MODULAR ROOF INSTALLATION SCAFFOLDING SYSTEM

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Serial No. 60/596,320, filed September 16, 2005.

BACKGROUND OF THE INVENTION Field of the Invention

The invention relates generally to scaffolding systems and particularly to a modular scaffolding system for use during installation of shingles and related roofing components.

Description of the Related Art

Building roofs, particularly roofs on residential buildings, frequently comprise shingles attached to an underlayment or roof deck. The shingles must be installed one-by- one by workers supported on the roof deck. The workers typically install a first row of shingles along the lower edge or eave of the roof deck, and progressively install rows of shingles up the roof deck to the peak. The workers may use hammers and nails, electric nailers, pneumatic nailers, and the like, to attach the shingles to the roof deck. Thus, the workers typically have bundles of shingles, hammers or nailers, a supply of fasteners, and, in the case, of electric or pneumatic nailers, power supply lines, with them on the roof deck during the installation process.

Depending upon the pitch of the roof, the roofers may utilize a support structure for themselves and their equipment to prevent workers and equipment from sliding toward the eaves and off the roof. If the roof has a shallow pitch, a support structure may be unnecessary. However, if the roof has a steep pitch, particularly if the roof is several stories above ground, a support structure is typically used. This can include ladders laid along the roof and anchored by ropes extending over the peak and down the opposite side, or jacks which are nailed to the roof deck for supporting wood planks extending across the roof parallel to the ridgeline. However, both of these systems are undesirable.

First, the use of ladders requires a readily available, sufficiently strong anchor point for attaching the rope. As work progresses, and it is necessary to move a ladder, the worker must dismount the roof, untie the rope, move the ladder, retie the rope, ascend the roof, and resume work. This is time consuming, and can be dangerous during the time that the worker

is no longer supported by the ladder. Secondly, as the installation of the shingles progresses, the ladder must be moved to allow shingles to be installed beneath the ladder.

If a jack system is used, the jacks are typically spaced as far apart as possible in order to minimize the number of jacks used. However, this necessitates the use of very long planks, which may bow excessively or break, and are heavy to move and install. , Furthermore, the planks can move while supported by the jacks, causing a worker or equipment to be thrown from the plank. Finally, the jacks must be removed and reset as work progresses, and in order to install shingles at the jack location. Again, this can be time consuming, and dangerous during the times that the worker is no longer supported by the jack system.

There is a need for a scaffolding system which is lightweight, easily assembled and disassembled, and enables roofing to progress without interference from the scaffolding system.

SUMMARY OF THE INVENTION

A modular roof installation scaffolding system for attachment to a roof having an inclined roof deck and a ridge comprises at least two rails spaced from each other and extending generally parallel to the roof deck, at least two feet movably coupled to each rail for supporting the rail a preselected distance away from the roof deck, at least one jack movably coupled to each rail independent of the at least two feet, and a movable plank extending between and affixed to the jacks on adjacent rails. The feet can be moved from a first position to a second position to maintain support for the rails on the roof deck while enabling roofing materials to be attached to the roof deck beneath the scaffolding system without having to move the jacks or the movable plank.

In another embodiment, the modular roof installation scaffolding system comprises a rigid framework comprising at least two rails with a supporting plank extending between them, the rigid framework being supported away from the roof deck by at least two movable feet coupled to each rail. The at least two movable feet can be relocated along each rail between a first area of the roof deck having no installed roofing materials and a seόond area of the roof deck having installed roofing materials without disassembling the rigid' framework. Roofing materials can be installed on the roof deck beneath the scaffolding system without moving the rigid framework.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

Figure 1 is a perspective view of a modular roof installation scaffolding system according to the invention installed on a roof undergoing the installation of shingles.

Figure 2 is an exploded view of the modular roof installation scaffolding system illustrated in Figure 1 comprising a rail, a first embodiment of a jack, a plank, a first embodiment of a foot, and a first embodiment of a ridge hook.

Figure 3 is a perspective view of a first embodiment of a jack comprising a portion of the modular roof installation scaffolding system illustrated in Figure 1.

Figure 4 is a perspective view of a second embodiment of a jack comprising a portion of the modular roof installation scaffolding system illustrated in Figure 1.

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Figure 5 is a perspective view of a third embodiment of a jack comprising a portion of the modular roof installation scaffolding system illustrated in Figure 1.

