FIELD OF THE DISCLOSURE
This disclosure relates to access systems, and particularly to systems designed to access undersurfaces and side surfaces of large stationary structures. More particularly, this disclosure relates to a monorail system which is used in combination with a scaffold structure and from which a further scaffold structure may be suspended and moved, relative to a structure being accessed, vertically and parallel with the monorail track.
BACKGROUND OF THE INVENTION
There are many instances in the building, repair and restoration industries where it is necessary to access side surfaces and undersurfaces of a structure being worked on and access to these surfaces from below (e.g., erecting standard scaffolding) is not practical or impossible. Some examples are bridges, and particularly arched bridges, for example, which span a gorge or river. It is oftentimes difficult to access the undersurfaces of these bridges because scaffolding cannot be built upward from the ground, and the presence of arches, which creates a surface of continually changing heights, makes access even more difficult. The same is true with certain side surfaces.
Suspended scaffolding is known and may be used in certain instances to access such side surfaces and undersurfaces. Suspended scaffolding comes with its own difficulties. For example, it may not be practical or possible to suspend scaffolding in a location from which workers are able to access the necessary surface. The length of a surface may also be a limiting factor. If the structure being accessed spans a great length, the amount of suspended scaffolding may require multiple rounds of assembly/disassembly to complete the entire job. Further, and particularly with arched structures, the suspended scaffolding may need to have multiple levels resulting in further complexity and time in assembly/disassembly.
Therefore, in view of the foregoing, it would be advantageous to provide a system or structure that addresses one or more of the above deficiencies or other problems.
SUMMARY
In accordance with at least some embodiments of the present disclosure, provided herein is a monorail assembly.
In accordance with at least some embodiments of the present disclosure, provided herein is a monorail system.
In accordance with at least some embodiments of the present disclosure, provided herein is a method of assessing a structure.
In an embodiment, the present disclosure provides a monorail assembly. In accordance with embodiments of the present disclosure, a monorail assembly comprises a first scaffold system comprising at least one framework member being an elongated structure having a bottom chord and a plurality of panel points along the bottom chord; at least one monorail beam; and at least one bracket structure configured to secure to the at least one framework member at or about at least two panel points and to the at least one monorail beam.
In an embodiment, the at least one monorail beam does not contact the at least one framework member when secured to the at least one bracket structure. In another embodiment, the monorail assembly further comprises at least one joist bracket which is connected to the at least one monorail beam and the at least one bracket structure. In still another embodiment, the monorail assembly further comprises at least one joist bracket and wherein the connection of the at least one monorail beam to the at least one framework member is accomplished by the connection of the at least one joist bracket and at least one bracket structure. In another embodiment, the monorail assembly further comprises at least one end stop secured to the at least one monorail beam.
In accordance with an embodiment, the monorail assembly further comprises at least two trolley structures slidingly secured to the first scaffold system and configured to secure a second scaffold system. In an embodiment, the at least two trolley structures are slidingly secured to the at least one elongated structure. In another embodiment, the first scaffold system comprises at least two framework members.
In an embodiment, the present disclosure provides a monorail system. IN accordance with embodiments of the present disclosure, a monorail system comprises a first scaffold system; a monorail assembly secured to the first scaffold system and comprising at least one monorail beam; and a second scaffold system suspended from the at least one monorail beam.
According to an embodiment, the second scaffold system moves both laterally along the at least one monorail beam and vertically with respect to the at least one monorail beam. In another embodiment, the first scaffold system is a suspended articulating scaffold system. In a further embodiment, the monorail assembly further comprises at least one bracket structure configured to secure to the first scaffold system. In yet another embodiment, the second scaffold system is a monorail car. In other embodiments, the second scaffold system is a suspension scaffold. In a further embodiment, the monorail assembly further includes at least two trolley structures slidingly secured to the first scaffold system.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1A is a side schematic view of a scaffold system containing a plurality of monorail systems in accordance with embodiments of the present disclosure;
FIG. 1B is a detailed view of callout 1B of FIG. 1A;
FIG. 2 is a side view of a monorail assembly secured to the underside of a scaffold system, in accordance with embodiments of the present disclosure;
FIG. 3A is a top perspective view of a joist bracket for use with a monorail assembly, in accordance with embodiments of the present disclosure;
FIG. 3B is an exploded view of the joist bracket of FIG. 3A;
FIG. 3C is a side perspective view of the assembled joist bracket of FIG. 3B;
FIG. 4A is a side view of a monorail beam for use with a monorail assembly, in accordance with embodiments of the present disclosure;
FIG. 4B is an end view of the monorail beam of FIG. 4A;
FIG. 5A is a side perspective view of a monorail beam and two monorail joining bracket assembly s, in accordance with embodiments of the present disclosure;
FIG. 5B illustrates a portion of FIG. 5A in further detail;
FIGS. 5C and 5D are exploded views illustrating the assembly of a monorail joining bracket assembly on a monorail beam, in accordance with embodiments of the present disclosure;
FIG. 5E is an end perspective view illustrating the assembled monorail joining bracket assembly of FIGS. 5C and 5D;
FIG. 6A is a side perspective view of an end stop for a monorail assembly, in accordance with embodiments of the present disclosure;
FIG. 6B is an exploded view of the end stop of FIG. 6A;
FIG. 6C is an end perspective view of the assembled end stop of FIG. 6A;
FIG. 7A is a top perspective view of a portion of a scaffold system with a joist bracket assembled and shown prior to attachment of a monorail beam, in accordance with embodiments of the present disclosure;
FIG. 7B is a top view of the embodiment of FIG. 7A with the monorail beam being positioned, in accordance with embodiments of the present disclosure;
FIG. 7C is a detailed top perspective view of a portion of the embodiment shown in FIG. 7A with the monorail beam in position and showing the attachment of the monorail beam to the joist bracket, in accordance with embodiments of the present disclosure;
FIG. 7D is a side view of the embodiment shown in FIG. 7C with the monorail beam connected to the joist bracket, in accordance with embodiments of the present disclosure;
FIG. 7E is a top perspective view illustrating the attachment of an end stop, in accordance with embodiments of the present disclosure;
FIG. 7F is a top perspective view of the embodiment shown in FIG. 7E with the end stop fully assembled;
FIG. 8A is a side view showing a monorail assembly secured to a portion of a suspended scaffold system, in accordance with embodiments of the present disclosure;
FIG. 8B is a bottom perspective view of the embodiment shown in FIG. 33A;
FIG. 8C is a side perspective view of the embodiment shown in 33A;
FIG. 9 is top perspective view of an interconnection structure for use in a suspended scaffold system, in accordance with the present disclosure;
FIG. 10 is top view of the interconnection structure of FIG. 9, in accordance with the present disclosure;
FIG. 11 is a side elevation view of the interconnection structure of FIG. 9, in accordance with the present disclosure;
FIG. 12 is bottom view of the interconnection structure of FIG. 9, in accordance with the present disclosure;
FIG. 13 is a top perspective view of an interconnection between an interconnection structure and joist for use in a suspended scaffold system, in accordance with the present disclosure;
FIG. 14A is an exploded top perspective view of the interconnection of FIG. 13, in accordance with the present disclosure;
FIG. 14B is a top perspective view of the view in FIG. 14A, in accordance with the present disclosure;
FIG. 15 is a top perspective view of a single unit of a suspended scaffold system, in accordance with embodiments of the present disclosure;
