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Title:
A SCAFFOLD SAFETY STILLAGE AND SYSTEM
Document Type and Number:
WIPO Patent Application WO/2014/197932
Kind Code:
A1
Abstract:
A scaffold safety system and stillage, wherein the stillage contains either all protective tubes for scaffold components, part protective tubes for scaffold components and part storage buckets for storing at least one type of protective component for a scaffold component, or all storage buckets for storing at least one type of protective component for a scaffold component, the protective tubes and protective components to minimise injury or damage to property from exposed scaffold components.

Inventors:
DARK DOUGLAS GEORGE (AU)
Application Number:
PCT/AU2014/000606
Publication Date:
December 18, 2014
Filing Date:
June 11, 2014
Export Citation:
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Assignee:
EZ2C SAFETY INNOVATIONS PTY LTD (AU)
International Classes:
E04G5/00; B65D19/02
Foreign References:
US5829362A1998-11-03
US5609451A1997-03-11
USD365506S1995-12-26
US6971518B12005-12-06
GB2491089A2012-11-28
Other References:
ANONYMOUS: "Scaffold Protection Products", COMPONENT FORCE, 20 September 2012 (2012-09-20), Retrieved from the Internet [retrieved on 20140722]
Attorney, Agent or Firm:
CULLENS PATENT AND TRADE MARK ATTORNEYS (239 George StreetBrisbane, Queensland 4000, AU)
Download PDF:
Claims:
CLAIMS

1. A scaffold safety system and stillage, including a stillage containing either

(a) all protective tubes for scaffold components;

(b) part protective tubes for scaffold components and part storage buckets for storing at least one type of protective component for a scaffold component; or

(c) all storage buckets for storing at least one type of protective component for a scaffold component,

the protective tubes and protective components to minimise injury or damage to property from exposed scaffold components.

2. A scaffold safety system including a stillage containing all protective tubes for scaffold components.

3. A scaffold safety system including a stillage containing part protective tubes for scaffold components and part storage buckets for storing at least one type of protective component for a scaffold component.

4. A scaffold safety system including a stillage containing all storage buckets for storing at least one type of protective component for a scaffold component.

5. A scaffold safety system as claimed in claim 1 wherein the stillage is provided containing protective tubes for scaffold components and storage buckets for storing at least one type of protective component for a scaffold component, the configuration and proportion of protective tubes and protective components allowing same to be provided to a scaffold site in appropriate numbers to allow operators to apply the protective tubes and protective components to the scaffold.

6. A scaffold safety system as claimed in any one of the preceding claims wherein one or more internal dividers is provided within the stillage in order to divide an internal volume of the stillage into areas.

7. A scaffold safety system as claimed in claim 6 wherein the at least one internal divider is removable from the stillage or reconfigurable within the stillage.

8. A scaffold safety system as claimed in any one of the preceding claims wherein the stillage is provided with a base wall and at least one sidewall upstanding from the base wall to define a storage volume with an open top, a number of leg members, each with a lower foot shaped to receive or at least abut a portion of a leg of another stillage in order to allow stacking of the stillages on top of one another.

9. A scaffold safety system as claimed in claim 5 wherein the configuration of the stillage is adjusted to suit the combination of the protective tubes and storage buckets for storing at least one type of protective component for a scaffold component.

10. A scaffold safety system as claimed in claim 9 wherein the storage buckets are provided in stillage with internal dividers such that the internal dividers define a volume or area into which a particularly size storage buckets are received to allow security during transport of the stillage.

11. A scaffold safety system as claimed in claim 5, claim 9 or claim 10 wherein the storage buckets are configured such that their dimensions are multiples of one another such that a large storage bucket occupies the same volume as two equally sized small storage buckets and vice versa.

12. A scaffold safety system as claimed in claim 10 wherein storage buckets are supported

directly by a base wall of the stillage. If suspension is required, an enlarged lip it may be provided about the bucket in order to support the bucket relative to the internal dividers.

13. A scaffold safety system as claimed in any one of the preceding claims wherein different types of protective component are provided in each storage bucket in a stillage, the protective component chosen from the group including surface protector shims, thread safety caps, coupler midrail adapters, star covers, the spigot covers, tube end caps and the protective tubes themselves.

14. A scaffold safety system as claimed in claim 13 wherein the protective tubes are placed

directly into the stillage and the other components are stored in a storage bucket located in the stillage.