Figure 6 is a perspective view of a fourth embodiment of a jack comprising a portion of the modular roof installation scaffolding system illustrated in Figure 1.

Figure 7 is a perspective view of a second embodiment of a foot comprising a portion of the modular roof installation scaffolding system illustrated in Figure 1.

Figure 8 is a side view of a portion of the modular roof installation scaffolding system illustrated in Figure 1 illustrating the jack installed to the rail and supporting a plank.

Figure 9 is a second embodiment of the ridge hook illustrated in Figure 1.

Figure 10 is a third embodiment of the ridge hook illustrated in Figure 1.

Figure 11 is a fourth embodiment of the ridge hook illustrated in Figure 1. ■

Figure 12 is a side elevational view of an alternate embodiment of a modular roof installation scaffolding system according to the invention comprising a pair of planks providing full foot support for a roofer.

Figure 13 is a perspective view of a third embodiment of a foot comprising a portion of the modular roof installation scaffolding system illustrated in Figure 1.

Figure 14 is an enlarged exploded view of a portion of the modular roof installation scaffolding system illustrated in Figure 1 comprising a line support pin for supporting pneumatic lines, electrical cords, and the like, above the roof.

DESCRIPTION OF AN EMBODIMENT OF THE INVENTION

Referring now to the drawings, and to Figure 1 in particular, a modular roof installation scaffolding system 10 is illustrated supported on a roof 12. Figure 1 illustrates a plurality of shingles 14 being installed over a roof deck 16 with fasteners 18 such as roofing nails, with the scaffolding system 10 used to support workers installing the shingles. The scaffolding system 10 comprises a pair of parallel rails 20 extending between and orthogonal

to the eaves and the ridgeline of the roof 12, at least two jacks 22 attached to the rails 20 for supporting at least one plank 24 extending between the rails 20 parallel to the ridgeline, and a ridge hook 28 extending over the ridgeline and supporting the rails 20 on the roof 12. A plurality of feet 26 are attached to and support the rails 20 away from the roof 12.

Referring also to Figure 2, the rails 20 comprise elongated rail members haying a generally rectilinear cross-section, terminating at one end in a rectilinear insert piece 40. It is anticipated that the cross-section of the rails 20 will be selected based upon the bending resistance required for the purposes described herein, and may vary from square, as illustrated in Figure 2, to rectangular, as illustrated in Figure 6. The rails 20 can comprise a suitable structural member, such as structural tubing, having sufficient strength and durability for the purposes described herein. Preferably, the rails 20 are fabricated of aluminum or steel. The rails 20 define an interior rectilinear channel way 50 extending longitudinally therethrough. The insert piece 40 is adapted for slidable registry with the channelway 50. A pair of apertures 42 extend coaxially through the opposed top and bottom walls of the insert piece 40. A pair of coaxial side apertures 44 can additionally or alternatively be provided in the side walls of the insert piece 40. A plurality of regularly-spaced apertures 46 extend coaxially through the opposed top and bottom walls of the rail 20, and a plurality of regularly-spaced coaxial side apertures 48 can additionally or alternatively be provided in the side walls of the rail 20.

'- The ridge hook 28 is an elongated, chevron-shaped member having a generally rectilinear cross-section comprising a connecting leg 60 rigidly attached to a retaining leg 62 defining' an angle therebetween corresponding to the ridgeline angle defined by the pitch of the roof. The connecting leg 60 comprises a suitable structural member, such as the structural tubing used for the rails 20, having a plurality of apertures 64 extending coaxially through the opposed top and bottom walls of the connecting leg 60, and a plurality of coaxial side apertures 48 additionally or alternatively provided in the side walls of the connecting leg 60. The connecting leg 60 is provided with an interior rectilinear channelway 68 extending longitudinally therethrough. The retaining leg 62 can be fabricated of the structural tubing used for the rails 20 and the connecting leg 60, or a solid member comprising a similar material adapted for rigid attachment to the connecting leg 60, such as by welding. The insert piece 40 of the rail 20 and the channelway 68 are adapted so that the insert piece 40 can be slidably inserted into the channelway 68. A suitable fastener, such as a pin 140, can be inserted through the apertures 64, 42 or the apertures 66, 44 to retain the ridge hook 28 to the

rail 20. The pin 140 is illustrated in Figure 2 as retained in place with a retaining clip 142. Other suitable fasteners can be utilized, such as bolts and the like.

