounts for decks

Abstract

Described herein are fascia rail mounts that are attached to a structure, such as a deck. The disclosed fascia rail mounts include threaded rods that mate with holes in a railing post to allow the railing post to be attached to the structure using the threaded rods, the threaded rods extending from a side plate that is adjacent to a fascia beam of the structure. The disclosed rail mounts are attached to the structure prior to applying any layers designed to protect the structure such that the fascia rail mounts, including the threaded rods, receive the protective layers. A waterproof layer can be applied to the structure after the fascia rail mounts have been affixed so that the threaded rods of the fascia rail mounts extend past the waterproof layer without compromising the waterproofing of the structure. In other words, the waterproof layer forms a waterproof barrier even with the threaded rods extending from the fascia rail mounts through the waterproof layer.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims the benefit of priority to U.S. Prov. App. No. 63 / 702,578 filed Oct. 2, 2024, the entire contents of which is expressly incorporated by reference herein for all purposes.BACKGROUNDField

[0002] The present disclosure generally relates to rail mounts for decks.Description of Related Art

[0003] A deck is typically an outdoor surface with a railing attached that can be free standing or adjacent to a building, such as a house, hotel, or office building. Railing is typically attached to a deck using one or more posts along the side of the deck and / or one or more posts at the corners of the deck. The railing is designed to prevent people from falling from the deck. Other than decks, railings can be used with stairs, balconies, patios, and the like.SUMMARY

[0004] According to a number of implementations, the present disclosure relates to a fascia rail mount for a deck, the fascia rail mount configured to enable installation of a post on the deck. The fascia rail mount includes a top plate forming one or more holes through which fasteners are configured to extend to secure the top plate to a top of the deck; a side plate extending perpendicularly from the baseplate in a direction to position the side plate adjacent to a fascia beam of the deck upon fastening the top plate to the top of the deck; a plurality of threaded rods affixed to the side plate and extending perpendicularly outward from the side plate; and a mounting strap extending downward from the side plate, extending horizontally in the same direction as the top plate, and then extending upward, to form a squared “J” shape that wraps around the fascia beam to further secure the fascia rail mount to the fascia beam. The fascia rail mount is configured to be secured to the deck along an edge of the deck in such a way that the plurality of threaded rods extends horizontally away from the fascia beam to pass through holes of a base of a post to be secured to the deck at the fascia beam of the deck.

[0005] In some embodiments, the mounting strap includes a removable portion to facilitate installation of the fascia rail mount on the fascia beam. In some embodiments, the mounting strap includes a movable portion to facilitate installation of the fascia rail mount on the fascia beam.

[0006] For purposes of summarizing the disclosure, certain aspects, advantages and novel features have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any particular embodiment. Thus, the disclosed embodiments may be carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] FIGS. 1A, 1B, 1C, and 1D illustrate various views of an example of a fascia rail mount for a deck.

[0008] FIGS. 2A and 2B illustrate various views of an example fascia rail mount for a deck mounted on a deck.

[0009] FIGS. 3A, 3B, 3C, and 3D illustrate various views of an example of a fascia rail mount for a deck.

[0010] FIGS. 4A, 4B, 4C, 4D, 4E, 4F, and 4G illustrate a process of installing railing on a deck using the disclosed fascia rail mounts.DETAILED DESCRIPTION OF SOME EMBODIMENTS

[0011] The headings provided herein, if any, are for convenience only and do not necessarily affect the scope or meaning of the claimed subject matter.Overview

[0012] Structures such as decks, patios, porches, balconies, staircases, and the like can use railings to prevent people from falling over the edge of such structures. To secure the railing to the structure, posts can be used. These posts can be secured to the structure by driving bolts into the top layer of the structure. This may result in the bolts penetrating one or more layers designed to protect the structure, such as a waterproofing layer. This can disadvantageously compromise the structural integrity of the structure. Alternatively, posts can be attached to the structure by attaching mounting hardware to a fascia of the structure, which may result in posts that lack strength and resilience. This can disadvantageously result in a railing that is unable to withstand forces applied to the railing.

[0013] Accordingly, described herein are fascia rail mounts that are attached to a structure, such as a deck, prior to a waterproofing layer. The fascia rail mounts are mounted to a top side of the structure using a top plate that is fastened to the top side of the structure with a side plate extending down from top plate, the side plate abutting the fascia of the structure. The side plate includes threaded rods that extend perpendicularly from the side plate to allow fascia-mounted posts to be mounted to the side plate of the disclosed fascia rail mounts. In some embodiments, the disclosed fascia rail mounts also include a mounting strap that is attached to the underside of the beam forming the fascia of the structure. The mounting strap can further anchor the disclosed fascia rail mounts to the structure.

[0014] The threaded rods mate with holes in a railing post to allow the railing post to be attached to along the fascia of the structure using the threaded rods. In some implementations, the disclosed fascia rail mounts are attached to the structure prior to applying any layers designed to protect the structure such that the fascia rail mounts, including the threaded rods, receive the protective layers. For example, a waterproof layer can be applied to the structure after the fascia rail mounts have been affixed to the structure. In this situation, the threaded rods of the fascia rail mounts extend past the waterproof layer without compromising the waterproofing of the structure because the threaded rods and the fascia rail mounts have been treated with the waterproof layer. In other words, the waterproof layer forms a waterproof barrier even with the threaded rods extending from the fascia rail mounts through the waterproof layer.

[0015] The disclosed fascia rail mounts include a top plate with a side plate attached to the top plate. The top plate is configured to be secured to a top part of the structure (e.g., a floor of a deck) while the side plate is configured to extend downward over the fascia of the structure. This configuration of the fascia rail mounts enhances the strength and resilience of posts attached at the fascia of a structure relative to posts attached directly to the fascia of the structure.

[0016] In addition, the disclosed fascia rail mounts can be secured to the structure by recessing one or more portions of the structure where the fascia rail mounts are to be secured. As a result, the disclosed rail mounts can be flush with one or more of the surfaces of the structure. This facilitates application of one or more layers, such as a waterproof layer, to the structure without having multiple different surface levels on the structure.

[0017] The disclosed fascia rail mounts provide a number of advantages. Certain of these advantages arise because the fascia rail mounts provide an alternative to mounting posts within the deck or structure and / or using posts mounted directly to the fascia.

[0018] The fascia rail mounts do not mount posts within the deck or structure (e.g., the fasteners for the post do not screw into the deck itself, the post is not set inside a clamp within the deck). For posts mounted within a deck, movement of the post can crack or otherwise deteriorate the waterproof layer. In addition, it is difficult to change posts without causing damage or requiring the waterproof layer to be reapplied. Thus, due at least in part to the posts being mounted to the disclosed fascia rail mounts, the above disadvantages or drawbacks are avoided.

[0019] The fascia rail mounts allow for posts to not be mounted directly to the fascia of the deck. Posts that are fascia mounted are typically not strong enough to be up to code or safety standards. As a result, fascia-mounted posts typically require the posts to also be attached to a building to achieve the required strength. Thus, due at least in part to the posts being mounted to the disclosed fascia rail mounts rather that directly to the fascia, the resulting installation of the posts is sufficiently strong so that the posts do not have to be attached to a building.

[0020] Another advantage of the disclosed fascia rail mounts is that it facilitates the use of interchangeable posts. The disclosed fascia rail mounts make it easy to remove installed posts, to service installed posts, to change installed posts, etc. In such instances, it is not required to reapply waterproofing because the fascia rail mounts maintain their waterproofing layer when a post is removed. In addition, the disclosed fascia rail mounts increase the longevity of a deck (or similar structure) because the deck can be serviced without causing structural damage or altering the structural integrity of the deck. In addition, the waterproofing warranty may be unaffected by servicing, removing, or changing posts because the waterproof layer is unaffected by the service, replacement, or change in posts.