FIG. 16A is a top perspective view of an interconnection between a joist and deck support for a suspended scaffold system, in accordance with embodiments of the present disclosure;
FIG. 16B is a exploded reverse top perspective view of the interconnection of FIG. 16A, in accordance with embodiments of the present disclosure;
FIG. 16C is a close-up top perspective view of the interconnection of FIG. 16B, in accordance with embodiments of the present disclosure;
FIG. 17 is a top perspective view of a single unit of a suspended scaffold system, in accordance with embodiments of the present disclosure;
FIG. 18 is a top perspective view of a second embodiment of a single unit of a suspended scaffold system, in accordance with embodiments of the present disclosure;
FIG. 19A is a top perspective view of a joist, interconnection structure, and portion of a deck retainer assembly for use in a suspended scaffold system, in accordance with embodiments of the present disclosure;
FIG. 19B is an exploded close-up perspective view of the joist, interconnection structure, and deck retainer assembly of FIG. 19A, in accordance with embodiments of the present disclosure;
FIG. 19C is an end sectional view of a joist and a portion of a deck retainer assembly such as shown in FIG. 19A, in accordance with embodiments of the present disclosure;
FIG. 20 is a top perspective view of an embodiment of a work platform of a suspended scaffold system, in accordance with embodiments of the present disclosure;
FIG. 21 is a bottom perspective view of the embodiment shown in FIG. 20, in accordance with embodiments of the present disclosure;
FIG. 22 is a top perspective view of a portion of the work platform shown in FIG. 20, having a single unit of the work platform for a suspended scaffold system shown prior to articulation, in accordance with embodiments of the present disclosure;
FIG. 23 is a top perspective view of the embodiment in FIG. 22 with the single unit undergoing articulation, in accordance with embodiments of the present disclosure;
FIG. 24 is a top perspective view of the embodiment in FIG. 23 with the single unit undergoing further articulation, in accordance with embodiments of the present disclosure;
FIG. 25 is a top perspective view of the embodiment in FIG. 24 with the single unit undergoing further articulation, in accordance with embodiments of the present disclosure;
FIG. 26 is a top perspective view of the embodiment in FIG. 22 with the single unit having completed articulation, in accordance with embodiments of the present disclosure;
FIG. 27A is a top perspective view of a joist and interconnection structure subassembly for use in a suspended scaffold system, in accordance with embodiments of the present disclosure;
FIG. 27B is a top perspective view of a second embodiment of a joist and interconnection structure subassembly for use in a suspended scaffold system, in accordance with embodiments of the present disclosure;
FIG. 27C is a top perspective view of a third embodiment of a joist and interconnection structure subassembly for use in a suspended scaffold system, in accordance with embodiments of the present disclosure;
FIG. 27D is a top perspective view of a fourth embodiment of a joist and interconnection structure subassembly for use in a suspended scaffold system, in accordance with embodiments of the present disclosure;
FIG. 28A is a top view of an embodiment of a suspended scaffold system, in accordance with embodiments of the present disclosure;
FIG. 28B is a top view of a second embodiment of a suspended scaffold system, in accordance with embodiments of the present disclosure;
FIG. 29 is a sectional elevation view of a suspended scaffold system suspended from a structure, in accordance with embodiments of the present disclosure;
FIG. 30A is a top perspective view of an interface between an interconnection structure and a suspension connector for use with a suspended scaffold system, in accordance with embodiments of the present disclosure;
FIG. 30B is a close-up of the interface shown in FIG. 30A, in accordance with embodiments of the present disclosure;
FIG. 31A is a sectional elevation view of an interconnection structure, suspension connector and a structure attachment device for use with a suspended scaffold system, in accordance with embodiments of the present disclosure;
FIG. 31B is a close-up sectional elevation view of the interconnection between the interconnection structure and suspension connector of FIG. 31A, in accordance with embodiments of the present disclosure;
FIG. 32A is a top, perspective view of an auxiliary suspender mounting bracket for use with a suspended scaffold system, in accordance with embodiments of the present disclosure;
FIG. 32B is a plan view of the auxiliary suspender mounting bracket of FIG. 32A;
FIG. 32C is a front elevation view of the auxiliary suspender mounting bracket of FIG. 32A;
FIG. 32D is a side elevation view of the auxiliary suspender mounting bracket of FIG. 32A;
FIG. 33 is an elevation sectional view showing suspension of a work platform for a suspended scaffold system from a structure via an auxiliary suspender mounting bracket, in accordance with embodiments of the present disclosure;
FIG. 34A is an elevation view of an embodiment of a suspended scaffold system employed in relation to an arched bridge, in accordance with embodiments of the present disclosure;
FIG. 34B is an elevation view of a second embodiment of a suspended scaffold system employed in relation to an arched bridge, in accordance with embodiments of the present disclosure;
FIG. 34C is an elevation view of a third embodiment of a suspended scaffold system employed in relation to a structure, in accordance with embodiments of the present disclosure;
FIG. 35 is a side perspective view of a second embodiment of a suspended scaffold system employed in relation to a structure, in accordance with embodiments of the present disclosure;
FIG. 36 is a detailed view of callout 7 of FIG. 1A;
FIG. 37 is a cross-sectional view taken from A-A of FIG. 1A;
FIG. 38 is a cross-sectional view taken from B-B of FIG. 1A;
FIG. 39 is a detailed view of callout 2 of FIG. 37;
FIG. 40 is a detailed view of callout 3 of FIG. 37;
FIG. 41 is a detailed view of callout 4 of FIG. 37;
FIG. 42 is a detailed view of callout 5 of FIG. 37;
FIG. 43 is a detailed view of callout 6 of FIG. 38;
FIG. 44 is a detailed view of callout 1 of FIG. 1A;
FIG. 45 is a detailed view of callout 1 of FIG. 44; and
FIG. 46 is a cross-sectional view taken from C-C of FIG. 44; and
FIG. 47 is a cross-sectional view taken from D-D of FIG. 1A.
Although certain preferred embodiments of the present disclosure will be shown and described in detail, it should be understood that various changes and modifications may be made without departing from the scope of the appended claims. The scope of the present disclosure will in no way be limited to the number of constituting components, the materials thereof, the shapes thereof, the relative arrangement thereof, etc., and are disclosed simply as an example of an embodiment. The features and advantages of the present disclosure are illustrated in detail in the accompanying drawings, wherein like reference numerals refer to like elements throughout the drawings.
DETAILED DESCRIPTION
As a preface to the detailed description, it should be noted that, as used in this specification and the appended claims, the singular forms “a”, “an” and “the” include plural referents, unless the context clearly dictates otherwise.
Articulation, as used herein, is defined as the capability to swing, and/or rotate, about a pivot point or axis.
As used herein, the terms “single section,” “unit,” or “single unit,” when used in reference to a scaffold system, refer to a planar structure composed of at least three corners and the elongated members (e.g., joist, bars, framework, etc.) and other structures which support and define a flooring area. The terms “section” and/or “unit” can be used interchangeably. Moreover, it will be appreciated that adjacent sections or units of a scaffold system may share one or more components, e.g., two adjacent sections of a scaffold system may have a common corner or share a framework member.
FIG. 1A is a side schematic view of a plurality, specifically three, monorail systems 700 employed with respect to a structure 90. Specifically, shown in FIG. 1A is a scaffold system 100 containing a plurality of monorail assemblies 600 in accordance with embodiments of the present disclosure, and FIG. 1B is a detailed view of callout 1B of FIG. 1A. Shown in FIGS. 1A and 1B is structure 90, which in the present embodiment is an arched bridge, but in further embodiments may be any structure to be accessed. Each arch 91 of the bridge includes 3 distinct surfaces—two side surfaces 91a, 91b (not shown) and a lower (under) surface 91c. In order to access each of the three surfaces 91a, 91b, 91c, the bridge 90 includes four monorail assemblies 600, two on either side of the bridge 90. Each of the monorail assemblies 600 is secured to the under portion of a scaffold system 100, an exemplary embodiment of which is shown in FIG. 2.
