Support system for a structure

Abstract

The present invention relates to a system for supporting a structure. The support system comprises an optional footing base which is placed at the bottom of a hole, which footing base has an upper surface with a textured material thereon, a post to be positioned on top of the footing base when the footing base is present, and a first cap attached to the bottom of the post. The first cap has a textured surface for engaging the textured material on the upper surface of the footing base when the footing base is present. The system further includes a second cap to be attached to an upper end of the post. The second cap is provided with a connection device for connecting the second cap to a structural member such as a wooden post. The system further has a pad for supporting a structural member. The pad may be placed on a load bearing surface such as the ground or on top of the post. To this end, the pad is provided with at least one recess for receiving the upper end of the post.

Description

BACKGROUND OF THE INVENTION

[0001] The present invention relates to a system for supporting structures such as decks, accessory, buildings, and related structures.

[0002] In the past, it has been conventional in connection with the building of wooden decks and other such structures to provide footings and piers for support posts. These footings and piers are generally placed in holes that extend below the frost line to insure solid support throughout the year. In the Northern parts of the United States, the frost line may be as much as 42 inches below the surface or even deeper. Generally speaking, in the past, these footings and piers have been constructed from concrete or pressure treated wood.

[0003] To conserve concrete, cardboard tubes, such as SONATUBES, have been inserted in the hole and back filled with earth. Such tubes are available in various lengths and diameters. The hollow center core is filled with concrete. Numerous bags of concrete are required for each footing and pier with water and mixing also being required to complete quality footings and piers. If the mix is not correct, structural problems can arise. Such footings are subject to degradation resulting in crumbling and premature failure.

[0004] Various types of alternative support structures have been proposed in the patent literature. For example, U.S. Pat. No. 4,972,642 to Strobl, Jr. illustrates a monolithic plastic moldable foot for supporting a wooden post in a hole in the ground. The foot includes a dish shaped lower wall configured to be supported by the earth at the bottom of the hole and rib structures on the bottom wall for distributing loads throughout the entire extent of the bottom wall. After the hole is back filled, the foot resists lateral and up loads as well as down loads.

[0005] U.S. Pat. No. 5,293,725 to Matticks et al. illustrates a building structure with interlocking components. The building is held in place by a plurality of anchors with threads.

[0006] U.S. Pat. No. 5,720,134 illustrates a base for supporting a post for a shelter type structure. The base is made of an impervious material to avoid any rotting or deterioration which might result from moisture in the ground. The base is formed to receive laminated posts as part of the structure.

[0007] U.S. Pat. No. 5,722,589 to Richards illustrates a composite load bearing structure with a main body portion having a top surface and a bottom surface defining a dimension of thickness therebetween, first and second side surfaces defining a dimension of width therebetween, first and second end surfaces defining a dimension of length therebetween, and a first longitudinal axis oriented along the length of the main body portion. The main body portion is made of a first composite material comprising a binding constituent in a proportion of about 10% to about 20% by volume, and an aggregate material in a proportion of about 80% to about 90% by volume. The binding constituent comprises polyethylene or a polyethylene blend having at least 10% polyethylene. The aggregate material is in the form of irregular multi-faceted pieces of crushed furnace slag, crushed gravel, crushed limestone, crushed granite, crushed basalt, crushed trap rock, and mixtures thereof, and the pieces of aggregate material are distributed and otherwise arranged within the main body portion so that opposed surfaces of the pieces of aggregate material have at least partial contact, one with another, in a contiguous manner. An inner strengthening member is disposed within the main body, and may comprise reinforcing bars.

[0008] U.S. Pat. No. 5,953,874 to Hoffman et al. relates to a deck construction which includes a plurality of supports for anchoring deck construction elements to a building site. The supports include a body having upper and lower portions. The upper portion includes at least one slot for seating a horizontally oriented construction member. The slot includes a center socket portion having four extended corners for seating the bottom end of a vertically oriented construction member. The slot and center socket are defined by connecting wall portions which may be integral to the body or may be of plastic or metal and suitably secured to the body. In some cases, two mutually perpendicular slots are provided.

[0009] U.S. Pat. No. 6,073,416 to Peter illustrates a cap for protecting wood construction members supported by an elevated base. The cap protects from rot and other deterioration the lowermost portion of a wood construction member. The cap has four lateral faces and a top face with a rectangular aperture formed by four flexible web portions which press against the member. The dimensions of the lateral faces are selected so that the lateral face bottom edges have a desired above-ground clearance.