[0021] Another advantage of the disclosed fascia rail mounts is the increased strength of the resulting posts and rails mounted to a deck. The disclosed fascia rail mounts are stronger than mounting posts directly to the fascia of a structure. The inventor found that combining the top plate with the side plate resulted in unexpected increases in strength and stability of the fascia rail mounts when posts and rails were mounted using the disclosed fascia rail mounts. Advantageously, this allows a longer warranty to be offered, and it also reduces risk and liability. In addition, because the fascia rail mounts provide a strong base for posts and rails, the rail can be free standing (e.g., the rail does not have to be secured to a building to achieve targeted or required strength, as is typically required for posts that are directly mounted to the fascia).

[0022] The disclosed fascia rail mounts can have a footprint that is between 3″ per side to around 24″ per side. The spacing and / or configuration of the threaded rods can be varied to fit a variety of posts. In some embodiments, the disclosed fascia rail mounts can have a continuous run along the side of a deck or other similar structure. In certain embodiments, this can also include corners in addition to a continuous run along the side of the deck. In some embodiments, the disclosed fascia rail mounts can also be used with a square cap that is applied with the post to cover the screws and threaded rods of the disclosed fascia rail mounts. This can increase the safety of the fascia rail mounts by reducing exposure to any threaded rods extending out of the side plate of the installed posts.

[0023] The disclosed fascia rail mounts can be useful in structures where the wood substrate has a fully encapsulated coating on top that is waterproof. The disclosed fascia rail mounts can also be useful in structures that includes a surface that has waterproofing underneath concrete or other cementitious product (e.g., a so-called “concrete deck over waterproof”). In some embodiments, the disclosed fascia rail mounts are configured to be embedded in a cementitious coating. Advantageously, the disclosed fascia rail mounts eliminate the need for drilling into the structure during railing installation because the threaded rods are already available and exposed at that point in construction. That is, the disclosed fascia rail mounts are installed on the structure before waterproofing and / or pouring or installation of concrete and / or other such cementitious products. Advantageously, this can reduce or eliminate liability for the railing installer because the threaded rods are already in the structure, providing a place for a contractor to mount the railing. In some embodiments, the disclosed fascia rail mounts can handle up to 1200 lbs. of lateral force (e.g., on a post mounted in the fascia rail mount) without damaging the coating or other layers applied on top of the fascia rail mounts. The fascia rail mounts can be made of a variety of materials including, for example and without limitation, plastic, wood, carbon fiber, steel, aluminum, tin, etc. In some implementations, the fascia rail mounts are configured so that coatings that are applied to the surfaces thereof adhere to those surfaces.

[0024] The disclosed fascia rail mounts make the installation of railing much faster and easier. The fascia rail mounts enable the removal of posts and railing with little or no damage to the deck or to the waterproofing. The fascia rail mounts also enable the removal of posts and railing with little or no damage to the fascia or finishes applied to the fascia (e.g., stucco, paint, trim, etc.). This allows the railing to be integral with the waterproofing, in some embodiments.

[0025] The fascia rail mounts are configured so that installation does not involve drilling or screwing into the fascia beam. The fascia rail mounts are secured to the top of the deck or other such structure. The installation process is such that all of the bolts and other fasteners used to install the fascia rail mounts are under an applied waterproofing layer. In some embodiments, the fascia rail mounts include a mounting strap or that is configured to extend from the side plate to go under and around the fascia beam to attach the fascia rail mounts to the fascia beam. These configurations of the fascia rail mount are configured so that anywhere the fascia beam is exposed to the elements there is no penetration of the fascia beam by the fasteners that secure the fascia rail mounts to the fascia beam. Advantageously, this inhibits or prevents dry-rot because there is no penetration into the fascia beam by the fasteners in places that are exposed to the elements. The mounting strap also creates a sturdier mount that reduces or eliminates stress from the railing when force is applied, either from pushing or pulling the railing. This reduces or eliminates the fascia rail mount from weakening relative to other designs because there are no fasteners in the fascia that might eventually wear out and become lose.Example Rail Mounts

[0026] FIGS. 1A, 1B, 1C, and 1D illustrate various views of an example of a fascia rail mount 100 for installation on a deck or other similar structure (e.g., a patio, balcony, staircase, porch, etc.). The fascia rail mount 100 is configured to support a post secured to the deck, the post configured to support a railing attached between posts. The fascia rail mount 100 includes a top plate 104 with top plate holes 112 that allow fasteners to be passed through to secure the fascia rail mount 100 to the top of the deck. The fascia rail mount 100 includes a side plate 102 extending downward from the top plate 104, the side plate 102 including threaded rods 110 extending outward (e.g., in a direction away from the top plate 104 and away from the deck or fascia beam when installed) from the side plate 102. A post to be attached to the deck includes holes that can be placed over the threaded rods 110 to allow a nut or bolt to be threaded over the threaded rods 110 to secure the post to the fascia rail mount 100, thereby securing the post to the deck.

[0027] The side plate 102 extends perpendicularly downward from the top plate 104. The side plate 102 can be secured to the top plate 104 using any suitable means including, for example and without limitation, fasteners, welding, adhesives, joint hardware, or any combination of these or the like. In some embodiments, the side plate 102 can be integrally formed with the top plate 104. For example, the top plate 104 can be formed from a larger material a portion of which is bent at 90 degrees to form the side plate 102.

[0028] The threaded rods 110 extend outward from the side plate 102. The threaded rods 110 are secured to the side plate 102 through any suitable means including, for example and without limitation, fasteners, welding, adhesives, friction fit, or any combination of these or the like. In some embodiments, the threaded rods 110 can be integrally formed with the side plate 102. The top plate holes 112 are formed in the top plate 104 to allow screws, nails, bolts, or other such fasteners to be used to secure the top plate 104 to the top of the deck.

[0029] The fascia rail mount 100 includes a mounting strap 106 extending downward from the side plate 102. The mounting strap 106 is configured to wrap around a fascia beam to further secure the fascia rail mount 100 to a fascia beam. In some embodiments, the mounting strap 106 is not as wide as the side plate 102. The mounting strap 106 is configured to extend downward from the side plate 102, to make a 90 degree turn to extend horizontally backwards (e.g., in the same direction as the top plate 104), and then to make another 90 degree turn upward, to form a squared “J” shape. In some embodiments, the mounting strap 106 or a portion of the mounting strap 106 is removable from the fascia rail mount to enable installation of the fascia rail mount 100 on the fascia beam. Then, once installed, the removed portion can be replaced and secured to the fascia rail mount 100 to further secure the fascia rail mount 100 to the fascia beam. In some embodiments, a portion of the mounting strap is movable downwards so that the fascia rail mount 100 can be installed on the fascia beam and then the movable portion can be tightened around the fascia beam.

[0030] Each component of the fascia rail mount 100 can be made from a suitable material. Examples of suitable materials include, without limitation, steel, plastic, aluminum, carbon fiber, wood, composites, metal alloys, and the like. In some embodiments, different components of the fascia rail mount 100 are made from different materials or different combinations of materials. In some embodiments, the top plate 104 and / or the side plate 102 is ¼-inch steel or ⅛-inch steel. That is, the top plate 104 and the side plate 102 can be made from the same material with the same thickness, from the same material with different thickness, from different materials with the same thickness, or from different materials with different thickness.

[0031] Thus, the fascia rail mount 100 can be configured to be mounted to a deck. The fascia rail mount 100 can be configured to enable installation of a post on the deck. In some embodiments, the fascia rail mount 100 includes a top plate 104 forming one or more top plate holes 112 through which fasteners are configured to extend to secure the top plate 104 to a top of the deck. The fascia rail mount 100 includes a side plate 102 extending perpendicularly from the top plate 104. The side plate 102 includes a plurality of threaded rods 110 affixed to the side plate 102, the threaded rods 110 extending perpendicularly from the side plate 102. The side plate 102 is configured to extend over a fascia of the deck with the top plate secured to a top portion of the deck. The fascia rail mount 100 is configured to be secured to the deck so that the side plate 102 is adjacent and parallel to the fascia of the deck in such a way that the plurality of threaded rods 110 extends horizontally to pass through holes of a base of a post to be secured to the deck.