The monorail assemblies 600 are used to suspend further scaffold systems 800. In the exemplary embodiment shown in FIGS. 1A-1B, suspended from the monorail assemblies 600 is a total of three scaffold systems—one to access each of the three surfaces 91a, 91b and 91c. To access the side surfaces 91a, 91b, a scaffold system is suspended from a single monorail assembly 600 on either side of the bridge 90. That is, each of the scaffold systems used to access the side surfaces 91a, 91b is suspended from a single monorail assembly 600. In contrast, the scaffold system used to access the underside surface 91c is suspended from two monorail assemblies 600 such that the scaffold system spans the width of the underside surface 91c and is supported on both ends.
Together, each monorail assembly (or monorail assemblies) 600, the scaffold system to which the monorail assembly (or assemblies) is (are) attached 100, and the scaffold system suspended from the monorail assembly (or assemblies) form a monorail system 700. Each monorail system 700 is operatively connected to a generator 720 to provide power to the monorail system 700. The generators 720 provide power to accomplish movement of the scaffold system 700 both along the monorail assembly (or assemblies) and vertically.
The monorail assembly 600 will not be described in further detail with reference to FIGS. 2-7F.
Monorail Assembly
FIG. 2 illustrates a monorail assembly 600. In the embodiment shown, the monorail assembly 600 is secured to under structures of a work platform system 100. The monorail assembly 600 includes joist brackets 605, monorail beams 630, monorail joining bracket assemblies 650 and end stops 680 (only one shown).
Joist Bracket FIGS. 3A-3C illustrate a joist bracket 605 in further detail. Each joist bracket 605 has two bracket plates 606. Each bracket plate 606 has a generally stepped configuration with a lower wall 607 generally perpendicular to a first midwall 608, a second midwall 609 generally perpendicular to the first midwall 608, and an upper wall 610 generally perpendicular to the second midwall 609. In the embodiment shown, the transitions 611 between the respective walls 607, 608, 609, 610 is rounded; however, in further embodiments, the transitions may be sharp or more gradual. The lower wall 607 and upper wall 610 each contain a plurality of openings 612, 614, respectively, therethrough, each of which is capable of receiving a bolt. As shown perhaps best in FIG. 3B, openings 614 are tunneled openings, that is, the openings have a flange around them on one side. The plates 606 each include a further plurality of openings 613, each opening of which extends through at least a portion of the upper wall 610 and first and second midwalls 608, 609. In the embodiment shown, each of the openings 613 of the further plurality of openings is squared.
Referring to FIG. 3B, specifically, when securing a joist bracket 605 to a scaffold frame member 30 of scaffold system 100, two bracket plates 606 are used. The bracket plates 606 are positioned on either side of the frame member and secured together using a plurality of bolts 615 and nuts 616.
In the embodiment shown, the scaffold frame member 30 has a structure similar to a truss having an upper chord 32 and a lower chord 33, with a number of diagonal support members 38. The point at which two diagonal support members 38 meet along a chord 32, 33 is a panel point 710. The joist bracket 605 is specifically designed to have a length which spans across at least two panel points 710, with each panel point 710 contained between the plates 606 being aligned with an opening 613. The upper walls 610 of the respective bracket plates 606 sandwich the diagonal support members 38, but do not press against or exert a force on the diagonal support members 38. The flanges of the tunneled openings 614 prevent the bracket plates 606 from tightening against the diagonal support members 38. Rather, the second midwall 609 sits on and is supported by the lower chord 33.
It will be appreciated that the exact dimensions and appearance of the bracket plates 606 and the joist bracket 605 overall may vary depending on the scaffold system with which the joist bracket 605 will be used. Specifically, the existence of panel points, distance between panel points, and shape of chords may all influence the specific design of the joist bracket 605.
Monorail Beam
FIGS. 4A and 4B illustrate an exemplary monorail beam 630. A monorail beam 630 is an I-beam having a central member 631 with flanges 632 projecting from length of the central member 631 in a generally perpendicular direction relative to the central member 631. The ends of the monorail beam 630 include a series of openings 635 which are used to secure various additional components of the monorail assembly 600 as described in further detail below.
Joining Bracket Assembly
To join monorail beams 630, a joining bracket assembly 650 is used. FIGS. 5A-5E illustrate an exemplary joining bracket assembly 650 used in the present disclosure. In short, a joining bracket assembly 650 engages at least two of the openings 635 on one end of a first monorail beam 630 and at least two openings 635 on a second adjacent monorail beam 630. The joining bracket assembly s 650 also secure a monorail beam 630 to the joist brackets 605.
In the embodiment shown in FIGS. 5A-5E, each joining bracket assembly 650 includes a side plate 651, a spacer plate 657 and a safety plate clamp 658. As shown in FIG. 5C, the side plate 651 as two portions—a first portion 652 which contacts the under surface of one of the flanges 632 of the monorail beam 630 and a second portion 653 which contacts the central member 631 of the monorail beam 630. The second portion 653 includes a first plurality of openings (not shown) and a second plurality of openings 642. When the side plate 651 is properly aligned with a monorail beam 630, the openings of the first plurality of openings are align with so as to be coaxial with at least two opening 635 of the monorail beam 630. Bolts 661, secured in place with nuts 661a pass through the coaxial openings to hold the side plate 651 to the monorail beam 630. As will be shown with respect to FIG. 7D, openings of the second plurality of openings 642 align with additional openings 635 on the monorail beam 630 and receive pins to further secure monorail beams 630 to one another.
When properly in position, the first portion 652 is against the understand of one of the flanges 632 of the monorail beam 630 with spacer 654 flush against the flange 632 of the monorail beam 630. It will be appreciate that spacer 655 will be likewise flush against the flange of a second adjacent monorail beam when the monorail beam 630 is connected to an adjacent monorail beam. A third spacer 656 is provided as a separate component on the side of the monorail beam 630 opposite the first portion 652. Each of the spacers 654, 655, 656 includes at least one opening 660, 667 and 668, respectively, therethrough which is configured to receive a bolt 670.
As shown perhaps best in FIG. 5E, the spacers 654, 655, 656 extend the width of the first portion 652 and raise the height of the first portion 652. The spacer plate 657 and safety plate clamp 658 then clamp around the upper flanges 632 of the monorail beam 630 to lock the joining bracket assembly 650 in position on the monorail beam 630. The spacer plate 657 is a generally planar, rectangular structure having an opening 663 through the ends which, when positioned with respect to a first portion 651, are coaxial with the at least one opening 660 and 668 of the spacer 654 and spacer 656, respectively.
The safety plate clamp 658 is likewise a generally planar, rectangular structure having an opening 665 through the ends and a flange extension 672. When positioned with respect to a first portion 651, the openings 665 are coaxial with the respective openings 663 and at least one opening 660 of the spacer plate 657, spacer 654 and spacer 656, respectively. Bolts 670 extend through the respective coaxial openings 667, 663 and 660 and are secured with a nut 662 to complete the joining bracket assembly 650.
It will be appreciated that the structure of the joining bracket assembly 650 creates a space between the top of the flanges 652 and the flange extension 672 of the safety plate clamp 658. As shown perhaps most clearly in FIG. 7C, the space receives the lower wall 607 of the joist bracket 605. When a joining bracket assembly 650 is positioned with respect to to joist bracket 605, one of the openings 612 of the lower wall 607 will be coaxial with the at least one opening 667 of spacer 655. A bolt secured through openings 612 and 667 secures the monorail bream 630 to the joist bracket 605 and therefore the scaffold system 100.
