Pallet with configurable deck height

Abstract

A pallet (10) includes an upper structure (18) and a lower structure (20). The upper structure includes an upper deck (12) and a plurality of upper column portions (32) projecting downward from the upper deck. The lower structure includes a plurality of lower column portions (22). The upper column portions and the lower column portions are configured such that the upper deck is configured at first height when the upper structure is secured to the lower structure in a first orientation and the upper deck is configured at a second height when the upper structure is secured to the lower structure at a second orientation. Optionally, the upper deck of the pallet includes a plurality of perimeter regions (60) into which a desired one of a plurality of inserts can be secured to produce pallets with different perimeter options.

Description

RACKABLE PALLET WITH CONFIGURABLE DECK HEIGHTBACKGROUND

[0001] Plastic pallets are well-known. A known plastic pallet includes an upper deck having a surface on which goods are supported. A plurality of columns extend downward from the upper deck to support the upper deck above a floor and to permit fork tines or pallet jack tines to enter the openings between the columns and below the upper deck. Runners may connect lower ends of each of the columns. The plastic pallet may be rackable, i.e. it is capable of being supported on racks that only support opposite edges of the pallet.

[0002] An opening between a lower surface of the upper deck and the top of the runners (or the floor) must be large enough to receive the material handling equipment being used with the pallet. However, reducing the height is desirable to improve efficiency of storage and shipping. Therefore it is desirable to use a pallet that is as short as possible, as long as it can still accommodate the material handling equipment in use.

[0003] As a result, some distribution systems use pallets with an increased height and others use pallets with a reduced height. The pallets could otherwise be nearly identical but will require two sets of molds to produce them.SUMMARY

[0004] The pallet components disclosed herein are capable of being assembled as a pallet in either of two configurations, each providing a different height. Only one set of molds is required to produce the pallet components, while still producing pallets with two different heights.

[0005] The different heights can be obtained by assembling the components in a first configuration or in a second configuration. In the first configuration, the pallet will have an increased height and in the second configuration, the pallet will have a decreased height. In one embodiment, one of the components is rotated 180 degrees relative to another component in order to provide the first configuration rather than the second configuration.

[0006] Optionally, the upper deck of the pallet includes a plurality of perimeter regions into which a desired one of a plurality of inserts can be secured. The inserts each provide a different textured region. Inserts are chosen based upon the particular application and the needs for the pallet. Only a single set of molds for the upper deck is required to produce a pallet with different perimeter options.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 is a perspective view of a pallet according to one embodiment.

[0008] Figure 2 is a bottom perspective view of the pallet.

[0009] Figure 3 is a top view of the pallet.

[0010] Figure 4 is an end view of the pallet.

[0011] Figure 5 is a side view of the pallet.

[0012] Figure 6 is a perspective view of the lower structure.

[0013] Figure 7 is a top view of the lower structure.

[0014] Figure 8 is an end view of the lower structure.

[0015] Figure 9 is a side view of the lower structure.

[0016] Figure is a top view of the lower structure.

[0017] Figure 11 is a section view taken along line A- A of Figure.

[0018] Figure 12 is a section view taken along line B-B of Figure.

[0019] Figure 13 is a section view taken along line C-C of Figure.

[0020] Figure 14 is an enlarged view of Figure 11.

[0021] Figure 15 is an enlarged view of one of the plurality of lower column portions of Figure, specifically, the right-most lower column portion of Figure 14.

[0022] Figure 16 is an upper perspective view of the lower column portion of Figure 15.

[0023] Figure 17 is an enlarged view of the left-most lower column portion of Figure 14.

[0024] Figure 18 is an enlarged view of the center column portion of Figure 14.

[0025] Figure 19 is a bottom perspective view of the upper structure.

[0026] Figure 20 is a bottom view of the upper structure.

[0027] Figure 21 is an end view of the upper structure.

[0028] Figure 22 is a side view of the upper structure.

[0029] Figure 23 is an enlarged bottom view of the upper structure.

[0030] Figure 24 is a section view taken along line E-E of Figure 23.

[0031] Figure 25 is a section view taken along line F-F of Figure 23.

[0032] Figure 26 is a section view taken along line G-G of Figure 23.

[0033] Figure 27 is an enlarged view of the upper structure of Figure 19.

[0034] Figure 28 is an enlarged view of the right-most upper column portion of Figure

[0035] Figure 29 is a bottom perspective view of the upper column portion of Figure28.

