ROOFTOP PERIMETER SAFETY SYSTEM

BACKGROUND OF INVENTION
Field of Invention

The present invention relates to a fall protection system, and more specifically, to a rooftop perimeter safety system.

Background

Rooftop perimeter safety systems protect workers from accidental falls from the roof and the injuries thereby incurred and protect bystanders below from injuries. Wood-based perimeter safety systems may include posts or uprights located proximate the perimeter of the roof and configured to blockade the edge of the roof. The use of lumber results in an unnecessarily heavy installation due to the inherent weight of the lumber, thereby exposing workers to risks associated with the effort in installing and removing the lumber and supporting uprights. Lumber based systems also vary in structural strength, especially over the course of time due to weathering and other forms of degradation. Wood-based perimeter safety systems may also be limited in application due to the varying types of roof perimeters, such as overhangs and parapet walls.

Metal-based systems of uprights or stanchions that form a barrier are also sometimes used. Due to a strength of such metal-based systems, spacing between upright supports can be greater than that of the wood-based systems, resulting in a decrease in the “footprint” of the system on the roof deck as compared to the wood-based systems and requiring easier movement and repositioning of the system during use.

Metal-based systems or wood-based systems may utilize tensioned cables to form the barrier. The tensioned cables extend through and are supported by the posts, uprights and/or stanchions and are anchored at two points on the rooftop. When equipment or materials require placement on the rooftop, removal of the barrier or release of tension in the tensioned cables to create a “staging area” is required. Release of the tension in the tensioned cables essentially eliminates the barrier such that those working on the rooftop, even in areas that are not in the staging area, would be required to use alternative fall protection equipment, such as harness systems, until the barrier is reestablished on the rooftop, including in the staging area.

What is needed is a different type of rooftop perimeter safety system that is easy to install and remove on a variety of roofs, durable in extreme conditions, and easily customizable as jobsite conditions and requirements change.

SUMMARY

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other aspects and advantages of the invention will be apparent from the following detailed description of the embodiments and the accompanying drawing figures.

In an embodiment, the description herein relates to a support for a barrier system. The support may include an upright member configured to be secured to a roof top and one or more brackets secured to the upright member. The one or more brackets may each include at least one cable retainer configured to support a cable therein to form a cable barrier and at least one rail retainer configured to support a rail therein to form a rail barrier.

In another embodiment, the description herein relates to a support for a barrier system. The support may include an upright member configured to be secured to a roof top and to support at least one cable and one or more brackets securable to the upright member to modify the upright member. The one or more brackets may each include at least one cable retainer configured to support a cable therein to form a cable barrier and at least one rail retainer configured to support a rail therein to form a rail barrier.

In yet another embodiment, the description herein relates to a barrier system that may include two or more primary supports each including one or more brackets secured to an upright member and a barrier extending between the two or more primary supports. The two or more primary supports each include at least one cable retainer configured to support a cable therein to form a cable barrier and at least one rail retainer configured to support a rail therein to form a rail barrier. The barrier may include at least one cable to form the cable barrier, at least one rail to form the rail barrier, or both the at least one cable and the at least one rail, depending on the application.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention are described in detail below with reference to the attached drawing figures, wherein:

FIG. 1A shows a front elevation view of a primary support that may be used in a rooftop perimeter safety system;

FIG. 1B shows a left side elevation view of the primary support shown in FIG. 1A;

FIG. 1C shows a right side elevation view of the primary support shown in FIG. 1A;

FIG. 1D shows a partial exploded view of the primary support shown in FIG. 1A;

FIG. 2A shows a front perspective view of a secondary support that may be used in a rooftop perimeter safety system;

FIG. 2B shows a front elevation view of the secondary support shown in FIG. 2A;

FIG. 2C shows an exploded view of the secondary support shown in FIG. 2A;

FIG. 3A shows a front elevation view of a primary support with rail support brackets that may be used in a rooftop perimeter safety system;

FIG. 3B shows a front perspective view of the primary support shown in FIG. 3A;

FIG. 3C shows a partial exploded view of the primary support shown in FIG. 3A;

FIG. 4A shows a front elevation view of a secondary support with rail support brackets that may be used in a rooftop perimeter safety system;

FIG. 4B shows a front perspective view of the secondary support shown in FIG. 4A; and

FIG. 4C shows an exploded view of the secondary support shown in FIG. 4A;

FIGS. 5A and 5B show an enlarged perspective view of a set of first slots on the primary support of FIGS. 1A-1D in engagement with a cable;

FIGS. 5C and 5D show an enlarged perspective view of a set of second slots on the primary support of FIGS. 1A-1D in engagement with a cable;

FIGS. 6A and 6B show an enlarged perspective view of a retainer hook and third slot on the secondary support of FIGS. 2A-2C in engagement with a cable;

FIGS. 6C and 6D show an enlarged perspective view of a second slot on the secondary support of FIGS. 2A-2C in engagement with a cable;

FIG. 7A is a plan view of a cable corner roller assembly;

FIG. 7B is a perspective view of the cable corner roller assembly of FIG. 7A;

FIG. 7C is a left side elevation view of the cable corner roller assembly of FIG. 7A;

FIG. 7D is a front elevation view of the cable corner roller assembly of FIG. 7A;

FIG. 7E is a perspective view of the cable corner roller assembly of FIG. 7A secured to first slots of the primary support shown in FIGS. 1A-1D;

FIG. 7F is a perspective view of the cable corner roller assembly of FIG. 7A secured to second slots of the primary support shown in FIGS. 1A-1D;

FIG. 8A shows a front perspective view of a rooftop perimeter safety system with a three-cable barrier;

FIG. 8B shows a front elevation view of the rooftop perimeter safety system of FIG. 8A;