End Stop
FIGS. 6A-6C illustrate an end stop 680. End stop 680 has a structure very similar to the joining bracket assembly 650 and indeed reuses a number of components. In the exemplary embodiment shown, the end stop 680 includes a side plate 681, a spacer plate 687 and a safety plate clamp 688 having structures substantially the same as side plate 651, a spacer plate 657 and a safety plate clamp 658. The difference is that the joining bracket assembly 650 is secured to a portion of a monorail beam 630 while the end stop 680 itself includes a stop portion 690 which is essentially a portion of monorail beam 630′ having a terminal plate 691 to stop further travel of a structure along the monorail beam 630′.
FIGS. 7A-7F illustrate assembly steps for an exemplary monorail assembly 600. As shown in FIGS. 7A and 7B, a scaffold system 100 is in position with joist brackets 605a, 605b positioned opposite one another on opposing framework pieces. A monorail beam 630 is being lowered into positon, such as by a crane. Turning now to FIG. 7C, once the monorail beam 630 is in position, with the lower wall 607 between the flange extension 672 and the flanges 632 of the monorail beam, bolts 670 secure the monorail beam 630 to the joist bracket 605 and therefore scaffold frame member 30. The monorail beam 630 is connected in the same manner to both joist brackets 605a and 605b.
As shown in FIG. 7D, two adjacent monorail beams 630 are in position relative to one another and secured using bolts 661 and pins 741 are inserted through the second plurality of openings 642 of the second portion 653 to further secure adjacent monorail beams 630 to one another.
As shown in FIGS. 7E and 7F, once the final monorail beam 630 is in position, an end stop 680 is secured to the end of the final monorail beam 630 using the same method to secure adjacent monorail beams 630 to one another.
Scaffold System/Monorail Assembly
FIGS. 8A-8C show the connection between a scaffold system 100 and monorail assembly 600 in further detail. The joist brackets 605 are shown secured to scaffold frame members 30 spanning two panel points 710 each. The second midwalls 609 of the plates 606 rests on the lower chord 33 of the scaffold frame members 30. The individual monorail beams 630 are connected to one another using joining bracket assembly 650.
From FIGS. 8A-8C, it will be appreciated that adjacent monorail beams 630 are secured to one another by two joining bracket assembly 650 arranged as mirror images of one another. That is, for a given monorail beam joint, a first joining bracket assembly 650 is positioned with respect to the monorail beams 630 with its side plate 651 against a first side of the central member 631. A second joining bracket assembly 650 is positioned with respect to the monorail beams 630 with its side plate 651 against the other side of the central member 631. As a result, the side plates 651 share a common set of bolts 661 and pins 741.
Exemplary Scaffold Systems
Suspended Articulating Scaffold System
In the embodiments shown herein, the monorail assembly 600 is shown secured to an exemplary scaffold system which includes scaffold frame members 30 which have upper and lower chords 32, 33. FIGS. 9-34C further describe an exemplary scaffold system which includes such scaffold frame members which is a suspended, articulating scaffold system. However, in further embodiments, it will be appreciated that the monorail assembly 600 may be secured to any style scaffold system, more preferably any style suspended scaffold system.
Interconnection Structure
FIG. 9 illustrates an interconnection structure 10 for a suspended, articulating scaffold system. The interconnection structure 10 is configured so that, when attached to a scaffold frame member 30 (see FIG. 13), allows for articulation of both the interconnection structure 10 and the scaffold frame member 30. An interconnection structure is any structure which connects one or more joist or other elongated structural member, such as a node, hinge, pivot, post, column, center, shaft, spindle, or the like.
The interconnection structure 10 includes a top element 11 and a bottom element 12 spaced at distal ends of a middle section 15. The top element 11 and bottom element 12 may be substantially planar in configuration, as well as, being parallel to each other. The top element 11 and bottom element 12, in the embodiment shown, are octagonal in plan. In other embodiments, the top element 11 and bottom element 12 can have other shapes, such as square, polygonal, circular, etc.
The middle section 15 may be a cylindrical section wherein a longitudinal axis of the middle section 15 is normal to the planes of the top element 11 and bottom element 12. In the embodiment shown, the middle section 15 is a right circular cylinder. However, in alternative embodiments, the middle section 15 can have different shape, such as any prism having a polygonal face. In FIG. 9, a lower portion of the middle section 15 is removed for clarity purposes to show that the middle section 15 is hollow.
There are a plurality of openings 13, 14, extending through both the top element 11 and bottom element 12, respectively. The plurality of openings 13 (e.g., 13A, 13B, 13C, 13D, 13E, 13F, 13G, 13H) are interspersed on the top element 11 so as to offer various locations for connecting to one, or more, scaffold frame members 30 (see e.g., FIG. 13). The plurality of openings 14 (e.g., 14A, 14B, 14C, 14D, 14E, 14F, 14G, 14H) are similarly spaced on the bottom element 12 so that respective openings (e.g., 13A and 14A) are coaxial.
At the center of the top element 11 is a center opening 16. In an embodiment, the center opening 16 receives a suspension connector 80 (see e.g., FIGS. 29-33). In other embodiments, the center opening 16 receives a vertical support member 75 (see e.g., FIG. 29). The center opening 16 may be generally cruciform in configuration due to its center opening area 19 with four slots 17 (e.g., 17A, 17B, 17C, 17D) extending therefrom. Transverse to each of the four slots 17A, 17B, 17C, 17D, and interconnected thereto, are a series of cross slots 18A, 18B, 18C, 18D, whose utility will be apparent as discussed below. For added strength a second reinforcing plate 20 is added to the underside of the top element 11 wherein openings on the reinforcing plate 20 correspond to the center opening 16 configuration and all the ancillary openings thereto (17, 18, 19). A handle 22 is optionally added to the side of the middle section 15.
FIGS. 10, 11, and 12 show the top, side, and bottom view of the same embodiment of the interconnection structure 10 depicted in FIG. 2. FIG. 5 shows inter alia a bottom opening 23 on the bottom element 12. In an embodiment, the bottom opening 23 receives a vertical support member (see e.g., FIG. 29). The bottom face of the reinforcing plate 20 can be seen within the bottom opening 23. Attached to the reinforcing plate 20 and the interior face of the middle section 15 are a plurality of gussets 25 that provide added support to the interconnection structure 10.
Scaffold Frame Member
FIG. 13 depicts a top perspective view of the interconnection between a single interconnection structure 10 and a single scaffold frame member 30, while FIGS. 14A and 14B shows an exploded close-up view, and a regular perspective close-up view, respectively, of a typical connection detail between the interconnection structure 10 and scaffold frame member 30. When used in a suspended, articulating scaffold system, a scaffold frame member 30 is referred to as a joist 30.
The joist 30 includes an upper element 32 and a bottom element 33. Interspersed between elements 32, 33 are a plurality of diagonal support members 38. Each element 32, 33 is made of two L-shaped pieces of angle iron 39A, 39B. Elements 32, 33 typically may be identical in construction, with the exception being upper element 32 includes connector holes 54A, 54B at its midspan (See e.g., FIGS. 16A, 16B). The joist 30 includes a first end 31A and a second end 31B. At either end 31A, 31B of both the upper element 32 and bottom element 33 extends an upper connecting flange 35 and a lower connecting flange 36. Through both upper and lower connection flanges 35, 36 are connecting holes 37. Thus, there are four upper connecting flanges 35A, 35B, 35C, 35D; four lower connecting flanges 36A, 36B, 36C, 36D. Thus, at a first end 31A, extending from the upper element 32, is an upper connection flange 35A and lower connection flange 36A, with a connecting hole 37A therethrough. Similarly, at the second end 31B of the upper element 32, extends an upper connection flange 35B and lower connection flange 36B, with a connecting hole 37B therethrough. Continuing, at the first end 31A of the lower element 33 extends an upper connection flange 35D and lower connection flange 36D. Through these connection flanges 35D, 36D are a connecting hole 37D. At the second end 31B of the joist 30 extending from the lower element 33 is an upper connection flange 35C and lower connection flange 36C with a connecting hole 37C therethrough.
