Breakdown Safety Rail System for Scaffold

Abstract

The present disclosure relates generally to a safety rail system for a scaffold that is designed to break down for shipment and storage. The breakdown safety rail system enables more compact packaging so as to significantly reduce shipping and operational expenses for manufacturers and sellers.

Description

TECHNICAL FIELD

The present disclosure relates generally to scaffolding and, more particularly, to a safety rail system for a scaffold.

BACKGROUND

Safety rail systems for scaffolds are well-known in the art. A conventional safety rail system comprises four vertical posts with side rails that can the detachably connected to the vertical posts. In conventional designs, the vertical posts and side rails are made of a single tube with a circular cross section. Each vertical post includes two stud posts disposed at an angle of ninety degrees relative to one another. The side rails include flattened outer ends with openings therein to engage with the stud posts on the vertical posts.

One drawback of the conventional design is that the relative angle between the stud posts on each vertical posts is the same for all vertical posts and each vertical post is rotated ninety degrees relative to the adjacent vertical posts. A consequence of this design is that opposing ends of the side rails engage with stud posts that are disposed at different heights so that the side rails are not level. This issue can be resolved by using two different vertical posts, but this solution requires the manufacturer and seller to inventory a greater number of parts.

Another drawback is that the packaging for the conventional design of the safety rail system is large. The large package size makes it costly to ship and consumes a large amount of storage space on store or warehouse shelves that could otherwise be used for other goods.

SUMMARY

The present disclosure relates generally to a safety rail system for a scaffold that is designed to break down for shipment and storage. The breakdown safety rail system enables more compact packaging so as to significantly reduce shipping and operational expenses for manufacturers and sellers.

In an exemplary embodiment, the safety rail system includes at least two vertical posts and a side rail extending between the vertical posts. According to a first aspect of the disclosure, each vertical post includes a lower member mountable to a scaffold and an upper member configured to detachably connect to the lower member in both a first rotational orientation and a second rotational orientation. A first stud post is disposed adjacent an upper end of the lower member of the vertical post. A second stud post is disposed adjacent a lower end of the upper member of the vertical post. The first and second stud posts are arranged such that the second stud post extends generally perpendicular to the first stud post in both the first and second rotational orientations. For example, in the first rotational orientation, the second stud post may be rotated ninety degrees Clockwise relative to the first stud post, and in the second rotational orientation, the second stud post may be rotated ninety degrees Counterclockwise relative to the first stud post. The side rail extends between the vertical posts and is configured such that opposite ends of the side rail are selectively engageable with either the first stud posts on respective ones of the vertical posts or the second stud posts on respective ones of the vertical posts depending on the arrangement of the vertical posts. For example, the side rail may connect to the first stud posts in a first arrangement of the vertical posts where the first stud post extends perpendicular relative to a line between the vertical posts. The side rail may connect to the second stud post in a second arrangement of the vertical posts where the second stud post extends perpendicular relative to a line between the vertical posts.

According to a second aspect of the disclosure, the side rail comprises three separable components: namely, two end segments and a connecting member. Each end segment comprises a flattened outer end with an opening designed to engage one of the stud posts on a vertical post. The opposite end has a straight tubular cross-section designed to fit into the connecting member without swagging. That is, the diameter of the end segment is not reduced to fit into the connecting member. Instead, the internal diameter of the connecting member is matched to the outer diameter of the end segment. A button lock may be used to releasably secure the end segment of the side rail to the connecting member. The central member includes internal stop members at each end thereof to constrain the axial movement of the central member relative to the end segments. The internal stops serve as a safety in the event that the button lock fails. When the side rail is connected between two vertical posts, the internal stops constrain the axial movement of the central member even when no button locks are present. This feature prevents the side rail from sliding off the end segment in the event that the button lock fails.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a fully assembled safety rail system according to an exemplary embodiment mounted on a scaffold.

FIG. 2 is a perspective view of a vertical post of the safety rail system including a lower member and an upper member assembled.

FIG. 3 is an elevation view of the lower member of the vertical post.

FIG. 4 is an elevation view of the upper member of the vertical post.

FIG. 5 is an elevation view of a vertical post of the safety rail system with the two parts assembled.