FIG. 9A shows a front perspective view of a rooftop perimeter safety system with a two-cable barrier;

FIG. 9B shows a front elevation view of the rooftop perimeter safety system of FIG. 9A;

FIG. 10A shows a front perspective view of the rooftop perimeter safety system with the three-cable barrier, as shown in FIG. 8A, forming a corner;

FIG. 10B shows a front perspective view of the rooftop perimeter safety system with the two-cable barrier, as shown in FIG. 9A, forming a corner;

FIG. 11A shows a rail securement mechanism of the primary support shown in FIGS. 1A-1D engaging a rail having a first diameter;

FIG. 11B shows the rail securement mechanism of FIG. 11A engaging a coupler for a rail;

FIG. 12A shows a view of a coupling member that includes a coupler that is configured to be used in a rooftop perimeter safety system;

FIG. 12B shows a view of a coupling member disengaged from a rail member of a rooftop perimeter safety system;

FIG. 12C shows a view of a coupling member engaged with two rail members of a rooftop perimeter safety system;

FIG. 13A shows a view of a coupling member that includes a telescoping coupler disengaged from a rail member of a rooftop perimeter safety system;

FIG. 13B shows a view of a telescoping coupler engaged with a rail member installed in a rooftop perimeter safety system;

FIG. 13C shows a telescoping coupler engaged with two rail members of a rooftop perimeter safety system;

FIG. 14A shows an elevation view of a corner bracket for use on a rooftop perimeter safety system;

FIG. 14B shows a plan view of the corner bracket for use on a rooftop perimeter safety system;

FIG. 14C shows an exploded view of the corner bracket assembly having one corner bracket secured below adjacent rails for use on a rooftop perimeter safety system;

FIG. 14D shows a perspective view of a corner bracket assembly installed on a rooftop perimeter safety system, having a corner bracket secured above and a corner bracket secured below adjacent rails;

FIG. 14E shows a perspective view of a corner section of a rooftop perimeter safety system;

FIG. 14F shows an exploded view of the corner bracket assembly having one corner bracket secured above adjacent rails for use on a rooftop perimeter safety system;

FIG. 15A shows a front perspective view of a rooftop perimeter safety system with a two-rail barrier;

FIG. 15B shows a front elevation view of the rooftop perimeter safety system shown in FIG. 15A;

FIG. 16A shows a plan view of a storage pallet used to store components of and tools used with a rooftop perimeter safety system;

FIG. 16B shows a perspective view of the storage pallet of FIG. 16A that includes a base and a stand to suspend components above the base;

FIG. 16C shows a front elevation view of the storage pallet of FIG. 16A; and

FIG. 16D shows a right side elevation view of the storage pallet of FIG. 16A.

The drawing figures do not limit the invention to the specific embodiments disclosed and described herein. The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following detailed description references the accompanying drawings that illustrate specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized, and changes can be made without departing from the scope of the invention. The following detailed description is, therefore, not to be taken in a limiting sense. The scope of the invention is defined only by the appended claims, along with the full scope of the equivalents to which such claims are entitled.

In this description, references to “one embodiment,” “an embodiment,” or “embodiments” mean that the feature or features being referred to are included in at least one embodiment of the technology. Separate references to “one embodiment,” “an embodiment,” or “embodiments” in this description do not necessarily refer to the same embodiment and are also not mutually exclusive unless so stated and/or except as will be readily apparent to those skilled in the art from the description. For example, a feature, structure, act, etc. described in one embodiment may also be included in other embodiments but is not necessarily included. Thus, the technology can include a variety of combinations and/or integrations of the embodiments described herein.

In this description of a rooftop perimeter safety system 100 and the components thereof, directional or orientational references are from a perspective of one viewing the system 100 in place from on a roof top and inside the rooftop perimeter safety system 100. Such references may include “inward,” “outward,” “downward,” “under, “toward,” “left,” “right,” and similar terms and variations thereof. A meaning of the referenced direction or orientation will be apparent from the description and drawings included herein.

In an embodiment disclosed herein, a rooftop perimeter safety system 100 that forms a safety barrier system for construction, repair, and maintenance on flat or low slope roofs is configured to accommodate a cable barrier formed from one or more cables 120, a rail barrier formed from one or more rails 130, such as a metal rail tubing, or a hybrid barrier formed from both the one or more cables 120 and the one or more rails 130. The installer of the rooftop perimeter safety system 100 is able to select the cable barrier and/or the rail barrier at any location on the roof within the system 100 to provide a safe environment on the roof while meeting safety requirements and needs of workers. The cables 120 and the rails 130 configured for use with the rooftop perimeter safety system 100 each has a selected diameter and gauge that has a strength to comply with safety standards. The rooftop perimeter safety system 100 is configured to be easily and quickly assembled with minimal tools and enables a user to form a rooftop staging area without disabling or disconnecting the cables 120 and/or the rails 130 of the entire rooftop perimeter safety system 100. One embodiment of the rooftop perimeter safety system 100 shown in FIGS. 8A and 8B includes three cables 120 that form a three-cable barrier that may be compliant with safety regulations of various governing bodies such as the Occupational Safety and Health Administration (“OSHA”) and/or the United States Army Corps of Engineers (“USACE”). The roof perimeter safety system 100 shown in FIGS. 9A and 9B includes two cables 120 that form a two-cable barrier that may be compliant with the Canada Occupational Health a Safety Regulations (“SOR”). The rooftop perimeter safety system 100 shown in FIGS. 15A and 15B includes two rails 130, such as, for example, metal tubing rails, that form a two-rail barrier that may be compliant with safety regulations of the aforementioned governing bodies and/or regulations.