[0036] Figure 30 is an enlarged view of the left-most one of the plurality of upper column portions of Figure 27.

[0037] Figure 31 is an enlarged view of the center one of the plurality of upper column portions of Figure 27.

[0038] Figure 32 is an exploded view of the pallet of Figure 1 with the upper structure aligned to be assembled in a first configuration.

[0039] Figure 33 shows the exploded pallet of Figure 32 with the upper structure being rotated toward a position to be assembled in a second configuration.

[0040] Figure 34 is a section view through the pallet in the first configuration.

[0041] Figure 35 is a section view through the pallet in the second configuration.

[0042] Figure 36 is an enlarged view of the left-most one of the columns of Figure 34 (first configuration).

[0043] Figure 37 is an enlarged view of the left- most one of the columns of Figure 35 (second configuration).

[0044] Figure 38 is a section view through one set of the plurality of snap tabs, plurality of upper snap-tabs and plurality of lower snap-tabs of the column of Figure 36 (first configuration).

[0045] Figure 39 is a section view through the plurality of snap tabs, the plurality of upper snap-tabs and the plurality of lower snap-tabs of the column of Figure 37 (second configuration).

[0046] Figure 40 is an enlarged perspective view of one of the first textured regions ofFigure 1.

[0047] Figure 41 is a section view taken along line 41-41 of Figure 3.

[0048] Figure 42 shows a pallet which may be identical to the pallet of Figures 1-39 but with second textured regions.

[0049] Figure 43 is an enlarged view of one comer area of the pallet of Figure 42.

[0050] Figure 44 shows the eight textured regions of the pallet of Figure 42.

[0051] Figure 45 is an enlarged view of one of the second textured regions of Figure 44.

[0052] Figure 46 shows a plurality of third textured regions that can be used on the upper deck.

[0053] Figure 47 is an enlarged view of one of the third textured regions of Figure 46.DETAILED DESCRIPTION

[0054] Figure 1 is a perspective view of a pallet 10 according to one embodiment. The pallet 10 includes an upper deck 12 having an upper support surface for supporting goods thereon. Columns 14 extend downward from the upper deck 12 to support the upper deck 12 above a floor and to create fork tine openings between the columns 14 and below the upper deck 12. Optionally, runners 16 may connect lower ends of the columns 14.

[0055] The pallet 10 includes two molded components: an upper structure 18 and a lower structure 20. The upper structure 18 includes the upper deck 12. The lower structure 20 includes the runners 16. Both the upper structure 18 and the lower structure 20 form the columns 14 together, as will be explained below.

[0056] The upper deck 12 optionally includes a plurality of perimeter regions 60 that may have one of a plurality of available configurations. In the example shown there are eight perimeter regions 60, with two along each edge of the upper deck 12. In Figure 1, each of the perimeter regions 60 includes a first option, which is a first textured region 52 that will be described in more detail later.

[0057] In the illustrated embodiment each of the plurality of perimeter regions 60 is a recessed portion of the upper deck 12 and the first textured regions 52 are separately injection- molded inserts that are subsequently inserted into the recessed portions and secured via adhesive, screws, snap-fit connections, or other suitable methods.

[0058] As another option, the textured regions 52 are integrally molded with the upper deck 12 and there may be inserts in the mold for injection molding the upper deck 12. The inserts can be swapped to provide the first textured region 52 or the other options described below.

[0059] Figure 2 is a bottom perspective view of the pallet 10. As shown, the upper deck 12 includes a plurality of intersecting ribs projecting downward from an upper planar portion. The runners 16 include a plurality of intersecting ribs projecting downward from upper planar portions. The columns 14 also include a plurality of intersecting ribs.

[0060] Figure 3 is a top view of the pallet 10. Figure 4 is an end view of the pallet 10. Figure 5 is a side view of the pallet 10.

[0061] Figure 6 is a perspective view of the lower structure 20. The lower structure 20 includes a plurality of lower column portions 22 molded integrally with the runners 16 as a single piece of plastic. Each of the plurality of lower column portions 22 is elongated in alongitudinal direction. The internal structure of the plurality of lower column portions 22 will be described in more detail later below.

[0062] Figure 7 is a top view of the lower structure 20. Figure 8 is an end view of the lower structure 20. Figure 9 is a side view of the lower structure 20.