FIGS. 6 and 7 are perspective views of side rails of different length.

FIGS. 8A and 8B are elevation views of an end segment for the side rails.

FIGS. 9A and 9B are elevation and end views respectively of a short connecting member.

FIGS. 10A and 10B are elevation and end views respectively of a long connecting member.

FIGS. 11 and 12 are elevation views of an assembled side rail of a first length.

FIGS. 13 and 14 are elevation views of an assembled side rail of a second length.

FIG. 15 is a detail cross-section of the side rail.

FIG. 16 is a schematic diagram showing the arrangement and configuration of the vertical posts.

FIG. 17 is a partial top view showing one corner of the side rail assembly with the side rails connected to the vertical post.

FIG. 18 is a partial elevation view showing one corner of the side rail assembly with the side rails connected to the vertical post.

FIG. 19A shows approximate dimension of the assembled safety rail system 10.

FIG. 19B illustrates packaging for the safety rail system.

FIG. 19C illustrates the components of the safety rail systems disassembled.

FIG. 19D illustrates components of a comparatively sized safety rail system of conventional design.

FIGS. 20 and 21 illustrate end segments of a cross-brace for a scaffold.

FIG. 22 illustrates the connecting members of a cross brace for a scaffold.

FIG. 23 is an end view of the connecting member of a cross-brace for a scaffold.

FIGS. 24 and 25 illustrate end segments of a cross-brace for a scaffold.

FIG. 26 illustrates a connecting member for a cross brace for a scaffold.

FIG. 27 is an end view of the connecting member of a cross-brace for a scaffold.

FIG. 28 illustrates two pivotally connected central members for a set of cross-braces.

FIGS. 29A-29D illustrate various methods of constructing cross-braces for a scaffold.

DETAILED DESCRIPTION

Referring now to the drawings, FIG. 1 illustrates a fully assembled safety rail system 10 for a scaffold 100. The scaffold 100 comprises two ladder frames 110 interconnected by cross-braces 120. A deck 140 is supported by the ladder frames 110. The safety rail system 10 surrounds the deck 140 to prevent workers from inadvertently falling.

Each ladder frames 110 comprises two vertical posts 112 interconnected by cross members 114. A connecting member 166 extends vertically between the cross members 114. Ladder rungs 118 extend between the connecting member 166 and one of the vertical posts 112 to form a ladder. The components of the ladder frame 110 are made of metal tubing which is welded together to form a single piece. The vertical posts 112 include stud posts 119 with latches for engagement by the cross-braces 120 as described below. The latches retain the cross-braces 120 on the stud posts 119 when the cross braces 120 are engaged with the stud posts 119.

The cross-braces 120 extend diagonally between vertical posts 112 on two ladder frames 110 to form a self-supporting structure and engage with stud posts 119 extending from the vertical posts 112. An exemplary multi-piece cross-brace 120 is shown in FIGS. 20-23. Each cross-brace 120 comprises two end segments 122 (FIGS. 20 and 21) and a connecting member 132 (FIG. 22). The connecting members 132 for a set of two cross-braces 120 may be pivotally connected by a pivot member 34 as shown in FIG. 22.

Each end segment 122 includes a flattened outer end 124 having an opening 126 formed therein sized to fit around the stud posts 119 on the vertical posts 112 of the ladder frames 110. The inner end 128 is designed to be inserted into one end of the connecting member 64 without swagging, i.e., without reducing the diameter of the inner end 128. In the embodiment shown, the inner diameter of the connecting member 64 is sized to match the outer diameter of the end segment 122 and the outer diameter of the connecting member 132 is larger than the outer diameter of the end segment 122. Reducing the diameter of the inner end 128 creates a weak point where the metal is deformed. An advantage of the overlapping tube design shown herein is that the side rail 50 can support more weight with less bending than a conventional design with a reduced diameter end.

The connecting members 132 for a set of cross-braces are pivotally connected at their center. The connecting member 132 is formed from a straight metal tube sized to receive the inner end 128 of the end segment 122. The inner ends 128 of the end segments 128 include openings 130 that align with corresponding openings 136 in the connecting members 132 when the parts are assembled. The end segments 122 are secured to the connecting member 64 by span pins (not shown) that pass through the aligned openings 130, 136 in the end segment 122 and connecting member 132 respectively. In some embodiments, the connecting member 132 includes internal stops 138 at each end thereof as shown in FIG. 23 to constrain the axial movement of the connecting member 132 relative to the end segments 122.

