GUARDRAIL APPARATUS AND SYSTEM

BACKGROUND OF THE INVENTION
1. Field of the Invention

The present invention relates generally to guardrail and guardrail systems.

2. Discussion of the Related Art

Various guardrail and fencing systems and processes are known in the art.

A guardrail, or guard rail, is a stationary, fixed fall protection system designed to prevent workers from stepping over the edge of a walking-working surface or protect workers from falls when working at heights. A guardrail does not require a worker to be trained to use, inspect, or wear a protective cover and are thus a preferred means of protecting workers and creating a safe work environment. Occupational Health and Safety Administration (OSHA) regulations contain requirements that employers must follow to ensure guardrail systems will protect workers from falling to lower levels. A common type of fence/guardrail installation known in the art for guardrail protection at construction sites consists of a bracket attachment, posts and 2×4 wooden planks.

However, the fence/guardrail installation systems lack durability and strength in the lumber used. Additionally, use of such systems is not sustainable as new planks are required with every new site built. Therefore, there is a need in the art for improved guardrail installation systems that include durability, strength of lumber, and sustainability.

SUMMARY

The present disclosure describes systems and methods for guardrail installation. Several embodiments of the invention advantageously address the needs above as well as other needs by providing a guardrail system comprising a guardrail including a plurality of guardrail members, wherein each guardrail member has a tubular cross-section, the plurality of guardrail members comprising two guardrail posts spaced a post-spacing distance apart; a top rail consisting of a single piece of material and rigidly connected to and spanning continuously over a top end of each guardrail post, wherein each end of the top rail is connected to a middle portion of the proximal guardrail post of the two guardrail posts by that end of the top rail extending continuously outward past the top end of the proximal guardrail post, turning continuously downward, and then extending continuously inward towards the proximal guardrail post such that that end of the top rail is juxtaposed with and connected to a mid-portion of the proximal guardrail post; and two post support devices, each post support device comprising an adjustable locking clamp including a generally horizontal cross-member; and a receptacle adapted to receive and support one of the two guardrail posts, the receptacle rigidly coupled to a top side of the cross-member and extending upward from the cross-member, wherein the guardrail system further comprises the guardrail coupled to the post support devices by each guardrail post being received by one receptacle.

In another embodiment, the invention can be characterized as a method for installing a guardrail on a wall element, comprising the steps of providing a guardrail including a plurality of guardrail members, wherein each guardrail member has a tubular cross-section, the plurality of guardrail members comprising two guardrail posts spaced a post-spacing distance apart and a top rail consisting of a single piece of material and rigidly connected to and spanning continuously over a top end of each guardrail post, wherein each end of the top rail is connected to a middle portion of the proximal guardrail post by that end of the top rail extending continuously outward past the top end of the proximal guardrail post, turning continuously downward, and then extending continuously inward towards the proximal guardrail post such that the end of the top rail is juxtaposed with the middle portion of the proximal guardrail post; clamping a first post support device to a top end of the wall element, the first post support device comprising: a first adjustable locking clamp including a generally horizontal first cross-member; and

- a first receptacle adapted to receive and support a post end of one guardrail post, the first receptacle rigidly coupled to a top side of the first cross-member and extending upward from the first cross-member; clamping a second post support device to the top end of the wall element at the post-spacing distance from the first post support device, the second post support device comprising: a second adjustable locking clamp including a generally horizontal second cross-member; and a second receptacle adapted to receive and support a post end of the other guardrail post, the second receptacle rigidly coupled to a top side of the second cross-member and extending upward from the second cross-member; and installing the guardrail on the wall element by receiving of the one guardrail post by the first post support device receptacle and receiving of the other guardrail post by the second support device receptacle.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an example of an exploded elevational view of a guardrail system comprising a guardrail coupled to a plurality of post support devices according to aspects of the present disclosure.

FIG. 2 shows an example of a sectional view of a guardrail installation system according to aspects of the present disclosure.

FIG. 3 shows an example of a guardrail joint system according to aspects of the present disclosure.

FIG. 4 shows an exploded view of a prior art post support device according to aspects of the present disclosure.

FIG. 5 shows an example of a guardrail installation system according to aspects of the present disclosure.

FIG. 6 shows an example of a post device coupled to a wall and supporting a guardrail post according to aspects of the present disclosure.

FIG. 7 shows an example of a guardrail system according to aspects of the present disclosure.

FIG. 8 shows an example of a method for installing a guardrail system on a wall according to aspects of the present disclosure.

FIG. 9 shows an example of an elevational view of a guardrail system according to aspects of the present disclosure.

FIG. 10 shows an example of a method for installing a guardrail system on a wall according to aspects of the present disclosure.

FIGS. 11-13 show examples of methods for fabricating a guardrail according to aspects of the present disclosure.