[0063] Figure 10 is a top view of the lower structure 20. Figure 11 is a section view taken along line A-A of Figure 10. Figure 12 is a section view taken along line B-B of Figure 10. Figure 13 is a section view taken along line C-C of Figure 10. In this embodiment, these section views are substantially similar to one another, but they could vary.

[0064] Figure 14 is an enlarged view of Figure 11. Figure 15 is an enlarged view of one of the plurality of lower column portions 22 of Figure 14, specifically, the right-most lower column portion 22 of Figure 14. The others would be similar, with some variations that will become clear.

[0065] Referring to Figure 15, the lower column portion 22 includes internal geometry that provides at least one and preferably a plurality of upper support surfaces 24 and at least one and preferably a plurality of lower support surfaces 26. The plurality of upper support surfaces 24 are higher than the plurality of lower support surfaces 26. The plurality of upper support surfaces 24 and the plurality of lower support surfaces 26 are each supported by vertical intersecting ribs that extend from the plurality of upper support surfaces 24 or the plurality of lower support surfaces 26 down to the lowermost plane of the lower structure 20 (i.e. to the floor).

[0066] Each of the plurality of lower column portions 22 also includes a plurality of snap tabs 28 (only one visible in the section view of Figure 15). Each of the plurality of snaptabs 28 includes a ramped surface leading to a shoulder under which a complementary component can be snap fit. The plurality of snap tabs 28 are flexible such that they will flex to permit complementary components to snap under the shoulders. Each of the plurality of lower column portions 22 includes a peripheral wall 30.

[0067] Figure 16 is an upper perspective view of the lower column portion 22 of Figure 15. As can be seen in Figure 16, the plurality of upper support surfaces 24 and plurality of lower support surfaces 26 alternate along the longitudinal direction of the lower column portion 22. The plurality of snap tabs 28 extend about the periphery of the plurality of upper support surfaces 24 and plurality of lower support surfaces 26. In this embodiment, the plurality of snap tabs 28 project radially outward into an annular space between the plurality of upper support surfaces 24 and the plurality of lower support surfaces 26 on one side and the peripheral wall 30 on the other.

[0068] Figure 17 is an enlarged view of the left-most lower column portion 22 of Figure 14. The arrangement of the interior structure, i.e. the plurality of upper support surfaces 24 and plurality of lower support surfaces 26 is not mirror image of the right-most lower column portion 22 (Figure 15). Rather, it is the same, i.e. the plurality of upper support surfaces 24 and plurality of lower support surfaces 26 alternate in the same pattern along the same longitudinal direction in both lower column portions 22. This is also true for the center lower column portion 22, as shown in Figure 18, and the rest of the lower column portions 22.

[0069] Figure 19 is a bottom perspective view of the upper structure 18. The upper structure 18 includes a plurality of upper column portions 32 molded integrally with the upperdeck 12. Figure 20 is a bottom view of the upper structure 18. Figure 21 is an end view of the upper structure 18. Figure 22 is a side view of the upper structure 18.

[0070] Figure 23 is an enlarged bottom view of the upper structure 18. Figure 24 is a section view taken along line E-E of Figure 23. Figure 25 is a section view taken along line F- F of Figure 23. Figure 26 is a section view taken along line G-G of Figure 23.

[0071] Figure 27 is an enlarged view of the upper structure 18 of Figure 24.

[0072] Figure 28 is an enlarged view of the right-most upper column portion 32 of Figure 27. The interior structure of each of the plurality of upper column portions 32 includes at least one and preferably a plurality of lower support surfaces 34 alternating with a plurality of upper support surfaces 36 along the longitudinal direction. The interior structure is spaced inward from a peripheral wall 40 of the upper column portion 32. A plurality of upper snaptabs 38a alternate with a plurality of lower snap-tabs 38b formed at a lower end of the peripheral wall 40. As shown in Figure 28, the plurality of lower snap-tabs 38b are positioned lower than the plurality of upper snap-tabs 38a.

[0073] Figure 29 is a bottom perspective view of the upper column portion 32 of Figure 28. As shown, the plurality of upper snap-tabs 38a alternate with the plurality of lower snaptabs 38b about the periphery of the plurality of upper column portions 32. The plurality of upper snap-tabs 38a and the plurality of lower snap-tabs 38b project inward toward an interior of the upper column portion 32.

