Deck Tile Support Structures for Brittle Tile Fall-Through Protection
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Solution Overview
Problem
Elevated decks constructed with brittle materials like porcelain or stone tiles require additional support to prevent fall-through risks due to their brittle nature, which existing deck frames designed for flexible materials like wood or polymer composites do not adequately address.
Innovation Solution
A deck frame system with metallic or polymeric support members, such as galvanized steel or PVC, that form a backing substrate for deck tiles, providing additional support and fall-through protection through a continuous adhesive surface and drainage gaps to manage brittle failure modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional deck frames designed for flexible materials are used, then the structure is simple and easy to manufacture, but brittle tiles cannot be adequately supported and fall-through risk increases
Solution Approach 1:
A metal support grid system acts as an intermediary between the traditional deck frame and the brittle tiles. This intermediate structure provides the necessary support surface for tiles while allowing the original deck frame to remain relatively simple. The support grid includes main support members spanning between frame elements and tile support members attached to the main supports, creating a dedicated substrate for brittle paving materials.
Solution Approach 2:
The support system is segmented into distinct functional components: perimeter support members forming the deck frame, main support members spanning between frame elements, and tile support members attached to main supports. This segmentation allows each component to be optimized for its specific function while maintaining overall structural integrity and providing adequate support for brittle tiles.
2Reliability
If additional support members are added to support brittle tiles, then fall-through protection is improved, but the device complexity and number of components increases
Solution Approach 1:
The support grid system is designed to be assembled before tile installation. Main support members are first attached to the deck frame, then tile support members are attached to the main supports. This preliminary assembly creates a ready-made substrate that simplifies the subsequent tile installation process and ensures proper support structure is in place before brittle materials are applied.
Solution Approach 2:
The support grid system serves multiple functions: it provides structural support for brittle tiles, creates a stable adhesive substrate, allows for drainage through gaps between members, and distributes loads across the deck frame. This multi-functionality reduces the need for additional separate components that would otherwise be required.
Data Source
AI summary
A deck tile support system includes a deck frame with at least one perimeter support member supporting a plurality of support joists, each with a top wall and at least one lateral wall extending downwardly from the top wall. A plurality of deck tile support straps is secured to the plurality of support joists and together form a backing substrate supporting a plurality of deck tiles. Each deck tile support strap includes a horizontal wall, a first vertical wall defining a plurality of first gaps each receiving one of the plurality of support joists, a second vertical wall defining a plurality of second gaps each receiving the one of the plurality of support joists, and a plurality of first connector tabs extending generally perpendicularly from the first vertical wall and secured to the at least one lateral wall of respective ones of the plurality of support joists.