Interior to each of the connector holes 37A, 37B, 37C, 37D are additional locking holes 360A, 360B, 360C, 360D also located on the connection flanges 35A, 35B, 35C, 35D.
As FIGS. 14A and 14B depict in further clarity, a pin 40 may be placed through the connecting holes 37 any two corresponding top and bottom openings 13, 14 of the interconnection structure 10. In this manner, the joist 30 can be connected in a virtually limitless number of ways, and angles, to the interconnection structure 10. For example, a pin 40 may be placed in through an upper connection flange 35A; through an opening 13A; through a lower connection flange 36A (all of the first end 31A of the upper element 32); through an upper connection flange 35D; through an opening 14A; and, then through the lower connection flange 36D. In this scenario, the pin 40 further threads through connecting holes 37A and 37D. The pin 40 includes two roll pins 42 at its upper end. The lower of the two roll pins 42 acts as a stop, thereby preventing the pin 40 from slipping all the way through the joist 30 and interconnection structure 10. The upper roll pin 42 acts as a finger hold to allow easy purchase and removal of the pin 40 from the joist 30 and interconnection structure 10.
The design of these various parts is such that free rotation of both the joist 30 and interconnection structure 10 is allowed, even while the joist 30 and interconnection structure 10 are connected together. Rotational arrow R1 show the rotation of the joist 30, while rotational arrow R2 shows the rotation of the interconnection structure 10. These rotational capabilities of the joist 30 and interconnection structure 10 provide, in part, the articulating capability of the present invention.
While free rotation of a joist 30 and interconnection structure 10 is allowed, such free rotation is restricted when a section or unit of a modular space frame support system is assembled and ready for use. In an embodiment, free rotation is restricted by at least one of: i) an additional (second) pin that is to be located proximate a perimeter of the at least one interconnection structure; and ii) at least a portion of a work platform when the platform is positioned with respect to the interconnection structures and joists in an extended position.
In the particular embodiment shown, a second optional locking pin 40B may be added through the locking holes 360A, 360C, 360C, 360D at the end of joist 30 in order to lock the joist 30 to prevent articulation, if so desired. The locking pin 40B abuts a groove 24 on the interconnection structure 10. The grooves are situated on both the top element 11 and bottom element 12. Similarly, the locking pin 40B can include additional two roll pins 42 as does the pin 40.
It should be apparent to one skilled in the art that, while the joist 30 depicted in the figures is made of particular shaped elements, there are other embodiments that provide the aspects of the present invention. A joist is any elongate structural member adapted for bearing or supporting a load, such as a bar joist, truss, shaped-steel (i.e., I-beam, C-beam, etc.), or the like. For example, the joist 30 in the figures may commonly be called a bar joist, or open-web beam or joist. The joist 30 could also be made of shaped steel (e.g., wide flange elements, narrow flange members, etc.), or other suitable shapes and materials.
The assembly of interconnection structures 10 and joists 30 to form a section or unit 115 of a modular space frame support system 100 is discussed in further detail below.
FIG. 15 depicts a single section or unit 115 of a modular space frame support system 100 made using interconnection structures 10 and joists 30. Note that four interconnection structures 10A, 10B, 10C, 10D are interconnected with four joists 30A, 30B, 30C, 30D. FIG. 15 shows the single frame unit 115 that is square in plan. It should be apparent to one skilled in the art, that other shapes and configurations can be made. By varying the lengths of joists 30, for example, other shapes can be made. For example, a frame unit 115 that is rectangular can be constructed. Also, by attaching joists 30 to various openings 13, 14 of the interconnection structure 10, various angles at which the joists 30 interconnect with the interconnection structure 10 can be achieved. For example, a frame unit 115 that is triangular in plan (not shown) may be constructed. Thus, by changing joist 30 lengths (See e.g., FIGS. 27A-27D) and/or changing the angle(s) at which the joists 30 extend from the interconnection structure 10, virtually any shape and size frame unit 115, and resulting modular space frame support system 100 and work platform systems 200 may be constructed. Further, different shape, size, and configuration of frame sections or units 115 can be joined and abutted with each other, so that the modular space frame support system design, and work platform system design, is virtually completely customizable. This adaptability of the modular space frame support system 100 provides a convenient way to gain access to virtually any shape work area required in construction.
FIGS. 16A, 16B, and 16C depict various views, and close-up views of the interconnection between a middle support deck joist 52 and the joist 30. The middle support deck joist 52 provides added support to support platforms 50 (see e.g., FIG. 17) and may span between two joists 30. At either end of the middle support deck joist 52 is a pin 53 which communicates with a corresponding hole 54 on the upper portion of the joist 30. For example, FIG. 16B depicts an exploded view of the interconnection, wherein pin 53 will go in hole 54A. In this manner, movement (both lateral and axial) of the middle support deck joist 52 is minimized.
FIG. 17 shows the embodiment of single frame section or unit 115 from FIG. 15 wherein a platform 50A has been placed on the single frame unit 115 thus transforming the single frame unit 115 into a single unit of a work platform system 200. The platform 50A rests, in this embodiment, on the middle support deck joist 52A and on the joists 30A, 30B, 30D. The edges of the platform 50A may rest on the top of the middle support deck joist 52 and the angle iron 39A, 39B on the top of the applicable joists 30A, 30B, 30D. The configuration of the top of the middle support deck joist 52 and the angle iron 39A, 39B is such that vertical and horizontal movement of the platform 50A is avoided. The work platform 50 typically is sized to be a 4″×8′ piece of material. The work platform 50A may include a wood panel 51A, for example. Suitable work platform 50 may be made from metal (e.g., steel, aluminum, etc.), wood, plastic, composite, or other suitable materials. Similarly, the work platform 50 may be made of items that are solid, corrugated, grated, smooth, or other suitable configurations. For example, the work platform 50 may be wood sheeting, plywood, roof decking material, metal on a frame, grating, steel sheeting, and the like. Thus, after placing a first work platform 50A on the unit 115 of the modular space frame support system 100, an installer may continue in this manner and place additional multiple work platforms 50A, 50B, such as shown in FIG. 18, so that an entire upper frame 110 and/or lower frame 120 is covered with wood platforms 51A, 51B so that a complete work platform system 200 is created.
FIGS. 19A, 19B, and 19C show various close-up views of an additional, optional feature that can be used with a modular space frame support system 100 to form a work platform system 200. A deck retainer plate 60 may be placed over the spacing between the multiple work platforms 50. The deck retainer plate 60 may include a plurality of holes 62 so that a plurality of deck retainer bolts 61 may adhere the deck retainer plate 60 to the joist 30. The deck retainer plate 60 is one way in which to secure work platforms 50 to the modular space frame support system 100.
As FIGS. 20 and 21 depict, there is virtually no limit as to the size and shape of the modular space frame support system 100 and work platform system 200 that can be made in accordance with the present disclosure. FIGS. 20 and 21 show top and bottom perspective views, respectively, of one large rectangular embodiment of a single level of modular space frame support system 100 with work platforms 50 in place to make a work platform system 200.
As stated above, one deficiency of numerous existing work platforms are their inability to be installed in situ and also their inability to be relocated, extended, or removed, while a portion of the work platform is already installed in place. The present disclosure overcomes this deficiency. That is, the modular space frame support system and resulting work platform system allows for a worker, or workers, to add on additional sections of a modular space frame support system 100 (and, ultimately, work platform system 200) while this worker(s) is physically on an existing installed portion or unit of a modular space frame support system and/or work platform system. That is the worker(s) can extend, relocate, or remove a portion of a work platform system 200 and/or modular space frame support system 100 with only the need of hand tools. No mechanical tools, hoists, cranes, or other equipment is required to add to, subtract from, or relocate the modular space frame support system 100. This advantage, thus, offers savings in labor, time, and equipment.