[0074] Referring again to Figures 19 and 29, each of the plurality of upper column portions 32 may include channels formed therein for receiving optional steel reinforcementmembers, such as hollow tubular steel rods with a rectangular cross section. This increases the strength and stiffness of the pallet 10.

[0075] Figure 30 is an enlarged view of the left-most one of the plurality of upper column portions 32 of Figure 27. The plurality of lower support surfaces 34 and the plurality of upper support surfaces 36 alternate along the longitudinal direction in the same way as the right-most one of the plurality of upper column portions 32 (Figure 28), i.e. not mirror image. The plurality of upper snap-tabs 38a and the plurality of lower snap- tabs 38b also alternate the same way along the longitudinal direction as those in the right-most one of the plurality of upper column portions 32.

[0076] Figure 31 is an enlarged view of the center one of the plurality of upper column portions 32 of Figure 27. Again the interior structure is the same as the other columns, i.e. the plurality of lower support surfaces 34 alternate with the plurality of upper support surfaces 36 in the same way, and the plurality of upper snap-tabs 38a and the plurality of lower snap-tabs 38b alternate in the same way. The other upper column portions 32 would be the same in these regards.

[0077] Referring to Figures 32 and 33, the upper structure 18 and the lower structure 20 can be assembled in a first configuration (Figure 32) or a second configuration (Figure 33). Compared to the first configuration, the upper structure 18 is rotated 180 degrees relative to the lower structure 20. The upper structure 18 is then snap-fit to the lower structure 20.

[0078] Figure 34 is a section view through the pallet 10 in the first configuration. Figure 35 is a section view through the pallet 10 in the second configuration. As shown, the pallet 10 in Figure 34 has an increased height (uppermost surface to lowermost surface (6” vs 5.625”),the difference being reflected completely in the height of the tine openings) compared to the pallet 10 in Figure 35.

[0079] Figure 36 is an enlarged view of the left-most one of the columns 14 of Figure 34 (first configuration). Figure 37 is an enlarged view of the left-most one of the columns 14 of Figure 35 (second configuration). Figure 38 is a section view through one set of the plurality of snap tabs 28, plurality of upper snap-tabs 38a and plurality of lower snap-tabs 38b of the column 14 of Figure 36 (first configuration). Figure 39 is a section view through the plurality of snap tabs 28, the plurality of upper snap-tabs 38a and the plurality of lower snap-tabs 38b of the column 14 of Figure 37 (second configuration).

[0080] To manufacture the pallet 10 in either configuration, the peripheral wall 40 of the upper structure 18 is received within the peripheral wall 30 of the lower structure 20 (Figures 36 and 37). In both configurations, some (approximately half) of the plurality of snap tabs 28 of the lower structure 20 are secured to the upper structure 18 - either to the plurality of lower snap-tabs 38b (first configuration, Figures 36 and 38) or to the plurality of upper snaptabs 38a (second configuration, Figures 37 and 39).

[0081] In the first configuration in Figure 36, the plurality of lower support surfaces 34 of the upper structure 18 are supported on the plurality of upper support surfaces 24 of the lower structure 20. This raises the overall height of the pallet 10 to x, which in this example is 6.0”. In the second configuration in Figure 37, the plurality of lower support surfaces 34 of the upper column portions 32 of the upper structure 18 extend downward past the upper support surfaces 24 of the lower column portions 22 of the lower structure 20. The plurality of lower support surfaces 34 of the upper structure 18 are supported on the plurality of lower supportsurfaces 26 of the lower structure 20. This results in an overall height of y, which is less than x, and which in this example is 5.625”.

[0082] Referring to Figure 38, when the upper structure 19 is assembled to the lower structure 20 in the first configuration, the plurality of upper snap-tabs 38a do not snap past the snap tabs 28 with which they are aligned, as shown. The plurality of upper snap-tabs 38a remain above the plurality of snap tabs 28 with which they are aligned. The plurality of lower snaptabs 38b do snap fit past the snap tabs 28 with which they are aligned and abut the shoulders of the plurality of snap tabs 28, thereby securing the upper structure 18 to the lower structure 20.

[0083] Referring to Figure 39, in the second configuration, the plurality of upper snaptabs 38a snap-fit just past the snap tabs 28 with which they are aligned, as shown (and abut the shoulders) thereby securing the upper structure 18 to the lower structure 20. The plurality of lower snap-tabs 38b snap past the snap tabs 28 with which they are aligned and keep traveling downward such that they are spaced away from the corresponding plurality of snap tabs 28. The plurality of lower snap-tabs 38b do not abut the shoulders of their corresponding plurality of snap tabs 28.

