Deck Surfacing

Abstract

A deck surfacing system is installed over an existing surface. The deck surfacing system comprises a plurality of planks. Spacers are located between at least some of the planks. The planks have top, bottom, and side surfaces. The side surfaces of the planks have side recesses. When installed, portions of the spacers are embedded in the side recesses of the planks. In addition to spacing the planks horizontally, the spacers can resist vertical and/or lengthwise movement of adjacent planks.

The claimed invention is: 
     
         1 . A deck surfacing system:
 a plurality of planks, each of the planks comprising:   a top surface;   a first side surface;   a second side surface, the second side surface disposed opposite to the first side surface, the first side surface and the second side surface shaped to define side recesses;   a bottom surface, the bottom surface disposed opposite the top surface; and   a plurality of spacers positioned between the planks, portions of each of the spacers disposed within the side recesses of adjacent ones of the planks.   
     
     
         2 . The deck surfacing system of  claim 1 , wherein the planks include exterior planks and interior planks, each of the interior planks positioned between two or more of the planks, one or more of the interior planks not secured directly to an existing surface. 
     
     
         3 . The deck surfacing system of  claim 1 , wherein one or more of the spacers comprises one or more cleats embedded in the planks, the cleats projecting from the spacers in a direction substantially perpendicular to lengths of the planks 
     
     
         4 . The deck surfacing system of  claim 3 , wherein the cleats act to resist motion of adjacent ones of the planks relative to each other. 
     
     
         5 . The deck surfacing system of  claim 1 , wherein the spacers include a given spacer and the planks include a given plank, the given spacer comprising a foot and a head, the head entering the side recess of the given plank, the foot having a height sufficient to align the head with the side recess of the given plank when the given spacer rests on the foot. 
     
     
         6 . The deck surfacing system of  claim 5 , wherein prior to installation of the given plank, an amount by which the head overhangs the foot is greater than a depth of the side recess of the given plank. 
     
     
         7 . The deck surfacing system of  claim 6 , wherein after installation of the given plank, the foot is in contact with the side surface of the given plank. 
     
     
         8 . The deck surfacing system of  claim 1 , wherein the planks include a given plank, wherein the side recesses of the given plank comprise grooves that extend at least a portion of a length of the given plank. 
     
     
         9 . The deck surfacing system of  claim 1 , wherein the planks include a given plank, the bottom surface of the given plank having a shape that defines a bottom recess, the bottom recess extending upward into the given plank, the bottom recess extending substantially an entire length of the given plank. 
     
     
         10 . The deck surfacing system of  claim 9 , the bottom recess permitting airflow between the given plank and an existing surface on which the given plank is installed. 
     
     
         11 . The deck surfacing system of  claim 1 , wherein the planks substantially consist of engineered wood. 
     
     
         12 . A method for installing a deck surfacing system over an existing surface, the method comprising:
 positioning a first plank on the existing surface, the first plank having a top surface, a first side surface, a second side surface, and a bottom surface, the first side surface of the first plank opposite the second side surface of the first plank, the second side surface of the first plank shaped to define a first side recess;   positioning a second plank on the existing surface adjacent to the first plank, the second plank having a top surface, a first side surface, a second side surface, and a bottom surface, the first side surface of the second plank opposite the second side surface of the second plank, the first side surface of the second plank shaped to define a second side recess;   positioning a spacer on the existing surface between the first plank and the second plank; and   attaching the first plank to the second plank such that portions of the spacer enter the first side recess and the second side recess.   
     
     
         13 . The method of  claim 12 ,
 wherein after attaching the first plank to the second plank, a head of the spacer is disposed within the first side recess and the second side recess; and   wherein positioning the spacer comprises positioning the spacer such that the spacer rests upright on a foot of the spacer, the head of the spacer being approximately a same distance above the existing surface as the first and second side recesses are above the existing surface when the spacer rests upright on the foot of the spacer.   
     
     
         14 . The method of  claim 12 ,
 wherein after attaching the first plank to the second plank, a head of the spacer is disposed within the first side recess and the second side recess; and   wherein after attaching the first plank to the second plank, cleats of the spacer are embedded in the first plank and the second plank, the cleats projecting substantially vertically from the head of the spacer.   
     
     
         15 . The method of  claim 14 ,
 wherein prior to attaching the first plank to the second plank, a distance by which the head of the spacer overhangs a foot of the spacer is greater than a depth of the first side recess;   wherein prior to attaching the first plank to the second plank, the distance by which the head of the spacer overhangs the foot of the spacer is greater than a depth of the second side recess; and   wherein after attaching the first plank to the second plank, the foot of the spacer contacts the first plank and the second plank.   
     
     
         16 . The method of  claim 14 , wherein after attaching the first plank to the second plank, the second side surface of the first plank and the first side surface of the second plank are approximately aligned with an upper end of a lip of a passage that extends through the spacer along a central axis of the spacer. 
     
     
         17 . The method of  claim 12 , when the existing surface is an existing deck. 
     
     
         18 . The method of  claim 12 , further comprising securing the first plank to the existing surface and not securing the second plank to the existing surface. 
     
     
         19 . The method of  claim 12 , wherein attaching the first plank to the second plank comprises using a hammer to force the second plank toward the first plank. 
     
     
         20 . The method of  claim 12 , wherein the second side surface of the first plank is shaped to define a series of discontinuous side recesses.