The rooftop perimeter safety system 100 may comprise at least two substantially vertical primary supports 140 that may be load bearing members supported at a lower end thereof by an anchor bracket 150 fastened to an outer edge of a roof perimeter. The rooftop perimeter safety system 100 may also include one or more mid-barrier or secondary supports 160 that support the barrier system between the primary supports. The primary supports 140 and the secondary supports 160 shown in the rooftop perimeter safety system 100 may be supports constructed specifically for use with the rooftop perimeter safety system 100 or supports modified for use with the rooftop perimeter safety system 100, both of which are described herein.

The rooftop perimeter safety system 100 is configured to enable multiple cable tensioning methods and termination points for a variety of applications. Each cable 120 in the rooftop perimeter safety system 100 may be tensioned as a whole or independently with use of various termination styles and termination anchors or plates 165 (see FIGS. 8A, 8B, 9A, 9B, 10A, and 10B). In an embodiment, the termination anchor plates 165 are mounting plates secured to the roof deck and configured to conform to a roofs edge with welded-on loops formed from steel rods. Winches or come-alongs may be used to tension each cable 120 in between selected termination points.

FIGS. 1A-1D show an embodiment of the primary support 140 of the rooftop perimeter safety system 100 configured for use with one or more cables 120 and/or one or more rails 130. FIG. 1A shows a front elevation view of the primary support 140. FIGS. 1B and 1C show a side elevation views of the primary support 140. FIG. 1D shows an exploded view of the primary support 140.

Each primary support 140 includes a frame 7, a first bracket 1, and a second bracket 2. A plurality of fasteners 5 and 6 secure the first and second brackets 1 and 2 on each side of the frame 7. The first and second brackets 1 and 2 are elongate members that function to secure and support the cable rails and/or the rigid rails therein. The frame 7 is an upright member that provides structural support to the first and second brackets 1 and 2 and secures the first and second brackets 1 and 2 above and to a roof. The frame 7 supports the first and second brackets 1 and 2 in a substantially vertical orientation on the roof and may include a main brace 180, a vertical brace 182, and a center brace 184.

The main brace 180 extends outward and downward from an upper end portion of the primary support 140 and curves around and under a roof perimeter feature to engage a portion of a structure that supports the roof and/or a portion of the roof. A lower portion of the main brace 180 has a sleeve 190 for receiving an adjustable wall-engaging member 200 to provide bracing against a wall of the structure. In an embodiment, the wall-engaging member 200 includes a support or extender shank 210, which may include a welded-on nut and a hand tightenable “L” shaped bolt for fixation, that is adjustably securable and may allow the wall-engaging member 200 to change an angle and/or a length to contact the structure or a soffit portion of an overhang of the structure or the roof. The adjustable wall-engaging member 200 and extender shank 210 may be one from a barrier system, such as the Roof Perimeter Cable Guard System of U.S. Pat. No. 7,806,232, incorporated herein in its entirety by reference.

The vertical brace 182 supports the first and second brackets 1 and 2 secured thereto. The vertical brace 182 may extend substantially vertically when secured to the roof or may be bent or angled inward or toward the roof and the inside of the rooftop perimeter safety system 100. The vertical brace 182 engages the main brace 180 at upper ends thereof and is secured at a lower end to the anchor bracket 150.

The center brace 184 of the frame 7 extends horizontally between the main brace 180 and the vertical brace 182 for stabilization and reinforcement of the braces 180 and 182 and may function as a receiving sleeve that includes one or more welded-on nuts that are able to secure a shank, such as extender shank 210, therein, such as, for example, for securing the primary support 140 to a parapet roof and for use and adjustment of a parapet engagement bracket, such as the adjustable wall-engaging member 200.

The first and second brackets 1 and 2 may be secured to the vertical brace 182 of the frame 7 in an alignment on a left-side and a right-side thereof, respectively, to support a barrier that includes the one or more cables 120 and/or the one or more rails 130. The first bracket 1 is formed with one or more slots or first slots 19 that are retainers for supporting the cable barrier, and the second bracket 2 is formed with one or more slots or first slots 19 that are retainers for supporting the cable barrier. Each slot 19 in the first bracket 1 is formed such that an opening of the slot 19 is offset from an opening of a corresponding slot 19 in the second bracket 2 to form a set of slots 19 that cooperate to engage the cable 120 and prevent the cable 120 from being released. As best shown in FIGS. 5A and 5B, each cable 120 enters a bottom of the slot 19 on the first bracket 1 and enters a top of the slot 19 on the second bracket 2. When the cable 120 is tensioned, the second bracket 2 functions as a support and the first bracket 1 functions as a retainer for the cable 120 extending therethrough. Each set of slots 19 is configured for extending and tensioning the cable 120 therethrough for retainment of the cable 120 therein. In an embodiment, the first and second brackets 1 and 2 include three sets of slots 19 though which three cables 120 are retainable therein to form the three-cable barrier. The three sets of slots 19 are positioned such that when the cables 120 extending therethrough are tensioned, the rooftop perimeter safety system 100 can form a roof perimeter barrier at a predetermined height to comply with the regulatory spacing requirements.

The first and the second brackets 1 and 2 are each formed with one or more rail retainers or supports 17 that each form a portion of a circle and that is used as a base to support a rail 130 therein. When the first and second brackets 1 and 2 are secured to the frame 7, each of the one or more rail supports 17 on the first bracket 1 is substantially identical to and in alignment with one of the one or more rail supports 17 on the second bracket 2 to from a set of rail supports 17. First and second arms or clamps 3, that each form a complementary portion of the circle of the supports 17, are rotatably secured with fasteners 5 and 6 adjacent to the rail support 17 on an outside of each of the first and second brackets 1 and 2, respectively, to form openings 220 through which the rails 130 can extend. The first and second arms 3 are rotatable into a first or closed position to form the openings 220 to secure the rail 130 therein and are rotatable into a second or open position for installation of the rail 130 therein and removal of the rail 130 therefrom.