[0032] FIGS. 2A and 2B illustrate various views of an example of a fascia rail mount 200 installed on a fascia beam 255 of a deck or other structure. The fascia rail mount 200 is similar to the fascia rail mount 100 described herein with reference to FIGS. 1A-1D. The fascia rail mount includes a top plate 204 that is fastened to a top surface 250 of the deck. The top plate 204 is fastened to the top surface 250 using a plurality of fasteners. In some embodiments, the top surface of the deck 250 is routed out so that the top plate 204 is flush with the top surface of the deck 250. This facilitates and improves applied coatings or layers, such as a waterproof layer, because the top surface of the deck is continuous and smooth, that is, it lacks sudden changes in surface height. The fascia rail mount 200 includes a side plate 202 extending downward from the top plate 204. The side plate 202 includes threaded rods 210 extending horizontally from the top plate 204, away from the fascia beam 255. The fascia mount 200 includes a mounting strap 206 that wraps around the fascia beam 255. In some embodiments, the mounting strap 206 includes a movable or removable portion that can be placed and tightened using fasteners to further secure the fascia rail mount 200 to the fascia beam 255.

[0033] A post to be attached to the deck includes holes that can be placed over the threaded rods 210 to allow a nut or bolt to be threaded over the threaded rods 210 to secure the post to the fascia rail mount 200, thereby securing the post to the deck. The fascia rail mount 200 includes the top plate 204 with the side plate 204 extending perpendicularly downward from the top plate 204. This enables the fascia rail mount 200 to be attached to top surface of the deck 250 in a way that the fascia rail mount 200 is secured to the top of the deck 250 while posts are secured adjacent to the fascia beam 255 of the deck.

[0034] The side plate 202 can be secured to the top plate 204 using any suitable means including, for example and without limitation, fasteners, welding, adhesives, joint hardware, or any combination of these or the like. In some embodiments, the side plate 202 can be integrally formed with the top plate 204. For example, the top plate 204 can be formed from a larger material a portion of which is bent at 90 degrees to form the side plate 202.

[0035] The fascia rail mount 200 also includes the threaded rods 210 that extend outward from the side plate 202. The threaded rods 210 are secured to the side plate 202 through any suitable means including, for example and without limitation, fasteners, welding, adhesives, friction fit, or any combination of these or the like. In some embodiments, the threaded rods 210 can be integrally formed with the side plate 202.

[0036] Each component of the fascia rail mount 200 can be made from a suitable material. Examples of suitable materials include, without limitation, steel, plastic, aluminum, carbon fiber, wood, composites, metal alloys, and the like. In some embodiments, different components of the fascia rail mount 200 are made from different materials or different combinations of materials.

[0037] Once installed on the deck, additional layers, coating, or surfaces 260 can be applied on top of the top plate 204, covering the top plate 204. By way of example, a waterproof coating can be applied to the top plate 204 and to the top surface of the deck 250 resulting in a waterproof layer that is not penetrated by the fascia rail mount 200. In this way, posts can be installed, removed, and changed without affecting the integrity of the applied coatings 260 on top of the top plate 204.

[0038] FIGS. 3A, 3B, 3C, and 3D illustrate various views of an example of a fascia rail mount 300 configured to be mounted to a fascia beam. The fascia rail mount 300 is similar to the fascia rail mount 100 described herein with reference to FIGS. 1A-1D and / or the fascia rail mount 200 described herein with reference to FIGS. 2A and 2B. The fascia rail mount 300 is also configured to support a post secured to the deck, the post configured to support a railing attached between posts. The fascia rail mount 300 includes threaded rods 310 extending from a side plate 302 that is adjacent to a fascia beam 355. A post to be attached to the deck includes holes that can be placed over the threaded rods 310 to allow a nut or bolt to be threaded over the threaded rods 310 to secure the post to the fascia rail mount 300, thereby securing the post to the fascia beam, which can be part of a deck or other similar structure.

[0039] The fascia rail mount 300 includes a top plate 304 that is configured to be fastened to a top surface of the deck 350. The top surface of the deck 350 can be routed out to cause the top plate 304 to be flush with the top surface of the deck 350. The side plate 302 extends downwards from the top plate 304 so that the side plate 302 is against or adjacent to the fascia beam 355. A mounting strap 306 extends downwards from the side plate 302, then back along the bottom of the fascia beam 355, and upwards along an inner side of the fascia beam. In this way, the mounting strap 306 further secures the fascia rail mount 300 to the fascia beam 355.

[0040] The top plate 304 can be secured to the side plate 302 using any suitable means including, for example and without limitation, fasteners, welding, adhesives, joint hardware, or any combination of these or the like. In some embodiments, the top plate 304 can be integrally formed with the side plate 302. For example, the top plate 304 can be formed from a larger material a portion of which is bent at 90 degrees to form the side plate 302.

[0041] The fascia rail mount 300 also includes the threaded rods 310 that extend outward from the side plate 302. The threaded rods 310 are secured to the side plate 302 through any suitable means including, for example and without limitation, fasteners, welding, adhesives, friction fit, or any combination of these or the like. In some embodiments, the threaded rods 310 can be integrally formed with the side plate 302.

[0042] A plurality of top plate holes 312 are formed in the top plate 304 to allow screws, nails, bolts, or other such fasteners to be used to secure the top plate 304 to the top of the fascia beam 355. In the figure, fasteners are shown securing the top plate 304 to the fascia beam 355 through the top plate holes 312.

[0043] Each component of the fascia rail mount 300 can be made from a suitable material. Examples of suitable materials include, without limitation, steel, plastic, aluminum, carbon fiber, wood, composites, metal alloys, and the like. In some embodiments, different components of the fascia rail mount 300 are made from different materials or different combinations of materials.Example Process for Installing Rail Mounts on a Deck

[0044] FIGS. 4A, 4B, 4C, 4D, 4E, 4F, and 4G illustrate a process of installing railing 479 on a deck 450 using a fascia rail mount 400. The deck 450 includes a top surface 452 and a side surface 453 (or fascia). The fascia rail mount 400 is similar to the fascia rail mount 100 described herein with reference to FIGS. 1A-1D, to the fascia rail mount 200 described herein with reference to FIGS. 2A and 2B, and to the fascia rail mount 300 described herein with reference to FIGS. 3A-3D.

[0045] FIGS. 4A and 4B illustrate a top view and a side view, respectively, of the deck 450 prepared to receive the fascia rail mount 400. The top surface 452 can be formed or cut to form a recessed portion 456 that mates with the fascia rail mount 400. The recessed portion 456 can be formed such that when the fascia rail mount 400 are secured to the deck 450, the top plate of the fascia rail mount 400 is flush with the top surface 452 of the deck 450.

[0046] FIGS. 4C and 4D illustrate a top view and a side view, respectively, of the fascia rail mount 400 secured to the deck 450. Securing the fascia rail mount 400 to the deck 450 can be accomplished using fasteners through holes 412 in the top plate 404 of the fascia rail mount 400 as well as using a mounting strap 406. When the fascia rail mount 400 is secured to the deck 450, threaded rods 410 of the fascia rail mount 400 extend outward from the fascia beam 453 of the deck 450.

[0047] In some embodiments, securing the fascia rail mount 400 to the deck 450 includes using an epoxy or other adhesive in addition to fasteners. For example, an epoxy can be used under the fascia rail mount 400 that is a wet set epoxy. In some implementations, an adhesive or epoxy is used that does not contain water to avoid inducing rust on the fascia rail mount 400. In some embodiments, flashing can be used under the fascia rail mount 400 to increase waterproofing.