For as FIGS. 22 through 26 depict the gradual articulation of just one section or unit of a single section or unit 115 of a modular space frame support system 100, when made using interconnection structures 10 and joists 30, into place. This can be readily accomplished by one, or two, workers by simply placing sequentially an additional joist 30D off of an existing interconnection structure 10A. Then a “new” interconnection structure 10D is connected to the first joist 30D. A second additional joist 30E is connected to the interconnection structure 30D. Further, another interconnection structure 10E and joist 30F are connected so that the final joist 30F is connected back to an existing interconnection structure 10B. In this manner, a worker(s) can install a new section or unit of a modular space frame support system (e.g., made up of “new” interconnection structures 10D, 10E and “new” joists 30D, 30E, 30F) off of an existing section of a modular space frame support system (e.g., made up of inter alia hubs 10Q, 10B, 10C and joists 30A, 30B). The worker(s) can install new, or relocate, sections or units of the modular space frame support system 100 while the worker remains on existing sections of work platform 50. That is, additional lift equipment, machinery is not required to install, relocate, or remove the additional units or sections of a modular space frame support system when made using interconnection structures 10 and joists 30.
Further, the installing worker(s) need not extend beyond the existing installed frame unit 115 or, they need only extend barely beyond the installed frame unit 115. For example, as shown in FIG. 22, the installer(s) can be on the existing work platforms 50A, 50B, 50C, 50D when relocating, or installing, the next section(s) of the modular space frame support system 100.
As FIGS. 23 through 25 clearly show via the motion arrows “M”, that by a combination of rotation of the new joists 30D, 30E, 30F and new interconnection structures 10D, 10E, that the new section or unit 115 of the modular space frame support system 100 is able to move and rotate into its final requisite location. That is, units of the modular space frame support system 100 articulate into place. Further, the articulation can be initiated and stopped (and even reversed) by an installer(s) while the installer(s) remains on the pre-existing frame units and/or work platform systems. Although not shown, additional supplemental devices to aid in the articulation (e.g., motors, hand tools, mechanical tools, hydraulics, etc.) can be used.
FIG. 26 shows a new section or units 115 of a modular space frame support system 100 articulated into place, prior to the installation of support platform(s) 50 and any other pieces, as discussed herein. The removal of a portion of the modular space frame support system 100 can essentially be done by reversing the aforementioned steps.
While the individual sections or units 115 of the modular space frame support system 100 (and, ultimately, work platform support system 200) described with reference to FIGS. 15-26 are square, that is, each individual section or unit 115 is made of four interconnection structures 10 and four joists 30, as mentioned above, in some embodiments the individual units 115 of the modular space frame support system 100 may take different geometries and shapes. For example, FIGS. 27A, 27B, 27C, and 27D show various embodiments of a joist 30 and interconnection structure 10 configuration. For example, FIG. 27D shows a “standard” length joist 30A (e.g., 8 foot nominal length) with two interconnection structures 10A, 10B. This “standard” length joist 30A could be termed a “6/6 unit”. FIG. 27C shows two joists 30A, 30B of equal length connected to interconnection structures 10A, 10B, 10C. The joists 30A, 30B in FIG. 27C, being half the length, each of the length of the joist 30A in FIG. 20D, may be termed a “3/6 unit” in that they are half the length of the aforementioned “6/6 unit”. Similarly, two unequal length joists 30A, 30B are depicted in FIG. 27B, and can be termed a “2/6 unit” and a “4/6 unit”, respectively. This is because the “2/6 unit” is approximately one third the length of a “standard” “6/6 unit” joist as shown in FIG. 27D, as is the “4/6 unit” is approximately two thirds the length of the “6/6 unit”. The same system is shown in FIG. 27A, wherein the first joist 30A is termed a “1/6 unit” and the second joist 30B is termed a “5/6 unit”. As stated above, by using different lengths of joist 30, and by extending joists 30 from interconnection structures 10 at different angles, one can obtain a nearly infinite variety of configurations and footprints of the modular space frame support system 100 and resulting work platform system 200. This variety, for example, allows the installer to set up the modular space frame support system 100 and work platform system 200 around various obstacles (e.g., columns, piers, abutments, etc.) and structures. The variety allows the installer to create numerous shapes to the work platform system beyond just a rectangle.
With reference to the teachings herein, including at least FIGS. 14A, 17 and 22-26, it is apparent that at least one of the joists is to be connected with at least one of the interconnection structures using a pin to provide free rotation of the at least one joist with respect to the at least one interconnection structure about the pin. Moreover, it is apparent that the free rotation is restricted by at least one of: i) an additional pin that is to be located proximate a perimeter of the at least one interconnection structure; and ii) at least a portion of a work platform when the platform is positioned with respect to the interconnection structures and the joists in the final position.
FIGS. 28A and 28B depict the plan view of just two embodiments of the invention. In these figures it can be seen that the work platform support system 100 is capable of various horizontal alignments. For example, FIG. 28A shows 8 foot length joists 30 interconnected with a plurality of hubs 10. Due to spacing between the pin 40 and hub 10, some flexibility is provided in the system 100 so that the system 100 can be curved, or “racked”, in the horizontal direction. This can help allow the system 100 to be installed around structures. FIG. 28B depicts a system 100 that is angled. For example, the joists 30C connected to hub 10C, can be shorter than joists 30B connected to hub 101B. Joists 30B, in turn, are shorter than joists 30A, which are connected to hub 10A. In this fashion, by using joists 30A, 30B, 30C of different length and/or altering the angle at which a joist 30 is connected to a hub 10, systems 100 that are angled, as in FIG. 28B can be configured. Similarly, this allows the system 100 to be installed, for example, around various impediments, structures, and the like.
FIG. 29 shows an elevation sectional view of one embodiment wherein a support system 100 and work platform system 120 are attached, via a suspension connector 80, to a structure 90. The structure 90 in this embodiment is a bridge 90. On the underside of the bridge 90 are a plurality of beams 92A series of suspension connectors 80, in this embodiment high strength chains, are attached to several of the beams 92 via structure attachment device 82, in this embodiment standard beam clamps. At the perimeter of the work platform system 120 are a plurality of railing standards 85, thereby creating a railing system around the work platform system 120. The plurality of chains 80 are attached to various hubs 10 in the support system 100 thereby providing structural connection to the bridge 90. In this manner, a work platform system 120 and support system 100 can be fully suspended from a suitable structure 90. Note that each hub 10 does not necessarily require a suspension connector 80 to be connected to the structure 90. For example, there is no suspension connector 80 connecting hub 10X to beam 92X. This may be because hub 10A does not line up underneath beam 92X or other suitable suspension point, and thus, using a chain 80 in that location is either not possible, or not desirable.
The suspension connector 80 may be any suitable support mechanism that can support both the work platform system 120, and all its ancillary dead loads, plus any intended live load that is placed upon the work platform system 120. In fact, the work platform system 120 may support its own weight plus at least four times the intended live load that is to be placed on the work platform system 120. Similarly, the suspension connector 80 is also suitable to support its own weight plus at least four times the intended live load placed on it. The suspension connector 80 may be a high-strength chain, cable, or the like. For example, one suitable suspension connector 80 is ⅜″ grade 100, heat-treated alloy chain.
The suspension connector 80 is attached to a beam clamp 82 which is further attached to a plurality of elements 92 on the underside of a structure 90. The structure 90 may be a bridge, viaduct, ceiling structure of a building, or the like. Similarly, the elements 92 which the suspension connector 80 are attached to may be beams, joists, or any other suitable structural element of the structure 90. Instead of beam clamps 82, other suitable structure attachment devices 82 may be used.