The rail supports 17 and the first and second arms 3 rotatably secured thereto may be referred to as a rail securement mechanism or feature 136, and as described herein, the openings 220 therethrough may be adjustable. In an embodiment, one of a plurality of securing apertures or holes 170 at an inner end of each arm 3 may be aligned with one of a plurality of securing apertures or holes 171 on an inner portion of the rail support 17 of the respective bracket 1 and 2 and secured with a pin 4 inserted through the apertures or openings 170 and 171 to secure the rail 130 therein. The pin 4 may extend through a securing aperture 170 of both of the first and second arms 3 and a securing aperture 171 of both of the first and second brackets 1 and 2 to lockingly engage the first and second arms 3 to the first and second brackets 1 and 2 in the first position to form the openings 220 configured to adjustably secure the rail 130 therein. Rail 130 may take a number of forms, including bars, tubular rails, L-shape rails, or U-channel rails.

In an embodiment, first and second arms 3 may have several securing openings 170 spaced to allow arms 3 to close around rails 130 of different sizes to accommodate a standard rail 18, which may form the rail 130, or coupler 21, which may form a coupling or telescoping tube configured to form a sleeve having a first or larger diameter than the rest of rail 130 formed by the standard rail 18. First securing apertures 171 in brackets 1 and 2 may align with a first securing apertures 170 formed in the first and second arms 3, such that the first and second arms 3 support and retain rail 130 formed from the standard rail 18 having a second or smaller diameter. Second securing apertures 171 in the brackets 1 and 2 may align with a second securing aperture 170 formed in the first and second arms 3, such that the first and second arms 3 support and retain rail 130 formed form the coupler 21 having the larger diameter. In an embodiment, the primary support 140 includes two rail securement mechanisms 136 that may be positioned such that the rails 130 retained therein are at a predetermined height to comply with regulatory spacing requirements. Details of the rail securement mechanism 136 is further described herein.

The first bracket 1 may be formed with one or more slots or second slots 27 that are retainers for supporting the cable barrier, and the second bracket 2 may be formed with one or more slots or second slots 27 that are retainers for supporting the cable barrier. Each slot 27 in the first bracket 1 is aligned with a corresponding slot 27 in the second bracket 2 to form a set of slots 27 that cooperate to engage the cable 120 and prevent the cable 120 from being released. Each slot 27 is formed in the first and second brackets 1 and 2 above the rail support 17 such that when the arm 3 is rotated and secured in a closed position with the pin 4, the arm 3 locks the cable 120 into the slot 27 and functions to retain the cable 120 therein, as shown in FIGS. 5C and 5D. In an embodiment the first and second brackets 1 and 2 include two sets of slots 27 through which two cables 120 are retainable therein to form the two-cable barrier. The two sets of slots 27 are positioned such that when the cables 120 extending therethrough are tensioned, the rooftop perimeter safety system 100 may form a roof perimeter barrier at a predetermined height to comply with regulatory spacing requirements.

FIGS. 2A-2C show an embodiment of the mid-barrier or secondary support 160 of the rooftop perimeter safety system 100 configured for use with the one or more cables 120 and/or the one or more rails 130. FIG. 2A shows a perspective view of the secondary support 160. FIG. 2B shows an elevation view of the secondary support 160. FIG. 2C shows an exploded view of the secondary support 160.

Each secondary support 160 includes a frame or upright member 8 configured to be secured to a roof deck and a secondary support bracket 29. Some of the components of the secondary support 160 are the same as those described relative to the primary support 140 and include the same reference numbers and descriptions. A plurality of fasteners 5 and 6 secure the secondary support bracket 29 to a side of the upright member 8 to support the one or more cables 120 and/or the one or more rails 130 in a manner that is the same or similar to that of the primary support 140, wherein the secondary support bracket 29 includes the one or more slots 27 and the one or more rail supports 17. The secondary support bracket 29 further includes one or more cable retainer hooks 28 that are rotatably secured with fasteners 5 and 6 through the upright member 8 adjacent one or more slots or third slots 30 that are retainers for securing a cable therein as shown in FIGS. 6A-6D. A cable 120 extending through each slot 30 is locked into the slot 30 by rotating the corresponding cable retainer hook 28 to engage the cable 120. In an embodiment, the one or more slots 30 and 27 and the one or more rail supports 17 of the secondary support 160 are positioned in alignment with the one or more sets of slots 19 and 27 and the one or more sets of rail supports 17 of a primary support which may form a compliant roof perimeter barrier.

The secondary support 160 may not include a main brace and may not be configured to withstand outward loading. The upright member 8 provides structural support to the secondary support bracket 29 and secures the secondary support bracket 29 to the roof deck. The upright member 8 supports the secondary support bracket 29 in a substantially vertical orientation on the roof, which may be approximately parallel to the primary supports, and the upright member 8 may extend substantially vertically when secured to the roof deck or may be bent or angled inward or toward the inside of the rooftop perimeter safety system 100. The upright member 8 of each secondary support 160 may be secured to the roof deck in a number of ways, including utilizing one or more fasteners extending through a base 230 secured at a lower end thereof to maintain the secondary support 160 in the substantially vertical orientation.

One or more secondary supports 160 may be positioned between the primary supports of a rooftop perimeter safety system 100 and may be used to support the cables 120 and/or the rails 130 when spans between the primary supports exceed a determinable distance. In an embodiment, one or more secondary supports 160 are used to support a cable or rail barrier when the on-center spacing between the primary supports is between ten and twenty feet.