[0010] U.S. Pat. No. 6,178,709 to Hertz relates to a plastic foundation system which includes plastic components having heating elements selectively embedded within for fusing abutting portions of adjacent components. The components include wall portions having a flange for insertion into the keyway of a base portion. The base portions can be segmented to provide adjustability to various angles. Heating elements are provided to fuse the segments of the adjustable base portion together. The base portion is also segmented with apertures to permit drainage through the base portion. In an alternate embodiment, connecting rods extend between adjacent wall portions.

[0011] Despite these support systems, there remains a need for support systems which are lightweight, easy to use, and economical.

SUMMARY OF THE INVENTION

[0012] Accordingly, it is an object of the present invention to provide an improved system for supporting structures.

[0013] It is a further object of the present invention to provide a system as above which is easily to assemble, environmentally sound, and cost effective.

[0014] The foregoing objects are attained by the support system of the present invention.

[0015] In accordance with the present invention, one embodiment of a support system for a structure broadly comprises a footing base which is placed at the bottom of a hole, the footing base has an upper textured surface, a post to be positioned on top of the footing base, and a first cap attached to the bottom of the post, which first cap has a textured surface for engaging the textured material on the upper surface of the footing base. The system further includes a second cap to be attached to an upper end of the post and a pad for supporting a structural feature such as the base of stairs or platforms. The pad is provided with at least one recess for mating with an upper end of the post. Alternatively, the pad may be placed directly on a load bearing surface. The second cap is preferably provided with suitable means for connecting the post to a structure to be supported.

[0016] The system of the present invention typically includes a plurality of spaced apart posts with the first and second caps attached thereto. A structure to be supported by the system is connected to each of the posts.

[0017] Other details of the support system of the present invention, as well as other objects and advantages attendant thereto, are set forth in the following detailed description and the accompanying drawings wherein like reference numerals depict like elements.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] FIG. 1 is a side view of a post and a footing base in accordance with the present invention;

[0019] FIG. 2 is an exploded view of the post and footing base of FIG. 1;

[0020] FIG. 3 is a perspective view of the footing base;

[0021] FIG. 4 is a side view of a post and a cap on the post;

[0022] FIG. 5 is a perspective view of a first embodiment of an upper cap to be used with the post;

[0023] FIG. 6 is a top view of a second embodiment of an upper cap to be used with the post;

[0024] FIG. 7 is a side view of a pad used in the system of the present invention;

[0025] FIG. 8 is a front view of the pad of FIG. 7;

[0026] FIG. 9 is a bottom view of the pad of FIG. 7;

[0027] FIG. 10 is a perspective view of a post with adjustable band cutting guides; and

[0028] FIG. 11 is an alternative embodiment of a post which can be used in the support system of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

[0029] Referring now to the drawings, FIG. 1 illustrates a portion of a structure supporting system 10 in accordance with the present invention. As shown therein, the system 10 includes a plurality of spaced apart structural support members 11. The system 10 may have as many structural support members 11 as needed to support the structure (not shown). If the structure is a deck, structural members 11 may be located at the corners of the deck and in locations between the corners. The structural members 11 include a post 12 and an optional footing base 14. The footing base 14 when used is positioned at the bottom of a hole 16 dug in the earth 18.

[0030] Each footing base 14 has a dimension D along a first axis greater than the dimension d of the post 12 along a second axis parallel to the first axis. When the footing base 14 is a cylinder which is circular in cross-section, D represents the diameter of the circular portion. Similarly, when the post is a cylinder which is circular in cross-section, d represents the diameter of the circular portion. The footing base 14 is provided with a wider dimension so as to distribute the load to be carried by the system 10 over a greater surface area.

[0031] The posts 12 may come in various lengths and diameters to support loads of different sizes. Similarly, the footing bases 14 may come in a variety of sizes and diameters.

[0032] Each footing base 14 preferably has a generally planar lower surface 20 and a textured upper surface 22 as shown in FIGS. 2 and 3. The textured surface 22 may be integrally formed with the rest of the footing base 14 or, alternatively, may be formed from a layer of texturized material adhesively joined to a surface of the footing base 14. Each footing base 14 is preferably formed from a high strength non-metallic material, such as a high strength plastic material, e.g. a high impact, UV protected polyethylene material, or a high strength, non-metallic composite material, which provides strength while being impervious to moisture which causes rot.

[0033] The post 12 may have any desired cylindrical configuration known in the art. Further, the post 12 may have a solid cross-section or a hollow interior portion if desired. Further, if desired, as shown in FIG. 11, the post 12 may have a central columnar structure 60, an outer wall 64, and radially extending support arms 62, extending between the columnar structure 60 and the outer wall 64.