[0084] The other columns 14 in the pallet 10 would operate substantially the same way as the column 14 shown in Figures 36-39 to achieve one of the two configurations. In this manner, pallets 10 of two different heights can be provided from the same upper structure 18 and lower structure 20. Therefore, only one set of molds is necessary to produce pallets 10 of different heights.

[0085] Figure 40 is an enlarged view of one of the first textured regions 52 of Figure 1.The first textured region 52 includes a generally planar base portion 84 and a plurality of bosses 86 projecting upwardly from the base portion 84. The bosses 86 provide some retention to crates or corrugated cardboard boxes on the upper deck 12 of the pallet 10.

[0086] An elongated lip 85 projects upward along an outer edge of the first textured region 52. The elongated lip 85 is integrally molded with the generally planar base portion 84 and would be positioned toward the nearest edge of the upper deck 12. The elongated lip 85 may extend above the generally planar base portion 84 by approximately 14 inch to approximately % inch and more preferably approximately 14 inch.

[0087] Figure 41 is a section view taken along line 41-41 of Figure 3. The generally planar base portion 84 is secured in the perimeter region 60 recess proximate the edge of the upper deck 12.

[0088] Figure 42 shows a pallet 10a, which may be identical to the pallet 10 of Figures 1-39 with the exception that the upper deck 12 includes second textured regions 62 in the plurality of perimeter regions 60 instead of first textured regions 52. Figure 43 is an enlarged view of one corner area of the pallet 10a of Figure 42.

[0089] In one embodiment each of the plurality of perimeter regions 60 is a recessed portion of the upper deck 12 and the second textured regions 62 are separately injection-molded inserts that are subsequently inserted into the recessed portions and secured via adhesive, screws, snap-fit connections, or other suitable methods.

[0090] As another option, the second textured regions 62 are integrally molded with the upper deck 12 and there may be inserts in the mold for injection molding the upper deck12. The inserts can be swapped to provide the second textured region 62 or the other options described below.

[0091] Figure 44 shows the eight second textured regions 62 as separate inserts. Figure 45 is an enlarged view of one of the second textured regions 62. The second textured region 62 includes a generally planar base portion 64 and a plurality of bosses 66 projecting upwardly from the base portion 64. The bosses 66 provide some retention to crates or corrugated cardboard boxes on the upper deck 12 of the pallet 10a.

[0092] Figure 46 shows a plurality of third textured regions 72 that can be used on the upper deck 12 of the pallet 10 . Again, the third textured regions 72 can either be molded separately and secured to recessed portions in the upper deck 12, or molded integrally with the upper deck 12 using complementary inserts in the mold.

[0093] Figure 47 is an enlarged view of one of the third textured regions 72. The third textured region 72 includes a generally planar base portion 74 having three longitudinal ribs 75 projecting upwardly therefrom and running parallel to one another. The three longitudinal ribs 75 would run parallel to the edge of the upper deck 12 nearest the third textured region 72. Each of the three longitudinal ribs 75 includes a ramped portion at each longitudinal end thereof.

[0094] A plurality of angled tapered ribs 77 extend at an oblique angle from the outer two of the three longitudinal ribs 75. A center tapered rib 78 extends perpendicularly outward from each of the outer two of the three longitudinal ribs 75. The plurality of angled tapered ribs 77 angle away from the center tapered ribs 78 as they extend from the outer two of the threelongitudinal ribs 75. The plurality of angled tapered ribs 77 taper downward from the longitudinal ribs 75.

[0095] In use, crates on the upper deck 12 of the pallet 10 provided with the third textured regions 72 are retained by the plurality of angled tapered ribs 77 and the three longitudinal ribs 75. However, the crates on the upper deck 12 can be forcibly slid up the plurality of angled tapered ribs 77 and over the three longitudinal ribs 75.

[0096] Optionally, two or three of the three different textured regions 52, 62, 72could all be secured in different ones of the plurality of perimeter regions 60 in the upper deck 12.