DETAILED DESCRIPTION

The following description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of exemplary embodiments. The scope of the invention should be determined with reference to the claims.

Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.

The present disclosure describes systems and methods for guardrail installation. Embodiments of the disclosure include installing a guardrail on a wall by receiving guardrail posts by the post support devices and clamping the devices to the wall element. The guardrail installation system includes a guardrail having two posts, a post support device to receive other guardrail post and rails that connect the posts. The guardrail installation system clamps a post support device to the top end of the wall element and another post support device to the wall element at a spacing distance. Thus, the guardrail system is stationary and prevents workers from stepping over the edge of the working surface.

Guardrail installation systems have been used to prevent workers from falling in a work environment. Occupational Health and Safety Administration (OSHA) regulations contain requirements that employers must follow to ensure guardrail systems will protect workers from falling to lower levels. Guardrails are commonly used for building and worker safety. Guardrails may be solid or split type with bars that may be assembled on-site. A common type of guardrail installation known in the art for guardrail protection consists of a bracket attachment, posts and 2×4 wooden planks. In some cases, the guardrail installation systems lack durability and strength in the lumber used. Additionally, use of such systems is not sustainable as new planks are required with every new site built.

Embodiments of the present disclosure include a guardrail installation system with a plurality of guardrail members configured to receive one guardrail post by a post support device and another guardrail post by another post support device. In some cases, the post support device can be removably coupled to a wall element. For example, the two guardrail posts are clamped to the top end of the wall element at a predetermined distance from each other.

Embodiments of the present disclosure may be used in the context of guardrail installation applications. For example, a guardrail installation system based on the present disclosure may include a guardrail with guardrail members that include guardrail posts and a top rail that connects the guardrail posts. For example, a post support device is included for each guardrail post. A guardrail installation system, according to some embodiments, is provided with reference to FIGS. 1-7 and 9. Details regarding methods for provision and setup of an example guardrail installation system are provided with reference to FIGS. 8 and 10. Details regarding methods for guardrail fabrication system are provided with reference to FIGS. 11-13.

In FIGS. 1-7 and 9, a guardrail system for installing a guardrail on a wall element is described.

FIG. 1 shows an example of a guardrail system according to aspects of the present disclosure. The example shown includes guardrail members 100, post support devices 120, first guardrail locking device 125, second guardrail locking device 130, and guardrail 140.

Referring to FIG. 1, an exploded elevational view of a guardrail system comprising a guardrail 140 coupled to a plurality of post support devices 120 is shown. Each post support device 120 is configured to couple to a wall element, as shown in FIGS. 6 and 7. The guardrail comprises at least one guardrail post. The exemplary guardrail 140 shown in FIG. 1 has two guardrail posts 105110. A guardrail may also have more than two guardrail posts.

In the embodiment shown in FIG. 1, the guardrail 140 comprises the top rail 145, the bottom rail 105, the first guardrail post 110, and the second guardrail post 115.

The guardrail posts 110115 are spaced a post-spacing distance apart, denoted as “A” in FIG. 1. The post spacing distance may vary. In some embodiments, A is not greater than 4 feet. In some embodiments, B is not greater than 2 feet. In some embodiments, the entire width of the guardrail, B+A+B, is not greater than 8 feet.

In some embodiments, a distance from the bottom of the guardrail posts 110115 to an underside of the bottom rail 105 is 1′-6″. In some embodiments, a distance from a top surface of the top rail 145 (i.e. at the portion spanning over the guardrail posts 110115) to the underside of the bottom rail 105 is 2′-2″.

In the embodiment of FIG. 1, the guardrail members 100 are connected together to form a guardrail shape that is generally a horizontally-oriented rectangle with rounded corners, with posts extending downward from a middle portion of the rectangle. This results in a middle portion of the guardrail located between the posts (i.e. the portion corresponding to distance “A”), and one cantilever portion on each side (i.e. the portions corresponding to distances “B”). This shape is constructed of three pieces: two vertical posts, a top rail member 145 that is bent to form the majority of the rounded rectangle shape, and a straight bottom rail 105 that completes the rounded rectangle shape. The top rail 145 is generally an inverted-U shape with added inward returns at the ends of the U-shape, as shown in FIG. 1, where the base of the inverted “U” is the top rail of the guardrail, the legs of the inverted “U” are the sides of the guardrail, and the inward returns form the cantilever portions of the bottom rail of the guardrail. The guardrail posts 110115 are continuous through the bottom rail of the guardrail, such that the guardrail posts are interposed between the ends of the top rail 145 and the bottom rail 105 at the bottom rail. In some embodiments the top rail includes at least one 90 degree bend. In some embodiments each bend has an inside radius of 4 inches.