15. A scaffold safety system as claimed in claim 13 or claim 14 wherein the protective tubes and protective components are all substantially the same high visibility colour to provide a visual warning to operators

Description:
A SCAFFOLD SAFETY STILLAGE AND SYSTEM

TECHNICAL FIELD

[0001] The present invention relates to a scaffold safety stillage and system. BACKGROUND ART

[0002] A variety of problems exist with the protective components used in relation to scaffold systems and the method for storage and transporting them.

[0003] The present invention is directed towards providing not only a coherent approach to protection of scaffold equipment for occupational health and safety reasons to minimise or prevent injury and damage to other equipment, but also to provide a convenient and efficient way of storage and transport of the various protective components that may be required.

[0004] It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.

SUMMARY OF INVENTION

[0005] The present invention is directed to a scaffold safety stillage and system, which may at least partially overcome at least one of the abovementioned disadvantages or provide the consumer with a useful or commercial choice.

[0006] With the foregoing in view, the present invention in one form, resides broadly in a scaffold safety system and stillage, including a stillage containing either;

(a) all protective tubes for scaffold components;

(b) part protective tubes for scaffold components and part storage buckets for storing at least one type of protective component for a scaffold component; or

(c) all storage buckets for storing at least one type of protective component for a scaffold component; the protective tubes and protective components to minimise injury or damage to property from exposed scaffold components.

[0007] Typically, the stillage is provided containing each of the above in various

configurations and proportions allowing protective component to be provided to a scaffold site in appropriate numbers to allow operators to apply the protective components to the scaffold.

[0008] A stillage generally is similar to a pallet or skid but with a cage or sides or some other similar form of support which may be specifically tailored to the material or items the stillage is intended to carry. The stillage is preferably designed to be stackable.

[0009] The stillage is generally rectangular in plan and preferably, the stillage is

substantially square with four equal length sides when viewed in plan. The stillage will normally include a base platform upon which items or materials placed into the stillage is supported.

Normally, this base platform will include a grate or grill and is typically planar. The base platform may have reinforcing or a support frame provided.

[0010] Alternatively, a planar support frame can be provided with a grill or grate thereon to support material or items.

[0011] The stillage includes at least one and preferably a number (usually four) upstanding sidewalls. Normally the upstanding sidewalls will extend upwardly from the edge or periphery of the base platform or substantially adjacent the edge of the base platform or support frame. Each of the sidewalls will preferably include a grill or grate extending between the base platform and an upper rail.

[0012] It is preferred that rigid members are provided to form a support frame for the stillage with the wall members then being grill or grate. The support frame will typically include four leg members. Preferably, the base platform or support frame is connected or attached to each of the leg members at or towards lower end of each of the leg members. A rail will typically extend between the legs at or towards an upper end of each of the leg members to form a substantially rectangular frame. Normally each rail will be parallel to the base platform. The sidewalls will then typically have grill or grate structures installed between the rail and the base platform to form an enclosed stillage with an open top.

[0013] A cap may be provided at an upper end of each leg in order to cover the end of the leg. Further, a foot may be provided on each leg at a lower end. Normally, the foot will be enlarged and will be designed to spread the weight of the stillage including the contents over a large area than the cross-sectional area of the leg. Preferably, each foot will be substantially circular.

[0014] The leg members will preferably extend below the base platform in order to keep the base platform spaced above the ground surface. This also allows a forklift to insert lifting tynes under and between stacked stillages.

[0015] Each of the support frame members provided including the legs, the rails and any support frame members associated with the base platform will normally be tubular and may be of any cross-section although a circular cross-sectional shape is preferred.

[0016] One or more internal dividers may be provided within the stillage in order to divide the internal volume of the stillage into areas. The internal dividers may be frame members only or dividing wall structures may be provided. Internal dividers may be provided between the rails of the stillage only.

[0017] The internal dividers may have any configuration but normally, the internal dividers will divide the internal volume of the stillage into regular shapes. The configuration of the regular shapes within the internal volume may differ between stillages in order to carry different components and different combinations of components.

[0018] The internal dividers may be removable from the stillage or reconfigurable. The internal dividers may be capable of being removably fixed in position in the stillage.

[0019] Typically, all of the components of the stillage itself are manufactured from metal for strength, rigidity and robustness.