[0034] The post 12 is also preferably formed from a nonmetallic material such as a high strength plastic material or a high strength, non-metallic composite material.

[0035] As shown in FIGS. 1 and 4, the post 12 is fitted with lower and upper caps 24 and 26. The caps 24 and 26 are designed to cover each end of the post 12. Each cap 24, 26 has an end surface 28 and sidewalls 30 and 32 integrally formed with the end surface 28. Further, each cap 24, 26 may have a solid interior portion 33.

[0036] The caps 24 and 26 are each designed to fit over an end portion of the post 12. The caps 24 and 26 may be secured to the post 12 in any suitable manner known in the art. For example, a fastening means 34, such as a screw or threaded bolt, could be passed through an opening 36 in each sidewall 30 and 32 and into the post 12. Alternatively, the caps 24 and 26 could be adhesively or frictionally secured to the post 12.

[0037] As can be seen in FIG. 2, the end surface 28 of the lower cap 24 is textured so as to frictionally engage with or interlock with the textured surface 22 of a respective footing base 14. The texturing of the surface 28 may be done during the formation of the lower cap 24 or alternatively, may be done by adhesively applying a textured panel to the surface 28. It has been found by providing such a frictional or interlocking engagement, it is not necessary to secure the lower cap 24 to the footing base 14 using mechanical connection means.

[0038] After the post 12 with the lower cap 24 fastened thereto has been placed on top of the footing base 14, the hole 16 may be backfilled to support the post 12 in an upright position.

[0039] The upper cap 26 is provided with means for connecting the support system 10 to a structural member 38 such as a column for supporting a portion of a building or a deck (not shown). As shown in FIG. 5, the connecting means may comprise a recess 40 for receiving an end portion of the structural member. The recess 40 may be sized to receive and trap typical wood posts such as 4″×4″ or 6″×6″ wood posts. Alternatively, as shown in FIG. 6, the connecting means may comprise a bore 42 for receiving a threaded bolt (not shown). The structural member (not shown) may be fitted over the threaded bolt or alternatively, a bracket for supporting the structural member may be secured to the threaded bolt. The bore 42 may be threaded or unthreaded.

[0040] If desired, the upper cap 26 may be provided with a plurality of drainage ports 54 to allow any water which gets into the cap 26 to drain. The drainage ports 54 may circumferentially surround the cap 26.

[0041] While it is preferred to use a footing base 14 to support each post 12, there may be occasions where the base(s) 14 are not needed and may be omitted.

[0042] To install the system 10, a user must first determine the locations for the structural support members 11. In each location, a hole 16 is excavated to a desired depth. The bottom of the hole 16 is cleaned, leveled, and compacted. A footing base 14, if necessary, is then placed at the bottom of each hole 16. The post(s) 12 may then be cut to a desired approximate length. After cutting, a lower cap 24 is installed on each cut post 12. Each post 12 with the lower cap 24 in place is then placed in a respective hole 16. Clean backfill material is placed around each post 12 while checking for accurate positioning of the respective post and plumbness. After the backfilling has been completed, the upper end of each post 12 may be cut to a desired finish elevation and an upper cap 26 may be installed on the upper end of each post 12. Thereafter, construction of a desired structure may be begin. To this end, structural members, such as joists and framing members, may be secured to the posts 12 to form a frame for a structure such as a deck, a storage shed, a small building, and the like.

[0043] The posts 12 may be cut using any suitable means known in the art. For example, as shown in FIG. 10, brackets 42 and 44 may be placed on a post 12 to be cut. The brackets 42 and 44 are separated by a distance which substantially corresponds to the width of a saw blade. Preferably, the posts 12 are formed from a material that can be cut by a hand saw or a power tool to a level surface to facilitate good bearing and contact.

[0044] Many building structures have features such as steps and entrances which require support. To this end, the system 10 includes a pad 46 for supporting such structures. As shown in FIGS. 7-9, the pad 46 may be rectangular in shape and may come in a variety of sizes such as 2′×4′, 2′×5′, 4′×4′, or 4′×5′. As with the other system components, the pad 46 may be formed from a high strength non-metallic material such as a high strength plastic material or a high strength non-metallic composite material.

[0045] The upper surface 48 of the pad 46 preferably has a textured surface to prevent slipping. If desired, the upper surface 48, as well as the posts 12, can have a concrete finish appearance. In some applications, where the pad 46 does not require support, the lower surface 50 of the pad 46 is placed into direct contact with the ground after the ground has been excavated to provide a solid, level surface. If needed, a fill material may be used to provide the solid, level surface. After the pad 46 has been installed, construction of the feature to be supported by the pad 46 may be started.