Rail support brackets or conversion brackets 9 and 10 may be used to modify primary and secondary supports from pre-existing barrier systems such that a pre-existing support is a frame in the rooftop perimeter safety system 100. The rail support brackets 9 and 10 may be configured such that a user may permanently install the rail support brackets 9 and 10 to the supports of the pre-existing barrier system without effecting the original functionality of the pre-existing system. The rail support brackets 9 and 10 are similar to the brackets 1 and 2, but rail support brackets 9 and 10 extend inwardly from a support such that the one or more slots 19 and 27 and the one or more rail supports 17 positioned on each bracket 9 and 10 are positioned inwardly a distance from the pre-existing support.

FIGS. 3A-3C show an embodiment of a primary support 250 that includes a pre-existing stanchion 11 that has been modified with rail support brackets 9 and 10 configured for use with the one or more cables 120 and/or the one or more rails 130. FIG. 3A shows an elevation view of the primary support 250. FIG. 3B shows a perspective view of the primary support 250. FIG. 3C shows an exploded view of the primary support 250.

The stanchion 11 may be one from a barrier system that supports cables, such as in U.S. Pat. No. 7,806,232. The stanchion 11 may be formed similar to the frame 7 in FIG. 1D and further includes a plurality of sets of cable support members 31 secured thereto that are each configured to engage a cable. The elements of the stanchion 11 that are the same as those in the frame 7, described herein, have the same reference numbers and descriptions as those used relative to the frame 7. The stanchion 11 includes the main brace 180 that extends outward and downward from an upper end portion of the primary support 140 and curves around and under a roof perimeter feature, the vertical brace 182 secured at a lower end to the anchor bracket 150 that is configured to be secured to a perimeter of a roof and secured at an upper end to an upper end of the main brace 180, and the center brace 184 that extends horizontally between the main brace 180 and the vertical brace 182 and may function as a receiving sleeve. The lower portion of the main brace 180 has a sleeve 190 for receiving an adjustable wall-engaging member 200 and/or extender shank 210 to provide bracing against a wall of a structure.

The rail support brackets 9 and 10 have the one or more sets of slots 19 and the one or more slots 27 for retaining one or more cables 120 therein and the one or more rail supports 17 for supporting one or more rails 130 therein. The rail support brackets 9 and 10 and each arm 12 that corresponds to the one or more rail securement mechanisms 136 have a profile that differs from the brackets 1 and 2 and arms 3 such that the rail support brackets 9 and 10 and each arm 12 are extended or modified to eliminate interference with the stanchion 11. The rail support brackets 9 and 10 modify the stanchion 11 to enable the primary support 250 formed therefrom to retain the one or more cables 120 and/or the one or more rails 130. The rail support brackets 9 and 10 have elements that are the same as those in the first and second brackets 1 and 2 described herein, and such elements have the same descriptions and reference numbers as used relative of the first and second brackets 1 and 2.

In an embodiment, each set of slots 19 on the rail support brackets 9 and 10 is spaced a distance inward from and on an inner (roof facing) side of the vertical brace 182 of the stanchion 11 for insertion and removal of the barrier formed by the one or more cables 120. In an embodiment, each rail securement mechanism 136 and each set of slots 27 may be spaced a distance apart from and on the inner side of the vertical brace 182 of the stanchion 11 for insertion and removal of the barrier formed by the one or more rails 130 and/or the one or more cables 120. Each set of slots 19 and 27 is positioned such that each cable 120 retained therein is held under tension at a predetermined height, and/or each rail securement mechanism 136 is positioned such that each rail 130 is secured therein at a predetermined height. In an embodiment, the primary support 250 that is used with the rooftop perimeter safety system 100 includes three sets of slots 19 each configured to support a cable 120 therein to form the three-cable barrier, two sets of slots 27 each configured to support a cable 120 therein to form the two-cable barrier, and two rail securement mechanisms 136 each configured to support a rail 130 therein to form the two-rail barrier.

The rail support brackets 9 and 10 may be secured with fasteners 5 and 6 through the plurality of sets of cable support members 31 secured to the vertical brace 182 of the stanchion 11 such that the rail support brackets 9 and 10 are secured on a left-side and a right-side thereof, respectively, and the primary support 250 formed therefrom is able to form a barrier that includes the one or more cables 120 and/or the one or more rails 130. In an embodiment, three pre-existing pairs of cable retainers 31 on the stanchion 11, that are formed similarly to the sets of slots 19, may be used to secure and support the first and second rail support brackets 9 and 10 thereon with fasteners 5 and 6 that extend through apertures in each of the first and second rail support brackets 9 and 10 and through at least one of each pair of cable support members 31. A plurality of spacers 13 may extend between the first and second rail support brackets 9 and 10 and maintain a spacing therebetween to prevent overtightening of the fasteners 5 and 6 which could result in damage to the stanchion 11 and/or the first and second rail support brackets 9 and 10. In an embodiment, five spacers 13 extend between the first and second rail support brackets 9 and 10 to maintain a spacing of the cable support members 31 and the rail support brackets 9 and 10 and to prevent overtightening of the fasteners 5 and 6 which could result in reduced usability and/or permanent damage or deformation of the stanchion 11 and/or the rail support brackets 9 and 10. In an embodiment, a spacer 13 extends through each of the pairs of cable support members 31 and fasteners 5 and 6 extend therethrough to secure the rail support brackets 9 and 10 to the stanchion 11. In an embodiment, spacers 13 may be located proximate the one or more rail supports 17 with fasteners 5 and 6 extending therethrough to rotatably secure the arms 12 to the rail support brackets 9 and 10.

FIGS. 4A-4C show an embodiment of a mid-barrier or secondary support 280 that includes a pre-existing mid-span support. 14 that has been modified with rail support brackets 9 and 10, which are the same as those described herein relative to the primary support 250, and that are configured for use with the one or more cables 120 and/or the one or more rails 130. FIG. 4A shows an elevation view of the secondary support 280. FIG. 4B shows a perspective view of the secondary support 280. FIG. 4C shows an exploded view of the secondary support 280.