[0048] FIGS. 4E and 4F illustrate a top view and a side view, respectively, of one or more layers 460 being applied to the top surface 452 of the deck 450. The one or more layers 460 can include, for example and without limitation, a waterproof layer, a structural support layer (e.g., a wire or metal mesh), a cementitious product, stucco, varnish, paint, or the like. In some embodiments, one or more of the one or more layers 460 can be applied to the fascia beam 453 as well. In some embodiments, where the one or more layers 460 includes a waterproof layer, the threaded rods 410 can be treated with the waterproof layer such that the waterproof layer forms a waterproof barrier that surrounds and includes the threaded rods 410. Thus, even though the threaded rods 410 extend outward through the one or more layers 460, waterproofing is not compromised.

[0049] In some embodiments, the one or more layers 460 includes a finish layer such as concrete or a cementitious product (e.g., poured gypsum). The finish layer can be poured over support mesh. In some embodiments, the one or more layers 460 encapsulates the fascia rail mount 400 (while still allowing the threaded rods 410 to be exposed).

[0050] FIG. 4G illustrates a side view of a post 475 being secured to the deck 450 using the fascia rail mount 400. Railing 479 runs between posts, being attached to post 470. It should also be understood that additional posts can be installed on the deck 450 using fascia rail mounts as described herein.

[0051] The post 470 includes a base 471 with holes that fit over the threaded rods 410. Installing the post 470 thus includes placing the base 471 in a way that the threaded rods 410 pass through the holes and securing the post 470 to the fascia 453 of the deck 450 using fasteners 472 such as nuts or bolts that thread on the threaded rods 410. In this way, the post 470 is secured to the deck 450 at the fascia beam 453 without penetrating the one or more layers 460 or any portion of the deck 450. This allows the functionality of the one or more layers 460 to be maintained and / or to be uncompromised as part of the installation of the railing 479. In some embodiments, the base 471 can have templates that vary and the fascia rail mount 400 can have the threaded rods 410 vary according to the template. This allows different hole patterns, positioning, spacing, etc. to be employed for the bases 471.

[0052] Advantageously, the fascia rail mount 400 allows posts to be attached to the deck 450 without compromising waterproofing. This is due at least in part to the threaded rods 410 being present during the waterproofing process and being treated with the waterproofing material. This is in contrast to a process that uses screws or nails or other such fasteners that penetrate into the deck 450, which would also penetrate through the waterproof layer thereby compromising waterproofing of the deck. This may be beneficial where there is a breach of the post (e.g., water penetrates into the interior of the post) because the water is still unable to penetrate the deck 450 because of the waterproofing that is maintained by the disclosed fascia rail mounts.

[0053] Advantageously, the fascia rail mount 400 increases the strength and resilience of the posts secured to them. The fascia rail mount 400 is secured to the deck 450 on both the top surface 452 and to the fascia beam 453 using the mounting strap 406, thereby increasing the strength and resilience of the post 470. In some embodiments, this allows the post 470 to be secured solely to the deck and not to the building to which the deck 450 is attached. The increased resilience and strength also improves the longevity of the post 470, the railing 479, and the deck 450 by extension.

[0054] The increased strength and resilience of the post 470 and railing 479 when secured to the deck 450 via the fascia rail mount 400 is particularly evident when compared to posts mounted directly to the fascia beam 453. In a fascia mount configuration, the post is secured directly to the fascia beam and only to the fascia beam using a fascia mount bracket that attaches to the side of the structure. In such a configuration, the fascia mount bracket is secured to the structure using only one surface, the fascia beam, resulting in a lack of structural integrity. Furthermore, posts typically slide into brackets that are attached to the fascia, rather than attaching to the structure itself. If this bracket is then covered in the one or more layers 460 (e.g., stucco), it may be difficult to service the posts without destroying a portion of the structure.

[0055] In contrast, the fascia rail mount 400 allows the post 470 and the railing 479 to be serviced without affecting the fascia rail mount 400 or the deck 450. For example, the post 470 can include a seal cap that can be removed and the bolts or nuts can be tightened. Similarly, the bolts or nuts can be easily removed to replace the post. After which, the seal cap can be replaced. This process again does not affect the structure and leaves unchanged the one or more layers 460 that may provide desired functionality, such as waterproofing or structural integrity, or aesthetics.

[0056] In some embodiments, the process of installing the disclosed fascia rail mounts can include routing out the wood so that the fascia rail mounts are flush with the wood. Flashing detail can then be added and an epoxy can be applied to the wood to wet set the fascia rail mount. Being prepared in this way, the fascia rail mount can then be attached to the wood. Fasteners, such as screws, can then be used to further secure the fascia rail mount to the wood. Once attached with fasteners, the surface can be covered in sand or other material so that additional layers adhere better to the surface of the fascia rail mount and threaded rods. In some implementations, the material that is added makes a superior surface for polymers to bond to. A wire lath can then be installed. In some implementations, the wire lath comprises a wire mesh. In certain instances, the wire lath does not cover the fascia rail mounts. In various instances, the wire lath covers the fascia rail mounts as well. Being prepared in this way, a polymer or other material can be applied to coat the wood and the fascia rail mounts. In some embodiments, the polymer or other material can be a waterproofing agent or other material that bestows desirable properties on the fascia rail mounts and deck. The coating applied can be five or six layers in combination, for example. A top coat applied over everything can be a polymer cement, cementitious product, epoxy, urethane, asphalt emulsion, aliphatic material, etc.Additional Embodiments and Terminology

[0057] The present disclosure describes various features, no single one of which is solely responsible for the benefits described herein. It will be understood that various features described herein may be combined, modified, or omitted, as would be apparent to one of ordinary skill. Other combinations and sub-combinations than those specifically described herein will be apparent to one of ordinary skill, and are intended to form a part of this disclosure. Various methods are described herein in connection with various flowchart steps and / or phases. It will be understood that in many cases, certain steps and / or phases may be combined together such that multiple steps and / or phases shown in the flowcharts can be performed as a single step and / or phase. Also, certain steps and / or phases can be broken into additional sub-components to be performed separately. In some instances, the order of the steps and / or phases can be rearranged and certain steps and / or phases may be omitted entirely. Also, the methods described herein are to be understood to be open-ended, such that additional steps and / or phases to those shown and described herein can also be performed.

[0058] Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,”“comprising,” and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to.” The word “coupled”, as generally used herein, refers to two or more elements that may be either directly connected, or connected by way of one or more intermediate elements. Additionally, the words “herein,”“above,”“below,” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. Where the context permits, words in the above Detailed Description using the singular or plural number may also include the plural or singular number respectively. The word “or” in reference to a list of two or more items, that word covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list. The word “exemplary” is used exclusively herein to mean “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations.

[0059] The disclosure is not intended to be limited to the implementations shown herein. Various modifications to the implementations described in this disclosure may be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other implementations without departing from the spirit or scope of this disclosure. The teachings of the invention provided herein can be applied to other methods and systems, and are not limited to the methods and systems described above, and elements and acts of the various embodiments described above can be combined to provide further embodiments. Accordingly, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made without departing from the spirit of the disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosure.

Examples

Embodiment Construction

[0011]The headings provided herein, if any, are for convenience only and do not necessarily affect the scope or meaning of the claimed subject matter.

Overview

[0012]Structures such as decks, patios, porches, balconies, staircases, and the like can use railings to prevent people from falling over the edge of such structures. To secure the railing to the structure, posts can be used. These posts can be secured to the structure by driving bolts into the top layer of the structure. This may result in the bolts penetrating one or more layers designed to protect the structure, such as a waterproofing layer. This can disadvantageously compromise the structural integrity of the structure. Alternatively, posts can be attached to the structure by attaching mounting hardware to a fascia of the structure, which may result in posts that lack strength and resilience. This can disadvantageously result in a railing that is unable to withstand forces applied to the railing.

[0013]Accordingly, describe...

CROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims the benefit of priority to U.S. Prov. App. No. 63 / 702,578 filed Oct. 2, 2024, the entire contents of which is expressly incorporated by reference herein for all purposes.BACKGROUNDField

[0002] The present disclosure generally relates to rail mounts for decks.Description of Related Art

[0003] A deck is typically an outdoor surface with a railing attached that can be free standing or adjacent to a building, such as a house, hotel, or office building. Railing is typically attached to a deck using one or more posts along the side of the deck and / or one or more posts at the corners of the deck. The railing is designed to prevent people from falling from the deck. Other than decks, railings can be used with stairs, balconies, patios, and the like.SUMMARY

[0004] According to a number of implementations, the present disclosure relates to a fascia rail mount for a deck, the fascia rail mount configured to enable installation of a post on the deck. The fascia rail mount includes a top plate forming one or more holes through which fasteners are configured to extend to secure the top plate to a top of the deck; a side plate extending perpendicularly from the baseplate in a direction to position the side plate adjacent to a fascia beam of the deck upon fastening the top plate to the top of the deck; a plurality of threaded rods affixed to the side plate and extending perpendicularly outward from the side plate; and a mounting strap extending downward from the side plate, extending horizontally in the same direction as the top plate, and then extending upward, to form a squared “J” shape that wraps around the fascia beam to further secure the fascia rail mount to the fascia beam. The fascia rail mount is configured to be secured to the deck along an edge of the deck in such a way that the plurality of threaded rods extends horizontally away from the fascia beam to pass through holes of a base of a post to be secured to the deck at the fascia beam of the deck.

[0005] In some embodiments, the mounting strap includes a removable portion to facilitate installation of the fascia rail mount on the fascia beam. In some embodiments, the mounting strap includes a movable portion to facilitate installation of the fascia rail mount on the fascia beam.

[0006] For purposes of summarizing the disclosure, certain aspects, advantages and novel features have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any particular embodiment. Thus, the disclosed embodiments may be carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] FIGS. 1A, 1B, 1C, and 1D illustrate various views of an example of a fascia rail mount for a deck.

[0008] FIGS. 2A and 2B illustrate various views of an example fascia rail mount for a deck mounted on a deck.

[0009] FIGS. 3A, 3B, 3C, and 3D illustrate various views of an example of a fascia rail mount for a deck.

[0010] FIGS. 4A, 4B, 4C, 4D, 4E, 4F, and 4G illustrate a process of installing railing on a deck using the disclosed fascia rail mounts.DETAILED DESCRIPTION OF SOME EMBODIMENTS

[0011] The headings provided herein, if any, are for convenience only and do not necessarily affect the scope or meaning of the claimed subject matter.Overview

[0012] Structures such as decks, patios, porches, balconies, staircases, and the like can use railings to prevent people from falling over the edge of such structures. To secure the railing to the structure, posts can be used. These posts can be secured to the structure by driving bolts into the top layer of the structure. This may result in the bolts penetrating one or more layers designed to protect the structure, such as a waterproofing layer. This can disadvantageously compromise the structural integrity of the structure. Alternatively, posts can be attached to the structure by attaching mounting hardware to a fascia of the structure, which may result in posts that lack strength and resilience. This can disadvantageously result in a railing that is unable to withstand forces applied to the railing.

[0013] Accordingly, described herein are fascia rail mounts that are attached to a structure, such as a deck, prior to a waterproofing layer. The fascia rail mounts are mounted to a top side of the structure using a top plate that is fastened to the top side of the structure with a side plate extending down from top plate, the side plate abutting the fascia of the structure. The side plate includes threaded rods that extend perpendicularly from the side plate to allow fascia-mounted posts to be mounted to the side plate of the disclosed fascia rail mounts. In some embodiments, the disclosed fascia rail mounts also include a mounting strap that is attached to the underside of the beam forming the fascia of the structure. The mounting strap can further anchor the disclosed fascia rail mounts to the structure.

[0014] The threaded rods mate with holes in a railing post to allow the railing post to be attached to along the fascia of the structure using the threaded rods. In some implementations, the disclosed fascia rail mounts are attached to the structure prior to applying any layers designed to protect the structure such that the fascia rail mounts, including the threaded rods, receive the protective layers. For example, a waterproof layer can be applied to the structure after the fascia rail mounts have been affixed to the structure. In this situation, the threaded rods of the fascia rail mounts extend past the waterproof layer without compromising the waterproofing of the structure because the threaded rods and the fascia rail mounts have been treated with the waterproof layer. In other words, the waterproof layer forms a waterproof barrier even with the threaded rods extending from the fascia rail mounts through the waterproof layer.

[0015] The disclosed fascia rail mounts include a top plate with a side plate attached to the top plate. The top plate is configured to be secured to a top part of the structure (e.g., a floor of a deck) while the side plate is configured to extend downward over the fascia of the structure. This configuration of the fascia rail mounts enhances the strength and resilience of posts attached at the fascia of a structure relative to posts attached directly to the fascia of the structure.

[0016] In addition, the disclosed fascia rail mounts can be secured to the structure by recessing one or more portions of the structure where the fascia rail mounts are to be secured. As a result, the disclosed rail mounts can be flush with one or more of the surfaces of the structure. This facilitates application of one or more layers, such as a waterproof layer, to the structure without having multiple different surface levels on the structure.

[0017] The disclosed fascia rail mounts provide a number of advantages. Certain of these advantages arise because the fascia rail mounts provide an alternative to mounting posts within the deck or structure and / or using posts mounted directly to the fascia.

[0018] The fascia rail mounts do not mount posts within the deck or structure (e.g., the fasteners for the post do not screw into the deck itself, the post is not set inside a clamp within the deck). For posts mounted within a deck, movement of the post can crack or otherwise deteriorate the waterproof layer. In addition, it is difficult to change posts without causing damage or requiring the waterproof layer to be reapplied. Thus, due at least in part to the posts being mounted to the disclosed fascia rail mounts, the above disadvantages or drawbacks are avoided.

[0019] The fascia rail mounts allow for posts to not be mounted directly to the fascia of the deck. Posts that are fascia mounted are typically not strong enough to be up to code or safety standards. As a result, fascia-mounted posts typically require the posts to also be attached to a building to achieve the required strength. Thus, due at least in part to the posts being mounted to the disclosed fascia rail mounts rather that directly to the fascia, the resulting installation of the posts is sufficiently strong so that the posts do not have to be attached to a building.

[0020] Another advantage of the disclosed fascia rail mounts is that it facilitates the use of interchangeable posts. The disclosed fascia rail mounts make it easy to remove installed posts, to service installed posts, to change installed posts, etc. In such instances, it is not required to reapply waterproofing because the fascia rail mounts maintain their waterproofing layer when a post is removed. In addition, the disclosed fascia rail mounts increase the longevity of a deck (or similar structure) because the deck can be serviced without causing structural damage or altering the structural integrity of the deck. In addition, the waterproofing warranty may be unaffected by servicing, removing, or changing posts because the waterproof layer is unaffected by the service, replacement, or change in posts.

[0021] Another advantage of the disclosed fascia rail mounts is the increased strength of the resulting posts and rails mounted to a deck. The disclosed fascia rail mounts are stronger than mounting posts directly to the fascia of a structure. The inventor found that combining the top plate with the side plate resulted in unexpected increases in strength and stability of the fascia rail mounts when posts and rails were mounted using the disclosed fascia rail mounts. Advantageously, this allows a longer warranty to be offered, and it also reduces risk and liability. In addition, because the fascia rail mounts provide a strong base for posts and rails, the rail can be free standing (e.g., the rail does not have to be secured to a building to achieve targeted or required strength, as is typically required for posts that are directly mounted to the fascia).

[0022] The disclosed fascia rail mounts can have a footprint that is between 3″ per side to around 24″ per side. The spacing and / or configuration of the threaded rods can be varied to fit a variety of posts. In some embodiments, the disclosed fascia rail mounts can have a continuous run along the side of a deck or other similar structure. In certain embodiments, this can also include corners in addition to a continuous run along the side of the deck. In some embodiments, the disclosed fascia rail mounts can also be used with a square cap that is applied with the post to cover the screws and threaded rods of the disclosed fascia rail mounts. This can increase the safety of the fascia rail mounts by reducing exposure to any threaded rods extending out of the side plate of the installed posts.