It will be obvious that a plurality of rails 20 can be assembled by inserting the insert piece 40 of one rail 20 into the channelway 50 of an adjoining rail 20 in order to extend the rail the full height of the roof 12.

Referring also to Figure 3, the jack 22 comprises a rectilinear, channel-like sliding portion 70 and a somewhat L-shaped plank support 72. The sliding portion 70 comprises a top wall 74 and two side walls 76, 78 extending orthogonally thereto in parallel, spaced-apart juxtaposition to define a channelway 80 extending therealong. A pair of apertures 82 extends through the top wall 74 at a spacing adapted for cooperative registry of the apertures 82 with the apertures 46 in the rail 20. Alternatively, as illustrated in Figure 4, the side walls of 70, 76 can be provided with apertures 90 extending therethrough for attachment of the jack 22 to the rails 20 by use of pins 140 extending through the apertures 90, 48. In yet another embodiment illustrated in Figure 5, the jack 22 can be provided with pins at 92 extending from the top wall 74 into the channelway 80 adapted for insertion through the apertures 46.

The channelway 80 is adapted so that the sliding portion 70 can be positioηed in slidable registry with the rail 20 and selectively moved along the rail 20. Pins 140 pan be inserted through the apertures 82 and the apertures of 46 to secure the jack 22 to the rail 20. The plank support 72 comprises a plank rest 84 extending orthogonally away from the top wall 74 and terminating in a flange 86 extending orthogonally from the plank rest 84, parallel to the top wall 74. The jack 22 is fabricated of a suitable material, such as aluminum or steel, having sufficient strength and durability for the purposes described herein. The length of the plank rest 84 is selected based upon the size of the plank 24 to be supported by the jack 22. The plank rest 84 is provided with an aperture 88 extending therethrough.

The plank 24 is an elongated member having a generally rectilinear cross-section and comprising a pair of parallel, spaced - apart support walls 100, 102 and a pair of parallel, spaced - apart side walls 104, 106 extending orthogonally therebetween. The support walls 100, 102 are provided with a plurality of regularly-spaced apertures 108 extending coaxially therethrough. The side walls 104, 106 can be selectively provided with a plurality of regularly-spaced apertures 110 extending coaxially therethrough. The apertures 108, 88 are adapted for receipt of a pin 140 therethrough to secure the plank 24 to the plank support 72 of the jack 22. Alternatively, as illustrated in Figure 5, the plank support 72 can be provided with a pin 92 adapted for insertion into an aperture at 108 in the plank 24 when the plank 24 is assembled to the jack 22.

Two or more rails 20, two or more jacks 22, and one or more planks 24 caii be interconnected by inserting pins through apertures to form a rigid framework. The framework can be configured to be as large or small as necessary for the area of roofing to be completed. When necessary, the framework can be readily moved, for example from one side of a roof to another, without disassembly. .

The foot 26 comprises a rail cradle 120 rigidly attached to a post 122, which is in turn rigidly attached to a support plate 124. The rail cradle 120 is a somewhat U-shaped clevis- the like member having a bottom wall 126 and a pair of parallel, spaced - apart side walls 128, 130 extending orthogonally therefrom. The side walls 130, 132 are provided with apertures in coaxial juxtaposition adapted for insertion of a pin 140 therethrough. The post 122 is illustrated as a solid cylindrical member extending orthogonally from the bottom wall 126 away from the side walls 128, 130. The support plate 124 is a generally rectilinear plate orthogonal to the post 122 and adapted for contact with the roof 12. The rail cradle 120 is adapted for slidable receipt of the rail 20 therein and the apertures 134 are adapted for coaxial alignment with the side apertures of 48 of the rail 20 so that the foot 26 can be connected to the rail 20 by insertion of a pin 140 through the apertures 132, 134 and the apertures 48. With the rails 20 supported by the foot 26, the rails 20 and the planks 24 will be spaced away from the roof 12, thereby providing virtually uninterrupted access to the roof deck 16 for installation of the shingles 14. When a foot 26 is encountered during shingling, the foot 26 can be readily moved by simply removing the pin 140 and sliding the foot 26 along the rail 20 to ^suitable position to be reattached to the rail 20 with the pin 140 so that shingling can continue ¹ , _. ,