[0020] The foot provided on the leg members may be shaped to receive or at least abut a portion of the leg or cap of another stillage in order to allow stacking of the stillages on top of one another. The walls of the stillage may be capable of being opened as this will allow access to the stillage if the stillage is provided in stacked format although this is less preferred. As mentioned above, preferably each stillage has an open top but a closure panel or assembly may be provided to allow the stillage to be closed or secured.

[0021] The two main types of components provided in the stillage according to the present invention will be protective tubes and/or storage buckets. As mentioned above, the configuration and combination of these two types of components will be adjusted according to the

requirements of the user and therefore, stillage will normally be provided in different

configurations to suit.

[0022] The storage buckets according to the present invention will normally be provided in stillage with internal dividers such that the internal dividers define a volume or area into which a particularly size storage buckets can be received to allow security during transport of the stillage. Normally, the storage bucket will be a container having one or more sidewalls and a base wall and normally be provided with a lid. The storage buckets will also normally be provided with a handle in order to allow removal of the storage bucket from the stillage and also to allow the storage buckets to be carried on site for distribution and/or collection of the protective components stored therein.

[0023] The storage bucket will normally be sized to allow a single person to carry the storage bucket, even when full or partially full. The storage bucket will normally be

manufactured from a lightweight but relatively strong plastic material in order to reduce weight. Typically, the buckets will be rigid and dimensionally stable.

[0024] The storage bucket may be of any shape, but preferably, the storage buckets will be substantially rectangular in cross-section to allow for easy configuration of the internal volume of the stillage and/or to minimise waste of space in stillage.

[0025] It is particularly preferred that the storage buckets be brightly coloured in order to increase the visibility of storage buckets. A particularly preferred colour is a vivid or bright yellow colour. One or more identification panels may be provided on a storage bucket in order to identify the nature and number of the contents of the storage bucket and/or the particular stillage into which the storage bucket is placed. This may allow the storage buckets to be more easily tracked and their whereabouts more easily ascertained.

[0026] Each stillage may contain one or more storage buckets. Normally, storage buckets will be provided in different sizes depending upon the protective components that are contained within the storage buckets. For example, the depth as well as the length and width of storage buckets may vary but normally, the dimensions will be multiples of one another such that a large storage bucket occupies the same volume as two equally sized small storage buckets and vice versa. Again, this will preferably allow more efficient use of the volume of the stillage when transporting storage buckets in the stillage.

[0027] Storage buckets may be suspended from the internal dividers provided in the stillage or more preferably, will be supported directly by the base platform of the stillage. If suspension is required, an enlarged lip it may be provided about the bucket in order to support the bucket relative to the internal dividers.

[0028] The protective tubes or components in the storage buckets provided according to the present invention are protective components to be used in relation to scaffold structures to minimise or prevent injury to workers and also to minimise or prevent damage to other equipment from accidental impact or contact with the scaffold structures. Normally, different types of protective components will be provided in association with the stillage of the present invention. The different types will normally include surface protector shims, thread safety caps, coupler midrail adapters, star covers, the spigot covers, tube end caps and the protective tubes themselves.

[0029] Normally, the protective tubes will be placed directly into the stillage and the other components will be stored in a storage bucket located in the stillage. Normally, the protective tubes are contained within a volume in the stillage (whether a part of the volume of the stillage or the entire volume of the stillage) and will normally be laid out substantially parallel to one another in order to increase storage capacity of the stillage. Typically, the protective tubes are sized to fit within the portion in which they are stored with a small clearance typically provided at either end to allow for easy insertion or removal of the protective tubes from the stillage.

[0030] The protective tubes are used to provide a visual warning to operators through the provision of the protective tubes in a bright colour as well as to provide cushioning if accidental impact occurs with a scaffold member. Normally, the protective tube is located around an elongate scaffold tube and normally, substantially along the length of the elongate scaffold tube. Although the protective tube is normally provided in one or more standard lengths, multiple protective tubes can be used to cover an elongate scaffold tube. Preferred dimensions are an inner diameter of approximately 48 mm, an outer diameter of approximately 68 mm resulting in a material thickness of approximately 10 mm and a preferred overall length of between 500 mm and 1000 mm and normally approximately 850 mm.