The mid-span support 14 may be one from a barrier system that supports cables, such as from U.S. Pat. No. 7,806,232. The mid-span support 14 is formed similar to the upright member 8 in FIG. 2C and may further include a plurality of sets of J-bolts 15 secured with wingnuts 16 to the mid-span support 14 and extending inwardly therefrom. Each J-bolt 15 is a cable support member configured to engage a cable. The rail support brackets 9 and 10 and the arms 12 are the same as those used on the primary support 250 to modify the stanchion 11, and the reference numbers and the components thereof are numbered the same and share the same descriptions.

The rail support brackets 9 and 10 modify the mid-span support 14, similar to the stanchion 11, to enable the secondary support 280 formed therefrom to retain the one or more cables 120 and/or the one or more rails 130. The plurality of fasteners 5 and 6 secure the first and second rail support brackets 9 and 10 on each side of the mid-span support 14 in an alignment on a left-side and a right-side thereof, respectively. Rail support brackets 9 and 10 support and retain the one or more cables 120 in the one or more sets of slots 19 or 27 and/or support the one or more rails 130 in the one or more rail securement mechanisms 136. In an embodiment, the secondary support 280 includes three sets of slots 19 that are each configured to retain a cable 120 therein to form a three-cable barrier, two sets of slots 27 that are each configured to retain a cable 120 therein to form a two-cable barrier, and two rail securement mechanisms 136 that are each configured to support a rail 130 therein to form a two-rail barrier. In an embodiment, each set of slots 19 and 27 may be positioned such that each cable 120 retained therein is held under tension at a predetermined height to comply with regulatory spacing requirements, and/or each rail securement mechanism 136 is positioned such that each rail 130 supported therein is at a predetermined height to comply with regulatory spacing requirements. In an embodiment, the one or more sets of slots 19 and 27 and the one or more sets of rail supports 17 of the secondary support 280 are in alignment with those of the primary support.

Fasteners 5 and 6 and spacers 13 are used to secure the rail support brackets 9 and 10 and the arms 12 to the mid-span support 14 in a similar manner than those described relative to the primary support 250. The rail support brackets 9 and 10 are secured to the mid-span support 14 by extending fasteners 5 and 6 through a spacer 13 secured within a curve or hook of each of the one or more J-bolts 15. In an embodiment, three J-bolts 15 secured to the mid-span support 14 are used to secure and support the first and second rail support brackets 9 and 10 thereon with fasteners 5 and 6 that extend through apertures in the first and second rail support brackets 9 and 10 and through spacers 13 extending through the J-bolts 15. In an embodiment, fasteners 5 and 6 extending through spacers 13 between each set of the rail supports 17 rotatably secure each of the sets of arms 12 to the first and second rail support brackets 9 and 10 to form the two rail securement mechanisms 136. Each set of arms 12 is adjustably securable with the pin 4 to secure one or more sizes of rails 130 through each openings 220 of each rail securement mechanism 136 as described relative to the primary support 250.

Similar to the secondary support 160, the secondary support 280 may not include a main brace and may not be configured to withstand outward loading. The mid-span support 14 provides structural support to the first and second rail support brackets 9 and 10 and secures the first and second rail support brackets 9 and 10 to the roof deck. The mid-span support 14 supports the first and second rail support brackets 9 and 10 in a substantially vertical orientation on the roof, which may be approximately parallel to the primary supports, and the mid-span support 14 may extend substantially vertically when secured to the roof deck or may be bent or angled inward or toward the inside of the rooftop perimeter safety system 100. The mid-span support 14 of each secondary support 280 may be secured to the roof deck in a number of ways including utilizing one or more fasteners extending through a base 230 secured at a lower end thereof to maintain the secondary support 280 in the substantially vertical orientation.

One or more mid-barrier supports 280 may be positioned between the primary supports of a rooftop perimeter safety system 100 and may be used to support the cables 120 and/or the rails 130 when spans between the primary supports exceed a determinable distance. In an embodiment, one or more mid-barrier supports 280 are used to support a cable or rail barrier when the on-center spacing between the primary supports is between ten and twenty feet.

FIGS. 11A and 11B show the rail securement mechanism 136 that includes two arms 3 rotatably secured with the fasteners 5 and 6 and adjustably secured in a closed position with the pin 4 to retain a rail 18 of a smaller or first diameter (in FIG. 11A) and a coupler 21 of a larger or second diameter (in FIG. 11B) in the same rail supports 17. One or both of the rails 18 and coupler 21 may be used to form the rail 130. The coupler or sleeve rail 21 shown herein may be used for a standard coupler assembly or a telescoping coupler assembly, further described herein. The rail securement mechanism 136 shown in FIGS. 11A and 11B is shown with the arms 3 and relative to the primary support 140 that includes the first and second brackets 1 and 2 secured to the frame 7, but may also be used with the secondary support 160, and with the primary support 250 and the secondary support 280 that each are configured to be used with one or more arms 12.

A plurality of supports described herein may be used to support a cable rail barrier, a rigid rail barrier, and/or a hybrid barrier having a run or selected length, such as, for example, a length of hundreds of feet. Multiple lengths of cables 120 may be clamped or secured together to form a cable rail barrier having a length that corresponds to a length of a roof. Excess lengths of cable 120 may be coiled and secured at the end of the run or roof line. Rails 130 may be shorter than that of a length of a roof line, such as for ease of handling, or may be formed or cut into lengths which are transportable and liftable onto a rooftop, such as, for example, lengths of rail extending between approximately 10 to 24 feet. Multiple lengths of rails 130 may be coupled together to form a rail barrier having a selected length or a length that corresponds to a length of a roof.