A plurality of rails 20 can be spaced along the roof 12 in order to provide a scaffolding system that extends over the entire roof area. One means of assembling the rails 20 and planks 24 into a unified scaffolding system is illustrated in Figure 6. In this configuration, a pair of rails 20 is placed in contact along their entire length and secured together with a second embodiment of the jack 150 adapted for slidable registry with both rails 20. The jack 150 is similar to the jack 22 except that the jack 150 is approximately twice the width of the jack 22 to accommodate two rails 20. The jack 150 comprises a sliding portion 152 and a plank support 154 in the same general configuration as the sliding portion 70 and the plank support 72. The a sliding portion 152 comprises a top wall 156 and a pair of parallel, spaced - apart side walls 158, 160 depending therefrom to define a channelway 162. Pairs of apertures 164 extend through the top wall 156 for coaxial registry with the apertures 46 in the rails 20.

Extending orthogonally upwardly from the top wall 156 is a plank rest 166 terminating in a flange 168. A pair of apertures 170 extends through the plank rest 166 for coaxial registry with the apertures 108 in the plank 24. It is anticipated that a first plank would be attached to the plank rest 166 by a first pin 140 extending through the plank aperture 108 and one of the apertures 170, and a second plank would be attached to the plank rest 166 by a second pin 140 extending through the plank aperture 108 and the other of the apertures 170 to provide a continuous plank having a joint corresponding to the jack 150. Similarly, as illustrated in Figure 7, a foot 180 has the same general configuration as the foot 26, except that the foot 180 is approximately twice the width of the foot 26. Thus, a rail cradle 182 comprises a bottom wall 188 and a pair of spaced apart, parallel side walls 190, 192 having a pair of apertures 194, 196 extending therethrough. A post 184 is rigidly attached to the bottom wall 188 to extend away from the side walls 190, 192. A support plate 186 is attached to the post 184 parallel to the bottom wall 188 and adapted for contact with the roof 12 to support the paired rails 20 illustrated in Figure 6. Pins 140 would extend through the apertures 194, 196 in the foot 180 and the apertures 48 in the rails 20.

Figure 8 illustrates a side view of the sliding portion 70 attached to the rail 20 through a pair of pins 140. A plank 24 is attached to the plank support 72 by a pin 140 extending through the apertures at 108 in the plank 24 and the aperture 88 in the plank support 72. The pin 140 is secured with the retainer 142.

Figure 9 illustrates a second embodiment of a ridge hook 200 comprising a connecting leg 202 rigidly attached to a hook end 204. The connecting leg 202 is identical to the rail\20 and is adapted with at least two apertures 208 so that the insert piece 40 of the rail 20 can engage the connecting leg 202 and be retained therein by a pin 140. The hook end 204 terminates in a bearing plate 206 adapted for contact with the roof deck 16 or the shingles 14, as the case may be, and has a curvature defining an angle α between the longitudinal axis 210 of the rail 20 and the plane of the bearing plate 206 corresponding to the ridgeline angle defined by the pitch of the roof.

Figure 10 illustrates a third embodiment of a ridge hook 220 comprising a connecting leg 222 hingedly attached to a retaining leg 224 through a hinged connection 228. .The retaining leg 224 has at least one adjustment plate 226 rigidly attached thereto having a plurality of apertures 234 extending along a circular arc having its center coaxial with the hinged connection 228. The apertures 234 of the adjustment plate 226 are adapted for coaxial registry with apertures in the side walls of the connecting leg 222 for receipt of a pin therethrough. The angle α between the retaining leg 224 and the longitudinal axis 232 of the

rail 20 can be selected to correspond with the ridgeline angle defined by the pitch of the roof 12 by pivoting the retaining leg 224 relative to the connecting leg 222 and securing the retaining leg 224 to the connecting leg 222 at the proper angle α by insertion of a pin 140 through the apertures in the adjustment plate 226 and the connecting leg 222. The connecting leg 222 is similar to the connecting leg 202, and is provided with apertures 230 for attachment of the insert portion 40 to the connecting leg 222 as previously described.

Figure 11 illustrates a fourth embodiment of a ridge hook 240 comprising a connecting leg 242 hingedly attached to a retaining leg 244 through a hinged connection 248. The retaining leg 244 is rigidly attached to a retaining plate 246 adapted to contact the opposed roof deck. The underside of the retaining plate 246 is provided with a plurality of teeth 252 adapted to bite into the roof deck. Additionally, the retaining plate 246 can be provided with a plurality of apertures 254 for attachment of the retaining plate 246 to the roof deck. The connecting leg 242 is similar to the connecting legs 202, 222, and is provided with apertures 250 for attachment of the insert portion 40 to the connecting leg 242 as previously described.