The guardrail 100 also includes first guardrail locking device 125 and second guardrail locking device 130. First guardrail locking device 125 is coupled to one guardrail side (i.e. one downward portion of top rail 145) and second locking device 130 is coupled to the other guardrail side (i.e. the other downward portion of top rail 145). Each locking device 125130 is configured to configure to one of the other type of locking device attached to an adjacent guardrail, i.e. the second locking device 130 is configured to couple to another one of first locking device 125 and vice versa. Coupling of adjacent guardrails to each other using the locking devices 125130 is shown in FIG. 7.

In some embodiments, first locking device 125 is two vertically-oriented pipe sections aligned axially and spaced a vertical distance apart. In some embodiments, second locking device 130 is a vertically-oriented pipe section coupled to the guardrail side. In some embodiments the locking devices 125130 include ASTM A53 grade B steel. In some aspects, locking devices 125130 comprise ¾″ diameter schedule 40 steel pipe.

In some embodiments the first guardrail locking device is configured for locking to the second guardrail locking device and the second guardrail locking device is configured for locking to the first guardrail locking device. In some embodiments the first guardrail locking device is a first part of a hinge, and the second guardrail locking device is a second part of a hinge. In some embodiments the first guardrail locking device and the second locking device together form a hinge knuckle configured to receive a hinge pin.

Guardrail locking devices 125130 may be examples of, or include aspects of, the corresponding elements described with reference to FIG. 7.

Guardrail members 100 may be examples of, or include aspects of, the corresponding element described with reference to FIGS. 2 and 3. In one aspect, guardrail members 100 includes top rail 145, bottom rail 105, first guardrail post 110, and second guardrail post 115.

Bottom rail 105 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2 and 9. Guardrail posts 110115 are examples of, or includes aspects of, the corresponding element described with reference to FIGS. 2 and 3 and 9. Top rail 145 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2, 3 and 9.

In some embodiments, the guardrail members include a pipe section. In some embodiments, the pipe section is a 1½″ diameter Schedule 40 pipe section. In some embodiments, the guardrail members include a round HSS section. In some embodiments the guardrail members include steel. In some embodiments the guardrail member steel includes ASTM A53 grade B steel. In some embodiments the guardrail member steel includes A500 grade C steel.

In some embodiments, the cross-member, the spine, the beam, and the leg of the post support device each includes a rectangular tube section. In some aspects, the leg, the spine, the cross-member, and the beam include steel. According to some embodiments, post support device 120 is configured such that each guardrail post has a corresponding post support device 120.

Each perpendicular guardrail member-to-guardrail member connection is a coped connection, where the end of the terminating guardrail member is coped to match the contour of the outside surface of the continuous guardrail member such that the terminating guardrail member butts up against the continuous member closely enough so that a continuous all-around fillet weld may be applied at the connection.

In some examples, post support device 120 clamps a second post support device 120 to the top end of the wall element at the post spacing distance from the first post support device 120. In some examples, post support device 120 installs the guardrail on the wall element by receiving of one guardrail post by the first post support device 120 receptacle and receiving of the other guardrail post by the second support device receptacle.

In some examples, the guardrail members further comprise a top rail 145 consisting of a single piece of material and rigidly connected to and spanning continuously over a top end of each guardrail post 110115, wherein each end 155 of the top rail 145 is connected to a middle portion 150 of the proximal guardrail post of the two guardrail posts by that end 155 of the top rail 145 extending continuously outward past the top end of the proximal guardrail post, turning continuously downward, and then extending continuously inward towards the proximal guardrail post such that that end 155 of the top rail 145 is juxtaposed with and connected to the mid-portion 150 of the proximal guardrail post.

In some examples the guardrail members further comprise a bottom rail 105, wherein the bottom rail 105 is interposed between the two guardrail posts 110115 and each end of the bottom rail 105 is connected to one guardrail post such that the bottom rail 105 is axially aligned with both ends of the top rail 145 at the middle portion of the guardrail posts. In some aspects, each end of the bottom rail 105 is coped to match an outside curvature of the connected guardrail post tubular cross-section.

In some aspects, the top end of each guardrail post is coped to match an outside curvature of the top rail tubular cross-section and each end of the top rail is coped to match an outside curvature of the guardrail post tubular cross-section.

In some aspects, each connection including one end of one guardrail member connected to another guardrail member comprises a welded connection. In other aspects, each welded connection is an all-around welded connection. In some aspects, each guardrail member connection is a rigid connection.

Post support device 120 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2, 7, and 9.