FIGS. 24-28 illustrate an alternate embodiment of the cross-braces 120. In this embodiment each cross brace includes five separable components: two end segments 122, a central member 132′, and two connecting members 142.

The end segments 122 are the same as previously described. Each end segment 122 includes a flattened outer end 124 having an opening 126 formed therein sized to fit around the stud posts 119 on the vertical posts 112 of the ladder frames 110. The inner end 128 is designed to be inserted into one end of the connecting member 64 without swagging, i.e., without reducing the diameter of the inner end 128. In the embodiment shown, the inner diameter of the connecting member 64 is sized to match the outer diameter of the end segment 122 and the outer diameter of the connecting member 132 is larger than the outer diameter of the end segment 122. Reducing the diameter of the inner end 128 creates a weak point where the metal is deformed. An advantage of the overlapping tube design shown herein is that the side rail 50 can support more weight with less bending than a conventional design with a reduced diameter end.

The central members 132′ for a set of cross-braces 120 are pivotally connected at their center as shown in FIG. 28. Each connecting member 132′ is formed from a straight metal tube of the same size, i.e., outer diameter, as the end segments 122. Each central member 132′ includes openings 136′ adjacent opposing ends of the central member 132′ for making connection with the connecting member 142.

The connecting member 142 comprises a straight metal tube having an inner diameter sized to match the outer diameter of the end segments 122 and central members 132′. The central member 132′ inserts into one end of each connecting member 142 (two for each cross-brace 120) and an end segment 122 (two for each cross brace 120) inserts into the opposite end of each connecting member 142. The openings 130, 136′ in the end segments 122 and central member 132′ align with the openings 144 in the connecting member 142. A span pin or bolt (not shown) can be inserted through the aligned openings, 130, 144 or 136′, 144 to detachably but firmly secure the components together. In the final assembly, the central member 132′ is connected at opposing ends to respective connecting members 142, which in turn are connected to respective end segment 122. The central members 132′ for two cross-braces 120 are pivotally connected at their center to form a set of cross-braces 120.

FIGS. 29A-29D illustrates various methods of constructing the cross-braces 120. The embodiment shown in FIG. 29A, includes four end segments 122 and two center members 132 that are pivotally connected to one another. In this embodiment, the center members 132 and end segments 122 are the same size and the inner ends of the end segments are swaged to fit into the center members.

The embodiment shown in FIG. 29B, includes four end segments 122 and two center members 132 that are pivotally connected to one another. In this embodiment, the inner diameter of the center members 132 are sized to match the outer diameter of the end segments 122 so that the end segments 122 fit into the center members 132 without swaging.

The embodiment shown in FIG. 29C, includes four end segments 122 and two center members 132 that are pivotally connected to one another. In this embodiment, the inner diameter of the end segments 122 are sized to match the outer diameter of the center members 132 so that the center members 132 fit into the end segments 122 without swaging.

The embodiment shown in FIG. 29D, includes four end segments 122: two long end segments that are pivotally connected and two short end segments 122 that connect to the long end segments 122. In this embodiment, the inner diameter of the long end segments 122 are sized to match the outer diameter of the short end segments so that the short end segments 122 fit into the long end segments 122 without swaging. Alternatively, the In this embodiment, the inner diameter of the short end segments 122 could be sized to match the outer diameter of the long end segments so that the long end segments 122 fit into the short end segments 122 without swaging.

The safety rail system 10 is designed to mount on top of the scaffold 100. The safety rail system 10 comprises four vertical posts 20 and eight side rails 50. The vertical posts 50 are designed to engage with the vertical posts 112 of the scaffold 100 and extend upward from the deck 140 on which workers stand. Two side rails 50 extend between each adjacent pair of vertical posts 20. The vertical posts 20 are designed such that the side rails 50 on all sides will remain level when connected with the vertical posts 20. Additionally, both the vertical posts 20 and side rails 50 are designed to breakdown into smaller components for more compact packaging and storage.