[0046] In other applications where frost action or bearing conditions do not allow support solely by the surface of the ground, the pad 46 may be supported by one or more posts 12. To this end, the lower surface 50 of the pad 46 may be provided with one or more recesses 52 for receiving an end of the post(s) 12. When the post(s) 12 is/are fitted into the recess(es) 52, the upper cap 26 may be omitted if desired. After the pad 46 has been positioned on top of the post(s) 12, the feature to be placed on the pad can be constructed.

[0047] The system 10 of the present invention has many advantages. For example, the system 10 is made from lightweight components which can be easily handled and installed with ordinary carpentry tools. If desired, the various components of the system 10 can be made from recycled products and/or materials which are UV protected and impervious to rot or insects. The posts 12 used in the system 10 may easily cut to required lengths and to a desired finish top elevation. The system components can be stored outdoors and be unaffected by temperature and weather. Still further, excess materials can be saved for other jobs.

[0048] The various components of the system 10 may be painted if desired and may be worked on immediately after installation. Thus, there is no need any more to wait for concrete to cure. Still further, the various components of the system 10 may be easily removed and relocated.

[0049] The most significant advantage of the system 10 of the present invention is that there is no need to wait for concrete delivery, no carrying of bags of concrete, no looking for water, no concern about mixing concrete properly, no mixing, no placing concrete in forms, no freezing, and no waiting for curing.

[0050] Yet another advantage is that the system can be installed by professional carpenters and ordinary people such as homeowners.

[0051] While it is preferred to provide the lower cap 24 with a textured end surface 28, the texturing on the end surface 28 may be omitted if desired.

[0052] It is apparent that there has been provided in accordance with the present invention a support system for a structure which fully satisfies the objects, means, and advantages set forth hereinbefore. While the present invention has been described in the context of specific embodiments thereof, other alternatives, modifications, and variations will become apparent to those skilled in the art having read the foregoing description. Therefore, it is intended to embrace those alternatives, modifications, and variations as fall within the broad scope of the appended claims.

Claims

1. A system for supporting a structure which comprises:

a footing base which is placed at the bottom of a hole;

said footing base having an upper textured surface;

a post to be positioned on top of said footing base;

a first cap attached to a bottom of said post; and

said first cap having a textured surface for engaging the textured surface of said footing base.

2. A system according to claim 1, wherein said post and said first cap are each formed from a composite material.

3. A system according to claim 1, further comprising a second cap attached to a top of said post.

4. A system according to claim 3, wherein said second cap is formed from a composite material.

5. A system according to claim 3, further comprising means for connecting a structural member to said second cap.

6. A system according to claim 5, wherein said connecting means comprises a bore in said second cap for receiving a bolt.

7. A system according to claim 5, wherein said connecting means comprises a recess in said second cap for receiving a portion of a structural member.

8. A system according to claim 1, wherein said post has a first dimension along a first axis and said footing base has a second dimension greater than said first dimension along a second axis parallel to said first axis.

9. A system according to claim 1, wherein said post has a first diameter and said footing base has a second diameter greater than said first diameter.

10. A system according to claim 1, wherein said post has a central columnar structure, an outer wall, and a plurality of radially extending support arms extending between said central columnar structure and said outer wall.

11. A system according to claim 3, further comprising means for connecting said first and second caps to said post.

12. A system according to claim 1, further comprising a pad for supporting a portion of said structure.

13. A system according to claim 12, wherein said pad is formed from a composite material.

14. A system according to claim 12, wherein said pad has at least one recess for receiving an upper end of said post.

15. A system according to claim 12, wherein said pad has a bottom surface which is direct contact with a load bearing surface.

16. A system for supporting a structure which comprises:

a plurality of structural support members; and

each structural support member comprising a post, a first cap attached to a lower end of said post, and means attached to an upper end of said post for supporting a structural member.

17. A system according to claim 16, wherein said support means comprises a second cap attached to an upper end of said post and wherein said second cap has means for connecting the second cap to a structural member.

18. A system according to claim 16, wherein said post is solid in construction.

19. A system according to claim 16, wherein said post has a central columnar structure, an outer wall, and a plurality of radially extending support arms extending between said central columnar structure and said outer wall.

20. A system according to claim 16, further comprising:

each said structural support member including a footing base having an upper textured surface; and

said first cap having a textured surface for engaging the textured surface of said footing base.

21. A system according to claim 16, wherein said supporting means comprises a pad with at least one recess for receiving said upper end of said post.