[0097] In accordance with the provisions of the patent statutes and jurisprudence, exemplary configurations described above are considered to represent preferred embodiments of the inventions. However, it should be noted that the inventions can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. Alphanumeric identifiers on method steps are solely for ease in reference in dependent claims and such identifiers by themselves do not signify a required sequence of performance, unless otherwise explicitly specified.

Claims

CLAIMSWHAT IS CLAIMED IS:

1. A pallet comprising: an upper structure having an upper deck and a plurality of upper column portions projecting downward from the upper deck; and a lower structure having a plurality of lower column portions, wherein the upper column portions and the lower column portions are configured such that the upper deck is configured at first height when the upper structure is secured to the lower structure in a first orientation and wherein the upper deck is configured at a second height when the upper structure is secured to the lower structure at a second orientation.

2. The pallet of claim 1 wherein the lower structure includes a plurality of runners connecting lower ends of the lower column portions.

3. The pallet of claim 1 wherein the upper column portions are securable to the lower column portions at the first orientation and at the second orientation.

4. The pallet of claim 3 wherein the lower column portions each include upper support surfaces and lower support surfaces and the upper column portions each include upper support surfaces and lower support surfaces, and wherein the lower support surfaces of the upper column portions abut the upper support surfaces of the lower column portions when the upper structure is secured to the lower structure in the first orientation and wherein the lower support surfaces of the upper column portions extend downward past the upper support surfaces of the lower column portions when the upper structure is secured to the lower structure in the second orientation.

5. The pallet of claim 4 wherein the lower support surfaces of the upper column portions abut the lower support surfaces of the lower column portions when the upper structure is secured to the lower structure in the second orientation.

6. The pallet of claim 5 wherein the plurality of upper column portions and the plurality of lower column portions are configured such that one is received within the other.

7. The pallet of claim 6 wherein the plurality of upper column portions and the plurality of lower column portions are securable to one another via snap-fit connections.

8. The pallet of claim 7 wherein the snap-fit connections include a plurality of upper snap-tabs that are configured to secure the plurality of upper column portions to the plurality of lower column portions in the first orientation and wherein the snap-fit connections include a plurality of lower snap-tabs that are configured to secure the plurality of upper column portions to the plurality of lower column portions in the second orientation.

9. The pallet of claim 8 wherein the plurality of upper snap-tabs are configured such that they do not secure the plurality of upper column portions to the plurality of lower column portions in the second orientation and wherein the plurality of lower snap-tabs are configured such that they do not secure the plurality of upper column portions to the plurality of lower column portions in the first orientation.

10. The pallet of claim 9 wherein the upper deck includes a plurality of perimeter regions configured to receive one of a plurality of inserts.

11. The pallet of claim 10 further including a first insert received in one of the plurality of perimeter regions, wherein the first insert includes a textured region.

12. The pallet of claim 11 wherein the textured region includes a plurality of bosses projecting upward from a base portion.

13. The pallet of claim 11 wherein the textured region includes a plurality of longitudinal ribs extending upward from a base portion in a direction parallel to a nearest edge of the upper deck.

14. The pallet of claim 11 further including a plurality of inserts each including an elongated lip projecting upward along an outer edge in a direction parallel to a nearest edge of the upper deck.

15. A pallet comprising: an upper deck including a plurality of perimeter regions configured to receive one of a plurality of inserts; a plurality of inserts received in the plurality of perimeter regions; and a plurality of upper columns extending downward from the upper deck.

16. The pallet of claim 15 wherein each of the plurality of inserts includes a textured region.

17. The pallet of claim 16 wherein each textured region includes a plurality of bosses projecting upward from a base portion.

18. The pallet of claim 16 wherein the textured region includes a plurality of longitudinal ribs extending upward from a base portion in a direction parallel to a nearest edge of the upper deck.

19. The pallet of claim 15 further including a plurality of inserts each including an elongated lip projecting upward along an outer edge in a direction parallel to a nearest edge of the upper deck.

20. A method of manufacturing a pallet including: molding an upper structure having an upper deck and a plurality of upper column portions projecting downward from the upper deck; molding a lower structure having a plurality of lower column portions; and securing the plurality of upper column portions to the plurality of lower column portions in a first orientation or a second orientation, wherein the upper deck is configured at first height when the upper structure is secured to the lower structure in a first orientation and wherein the upper deck is configured at a second height when the upper structure is secured to the lower structure at a second orientation.

21. The method of claim 20 further including: inserting a plurality of inserts into a plurality of perimeter regions in the upper deck.

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