Table of Contents
Design 2 Summary
The Deckloo is constructed from plastic lumber boards made from 100% recycled HDPE. The design has thinner sections of HDPE which lay next to each other to form the top surface to stand on. This is supported by several thicker cross-member sections of HDPE under the top surface that run perpendicular to the top boards. The inspiration for the design was based on the standard design layout for most common household decks and patios. The design is slightly inset into the ground to provide stability and prevent movement while in use. Also, there is an additional piece of HDPE to cover the opening to the hole below while the device is not in use. The entire device weighs 17.4lbs when assembled and is designed to support 270lbs.
Design 2 Assembly
The Deckloo was made from 100% recycled HDPE plastic lumber. This material is often used as an alternative to pressure treated lumber and is excellent in outdoor applications. HDPE’s resistance to environmental stress cracking makes it ideal for outdoor structural use, satisfying ER S13. Because the Deckloo is made from 100% recycled material, it’s impact on the environment is greatly reduced, meeting ER S14. The structural support comes from seven rows of 1.5 inch by 1.5 inch runners that span the width of the Deckloo. Supports are spaced at 5.75 inches apart to ensure that the stress is distributed properly and that the deflection between the supports is not too high. The total deflection under the loading condition of 270lbs in a single location was found to be approximately 0.44 inches. This was validated during load testing when the maximum deflection was found to be 0.45 inches under a load of 572 lbs, distributed across two locations; fulfilling ER S2. The runners are attached to the top platform with standard deck screws. The top platform is made of 0.25 inch thick by 10.25 inch wide sheets cut in 36 inch lengths. The sheets are cut so that an 8 inch by 10.25 inch rectangular gap can be used as the squat hole. Leftover 0.25 inch sheet strips are used to cover the side gaps left by the runners, and a lid is fashioned from extra 0.25 inch sheet. The completed design weighs 17.4lbs, meeting ER S9 and ER S10 and can be seen below.
Design 2 Documents
Design 2 Fixture
The fixture for assembling the Deckloo is made from a particle wood base and sections of 2 by 4’s to space the floor stringers at the correct location without having to measure. There are also perimeter stops to line the ends of the stringers and the deck pieces.