FIGS. 30A, 30B, 31A, 31B all depict various views of the interconnection between the suspension connector 80 (e.g., chain, cable, etc.) and the hub 10. In the embodiment shown, a free end of the chain 80 (i.e., end distal to structure 90) is placed through the center opening area 19 of the top element 11 of the hub 10. The chain 80 is then slid over and in to one of the four slots 17 (e.g., 17A). Once the chain 80 is place within slot 17A, a chain retainer pin 200 is placed in the adjacent transverse slot 18A so that the chain 80 kept retained in the distal end of slot 17A. The chain 80 and slot 17A are sized and configured so that upon proper placement of the keeper pin 200 with in the transverse slot 18A, the chain 80 is effectively locked to the hub 10 and is unable to slip, vertically or horizontally, from its position in 17A. This locking system effectively fixes the hub 10 to the chain 80. As an added safety check, a zip tie 201 may be placed between a hole 202 in the chain retainer pin 200 and an adjacent link in the chain 80. This further provides a visual aid to the installer to ensure that the chain retainer pin 200 has been installed.
An alternative device for connecting a suspension connector 80 to the work platform support system 100 is an auxiliary suspender mounting bracket 300. The auxiliary mounting bracket 300 is typically used when a particular hub 10 cannot be accessed for connection with a suspension connector 80. As the various FIGS. 32A, 32B, 32C, and 32D depict, one embodiment of the auxiliary suspender mounting bracket 300 includes two opposing and parallel flanges 303. Spanning the flanges 303 is an interconnecting tube 304 and a base plate 302. Through the base plate 302 are a plurality amounting holes 305. The auxiliary suspender mounting bracket 300 can be used in lieu of, or in addition to, the hub 10 for a suspension point. The bracket 300 allows a suspension connector 80 to be connected to the system 100 at locations other than a hub 10.
For example, FIG. 33 depicts a scenario that may typically be encountered when installing a work platform system 120. Note that FIG. 33 is not drawn to scale. One or more obstructions 95A may be located on the underside of the structure 90, or between the structure 90 and the work platform system 120. These obstruction(s) 95A may be man-made, or natural. For example, the obstructions 95A may be concrete beams, box-beams, inadequately sized framework, ductwork, lighting, finished surfaces, and the like. The obstructions 95A are such that a particular hub 10B is not practical, or possible, as a connecting point for the system 120 to a suspension connector 80. In this case, one or more auxiliary suspender mounting brackets 300 may be attached to a joist 30. High strength bolts (not shown) may be passed through the mounting holes 305 and then through holes on an upper element 32 and connected to bolts below the upper element 32. (See for similar connection detail the connection of plate 60 in FIG. 19B). The suspension connector 80 (e.g., chain) may be connected, via a beam clamp 82, to a beam 92 that is on the underside of the structure 90.
As shown in FIG. 33, obstruction 95B is directly vertically over hub 10B, thereby rendering hub 10B inadequate for a suspension point. Thus, a bracket 300 can be attached to a joist 30 adjacent to hub 10B, thereby allowing a suspension connector 80 to get proper attachment to a nearby beam 92. The angle, Φ, between the suspension connector 80 and vertical, denoted by V, allows for the suspension connector 80 to be either non-vertical, or slightly off of vertical.
FIGS. 34A, 34B, and 34C show elevation views of various embodiments wherein the vertical flexibility of the present invention is apparent. For example, FIG. 34A shows a portion of a work platform system 120 suspended from the non-flat underside of a structure 90 (e.g., arched bridge). The suspension connector 80 and other connection details are not shown for ease of illustration. There is flexibility, due to the design, in the interconnections between hub 10 and joist 30. This flexibility allows for some bendability in the vertical direction (See e.g., FIG. 34A). This allows the system 120, for example, to parallel, or “mirror”, the underside of a curved, arched bridge.
Alternatively, should the curvature of the supporting structure 90 be even greater, a configuration such as shown in FIG. 34B can be installed. That is multiple portions of the system 120 are not co-planar, but rather stepped, or tiered. If required, various suspension connectors 80 may be installed of such length so that multiple hubs 10A, 10B may be installed to the same suspension connector 80. As discussed above, the suspension connector 80 may be connected to a slot 17 of the upper hub 10A, then passed through the bottom opening 23 of the upper hub 10A and then connected also to a slot 17 of the lower hub 10B (See e.g., FIGS. 30A, 30B).
As FIG. 34C shows another configuration of the present invention is the capability to install the system 120 in a multi-level configuration. For example, where work perhaps needs to be done on a vertical structure 99 (e.g., bridge pier), at least two systems 120A, 120B may be installed. Similar to the connection scenario used in FIG. 34B (above), suspension connector 80 can, again, be of suitable length so as to pass from hubs 10A on the upper system 120 on to, and also connect up to, the hubs 10B on the lower system 120. In this manner, multiple levels of system 120 may be installed in a vertical orientation
Suspension Scaffold
In the embodiments shown herein, a further scaffold system 800 is shown in use as a monorail car which is moveably attached to the monorail assemblies 600, and the further scaffold system is a suspension scaffold system. FIG. 35 illustrates an exemplary suspension scaffold system. It will be appreciated, however, the in further embodiments, the monorail car 800 may made of any form of scaffolding system, and preferably any form of suspended scaffold system, including a suspended articulating scaffold system as described above. Further, a “further scaffold system, “second scaffold system,” and “monorail car” may be used interchangeably herein.
In the embodiment shown in FIG. 35, the suspension scaffold system 800 has a platform 810 formed from a frame 815 which supports flooring 820. A series of braced railing members at least partially surround the platform.
Additional Components
The scaffold systems 100, 800 used in combination with monorail assemblies of the present disclosure may include further additional components.
For example, in some embodiments, railings, toe boards, tarps, sheets, gates, ladders, doors/doorways, wheels, bumpers, and other accessories may be used in combination with any scaffold system disclosed herein.
Monorail System
Referring again to FIGS. 1A and 1B, as well as FIGS. 36-46, shown are multiple embodiments of monorail systems 700. Each monorail system 700 includes a first scaffold system 100, a monorail assembly 600 connected to the first scaffold system 100, and a monorail car 800 made of a second scaffold system. Specifically, in the embodiment shown in FIGS. 1A, 1B and 36-46 there are three monorail systems 700. A first monorail system 700a includes a single monorail assembly 600a connected to the scaffold system 100a with a single monorail car 800a positioned on the outside of the structure 90. A second monorail system 700b is located on the opposite side of the structure 90 and includes a single monorail assembly 600b connected to the scaffold system 100b with a single monorail car 800b positioned outside the structure 90. A third monorail system 700c includes two monorail assemblies 600c, 600d connected to scaffold system 100a and 100b, respectively, with a single monorail car 800c extending under the structure 90 with a first end of the monorail car 800c operatively coupled with the first monorail assembly 600c and a second end of the monorail car 800c operatively coupled with the second monorail assembly 600d.
Generators 720 located on the structure 90 or otherwise apart from the monorail systems 700 provide power to the monorail cars 800 to effectuate their movement both along the respective monorail(s) and vertically.
The monorail systems 700a, 700b, 700c will now be explained in further detail.
FIG. 36 is a detailed view of callout 7 of FIG. 1A and again shows the connection of monorail beams 630 to each other and to a scaffold system 100.
FIG. 37 is a cross-sectional view taken from A-A of FIG. 1A and illustrates the third monorail system 700c. In the embodiment shown, two scaffold systems 100a, 100b are provided. Each scaffold system 100a, 100b is shown as a suspended articulating scaffold system as described above and made of a plurality of interconnection structures 10 and joists 30. The scaffold systems 100a, 100b are connected to the structure both from above so as to be suspended from the structure 90 and at the side closest to the structure 90.