[0031] Normally, the protective tubes will be provided with bright or contrasting colours. Normally, a bright yellow is preferred or alternatively, alternating red-and- white diagonal stripes may be used over the length of the protective tube. This will increase visibility of the protective tube. Each protective tube is normally manufactured to be slightly resilient to provide a cushioning effect and preferably, a foam material is preferred. It is also particularly preferred that the material used be UV resistant or resist UV degradation.

[0032] The tube is normally hollow or annular in cross-section with a split along the length of the tube allowing the tube to be opened along its length to receive a scaffold member. A bore will normally be provided through the centre of the tube and the bore is normally approximately equal to the dimension of the scaffold tube to which the tube is to be fitted.

[0033] The surface protector shim provided according to the present invention is preferably provided to reduce or eliminate damage caused by the impact and fastening of a locking bolt component of a scaffold beam clamp or Gravlock ® clamp to a painted or coated metal structure. It is to be noted that a scaffold beam clamp or Gravlock ® clamp is required to be tightened with a minimum torque of 54 Nm and this can cause damage, cracking or flaking of the paint or coat provided on a metal structure.

[0034] The surface protector shim will typically be interposed between the structure and the locking bolt component. It is important that the surface protector shim not affect the quality of the attachment or connection between the locking bolts component and the structure.

[0035] It is preferred that the surface protector shim be a substantially planar blank of material. The shim will normally be provided in a bright colour such as yellow to increase visibility of the shim in order to allow both confirmation of its use and location and also to allow easy identification of the shim. Again, it is preferred that the material used be resistant to UV degradation. It is also preferred that the material used be at least somewhat shock and impact absorbing. A metal shim can therefore be used but plastic is typically preferred and nylon is particularly preferred.

[0036] The shim itself is generally rectangular in shape and between about 1mm and 5 mm in thickness. Multiple shims will normally be stored in any storage bucket provided with the stillage of the present invention.

[0037] The thread safety cap provided according to the present invention is directed towards covering a protmding fastening component of a scaffold coupler fitting or accessory. Again, the thread safety cap will normally be at least slightly resilient in order to provide a cushioning effect. The thread safety cap will normally be provided with a body portion having an internal thread provided in order to engage with the thread of a protruding fastening component.

[0038] The body portion can be any shape but is normally rounded or partially spherical. Again, the body portion is normally brightly coloured for enhanced visibility. The body will normally be manufactured from a plastic or rubber compound material with polyethylene being preferred and foamed low-density polyethylene being particularly preferred.

[0039] A threaded portion is normally provided in the body in order to engage the end of a fastening component. Normally the body will have a stepped opening with an inner opening of a smaller dimension than an outer opening. This allows a threaded component to be inserted into the inner opening and the outer opening being provided to receive or at least partially receive a nut or similar provided on the end of the threaded fastener of the scaffold assembly. If the nut is not present, then the thread safety cap will still function. Normally, a small clearance gap is provided when sizing the outer opening to provide clearance between the inner surface of the outer opening and any nut to be received therein to minimise or prevent friction with the thread safety cap when attaching or detaching from the threaded fastener.

[0040] The threaded portion is typically provided as a tubular insert within the body of the thread safety cap. The insert will normally be internally threaded and have an outer surface which is adapted to be fixed within the body portion. Any mechanism can be used to fix the threaded portion within the body and normally an adhesive or similar will be used.

[0041] Alternatively, the thread can be directly formed into the safety cap.

[0042] The coupler adapter provided according to the present invention is to be used typically where standard outer diameter scaffold tubing needs to be coupled to other tubing members of different dimension. The adapter is typically arch shaped having an intrados and an extrados.

[0043] Preferably, the radius of the intrados of the preferred arch configuration is smaller than the radius of the extrados. This allows the respective surfaces to abut tubing components having different radiuses or diameters. For example, a smaller external diameter member will abut the intrados and then the extrados can be received within a portion of a coupler adapted to normally receive a larger diameter member. This allows the same coupler to be used with either the smaller or larger diameter members.

[0044] Typically, a side flange is provided on either side extending radially outward from the edges of the extrados in order to receive a coupler portion therebetween to properly locate the adapter relative to the coupler by abutting the extrados and the side flanges.

[0045] Again, it is preferred that the coupler adapter is manufactured of a lightweight but rigid and strong material such as plastic and high density polyethylene or polypropylene or nylon is preferred. Due to its use, the coupler adapter may be brightly coloured to increase visibility but due to its location during use, it may not be.