FIGS. 2-5 illustrate a vertical post 20. All four vertical posts 20 are the same. The vertical post 20 comprises a lower member 22 (FIG. 3) and an upper member 32 (FIG. 4). The lower member 22 is designed to be mounted to a scaffold 100. The upper member 32 can be releasably connected to the lower member 22.

The lower end of the lower member 22, shown in FIG. 3, is designed to fit into a vertical post 112 of the scaffold 100. A collar 24 is welded or otherwise secured a predetermined distance from the lower end of the lower member 22. The position of the collar 24 sets the vertical height of the vertical post 20. An opening 24 for a span pin or bolt extends through the lower end of the lower member 22 and aligns with an opening in the scaffold. A span pin or bolt passes through the aligned openings to secure the lower member 22 to the scaffold.

A first stud post 26 is disposed adjacent an upper end of the lower member 22 and extends outward a short distance from the lower member 22. A latch 28 with a slot is attached to the stud post 26. As will be herein after described, the first stud post 26 is designed to engage the side rail 50 when the safety rail system 10 is assembled and the latch 28 retains the side rail 50 on the stud post 26. A second opening 30 for a span pin 48 or bolt extends through the lower member 22 a predetermined distance below the first stud post 22. The span pin 48 or bolt is used to secure the lower member 22 and upper member 32 together when the safety rail system 10 is assembled.

The upper member 32, shown in FIG. 4, is designed to connect to the lower member 22 in first and second rotational orientations. The upper member 32 includes a reduced diameter section 34 at its lower end sized to fit into the upper end of the lower member 22. The reduced diameter section 34 includes an opening 36 for a span pin 48 or bolt. The opening 36 aligns with the opening 30 in the lower member 22 in both the first and second rotational orientations. When the upper member 32 is assembled to the lower member 22, the span pin 48 can be inserted through the aligned openings 30, 36 in the lower member 22 and upper member 32 respectively to secure the upper member 32 to the lower member 22.

A second stud post 38 is disposed adjacent the lower end of the upper member 32 and extends outward a short distance from the upper member 32. A latch 40 with a slot is attached to the stud post 38. The second stud post 38 is designed to engage a side rail 50 when the safety rail system 10 is assembled and the latch 40 retains the side rail 50 on the stud post 38. The second stud post 38 is arranged such that the second stud post 38 will be perpendicular with respect to the first stud post 26 is both the first and second rotational orientations. For example, the second stud post 38 may be rotated ninety degrees Clockwise with respect to the first stud post 26 in the first rotational orientation and ninety degrees counter-clockwise with respect to the first stud post 26 in the second rotational orientation, or vice versa.

A third stud post 42 extends axially from an upper end of the upper member 32. A latch 44 with a slot is attached to the stud post 38. As will be herein after described, the third stud post 42 is designed to engage a side rail 50 when the safety rail system 10 is assembled.

FIG. 5 illustrates a vertical post 20 assembled. When assembled, the reduced diameter section 34 of the upper member 32 fits into the upper end of the lower member 22 with the first and second stud posts 26, 38 disposed at ninety degree angles relative to one another. The upper member 32 can be inserted into the lower member 22 in two different orientations, i.e., with the second stud post rotated ninety degrees clockwise or ninety degrees clockwise.

FIGS. 6 and 7 illustrate side rails 50 of two different lengths. The side rails 50 in FIGS. 6 and 7 are the same except for the difference in length of the connecting members 64 for side rails of different length. Therefore, the same reference numbers are used to identify similar components of the two side rails.

Each side rail 50 includes two end segments 52 (FIGS. 8A and 8B) and a connecting member 64 (FIGS. 9 and 10). The end segments 52 and connecting members 64 are the same for all side rails 50 except that the connecting members 64 are different for side rails 50 of different length. Otherwise, all side rails 50 are the same.