FIG. 39 is a detailed view of callout 2 of FIG. 37 and shows the connection of the scaffold system 100 to the structure 90 above. Specifically, a concrete anchor 830, such as a threaded rod, is inserted into the underside of the structure 90. A rotating suspension point, such as that described in co-pending application [to be filed in before filing] receives the chain 835 which connects to the interconnection structure 10 or other portion of the scaffold system 100, as described in detail above with respect to FIGS. 29-32D. FIG. 40 is a detailed view of callout 3 of FIG. 37 and illustrates such an exemplary connection.
FIGS. 41 and 42 illustrate exemplary connections between the scaffold systems 100a, 100b to the side of the structure 90. As shown in FIG. 41, depending on the direction of anticipated wind forces, if any, an adjustable tube 872 having a foot 873 at its end may be used to push against the structure 90 and prevent movement of the scaffold system 100 towards the structure 90. The adjustable tube 872 is secured to an interconnection structure 10 of the scaffold system 100. As shown in FIG. 42, to prevent movement of the scaffold system 100 away from the structure 90, a chain 876 may be connected to the interconnection structure 10 and wrapped around a portion of the structure 90 such as a column or post.
The monorail car 800 spans the width of the underside of the structure 90 to permit access to the undersurface 91c. In the embodiment shown, the monorail car 800 is made of suspension scaffolding as described above. At either end of the monorail car 800 is a hoist motor 801 to effectuate movement of the monorail car 800 in a vertical direction, that is, up and down in relation to the structure.
FIG. 46 is a cross-sectional view taken from C-C of FIG. 44 and illustrates the mechanisms which permit movement of the monorail car 800c both along the monorail beams 630 and vertically in further detail.
The structures and devices used to move scaffolding along a rail, and power and control that movement, are known in the art. Generally, such a structure and/or device includes a plurality of wheels which engage the lower flanges 632 of the monorail beam 630. The movement of the structures and/or devices along that monorail beam 630 is control and actuated using power from the one or more generators 720. In particular, as shown in FIGS. 44-45, two trolley structures 727, 728 are provided on each monorail assembly. One of the trolley structures 728 is passive and just facilitates travel along the monorail beam 630. The other of the trolley structures 727 is active, that is, has power and is connected to controls, to facilitate movement of the monorail car 800c along the monorail beams 630.
It will be appreciated that, in permitting both vertical movement and movement along the monorail beams, workers on the monorail car 800 are able to access substantially the entire undersurface 91c of the structure 90.
FIG. 38 is a cross-sectional view taken from B-B of FIG. 1A and illustrates the first and second monorail systems 700a, 700b. The first and second monorail system 700a, 700b also utilize the two scaffold systems 100a, 100b. As opposed to the embodiments shown in FIG. 37, the embodiments shown in FIG. 38 illustrate an additional means of providing stability of the scaffold systems 100a, 100b relative to the structure 90. The callouts shown in FIGS. 41 and 42 illustrated additional means of securing the scaffold system 100 to the structure 90 in view of lateral forces. FIG. 43 is a detailed view of callout 6 of FIG. 38 and illustrates a stabilizing means in view of vertical forces, e.g., updraft. As shown in FIG. 43, a third scaffold system (such as a standard scaffold system) is erected on the scaffold system 100 and extends between the scaffold system 100 and the bottom of the structure 90 to prevent upward movement of the scaffold system 100.
Each monorail system 700a, 700b includes a monorail car 800a, 800b. While the embodiment shown in FIG. 37 includes a single monorail car 800c connected to two monorail assemblies, the monorail cars 800a, 800b shown in FIG. 38 are each connected to just a single monorail assembly at two points. Like monorail car 800c, the monorail cars 800a, 800b are made of suspension scaffolding as described above. At either end of the monorail cars 800a, 800b is a hoist motor 801 to effectuate movement of the respective monorail car 800a, 800b in a vertical direction, that is, up and down in relation to the structure.
FIGS. 44 and 45 illustrate an exemplary monorail car such as 800a, 800b. With reference to FIGS. 44 and 45, the description will make reference to monorail car 800a for simplicity, with the understanding the same description will apply to monorail car 800b.
The structures and devices used to move scaffolding along a rail, and power and control that movement, are known in the art. Generally, such a structure and/or device includes a plurality of wheels which engage the lower flanges 632 of the monorail beam 630. The movement of the structures and/or devices along that monorail beam 630 is control and actuated using power from the one or more generators 720. In particular, as shown in FIGS. 44-45, two trolley structures 727, 728 are provided. One of the trolley structures 728 is passive and just facilitates travel along the monorail beam 630. The other of the trolley structures 727 is active, that is, has power and is connected to controls, to facilitate movement of the monorail car 800a along the monorail beams 630.
It will be appreciated that, in permitting both vertical movement and movement along the monorail beams, workers on the monorail cars 800a, 800b are able to access substantially the entirety of the side surfaces 91a, 91b of the structure 90.
FIG. 47 is a cross-sectional view taken from D-D of FIG. 1A and illustrates an exemplary cable configuration to get power from the generator(s) to the hoist motors and power trolleys.
Method of Accessing a Surface
When accessing a surface using a monorail system as described herein, it is possible to access surfaces previously inaccessible (or not easily accessible) and do so without assembling numerous levels and lengths of scaffolding.
Generally, a first scaffold system is assembled and suspended from the structure to be accessed. A monorail assembly is attached to the first scaffold system as needed to permit access to the structure. A monorail car is then built of a second scaffold system and suspended from the monorail assembly using at least one powered trolley to permit lateral movement of the monorail car parallel with the monorail beams. The monorail car also includes at least one hoist which permits vertical movement of the monorail car.
In an embodiment, the first scaffold system is a suspended articulating scaffold system. When using a suspended articulating scaffold system as disclosed herein, it is possible to assemble the first scaffold system in the air off of an existing structure, such as detailed with reference to FIGS. 22-26. The first scaffold system is also secured and suspended from the structure as described with further reference to FIGS. 29-33 and 39-42.
Once the first scaffold system is assembled and secured, the monorail assembly or assemblies are attached to the first scaffold system. First, the location of the monorail beams must be determined in order to position the joist brackets in the appropriate locations. The joist brackets are then secured to the first scaffold system, and specifically, in embodiments in which the first scaffold system is a suspended articulating scaffold system, to the joists of the first scaffold system, as described with reference to FIGS. 3A-3C. Monorail beams (which are fitted with joining bracket assembly s) are secured to each other and the first scaffold system using the joining bracket assembly s and joist brackets, as described with reference to FIGS. 5A-5E and 7A-7F. An end stop is put on both terminal ends of the monorail assembly in accordance with the description provided with respect to FIGS. 6A-7F.
A monorail car is assembled using a second scaffold system, such as, for example, a suspension scaffold as described herein. The monorail car is suspended from the monorail beam using at least one power trolley, and preferably at least one power trolley and one passive trolley.
In some embodiments, such as shown with reference to FIG. 37, it may be desirable to use two monorail assemblies with a single monorail car. In that case, two first scaffold systems are assembled at a distance away from one another with a plurality of scaffold frame members, or joists, in each system being parallel to one another. If scaffold frame members, or joists, in one of the first scaffold systems are not parallel with scaffold frame members, or joists, in the other of the first scaffold system, it will be difficult, if not impossible, to create two parallel monorail assemblies.
A monorail car is assembled as described above, and secured to both first scaffold systems using at least one power trolley and at least one passive trolley with each first scaffold system.
Thus, it is specifically intended that the present disclosure not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims.
Patent Application
20220412022