According to some embodiments, a guardrail system is described. One or more aspects of the system include a guardrail including a plurality of guardrail members, wherein each guardrail member has a tubular cross-section, the plurality of guardrail members comprising two guardrail posts spaced a post-spacing distance apart; a top rail consisting of a single piece of material and rigidly connected to and spanning continuously over a top end of each guardrail post, wherein each end of the top rail is connected to a middle portion of the proximal guardrail post of the two guardrail posts by that end of the top rail extending continuously outward past the top end of the proximal guardrail post, turning continuously downward, and then extending continuously inward towards the proximal guardrail post such that that end of the top rail is juxtaposed with and connected to a mid-portion of the proximal guardrail post; and two post support devices, each post support device comprising an adjustable locking clamp including a generally horizontal cross-member and a receptacle adapted to receive and support one of the two guardrail posts, the receptacle rigidly coupled to a top side of the cross-member and extending upward from the cross-member, wherein the guardrail system further comprises the guardrail coupled to the post support devices by each guardrail post being received by one receptacle.

FIG. 2 shows an example of a sectional view of a guardrail installation system according to aspects of the present disclosure. The example shown includes top rail 200, bottom rail 205, post support device 210, and first guardrail post 245.

Referring to FIG. 2, a sectional view of a guardrail coupled to the first post support device 210 is shown. The first post support device 210 comprises a receptacle 225 coupled to an adjustable locking clamp 250. The adjustable locking clamp comprises a cross-member 215, a spine 220, a beam 230, a locking mechanism 235, and a leg 240.

The first post support device 210 has a clamping throat distance which is the clear distance between the spine 220 and the leg 240. The clamping throat distance is variable by the amount of beam 230 that is passed through the passage of the cross-member 215. The cross-member 215 has at least two holes in each side of the cross-member 215, and the leg 240 has at least three holes in each side at the same spacing, such that the holes in the cross-member 215 can be aligned with the same number of holes in the leg 240, and removable bolts (or other suitable fastener) can be passed through the aligned holes to rigidly, and removably, couple the beam 230 to the leg 240. In operation, the amount of beam 230 passed through the cross-member 215 is such that the clamping throat distance is greater than the thickness of the wall element.

Top rail 200 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1 and 3. Bottom rail 205 is an example of, or includes aspects of, the corresponding element described with reference to FIG. 1.

Post support device 210 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1 and 7. In one aspect, post support device 210 includes cross-member 215, spine 220, receptacle 225, beam 230, locking mechanism 235, and leg 240.

According to some aspects, cross-member 215 has a passage therethrough. Cross-member 215 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 4-6.

According to some aspects, spine 220 is rigidly coupled to an underside of the cross-member 215 and extending downward from the cross-member 215. In some aspects, the spine 220 further includes an internally-threaded bore configured to receive the threaded rod. In some aspects, the internally-threaded bore is part of an internally threaded tap-thru coupler rigidly coupled to the spine 220. According to some aspects, spine 220 is rigidly coupled to an underside of the cross-member 215 and extending downward from the cross-member 215. Spine 220 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 4 and 5.

According to some aspects, receptacle 225 is adapted to receive and support a post end, the receptacle 225 rigidly coupled to a top side of the cross-member 215 and extending upward from the cross-member 215 such that the cross-member 215 interposed passage is between the receptacle 225 and the spine 220. In some aspects, the receptacle 225 includes a pipe section. In some aspects, the receptacle 225 is vertically aligned with the spine 220. According to some aspects, receptacle 225 is adapted to receive and support one of the at least two guardrail posts, the receptacle 225 rigidly coupled to a top side of the cross-member 215 and extending upward from the cross-member 215 such that the cross-member 215 passage is interposed between the receptacle 225 and the spine 220. Receptacle 225 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 4-6.

According to some aspects, beam 230 is coupled to the cross-member 215 and having a first end and a second end, wherein the second end is passed through at least a portion of the passage. According to some aspects, beam 230 is coupled to the cross-member 215 and having a first end and a second end, wherein the second end is passed through at least a portion of the passage. Beam 230 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 4-6.

According to some aspects, locking mechanism 235 is for locking a position of the cross-member 215 relative to the beam 230, wherein a portion of the locking mechanism 235 laterally crosses the cross-member 215 passage and wherein adjustment of the locking mechanism 235 changes the clamping throat distance. In some aspects, the portion of the locking mechanism 235 that laterally crosses the cross-member 215 passage includes at least one rod. In some aspects, the locking mechanism 235 further includes the cross-member 215 and the second end of the beam 230 being adapted to receive the at least one rod.

In some aspects, the second end includes a set of holes, wherein the holes are located for receiving the rod at at least two different locations along a length of the beam 230, where adjustment of the locking mechanism 235 includes moving the rod from being coupled to the beam 230 at one location along the length of the beam 230 to being coupled to the beam 230 at a different location along the length of the beam 230.