Each end segment 52, shown in FIGS. 8A and 8B, is formed from a straight metal tube and includes a flattened outer end 54 having an opening 56 formed therein sized to fit around the stud posts 26, 38 and 42 on the vertical posts 20. The inner end 58 is designed to be inserted into one end of the connecting member 64 without swagging, i.e., without reducing the diameter of the inner end 58. In the embodiment shown, the inner diameter of the connecting member 64 is sized to match the outer diameter of the end segment and the outer diameter of the connecting member 64 is larger than the outer diameter of the end segment 52. Reducing the diameter of the inner end 58 creates a weak point where the metal is deformed. An advantage of the overlapping tube design shown herein is that the side rail 50 can support more weight with less bending than a conventional design with a reduced diameter end.

The connecting members 64, shown in FIGS. 9A and 10A, are formed from a straight metal tube and include openings 66 that aligns with the opening 60 in the end segments 52 when the parts are assembled. As noted above, the connecting member is sized to receive the inner end 58 of the end segment 52 without reducing the diameter of the inner end 58. The inner end 58 of each end segment 52 includes an opening 60 that extends through the end segment 52 and aligns with corresponding openings 66 in the connecting member 64 when the parts are assembled.

The end segments 52 are secured to the connecting member 64 by button locks 62, shown in FIG. 15, inserted into the inner ends 58 of the end segments 52. Each button lock 62 includes a u-shaped spring with button at each end thereof. The buttons project through the openings 60 in the end segments 52 and engage with the openings 66 in the connecting member 64 to secure the end segment 52 to the connecting member 64. Alternatively, for increased strength and resistance to axial loads, the end segments 52 can be secured to the connecting member 64 by span pins or bolts (not shown) that pass through the aligned opening 60, 66 in the end segment 52 and connecting member 64 respectively.

In some embodiments, the connecting member 64 includes internal stops 68 at each end thereof as shown in FIGS. 9B and 10B to constrain the axial movement of the connecting member 64 relative to the end segments 52. The internal stops 68 serve as a safety in the event that the button lock 62 fails. When the side rail 50 is connected between two vertical posts 20, the internal stops 68 constrain the axial movement of the connecting member 64 even when no button locks 62 are present. This feature prevents the connecting member 64 from sliding axially off the end of one of the end segments 52 when the button lock 62 fails.

FIG. 16 is a schematic diagram illustrating the vertical posts 20 of the side rail assembly 10. The vertical posts are labeled A-D to match FIG. 1. Vertical posts A and C are assembled in a first rotational orientation and vertical posts B and D are assembled in a second rotational orientation. For vertical posts A and C, the second stud posts 38 are rotated ninety degrees Counterclockwise (CCW) relative to the first stud post 26. For vertical posts B and D, the second stud posts 38 are rotated ninety degrees Clockwise (CW) relative to the first stud post 26. Because the vertical posts 20 can be assembled in two different orientations, the first stud posts 26 are all vertically aligned (at the same height) and the second stud post 38 are all vertically aligned. As a result the side rails 50 connected between any two first stud posts 26 will be level and the side rails connected between any two second stud posts 38 will be level.

FIG. 17 is a top view showing one corner of the assembled side rail assembly 10 with the side rails 50 attached to the vertical posts 20. In FIG. 17, the side rails 50 extend to the right and downward from the vertical posts 20.

FIG. 18 is an elevation view showing the same corner of the assembled side rail assembly 10 with the side rails 50 attached to the vertical posts 20. In FIG. 18, the side rails 50 extend to the right and toward the viewer from the vertical posts 20.

FIGS. 19A-19D shows a comparison of the safety rail system 10 herein described to a conventional safety rail system. FIG. 19A shows approximate dimension of the assembled safety rail system 10. FIG. 19B illustrates packaging for the safety rail system. FIG. 19C illustrates the components of the safety rail systems disassembled. FIG. 19D illustrates components of a safety rail system of conventional design. As can be seen in FIG. 8, a package for the components of a conventional design would be nearly three time greater in length than the packaging for the safety rail system 10 herein described.

In the illustrated embodiments, the rails 20 extend generally horizontally between the vertical posts 20. In some embodiments, one or more of the rails 20 can extend diagonally between the vertical posts 20 to serve as a cross brace. For example, the safety rail system 10 may include rails that extend from a first stud post 26 on one vertical post 20 to a second stud post 38 on an adjacent vertical post 20.