The brackets 1 and 2 and rail support brackets 9 and 10 and the one or more rails 130 extending between the supports are configured such that the primary supports 140 and 250 may be adaptably positionable within a twenty foot span and the span therebetween is not limited to a fixed length of a rail. Such adjustability makes it possible to avoid placement of the supports 140 and 250 at specific locations and possible to place the supports 140 and 250 at selected locations, such as around a perimeter of a roof. The rails 130 may be secured together by a coupler 21 that is in overlapping relationship with rail members 18 to form a barrier rail that extends across a length of the roof. In an embodiment, a coupling member 300 secures multiple lengths of rails 130 together and comprises the coupler 21 having at least one notched end 310 and one or more clamps 20 for securing one or more rail members 18 thereto to assure structural integrity of the rooftop perimeter safety system 100. The coupler 21 may have an inside diameter that is larger than an outside diameter of the rail member 18 such that rail members 18 are slidable therein. The coupler 21 has at least one view port 22 formed therein at a selected distance from an end of the coupler 21 to ensure that each rail member 18, which may be a standard rail or a metal rail tubing having a smaller diameter than the coupler 21, extends therein at least to the view port 22 such that each rail member 18 is inserted at least a minimum distance for a required overlap of the coupler 21 and the rail member 18. Each notched end 310 of the coupler 21 is configured such that a clamp 20 extending therearound is compressible onto the end of the coupler 21 to secure the rail member 18 therein.

FIGS. 12A and 12B show views of the coupling member 300 that includes the coupler 21 with the notched ends 310, and the clamp 20 that is configured to secure the rail member 18 to the notched end 310 of the coupling tube 21. The coupler 21 is configured to couple multiple rails 130 together to form a desired length of rail 130. FIG. 12C shows the coupling member 300 with two rail members 18 secured within the coupler 21. The clamps 20 independently secure each rail member 18 to an end of the coupler 21 such that each rail member 18 is independently adjustable or removeable. A hole or view port 22 may be positioned on the coupler 21 to verify a positioning or insertion of the one or more rail members 18 inside the coupler 21 to a sufficient depth to withstand forces for proper functioning. The coupler 21 may have a length that is shorter than the rail members 18. In an embodiment, the coupler 21 is approximately two feet in length and one view port 22 is formed at a center thereof.

FIG. 13A show views of the coupling member 300 that includes a coupler or telescoping coupler 23 with notched ends 310 and the clamp 20, that is the same as the clamp 20 shown in FIG. 12A and configured to secure the rail member 18 to the notched end 310 of the telescoping coupler 23. The telescoping coupler 23 is a formed the same as the coupler 21 shown in FIG. 12A and is configured such that the rail member 18 is telescopically extendable relative to the telescoping coupler 23 to provide a variable extension for ending a run of a rail 130, such as to adjustably complement a length of a roof line and/or avoid overhang beyond a roof edge. FIG. 13B shows the telescoping coupler 23 secured to a primary support, wherein the telescoping coupler 23 is a variable extender at the end of a run of rail 130. FIG. 13C shows a telescoping coupler 23 secured to two rail members 18 by a clamp 20 at each of the ends 310 thereof. The clamps 20 independently secure the rail members 18 to each end 310 of the telescoping coupler 23 such that the rail members 18 are independently adjustable or removeable. A hole or view port 22 is positioned a distance from each end of the telescoping coupler 23 to verify a positioning or insertion of the rail member 18 inside the telescoping coupler 23 to a sufficient depth to withstand forces for proper functioning. In an embodiment, the telescoping coupler 23 is approximately six feet in length and one view port 22 is formed approximately one foot from each of the ends thereof. One or more rails members 18 adjustably extend from one or both of the ends of the telescoping coupler 23, and, in an embodiment, the rail members 18 may be approximately five feet in length. The clamp 20 is secured around the notched end 310 of the telescoping coupler 23 to adjustably secure the rail member 18 extending therefrom.

Cable rail barriers may be configured to follow a contour or perimeter shape of a roof, including angles and corners, using a cable corner roller assembly 350 as shown in FIGS. 7A-7D to form a corner section of the rooftop perimeter safety system 100. The corner roller assembly 350 includes a body 32 through which a bolt 33 extends for engaging the cable 120. The body includes one or more apertures extending therethrough to fix the corner roller assembly 350 to a support. A cable retention washer 34 prevents the cable 120 from sliding off of the bolt 33 as the cable 120 bends around a contour, and a spacer 35 is a support that may be rotatable to maintain the bolt 33 in a position and in engagement with a welded-on nut 36. The corner roller assembly 350 enable cables 120 to smoothly change direction and avoid binding as each cable 120 is tensioned and released. FIG. 7E shows the corner roller assembly 350 secured to the primary support 140 adjacent the set of slots 19 and secured thereto by a pin 4 extending through a hole in the body 32 of the corner roller assembly 350 and the set of slots 19. FIG. 7F shows the corner roller assembly 350 secured to the primary support 140 adjacent the set of slots 27 and secured thereto by extending a U-shaped bolt 37 through a hole in the body 32 of the corner roller assembly 350 and fastening the U-shaped bolt 37 around the frame 7 with nuts 39 to secure the U-shaped bolt 37 to a mounting plate 38. FIG. 10A shows a perspective view of a corner of a rooftop perimeter safety system 100 that includes corner roller assemblies 350 that engage the cables 120 at the corners and extend through the three set of slots 19 on each support to form a cable barrier having three cables 120. FIG. 10B shows a perspective view of a corner of a rooftop perimeter safety system 100 that includes corner roller assemblies 350 that engage the cables 120 at the corners and extend through the two sets of slots 27 on each support to form a cable barrier having two cables 120.