In some aspects, the portion laterally crossing the cross-member 215 consists of two rods. In some aspects, each of the at least one rod is a threaded rod. In some aspects, the rod includes a bolt, the bolt having a shaft and a bolt head. In some examples, locking mechanism 235 comprises a nut removably coupled to the shaft, where the bolt is coupled to the cross-member 215 and the second end such that the cross-member 215 and the second end are interposed between the bolt head and the nut.

According to some aspects, locking mechanism 235 is for locking a position of the cross-member 215 relative to the beam 230, wherein a portion of the locking mechanism 235 laterally crosses the cross-member 215 passage and wherein adjustment of the adjustable locking mechanism 235 changes the clamping throat distance; wherein the guardrail system further comprises the guardrail portion coupled to the post support devices 210 by each guardrail post being received by the corresponding receptacle 225. Locking mechanism 235 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 4-6.

According to some aspects, leg 240 is rigidly coupled to and extending downward from the beam 230 such that the leg 240 and the spine 220 form a clamping throat distance therebetween. In some aspects, the leg 240 includes a set of holes. In some aspects, the leg 240 is coupled to the beam 230 by a rigid mitered joint. According to some aspects, leg 240 is rigidly coupled to and extending downward from the beam 230 such that the leg 240 and the spine 220 form a clamping throat distance therebetween. Leg 240 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 4-6.

First guardrail post 245 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1 and 3.

Adjustable locking clamp 250 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1, 5, and 6.

In the embodiment shown each guardrail member 100 is a pipe section. At each joint (i.e., connection of one guardrail member 100 to another guardrail member 100), the end of one guardrail member 100 is coped or notched to fit over the other guardrail member 100 and the guardrail members 100 are rigidly connected by welding at the intersection (as shown in FIG. 3). For example, the top of the first guardrail post 245 is coped/notched to fit under top rail 200. The end of bottom rail 205 is coped/notched to fit over the first guardrail post 245.

In some embodiments, the pipe sections are the same size. In some embodiments, the pipe sections are different sizes. In some embodiments, the pipe section material is steel. Each post support device 120 is configured to removably couple to a wall element. For support of guardrails with a plurality of guardrail posts, each guardrail post may be coupled to the same wall element or each post may be coupled to the same wall element. For guardrails with a plurality of guardrail posts, the distance between the installed post support devices 120 must match the corresponding guardrail post spacing distance.

FIG. 3 shows an example of a guardrail joint system according to aspects of the present disclosure. The example shown includes first guardrail post 300, welded joint 305, and top rail 310.

Referring next to FIG. 3, a detail of a guardrail joint is shown. The first guardrail post 300 is coped to match the curvature of an underside of the top rail 310. The intersection between the first guardrail post 300 and the top rail 310 is welded. In one embodiment, the weld is an all-around fillet weld. The fillet weld is of type and size suitable for the pipe material and size. In the embodiment shown, the fillet weld size is ⅛″.

First guardrail post 300 and top rail 310 are examples of, or includes aspects of, the corresponding elements described with reference to FIGS. 1 and 2.

FIG. 4 shows an example of an exploded view of a prior art post support device. The example shown includes cross-member 400, receptacle 410, locking mechanism 415, cap 435, beam 440, leg 445, spine 450, and clamping adjustment 455.

Referring next to FIG. 4, an exploded view of the prior art post support device of FIGS. 1 and 2 is shown. In the embodiment shown, the post support device is Adjustable Guard Rail Saddle TG009 from Arcosa Shoring Products. It will be understood that any post support device configured to suitably receive the guardrail post and support the guardrail system by removably coupling to a wall element may be used.

In some embodiments the receptacle 410 is a pipe segment. In the embodiment shown, the pipe is approximately 6″ long. The locking mechanism 415 may be of any type suitable for fine adjustment of the leveling pad with respect to the leg 445. In the embodiment shown, a T-handle 430 is coupled to a threaded rod 420 which passes transversely through a lower portion of the spine 450 via a coupler with interior threads. The end of the threaded rod 420 is coupled to the leveling pad.

According to some embodiments, rotation of the T-handle 430 clockwise/counterclockwise extends the leveling pad towards the leg 445 (to secure the post support device to the wall element) or retracts the leveling pad away from the leg 445 (to remove the post support device from the wall element). The threaded bolt 425/washer/nut assemblies rigidly and removably attach the beam 440 to the cross-member 400 via the plurality of holes in the beam 440 and the cross-member 400 when the beam 440 is passed through the passage of the cross-member 400.

Cross-member 400 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2, 5, and 6. In one aspect, cross-member 400 includes cross-member passage 405.

Receptacle 410 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2, 5, and 6.

Locking mechanism 415 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2, 5, and 6. In one aspect, locking mechanism 415 includes threaded rod 420.

In one aspect, threaded rod 420 includes threaded bolt 425 and handle 430. Threaded bolt 425 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 5 and 6. According to some aspects, cap 435 is coupled to an end face of the second end.