[0046] The star cover provided according to the present invention is typically provided to cover a portion of a scaffold member which is used to mount other components relative thereto. The scaffold member normally has a number of triangular portions extending radially from the member which gives the appearance of a "Star shaped portion". [0047] Again, it is preferred that the star cover is brightly coloured in order to increase visibility. As with other protective components described above, it is preferred that the star cover be slightly resilient to provide a cushioning effect, and be resistant to UV degradation. Therefore, it is again preferred that the star cover is manufactured from a plastic or rubber compound material and particularly foamed low-density polyethylene.

[0048] The shape of the star cover will generally be determined according to the shape of the portion to which it is to be engaged. Generally, the star shaped portion of the scaffold member is formed by triangular shaped extensions extending radially from a tube. Typically there are four extensions but there may be more or fewer. The star cover therefore is typically generally triangular in shape to engage one of the extensions.

[0049] It is particularly preferred that the star cover have a triangular cover portion with a concentric locator portion provided within the triangular cover portion. The cover portion will preferably include a pair of side walls angled relative to one another with a top wall linking the sidewalls, and an open bottom. The locator portion will preferably extend from an underside of the top wall in order to define a V-shaped recess in the star cover in order to receive a triangular shaped extension on a scaffold member. Typically, the recess will be dimensioned to provide a friction or interference fit of the star cover with the extension.

[0050] The spigot cover of the present invention is provided to cover an end of a scaffold member. Typically, the spigot cover receives the end of the scaffold member entirely and contains the end of the scaffold member within the spigot cover.

[0051] The spigot cover is again typically resilient to provide some cushioning as well as being resistant to UV degradation. Again therefore, a plastic or rubber compound material is preferred and foamed low-density polyethylene is particularly preferred. Further, it is again preferred that the spigot cover is brightly coloured in order to increase visibility.

[0052] The spigot cover will normally be configured as a tubular portion with a partially spherical end. The tubular portion therefore typically defines an opening therein for receiving the end of a spigot or tube. The spigot cover is typically resilient and therefore, may require some deformation in order to fit the cover over the spigot. Normally this will create an interference or friction fit to hold the spigot cover on the spigot or tube until forcibly removed.

[0053] The tube end cap of the present invention is typically resilient to provide some cushioning as well as being resistant to UV degradation. Again therefore a plastic or rubber compound material is preferred and foamed low-density polyethylene is particularly preferred. Further, it is again preferred that the tube end cap is brightly coloured in order to increase visibility.

[0054] The tube end cap will normally have a head and an insert portion. The head is typically enlarged so as to abut and cover the end of a tube with the insert portion received inside the tube. The head can have any shape but is normally spherical or rounded to some degree. The head may be provided with a peripheral dependent lip, substantially parallel to the insert portion, in order to define an opening into which the end edge of the tube can be received. This may assist with location of the tube end cap on the tube and minimise the chance of accidental removal.

[0055] The insert portion will generally be shaped and dimensioned to fit within a scaffold tube which is typically of one of a number of standard internal diameters. The insert portion can have any shape although normally, the internal shape of the tube is circular and therefore, the shape of the insert portion will normally be cylindrical or annular (if hollow). Typically, the insert portion is elongate extending some distance into the end of the tube.

[0056] Typically, the insert portion will be resilient in order to allow some deformation of the insert portion during insertion. A number of circumferentially extending fins or similar such as one or more helical ridges or thread portions may be provided on an outer surface of the insert portion and these fins may be deformable, at least to a small degree, in order to provide an interference or friction fit when inserted but to allow easier removal because of the decrease in contact area between the fins and the inner surface of the tube. Normally, the fins are provided spaced equally along the insert portion.

[0057] In an alternative embodiment, the present invention resides in a scaffold safety system including a stillage containing all protective tubes for scaffold components.

[0058] In a further alternative embodiment, the present invention resides in a scaffold safety system including a stillage containing part protective tubes for scaffold components and part storage buckets for storing at least one type of protective component for a scaffold component.

[0059] In still a further alternative embodiment, the present invention resides in a scaffold safety system including a stillage containing all storage buckets for storing at least one type of protective component for a scaffold component.

[0060] Further, any of the particular protective components may be considered as a separate invention. [0061] Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the invention.