The safety rail system 10 of the present disclosure comprises components that can be disassembled for more compact packaging and storage. The ability to assemble the vertical posts 20 in first and second rotational orientations enables the side rails to remain level when properly assembled. Additionally, the design of the side rails provides increased strength compared to a swagged connection and includes a fail safe to prevent failure of the side rail.

Claims

1. A safety rail system for a scaffold, the safety rail system comprising: at least two vertical posts, each including a lower member mountable to the scaffold and an upper member configured to detachably connect to the lower member in both a first rotational orientation and a second rotational orientation;a first stud post adjacent an upper end of the lower member of the vertical post;a second stud post adjacent a lower end of the upper member of the vertical post and configured such that the second stud post extends generally perpendicular to the first stud post in both the first and second rotational orientations respectively;a side rail extending between the vertical posts and configured such that opposite ends of the side rail are selectively engageable with either the first stud posts on respective ones of the vertical posts or the second stud posts on respective ones of the vertical posts.

2. The safety rail system of claim 1, further comprising a third stud post extending from an upper end of the upper member of the post, and wherein opposing ends of the side rail are selectively engageable with the third stud post.

3. The safety rail system of claim 2, wherein the third stud posts extend axially from the upper ends of the upper members of the vertical posts.

4. The safety rail system of claim 1, wherein each side rail comprises configured to engage respective ones of the vertical posts and a connecting member detachably connected to the two end segments to from a single rail.

5. The safety rail system of claim 4, wherein each end segment includes a flattened outer end having an opening therein for engagement with one of the first, second or third stud posts, and a straight tubular end insertable into one end of the connecting member.

6. The safety rail system of claim 5, wherein each end segment further comprising a button lock on the straight tubular end and engageable with an opening in the connecting member.

7. The safety rail system of claim 6, wherein the connecting member further comprises an internal stop disposed within each end of the connecting member to limit axial movement of the connecting member relative to the end segments in the event of a failure of the button lock.

8. The safety rail system of claim 1, wherein each of the first, second and third stud posts includes a latch to prevent the side rails from disengaging with the stud posts.

9. A safety rail system for a scaffold, the safety rail system comprising: at least two vertical posts configured to be mounted to a scaffold;a rail extending between the vertical posts and configured such that opposite ends of the side rail are selectively engageable with either the first stud posts on respective ones of the vertical posts or the second stud posts on respective ones of the vertical posts;wherein the rail comprises two end segments configured to engage respective ones of the vertical posts and a connecting member detachably connected to the two end segments to from a single rail.

10. The safety rail system of claim 4, wherein each end segment includes a flattened outer end having an opening therein for engagement with one of the first, second or third stud posts, and a straight tubular end insertable into one end of the connecting member.

11. The safety rail system of claim 5, wherein each end segment further comprising a button lock on the straight tubular end and engageable with an opening in the connecting member.

12. The safety rail system of claim 6, wherein the connecting member further comprises an internal stop disposed within each end of the connecting member to limit axial movement of the connecting member relative to the end segments in the event of a failure of the button lock.

13. The safety rail system of claim 9, wherein the rail extends generally horizontally between the vertical posts.

14. The safety rail system of claim 9, wherein the rail extends diagonally between the vertical posts.

15. A scaffold comprising: at least two vertical posts;a cross-brace extending between the vertical posts and configured such that opposite ends of the side rail are selectively engageable with either the first stud posts on respective ones of the vertical posts or the second stud posts on respective ones of the vertical posts;wherein the cross-brace comprises two end segments configured to engage respective ones of the vertical posts and one or more intermediate members connected between the two end segments to form a single structural member.

16. The scaffold of claim 15, wherein each end segment includes a flattened outer end having an opening therein for engagement with one of the first, second or third stud posts, and a straight tubular end insertable into one end of an intermediate member.

17. The scaffold of claim 16, wherein each cross-brace comprises a single connecting member connected between two end segments.

18. The scaffold system of claim 17, wherein the connecting member further comprises an internal stop disposed within each end of the connecting member to limit axial movement of the connecting member relative to the end segments in the event of a failure of the button lock.

19. The scaffold of claim 16, wherein each cross-brace comprises a central member and two connecting members connected in series between two end segments.

20. The scaffold of claim 15, wherein the cross-brace extends diagonally between the vertical posts.