Beam 440 and leg 445 are examples of, or include aspects of, the corresponding element described with reference to FIGS. 2, 5, and 6. Spine 450 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2 and 5.

According to some embodiments, clamping adjustment 455 is a device coupled to the spine 450 such that a bearing pad 460 of the fine adjustment device is extendable towards the leg 445 and retractable away from the leg 445, whereby a distance between the leg 445 and the bearing pad 460 is adjustable. In some aspects, the fine clamping adjustment 455 device further includes a threaded rod 420 coupled to the spine 450, where the bearing pad 460 is coupled to an end of the threaded rod 420 proximate to the leg 445.

In some aspects, the bearing pad 460 is coupled to the threaded rod 420 via a swivel mount. In some aspects, the threaded rod 420 further includes a handle 430 located at an end of the threaded rod 420 distal to the leg 445. In one embodiment, clamping adjustment 455 includes bearing pad 460.

FIG. 5 shows an example of a guardrail installation system according to aspects of the present disclosure. The example shown includes guardrail post 500, receptacle 505, adjustable locking clamp adjustable locking clamp 550, cross-member 510, beam 515, locking mechanism 520, spine 530, and leg 535.

Referring next to FIG. 5, the post support device comprising the adjustable locking clamp 550 and the receptacle 505 is shown receiving a guardrail post 500. A lower end of each guardrail post 500 of the guardrail slides into and is received by a corresponding receptacle 505 of the post support device.

Guardrail post 500 is an example of, or includes aspects of, the corresponding element described with reference to FIG. 6. Receptacle 505, cross-member 510, beam 515, and leg 535 are examples of, or includes aspects of, the corresponding element described with reference to FIGS. 2, 4, and 6.

Locking mechanism 520 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2, 4, and 6. In one embodiment, locking mechanism 520 includes threaded bolt 525.

Threaded bolt 525 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 4 and 6. Spine 530 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2 and 4.

Adjustable locking clamp 550 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2 and 6.

FIG. 6 shows an example of a post support device coupled to a wall element 635 and supporting a guardrail post 600 according to aspects of the present disclosure. The example shown includes guardrail post 600, receptacle 605, locking mechanism 610, beam 620, leg 625, cross-member 630, wall element 635, and adjustable locking clamp 650.

Referring next to FIG. 6, the post support device comprising the adjustable locking clamp 650 and the receptacle 605 is shown coupled to a wall and supporting the guardrail post 600. Coupling of the post support device to a wall element 635 is shown. The post support device has been adjusted by using the bolts to provide a clamping throat distance greater than the wall thickness but small enough that the post support device can be rigidly clamped to the wall element 635 by using the locking mechanism 610. The post support device is placed such that the beam 620 sits on top of the wall element 635 and the leg 625 extends downward on the far side of the wall. The T-handle of the locking mechanism 610 is rotated, extending the leveling plate until the wall element 635 is firmly and rigidly clamped between the leg 625 and the leveling pad, thus rigidly (yet removably) clamping the post support device to the wall element 635.

Guardrail post 600 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1, 2, and 5. Receptacle 605, beam 620, leg 625, and cross-member 630 are examples of, or includes aspects of, the corresponding element described with reference to FIGS. 2, 4, and 5.

Locking mechanism 610 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2, 4, and 5. In one embodiment, locking mechanism 610 includes threaded bolt 615.

Threaded bolt 615 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 4 and 5. Wall element 635 is an example of, or includes aspects of, the corresponding element described with reference to FIG. 7.

Adjustable locking clamp 650 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 2 and 5.

FIG. 7 shows an example of a guardrail system according to aspects of the present disclosure. The example shown includes guardrail 700, guardrail posts 705, post support device 715, wall element 710, first guardrail locking devices 720, second guardrail locking devices 725, and hinge pin 730.

Referring next to FIG. 7, guardrails 700 are shown installed on a wall element 710. Multiple guardrails can be installed side-by-side to form a continuous guardrail 700. For clarity, only two guardrails are shown, but it will be understood that any number of guardrails can be installed, as long as there is adequate space to install the corresponding post support brackets. The guardrails 700 shown have two guardrail posts 705, but a guardrail may have one, two, three, four, or more than four guardrail posts. The guardrails 700 shown have two horizontal rails, but the guardrails may have one, two, three, four, or more than four rails. Referring again to FIGS. 1-7, the guardrail system includes guardrails that are capable of withstanding higher force than conventional wood guardrails. The guardrails are sustainable and more cost effective in the long run. They are easier to assemble and can be painted for added visibility.