Rails 130 that form rail barriers are rigid and extend in a straight line. To address direction changes in rail barriers, such as corners, at least one corner bracket 26 forms a corner bracket assembly 370 that may be used to connect rails 130 of two adjacent rail barriers or adjacent rails 130 that extend at different angles. The corner brackets 26 are adjustable such that the rails 130 of adjacent rail barriers at different angles are connectable. The corner brackets 26 are coupled to a top and/or a bottom of the adjacent rails 130 via fasteners 24 and 25 to enclose a junction and provide rigidity to each of the rail barriers and for easy assembly and/or disassembly with minimal tools.

FIG. 14A shows an elevation view of the corner bracket 26, and FIG. 14B shows a plan view of the corner bracket 26. Each corner bracket 26 is formed from a panel or plate with at least one edge of each corner bracket 26 bent or creased to form a lip 380. The lip 380 increases a rigidity of the corner bracket 26 to prevent flexing that may occur with the flat panel or plate. The corner bracket assembly 370 includes at least one corner bracket 26 that is secured to adjacent rails 130. A semi-circular slot 390 with a bole or aperture 395 centered therein is placed near each end of the corner bracket 26. At least one corner bracket assembly 370 may be utilized for each corner section of the rooftop perimeter safety system 100.

FIG. 14C shows an exploded view of the corner bracket assembly 370 that includes one corner bracket 26 positioned below two rails 130 such that the lip 380 extends downward from the corner bracket 26, and fasteners 24 and 25, which may each be a U-bolt secured with nuts, are securable around each of the two rails 130 to adjustably secure the corner bracket 26 thereto. FIG. 14F shows an exploded view of the corner bracket assembly 370 that includes one corner bracket 26 positioned above the two rails 130 such that the lip 380 extends upward from the corner bracket 26, and fasteners 24 and 25 are securable around the two rails 130 to adjustably secure the corner bracket 26 thereto. Fasteners 24 and 25 secure the corner brackets 26 close to ends of the adjacent rails. Fasteners or U-bolts 24 extend through the apertures 395 on each side of the aligned corner bracket 26 on a first side of the rails 130, extend around each rail 130, and through the semi-circular slot 390 on a second side of the rails 130. The semi-circle slot 390 functions such that the corner bracket assembly 370 is able to join adjacent rails 130 that are angled relative to each other up to almost 180 degrees to accommodate a range of angles of roof lines that require multiple barrier rails at different angles. The corner bracket 26 may be positioned above and/or below the two rails 130 to which it adjustably secures.

FIGS. 14D and 14E show views of the corner bracket assembly 370 that includes one corner bracket 26 positioned on top of two rails 130 such that the lip 380 extends upward from the corner bracket 26, and one corner bracket 26 inverted and placed under the two rails 130 in alignment with and directly under the top corner bracket 26 such that the lip 380 extends downward from the corner bracket 26. Fasteners 24 and 25, such as bolts and nuts, secure the corner brackets 26 close to ends of the adjacent rails. First fasteners 24 are extended through the apertures 395 on each side of the aligned corner brackets 26 and extend on a first side of the rails 130. Second fasteners 24 are extended through the semi-circular slot 390 on each side of the aligned corner brackets 26 and extend on a second side of the rails 130. The fasteners 24 and 25 are secured such that compressive forces on the top and under of the rails 130 retain or clamp the two rails 130 in a position. The semi-circle slot 390 functions such that the corner bracket assembly 370 is able to join adjacent rails 130 that are angled relative to each other up to almost 180 degrees to accommodate a range of angles of roof lines that require multiple barrier rails at different angles.

FIGS. 14D and 14E show adjacent rails 130 joined by the corner bracket assembly 370 to form a corner section of a rooftop perimeter safety system 100. It is foreseeable that one corner bracket assembly 370 may be used at each corner to form the corner section of the rooftop perimeter safety system 100.

For convenience, storage, and shipping, the rooftop perimeter safety system 100 is able to be disassembled for use in more than one location and may be housed within a storage system or pallet 400, shown in FIGS. 16A-16D. The storage pallet 400 may be formed from a metal or wooden material or various other materials. The storage pallet 400 formed from metal may be constructed of welded steel and powder coated for durability. The storage pallet 400 may be configured such that the disassembled rooftop perimeter safety system 100 is able to be stored within a footprint of a standard shipping pallet. The storage pallet 400 may include loops 46 for hoisting with a crane and a base raised on four feet 45 for fork-style lifting machines. FIG. 16A shows a plan view of the storage pallet 400. FIG. 16B shows a perspective view of the storage pallet 400 that includes a base 40 having compartments for storage and a stand 41 that is positioned such that racks 42, 43, and 44 are secured above the base 40 and configured to support or suspend components of the disassembled rooftop perimeter safety system 100 over the base 40. In an embodiment, the racks 42 are configured to support or suspend the secondary supports 160 and 280 and are positioned at each outermost end of a top of the stand 41 to balance a weight of the disassembled rooftop perimeter safety system 100 across the storage pallet 400. In an embodiment, the beams or racks 43 are configured to support or suspend the primary supports 140 and 250. In an embodiment, the rack 44 is configured to support or suspend the adjustable wall-engaging members 200. FIGS. 16C and 16D show elevation views of the storage pallet 400 from a side (in FIG. 16C) and from a front or back (in FIG. 16D).

Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the spirit and scope of the present disclosure. Embodiments of the present disclosure have been described with the intent to be illustrative rather than restrictive. Alternative embodiments will become apparent to those skilled in the art that do not depart from its scope. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the present disclosure. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims.

ROOFTOP PERIMETER SAFETY SYSTEM

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CPC

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Provisional Applications (1)