[0023] The disclosed fascia rail mounts can be useful in structures where the wood substrate has a fully encapsulated coating on top that is waterproof. The disclosed fascia rail mounts can also be useful in structures that includes a surface that has waterproofing underneath concrete or other cementitious product (e.g., a so-called “concrete deck over waterproof”). In some embodiments, the disclosed fascia rail mounts are configured to be embedded in a cementitious coating. Advantageously, the disclosed fascia rail mounts eliminate the need for drilling into the structure during railing installation because the threaded rods are already available and exposed at that point in construction. That is, the disclosed fascia rail mounts are installed on the structure before waterproofing and / or pouring or installation of concrete and / or other such cementitious products. Advantageously, this can reduce or eliminate liability for the railing installer because the threaded rods are already in the structure, providing a place for a contractor to mount the railing. In some embodiments, the disclosed fascia rail mounts can handle up to 1200 lbs. of lateral force (e.g., on a post mounted in the fascia rail mount) without damaging the coating or other layers applied on top of the fascia rail mounts. The fascia rail mounts can be made of a variety of materials including, for example and without limitation, plastic, wood, carbon fiber, steel, aluminum, tin, etc. In some implementations, the fascia rail mounts are configured so that coatings that are applied to the surfaces thereof adhere to those surfaces.

[0024] The disclosed fascia rail mounts make the installation of railing much faster and easier. The fascia rail mounts enable the removal of posts and railing with little or no damage to the deck or to the waterproofing. The fascia rail mounts also enable the removal of posts and railing with little or no damage to the fascia or finishes applied to the fascia (e.g., stucco, paint, trim, etc.). This allows the railing to be integral with the waterproofing, in some embodiments.

[0025] The fascia rail mounts are configured so that installation does not involve drilling or screwing into the fascia beam. The fascia rail mounts are secured to the top of the deck or other such structure. The installation process is such that all of the bolts and other fasteners used to install the fascia rail mounts are under an applied waterproofing layer. In some embodiments, the fascia rail mounts include a mounting strap or that is configured to extend from the side plate to go under and around the fascia beam to attach the fascia rail mounts to the fascia beam. These configurations of the fascia rail mount are configured so that anywhere the fascia beam is exposed to the elements there is no penetration of the fascia beam by the fasteners that secure the fascia rail mounts to the fascia beam. Advantageously, this inhibits or prevents dry-rot because there is no penetration into the fascia beam by the fasteners in places that are exposed to the elements. The mounting strap also creates a sturdier mount that reduces or eliminates stress from the railing when force is applied, either from pushing or pulling the railing. This reduces or eliminates the fascia rail mount from weakening relative to other designs because there are no fasteners in the fascia that might eventually wear out and become lose.Example Rail Mounts

[0026] FIGS. 1A, 1B, 1C, and 1D illustrate various views of an example of a fascia rail mount 100 for installation on a deck or other similar structure (e.g., a patio, balcony, staircase, porch, etc.). The fascia rail mount 100 is configured to support a post secured to the deck, the post configured to support a railing attached between posts. The fascia rail mount 100 includes a top plate 104 with top plate holes 112 that allow fasteners to be passed through to secure the fascia rail mount 100 to the top of the deck. The fascia rail mount 100 includes a side plate 102 extending downward from the top plate 104, the side plate 102 including threaded rods 110 extending outward (e.g., in a direction away from the top plate 104 and away from the deck or fascia beam when installed) from the side plate 102. A post to be attached to the deck includes holes that can be placed over the threaded rods 110 to allow a nut or bolt to be threaded over the threaded rods 110 to secure the post to the fascia rail mount 100, thereby securing the post to the deck.

[0027] The side plate 102 extends perpendicularly downward from the top plate 104. The side plate 102 can be secured to the top plate 104 using any suitable means including, for example and without limitation, fasteners, welding, adhesives, joint hardware, or any combination of these or the like. In some embodiments, the side plate 102 can be integrally formed with the top plate 104. For example, the top plate 104 can be formed from a larger material a portion of which is bent at 90 degrees to form the side plate 102.

[0028] The threaded rods 110 extend outward from the side plate 102. The threaded rods 110 are secured to the side plate 102 through any suitable means including, for example and without limitation, fasteners, welding, adhesives, friction fit, or any combination of these or the like. In some embodiments, the threaded rods 110 can be integrally formed with the side plate 102. The top plate holes 112 are formed in the top plate 104 to allow screws, nails, bolts, or other such fasteners to be used to secure the top plate 104 to the top of the deck.

[0029] The fascia rail mount 100 includes a mounting strap 106 extending downward from the side plate 102. The mounting strap 106 is configured to wrap around a fascia beam to further secure the fascia rail mount 100 to a fascia beam. In some embodiments, the mounting strap 106 is not as wide as the side plate 102. The mounting strap 106 is configured to extend downward from the side plate 102, to make a 90 degree turn to extend horizontally backwards (e.g., in the same direction as the top plate 104), and then to make another 90 degree turn upward, to form a squared “J” shape. In some embodiments, the mounting strap 106 or a portion of the mounting strap 106 is removable from the fascia rail mount to enable installation of the fascia rail mount 100 on the fascia beam. Then, once installed, the removed portion can be replaced and secured to the fascia rail mount 100 to further secure the fascia rail mount 100 to the fascia beam. In some embodiments, a portion of the mounting strap is movable downwards so that the fascia rail mount 100 can be installed on the fascia beam and then the movable portion can be tightened around the fascia beam.

[0030] Each component of the fascia rail mount 100 can be made from a suitable material. Examples of suitable materials include, without limitation, steel, plastic, aluminum, carbon fiber, wood, composites, metal alloys, and the like. In some embodiments, different components of the fascia rail mount 100 are made from different materials or different combinations of materials. In some embodiments, the top plate 104 and / or the side plate 102 is ¼-inch steel or ⅛-inch steel. That is, the top plate 104 and the side plate 102 can be made from the same material with the same thickness, from the same material with different thickness, from different materials with the same thickness, or from different materials with different thickness.

[0031] Thus, the fascia rail mount 100 can be configured to be mounted to a deck. The fascia rail mount 100 can be configured to enable installation of a post on the deck. In some embodiments, the fascia rail mount 100 includes a top plate 104 forming one or more top plate holes 112 through which fasteners are configured to extend to secure the top plate 104 to a top of the deck. The fascia rail mount 100 includes a side plate 102 extending perpendicularly from the top plate 104. The side plate 102 includes a plurality of threaded rods 110 affixed to the side plate 102, the threaded rods 110 extending perpendicularly from the side plate 102. The side plate 102 is configured to extend over a fascia of the deck with the top plate secured to a top portion of the deck. The fascia rail mount 100 is configured to be secured to the deck so that the side plate 102 is adjacent and parallel to the fascia of the deck in such a way that the plurality of threaded rods 110 extends horizontally to pass through holes of a base of a post to be secured to the deck.

[0032] FIGS. 2A and 2B illustrate various views of an example of a fascia rail mount 200 installed on a fascia beam 255 of a deck or other structure. The fascia rail mount 200 is similar to the fascia rail mount 100 described herein with reference to FIGS. 1A-1D. The fascia rail mount includes a top plate 204 that is fastened to a top surface 250 of the deck. The top plate 204 is fastened to the top surface 250 using a plurality of fasteners. In some embodiments, the top surface of the deck 250 is routed out so that the top plate 204 is flush with the top surface of the deck 250. This facilitates and improves applied coatings or layers, such as a waterproof layer, because the top surface of the deck is continuous and smooth, that is, it lacks sudden changes in surface height. The fascia rail mount 200 includes a side plate 202 extending downward from the top plate 204. The side plate 202 includes threaded rods 210 extending horizontally from the top plate 204, away from the fascia beam 255. The fascia mount 200 includes a mounting strap 206 that wraps around the fascia beam 255. In some embodiments, the mounting strap 206 includes a movable or removable portion that can be placed and tightened using fasteners to further secure the fascia rail mount 200 to the fascia beam 255.