Each guardrail 700 includes the first guardrail locking device 720 on one side of the guardrail and a second guardrail locking device 725 on the opposite side of the guardrail, as shown in FIG. 7. The first guardrail locking device 720 of one guardrail is configured to lock to the second guardrail locking device 725 of the adjoining guardrail 700. In the embodiment shown, the first guardrail locking device 720 is a first part of a hinge, and the second guardrail locking device 725 is a second part of a hinge, whereby the locking devices 720725 together form a form a hinge knuckle. As shown in FIG. 7, the locking devices 720725 are removably coupled together by the hinge pin 730 being inserted into the hinge knuckle formed by the locking devices 720725.

According to some aspects, guardrail 700 is including a plurality of guardrail members, wherein the guardrail members include at least two guardrail posts and a guardrail rail connecting the at least two guardrail posts. In some aspects, the at least two guardrail posts consist of two guardrail posts. In some aspects, each guardrail member consists of a pipe section. In some aspects, each joint of the guardrail 700 includes coping of one of the guardrail members to fit over an exterior surface of another one of the guardrail members. In some aspects, each joint of the guardrail 700 is a welded joint directly welding a post to a rail.

Post support device 715 is an example of, or includes aspects of, the corresponding element described with reference to FIGS. 1 and 2. Wall element 710 is an example of, or includes aspects of, the corresponding element described with reference to FIG. 6.

FIG. 8 shows an example of a method 800 for installing a guardrail system on a wall according to aspects of the present disclosure.

At operation 805, a guardrail is provided including a plurality of guardrail members, wherein each guardrail member has a tubular cross-section, the plurality of guardrail members comprising two guardrail posts spaced a post-spacing distance apart.

At operation 810, a first post support device is clamped to a top end of the wall element

At operation 815, a second post support device is clamped to the top end of the wall element at the guardrail spacing distance from the first post support device

At operation 820, the guardrail is installed on the wall element by receiving of one guardrail post by the first post support device receptacle and receiving of the other guardrail post by the second support device receptacle

At operation 825, the method provides a leg rigidly coupled to and extending downward from the beam such that the leg and the spine form a clamping throat distance therebetween. In some cases, the operations of this step refer to a leg as described with reference to FIGS. 2, and 4-6.

FIG. 9 shows an example of a single-post guardrail system according to aspects of the present disclosure. The example shown includes guardrail 900, top rail 905, guardrail post 910, post support device 920, first guardrail locking device 922, and second guardrail locking device 930.

FIG. 9 shows an alternative embodiment guardrail system with a single-post guardrail. In this embodiment, a single piece forms the top rail 905, bottom rail, and sides of the guardrail by spanning over the top of the guardrail post 910, and on each side of the guardrail post 910 extending outward, then turning downward to form a vertical side portion of the guardrail, and then turning inward to terminate at the middle portion of the guardrail post. The first and second guardrail locking devices 925930 are the same as shown in FIG. 1.

The single post embodiment requires only a single wall element attachment, and can be installed where the opening is too small to allow for the wider two-post guardrail of FIG. 1. The single post embodiment can also be rotated with respect to the receptacle of the post support device 920.

In some embodiments the width of the single-post guardrail is less than 2 feet. In other embodiments the width of the single-post guardrail is less than 1 foot.

FIG. 10 shows an example of a method 1000 for installing a guardrail system on a wall according to aspects of the present disclosure.

At operation 1005, a guardrail is provided including a plurality of guardrail members, wherein each guardrail member has a tubular cross-section, the plurality of guardrail members comprising one guardrail post

At operation 1010, a first post support device is clamped to a top end of the wall element.

At operation 815, the guardrail is installed on the wall element by receiving of the one guardrail post by the first post support device receptacle.

FIG. 11 shows an example of a method 1100 for fabricating a guardrail according to aspects of the present disclosure. In some examples, these operations are performed manually or by an automated system, such as an automated manufacturing or installation system, e.g., a system employing robotics, including a processor executing a set of codes to control functional elements of an apparatus. Additionally or alternatively, certain processes are performed using special-purpose hardware. Generally, these operations are performed according to the methods and processes described in accordance with aspects of the present disclosure. In some cases, the operations described herein are composed of various substeps, or are performed in conjunction with other operations.

At operation 1105, first a guardrail post is fabricated from a first piece having a tubular cross-section wherein a top end of the first guardrail post is coped for receiving a member with an outside curvature.

At operation 1110, a second guardrail post is fabricated from a second piece having a tubular cross-section wherein a top end of the second guardrail post is coped for receiving the member with the outside curvature.

At operation 1115, a top rail is fabricated from a third piece having a tubular cross-section by bending the third piece in four locations, wherein each bend is an approximately 90 degree bend and in the same plane, such that the top rail includes a middle rail portion, a side rail portion bent downward from the middle rail portion on each side of the top rail, and a lower rail portion bent inward from the middle rail portion on each side of the top rail, terminating at an end of the top rail, wherein a first end of the top rail is coped to match an outside curvature of the first guardrail post and a second end of the top rail is coped to match an outside curvature of a second guardrail post.