As an alternative to the pins 140 and retainers 142 described herein, one or more of the rails, the jacks, the planks, and the feet can be provided with generally well-known spring-loaded pins to eliminate the need for an adequate supply of pins and the inadvertent r misplacement of pins that can occur. In addition to the components described herein, the scaffolding system 10 can also comprise storage receptacles (not shown) for tools, supplies, materials, and the like, which are attached to and supportable by the rails 20 and/or the planks 24. The storage receptacles can be adapted with cradles, apertures, and the like, for securing the receptacles to the rails 20 and/or the planks 24 with pins as generally previously described. Furthermore, the scaffolding system 10 can be provided with clips or similar devices which can be inserted in the apertures in the rails 20 and/or the planks 24 to secure electrical and pneumatic power lines to the scaffolding system 10 along the rails 20 and/or the planks 24. Alternatively, the rails 20 and/or the planks 24 can be provided with integrated electrical and pneumatic power lines extending through the interior channelways thereof to provide sufficient electrical and pneumatic power in a self-contained, organized assembly. Quick-connect fittings would be utilized to interconnect the pneumatic power lines as rails and planks are assembled into the completed scaffolding system. Alternatively, the electrical and pneumatic power lines can be adapted for automatic interconnection upon connecting adjacent rails 20 or planks 24.

Figure 12 illustrates an alternate embodiment of the invention comprising an alternate configuration of the elements previously described herein. Thus, like elements are identified with like numerals. The modular roof installation scaffolding system 30 is identical to the modular roof installation scaffolding system 10 except for the inclusion of a second plank 24 attached directly to the rails 20 parallel to the first plank 24 supported by the jack 22. The second plank 24 is attached to the rails 20 through the previously described pins 140 and retainers 142. The second plank 24 provides additional support for a roofer, and further inhibits contact of the roofer's feet with the underlying installed roofing materials. Additionally, when a plurality of rails 20 are assembled into a framework extending across a roof 12, the second plank 24 can be staggered relative to the first plank 24 to enhance the rigidity and strength of the framework. The second plank 24 can be readily moved along the rails 20 by removing the pins 140 and resetting the pins at a new location.

Figure 13 illustrates an alternative embodiment of a foot 270 comprising a rail cradle 272 having a bottom wall 278 and a pair of side walls 280, 282, a post 274, and a support plate 276, generally as previously described herein. However the support plate 276 has increased lateral dimensions, i.e. length and width, to reduce the pressure of the foot 270 on the underlying installed roofing materials. This is particularly important when installing readily deformable roofing materials such as steel roofing, copper roofing, and the like. The foot 270 can also be provided with a cushion 288 attached to the underside of the support plat&276 to further cushion the contact of the foot 270 with the underlying roofing materials.

\Figure 14 illustrates a line support pin 260 supporting and managing supply lines, such as pneumatic lines, electrical cords, vacuum hoses, water hoses, and the like. The line support pin 260 comprises a pin portion 262 rigidly attached to a cradle portion 264. The pin portion 262 is adapted for slidable insertion into the apertures 46 and the side apertures 48 in the rails 20. The pin portion 262 can be adapted for selective attachment of a retainer 142, particularly when the pin portion 262 is inserted into the side apertures 48. The cradle portion 264 is a generally upwardly opening, C-shaped element adapted for insertion and cradling of one or more supply lines, such as a pneumatic hose 266. The upwardly opening, C-shaped cradle portion 264 enables a selected supply line to be inserted or removed without disturbing the other supply lines that may be supported by the line support pin 260. It will be evident to a person of ordinary skill in the art that other configurations of the cradle portion 264 can be utilized, for example a configuration providing a friction engagement with the one or more supply lines.

A plurality of line support pins 260 can be readily attached to the rails 20 and the planks 24 at a suitable spacing to maintain the supply lines neatly along the rails 20 and the planks 24, thereby keeping the supply lines organized and reducing the potential for injury due to a roofer tripping over a line. The line support pins 260 can be inserted laterally into the rails 20 and the planks 24 to minimize the vertical profile of the supply lines, thereby further reducing the potential for tripping.

While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation. Reasonable variation and modification are possible within the scope of the forgoing disclosure and drawings without departing from the spirit of the invention which is defined in the appended claims.