[0033] A post to be attached to the deck includes holes that can be placed over the threaded rods 210 to allow a nut or bolt to be threaded over the threaded rods 210 to secure the post to the fascia rail mount 200, thereby securing the post to the deck. The fascia rail mount 200 includes the top plate 204 with the side plate 204 extending perpendicularly downward from the top plate 204. This enables the fascia rail mount 200 to be attached to top surface of the deck 250 in a way that the fascia rail mount 200 is secured to the top of the deck 250 while posts are secured adjacent to the fascia beam 255 of the deck.

[0034] The side plate 202 can be secured to the top plate 204 using any suitable means including, for example and without limitation, fasteners, welding, adhesives, joint hardware, or any combination of these or the like. In some embodiments, the side plate 202 can be integrally formed with the top plate 204. For example, the top plate 204 can be formed from a larger material a portion of which is bent at 90 degrees to form the side plate 202.

[0035] The fascia rail mount 200 also includes the threaded rods 210 that extend outward from the side plate 202. The threaded rods 210 are secured to the side plate 202 through any suitable means including, for example and without limitation, fasteners, welding, adhesives, friction fit, or any combination of these or the like. In some embodiments, the threaded rods 210 can be integrally formed with the side plate 202.

[0036] Each component of the fascia rail mount 200 can be made from a suitable material. Examples of suitable materials include, without limitation, steel, plastic, aluminum, carbon fiber, wood, composites, metal alloys, and the like. In some embodiments, different components of the fascia rail mount 200 are made from different materials or different combinations of materials.

[0037] Once installed on the deck, additional layers, coating, or surfaces 260 can be applied on top of the top plate 204, covering the top plate 204. By way of example, a waterproof coating can be applied to the top plate 204 and to the top surface of the deck 250 resulting in a waterproof layer that is not penetrated by the fascia rail mount 200. In this way, posts can be installed, removed, and changed without affecting the integrity of the applied coatings 260 on top of the top plate 204.

[0038] FIGS. 3A, 3B, 3C, and 3D illustrate various views of an example of a fascia rail mount 300 configured to be mounted to a fascia beam. The fascia rail mount 300 is similar to the fascia rail mount 100 described herein with reference to FIGS. 1A-1D and / or the fascia rail mount 200 described herein with reference to FIGS. 2A and 2B. The fascia rail mount 300 is also configured to support a post secured to the deck, the post configured to support a railing attached between posts. The fascia rail mount 300 includes threaded rods 310 extending from a side plate 302 that is adjacent to a fascia beam 355. A post to be attached to the deck includes holes that can be placed over the threaded rods 310 to allow a nut or bolt to be threaded over the threaded rods 310 to secure the post to the fascia rail mount 300, thereby securing the post to the fascia beam, which can be part of a deck or other similar structure.

[0039] The fascia rail mount 300 includes a top plate 304 that is configured to be fastened to a top surface of the deck 350. The top surface of the deck 350 can be routed out to cause the top plate 304 to be flush with the top surface of the deck 350. The side plate 302 extends downwards from the top plate 304 so that the side plate 302 is against or adjacent to the fascia beam 355. A mounting strap 306 extends downwards from the side plate 302, then back along the bottom of the fascia beam 355, and upwards along an inner side of the fascia beam. In this way, the mounting strap 306 further secures the fascia rail mount 300 to the fascia beam 355.

[0040] The top plate 304 can be secured to the side plate 302 using any suitable means including, for example and without limitation, fasteners, welding, adhesives, joint hardware, or any combination of these or the like. In some embodiments, the top plate 304 can be integrally formed with the side plate 302. For example, the top plate 304 can be formed from a larger material a portion of which is bent at 90 degrees to form the side plate 302.

[0041] The fascia rail mount 300 also includes the threaded rods 310 that extend outward from the side plate 302. The threaded rods 310 are secured to the side plate 302 through any suitable means including, for example and without limitation, fasteners, welding, adhesives, friction fit, or any combination of these or the like. In some embodiments, the threaded rods 310 can be integrally formed with the side plate 302.

[0042] A plurality of top plate holes 312 are formed in the top plate 304 to allow screws, nails, bolts, or other such fasteners to be used to secure the top plate 304 to the top of the fascia beam 355. In the figure, fasteners are shown securing the top plate 304 to the fascia beam 355 through the top plate holes 312.

[0043] Each component of the fascia rail mount 300 can be made from a suitable material. Examples of suitable materials include, without limitation, steel, plastic, aluminum, carbon fiber, wood, composites, metal alloys, and the like. In some embodiments, different components of the fascia rail mount 300 are made from different materials or different combinations of materials.Example Process for Installing Rail Mounts on a Deck

[0044] FIGS. 4A, 4B, 4C, 4D, 4E, 4F, and 4G illustrate a process of installing railing 479 on a deck 450 using a fascia rail mount 400. The deck 450 includes a top surface 452 and a side surface 453 (or fascia). The fascia rail mount 400 is similar to the fascia rail mount 100 described herein with reference to FIGS. 1A-1D, to the fascia rail mount 200 described herein with reference to FIGS. 2A and 2B, and to the fascia rail mount 300 described herein with reference to FIGS. 3A-3D.

[0045] FIGS. 4A and 4B illustrate a top view and a side view, respectively, of the deck 450 prepared to receive the fascia rail mount 400. The top surface 452 can be formed or cut to form a recessed portion 456 that mates with the fascia rail mount 400. The recessed portion 456 can be formed such that when the fascia rail mount 400 are secured to the deck 450, the top plate of the fascia rail mount 400 is flush with the top surface 452 of the deck 450.

[0046] FIGS. 4C and 4D illustrate a top view and a side view, respectively, of the fascia rail mount 400 secured to the deck 450. Securing the fascia rail mount 400 to the deck 450 can be accomplished using fasteners through holes 412 in the top plate 404 of the fascia rail mount 400 as well as using a mounting strap 406. When the fascia rail mount 400 is secured to the deck 450, threaded rods 410 of the fascia rail mount 400 extend outward from the fascia beam 453 of the deck 450.

[0047] In some embodiments, securing the fascia rail mount 400 to the deck 450 includes using an epoxy or other adhesive in addition to fasteners. For example, an epoxy can be used under the fascia rail mount 400 that is a wet set epoxy. In some implementations, an adhesive or epoxy is used that does not contain water to avoid inducing rust on the fascia rail mount 400. In some embodiments, flashing can be used under the fascia rail mount 400 to increase waterproofing.

[0048] FIGS. 4E and 4F illustrate a top view and a side view, respectively, of one or more layers 460 being applied to the top surface 452 of the deck 450. The one or more layers 460 can include, for example and without limitation, a waterproof layer, a structural support layer (e.g., a wire or metal mesh), a cementitious product, stucco, varnish, paint, or the like. In some embodiments, one or more of the one or more layers 460 can be applied to the fascia beam 453 as well. In some embodiments, where the one or more layers 460 includes a waterproof layer, the threaded rods 410 can be treated with the waterproof layer such that the waterproof layer forms a waterproof barrier that surrounds and includes the threaded rods 410. Thus, even though the threaded rods 410 extend outward through the one or more layers 460, waterproofing is not compromised.

[0049] In some embodiments, the one or more layers 460 includes a finish layer such as concrete or a cementitious product (e.g., poured gypsum). The finish layer can be poured over support mesh. In some embodiments, the one or more layers 460 encapsulates the fascia rail mount 400 (while still allowing the threaded rods 410 to be exposed).

[0050] FIG. 4G illustrates a side view of a post 475 being secured to the deck 450 using the fascia rail mount 400. Railing 479 runs between posts, being attached to post 470. It should also be understood that additional posts can be installed on the deck 450 using fascia rail mounts as described herein.