At operation 1120, the coped end of the first guardrail post is welded to the middle rail portion of the top rail.

At operation 1125, the coped end of the second guardrail post is welded to the middle rail portion of the top rail such that the first guardrail post is spaced a post-spacing distance from the second guardrail post.

At operation 1130, the first end of the top rail is welded to the first guardrail post.

At operation 1135, the second end of the top rail is welded to the second guardrail post, such that a guardrail is formed with the top rail spanning over the top of each guardrail post and each end of the top rail extending inwards towards and is connected to a middle portion of the proximal guardrail post.

FIG. 12 shows an example of a method 1200 for additional fabrication operation performed on the guardrail fabricated in method 1100 according to aspects of the present disclosure. In some examples, these operations are performed manually or by an automated system, such as an automated manufacturing or installation system, e.g., a system employing robotics, including a processor executing a set of codes to control functional elements of an apparatus. Additionally or alternatively, certain processes are performed using special-purpose hardware. Generally, these operations are performed according to the methods and processes described in accordance with aspects of the present disclosure. In some cases, the operations described herein are composed of various substeps, or are performed in conjunction with other operations.

At operation 1205, a bottom rail is fabricated from a third piece having a tubular cross-section, wherein a first end of the bottom rail is coped for receiving the first guardrail post and a second end of the bottom rail is coped for receiving the second guardrail post;

At operation 1210, a second guardrail post is fabricated from a second piece having a tubular cross-section wherein a top end of the second guardrail post is coped for receiving the member with the outside curvature.

At operation 1215, welding the first end of the bottom rail to the first guardrail post;

At operation 1220, welding the second end of the bottom rail to the second guardrail post, such that when the bottom rail is welded to the guardrail posts the bottom rail is axially aligned with both ends of the top rail at the middle portion of the guardrail posts.

FIG. 13 shows an example of a method 1300 for fabricating a guardrail according to aspects of the present disclosure. In some examples, these operations are performed manually or by an automated system, such as an automated manufacturing or installation system, e.g., a system employing robotics, including a processor executing a set of codes to control functional elements of an apparatus. Additionally or alternatively, certain processes are performed using special-purpose hardware. Generally, these operations are performed according to the methods and processes described in accordance with aspects of the present disclosure. In some cases, the operations described herein are composed of various substeps, or are performed in conjunction with other operations.

At operation 1305, a first guardrail post is fabricated from a first piece having a tubular cross-section wherein a top end of the first guardrail post is coped for seating a member with an outside curvature.

At operation 1310, a top rail is fabricated from a second piece having a tubular cross-section by bending the second piece in four locations, wherein each bend is an approximately 90 degree bend and in the same plane, such that the top rail includes a middle rail portion, a side rail portion bent downward from the middle rail portion on each side of the top rail, and a lower rail portion bent inward from the middle rail portion on each side of the top rail, terminating at an end of the top rail, wherein a first end of the top rail is coped to match an outside curvature of the first guardrail post and a second end of the top rail is coped to match an outside curvature of the first guardrail post.

At operation 1315, the coped end of the first guardrail post is welded to the middle rail portion of the top rail such that the middle rail portion is seated in the coped end.

At operation 1320, the first end of the top rail is welded to the first guardrail post.

At operation 1325, the second end of the top rail is welded to the second guardrail post, such that a guardrail is formed with the top rail spanning over the top of each guardrail post and each end of the top rail axially aligned with the first guardrail post interposed between the top rail ends.

The description and drawings described herein represent example configurations and do not represent all the implementations within the scope of the claims. For example, the operations and steps may be rearranged, combined or otherwise modified. Also, structures and devices may be represented in the form of block diagrams to represent the relationship between components and avoid obscuring the described concepts. Similar components or features may have the same name but may have different reference numbers corresponding to different figures.

Some modifications to the disclosure may be readily apparent to those skilled in the art, and the principles defined herein may be applied to other variations without departing from the scope of the disclosure. Thus, the disclosure is not limited to the examples and designs described herein, but is to be accorded the broadest scope consistent with the principles and novel features disclosed herein.

In this disclosure and the following claims, the word “or” indicates an inclusive list such that, for example, the list of X, Y, or Z means X or Y or Z or XY or XZ or YZ or XYZ. Also, the phrase “based on” is not used to represent a closed set of conditions. For example, a step that is described as “based on condition A” may be based on both condition A and condition B. In other words, the phrase “based on” shall be construed to mean “based at least in part on.” Also, the words “a” or “an” indicate “at least one.”

While the invention herein disclosed has been described by means of specific embodiments, examples and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims.

GUARDRAIL APPARATUS AND SYSTEM

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CPC

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