[0051] The post 470 includes a base 471 with holes that fit over the threaded rods 410. Installing the post 470 thus includes placing the base 471 in a way that the threaded rods 410 pass through the holes and securing the post 470 to the fascia 453 of the deck 450 using fasteners 472 such as nuts or bolts that thread on the threaded rods 410. In this way, the post 470 is secured to the deck 450 at the fascia beam 453 without penetrating the one or more layers 460 or any portion of the deck 450. This allows the functionality of the one or more layers 460 to be maintained and / or to be uncompromised as part of the installation of the railing 479. In some embodiments, the base 471 can have templates that vary and the fascia rail mount 400 can have the threaded rods 410 vary according to the template. This allows different hole patterns, positioning, spacing, etc. to be employed for the bases 471.

[0052] Advantageously, the fascia rail mount 400 allows posts to be attached to the deck 450 without compromising waterproofing. This is due at least in part to the threaded rods 410 being present during the waterproofing process and being treated with the waterproofing material. This is in contrast to a process that uses screws or nails or other such fasteners that penetrate into the deck 450, which would also penetrate through the waterproof layer thereby compromising waterproofing of the deck. This may be beneficial where there is a breach of the post (e.g., water penetrates into the interior of the post) because the water is still unable to penetrate the deck 450 because of the waterproofing that is maintained by the disclosed fascia rail mounts.

[0053] Advantageously, the fascia rail mount 400 increases the strength and resilience of the posts secured to them. The fascia rail mount 400 is secured to the deck 450 on both the top surface 452 and to the fascia beam 453 using the mounting strap 406, thereby increasing the strength and resilience of the post 470. In some embodiments, this allows the post 470 to be secured solely to the deck and not to the building to which the deck 450 is attached. The increased resilience and strength also improves the longevity of the post 470, the railing 479, and the deck 450 by extension.

[0054] The increased strength and resilience of the post 470 and railing 479 when secured to the deck 450 via the fascia rail mount 400 is particularly evident when compared to posts mounted directly to the fascia beam 453. In a fascia mount configuration, the post is secured directly to the fascia beam and only to the fascia beam using a fascia mount bracket that attaches to the side of the structure. In such a configuration, the fascia mount bracket is secured to the structure using only one surface, the fascia beam, resulting in a lack of structural integrity. Furthermore, posts typically slide into brackets that are attached to the fascia, rather than attaching to the structure itself. If this bracket is then covered in the one or more layers 460 (e.g., stucco), it may be difficult to service the posts without destroying a portion of the structure.

[0055] In contrast, the fascia rail mount 400 allows the post 470 and the railing 479 to be serviced without affecting the fascia rail mount 400 or the deck 450. For example, the post 470 can include a seal cap that can be removed and the bolts or nuts can be tightened. Similarly, the bolts or nuts can be easily removed to replace the post. After which, the seal cap can be replaced. This process again does not affect the structure and leaves unchanged the one or more layers 460 that may provide desired functionality, such as waterproofing or structural integrity, or aesthetics.

[0056] In some embodiments, the process of installing the disclosed fascia rail mounts can include routing out the wood so that the fascia rail mounts are flush with the wood. Flashing detail can then be added and an epoxy can be applied to the wood to wet set the fascia rail mount. Being prepared in this way, the fascia rail mount can then be attached to the wood. Fasteners, such as screws, can then be used to further secure the fascia rail mount to the wood. Once attached with fasteners, the surface can be covered in sand or other material so that additional layers adhere better to the surface of the fascia rail mount and threaded rods. In some implementations, the material that is added makes a superior surface for polymers to bond to. A wire lath can then be installed. In some implementations, the wire lath comprises a wire mesh. In certain instances, the wire lath does not cover the fascia rail mounts. In various instances, the wire lath covers the fascia rail mounts as well. Being prepared in this way, a polymer or other material can be applied to coat the wood and the fascia rail mounts. In some embodiments, the polymer or other material can be a waterproofing agent or other material that bestows desirable properties on the fascia rail mounts and deck. The coating applied can be five or six layers in combination, for example. A top coat applied over everything can be a polymer cement, cementitious product, epoxy, urethane, asphalt emulsion, aliphatic material, etc.Additional Embodiments and Terminology

[0057] The present disclosure describes various features, no single one of which is solely responsible for the benefits described herein. It will be understood that various features described herein may be combined, modified, or omitted, as would be apparent to one of ordinary skill. Other combinations and sub-combinations than those specifically described herein will be apparent to one of ordinary skill, and are intended to form a part of this disclosure. Various methods are described herein in connection with various flowchart steps and / or phases. It will be understood that in many cases, certain steps and / or phases may be combined together such that multiple steps and / or phases shown in the flowcharts can be performed as a single step and / or phase. Also, certain steps and / or phases can be broken into additional sub-components to be performed separately. In some instances, the order of the steps and / or phases can be rearranged and certain steps and / or phases may be omitted entirely. Also, the methods described herein are to be understood to be open-ended, such that additional steps and / or phases to those shown and described herein can also be performed.

[0058] Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,”“comprising,” and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to.” The word “coupled”, as generally used herein, refers to two or more elements that may be either directly connected, or connected by way of one or more intermediate elements. Additionally, the words “herein,”“above,”“below,” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. Where the context permits, words in the above Detailed Description using the singular or plural number may also include the plural or singular number respectively. The word “or” in reference to a list of two or more items, that word covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list. The word “exemplary” is used exclusively herein to mean “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations.

[0059] The disclosure is not intended to be limited to the implementations shown herein. Various modifications to the implementations described in this disclosure may be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other implementations without departing from the spirit or scope of this disclosure. The teachings of the invention provided herein can be applied to other methods and systems, and are not limited to the methods and systems described above, and elements and acts of the various embodiments described above can be combined to provide further embodiments. Accordingly, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made without departing from the spirit of the disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosure.

Examples

Embodiment Construction

[0011]The headings provided herein, if any, are for convenience only and do not necessarily affect the scope or meaning of the claimed subject matter.

Overview

[0012]Structures such as decks, patios, porches, balconies, staircases, and the like can use railings to prevent people from falling over the edge of such structures. To secure the railing to the structure, posts can be used. These posts can be secured to the structure by driving bolts into the top layer of the structure. This may result in the bolts penetrating one or more layers designed to protect the structure, such as a waterproofing layer. This can disadvantageously compromise the structural integrity of the structure. Alternatively, posts can be attached to the structure by attaching mounting hardware to a fascia of the structure, which may result in posts that lack strength and resilience. This can disadvantageously result in a railing that is unable to withstand forces applied to the railing.

[0013]Accordingly, describe...

Claims

1. A fascia rail mount for a deck, the fascia rail mount configured to enable installation of a post on the deck, the fascia rail mount comprising:a top plate forming one or more holes through which fasteners are configured to extend to secure the top plate to a top of the deck;a side plate extending perpendicularly from the baseplate in a direction to position the side plate adjacent to a fascia beam of the deck upon fastening the top plate to the top of the deck;a plurality of threaded rods affixed to the side plate and extending perpendicularly outward from the side plate; anda mounting strap extending downward from the side plate, extending horizontally in the same direction as the top plate, and then extending upward, to form a squared “J” shape that wraps around the fascia beam to further secure the fascia rail mount to the fascia beam,wherein the fascia rail mount is configured to be secured to the deck along an edge of the deck in such a way that the plurality of threaded rods extends horizontally away from the fascia beam to pass through holes of a base of a post to be secured to the deck at the fascia beam of the deck.

2. The fascia rail mount of claim 1, wherein the mounting strap includes a removable portion to facilitate installation of the fascia rail mount on the fascia beam.

3. The fascia rail mount of claim 1, wherein the mounting strap includes a movable portion to facilitate installation of the fascia rail mount on the fascia beam.

Images