[0062] The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.

BRIEF DESCRIPTION OF DRAWINGS

[0063] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

[0064] Figure 1 A is an isometric view of a four bay stillage according to a preferred embodiment of the present invention.

[0065] Figure IB is an isometric view of a surface protector shim according to a preferred embodiment of the present invention.

[0066] Figure 1C is an isometric view of a thread safety cap according to a preferred embodiment of the present invention.

[0067] Figure ID is an isometric view of a coupler midrail adapter according to a preferred embodiment of the present invention.

[0068] Figure IE is an isometric view of a star cover according to a preferred embodiment of the present invention.

[0069] Figure IF is an isometric view of a protective tube according to a preferred embodiment of the present invention.

[0070] Figure 1G is an isometric view of a spigot cover according to a preferred embodiment of the present invention.

[0071] Figure 1H is an isometric view of a tube end cap according to a preferred embodiment of the present invention.

[0072] Figure 2A is an isometric view of a 100% bucket storage stillage according to a preferred embodiment of the present invention.

[0073] Figure 2B is a top view of the stillage illustrated in Figure 2A.

[0074] Figure 2C is a front elevation view of the stillage illustrated in Figure 2A.

[0075] Figure 2D is a side elevation view of the stillage illustrated in Figure 2A.

[0076] Figure 3A is an isometric view of a 50% protective tubing/50% bucket storage stillage according to a preferred embodiment of the present invention.

[0077] Figure 3B is a top view of the stillage illustrated in Figure 3 A.

[0078] Figure 3C is a front elevation view of the stillage illustrated in Figure 3A.

[0079] Figure 3D is a side elevation view of the stillage illustrated in Figure 3A.

[0080] Figure 4A is an isometric view of a 100% protective tubing stillage according to a preferred embodiment of the present invention.

[0081] Figure 4B is a top view of the stillage illustrated in Figure 4 A.

[0082] Figure 4C is a front elevation view of the stillage illustrated in Figure 4A.

[0083] Figure 4D is a side elevation view of the stillage illustrated in Figure 4A.

[0084] Figure 5 A is an isometric view from above of a scaffold fitting safety bucket according to a preferred embodiment of the present invention.

[0085] Figure 5B is an isometric view from below of the scaffold fitting safety bucket illustrated in Figure 5A.

[0086] Figure 5C is a plan view of the scaffold fitting safety bucket illustrated in Figure 5A.

[0087] Figure 5D is a side view of the scaffold fitting safety bucket illustrated in Figure 5 A.

[0088] Figure 5E is a front elevation view of the scaffold fitting safety bucket illustrated in Figure 5 A.

[0089] Figure 5F is a view from the bottom of the scaffold fitting safety bucket illustrated in Figure 5 A.

[0090] Figure 6A is an isometric view of a coupler midrail adapter according to a preferred embodiment of the present invention.

[0091] Figure 6B is a view from below of the coupler midrail adapter illustrated in Figure 6A.

[0092] Figure 6C is an end view of the coupler midrail adapter illustrated in Figure 6A.

[0093] Figure 6D is a side elevation view of the coupler midrail adapter illustrated in Figure 6A.

[0094] Figure 7A is an isometric view of a protective tube according to a preferred embodiment of the present invention.

[0095] Figure 7B is a view from below of the protective tube illustrated in Figure 7A.

[0096] Figure 7C is a view from the rear of the protective tube illustrated in Figure 7A.

[0097] Figure 7D is a left end view of the protective tube illustrated in Figure 7A.

[0098] Figure 7 E is a plan view of the protective tube illustrated in Figure 7A.

[0099] Figure 7F is a right end view of the protective tube illustrated in Figure 7A.

[0100] Figure 7G is a view from the front of the protective tube illustrated in Figure 7A.

[0101] Figure 8A is an isometric front view of a tube end cap according to a preferred embodiment of the present invention.

[0102] Figure 8B is an isometric rear view of the tube end cap illustrated in Figure 8A.

[0103] Figure 8C is a front view of the tube end cap illustrated in Figure 8A.

[0104] Figure 8D is a side elevation view of the tube end cap illustrated in Figure 8A.

[0105] Figure 8E is a rear view of the tube end cap illustrated in Figure 8 A.

[0106] Figure 8F is a plan view of the tube end cap illustrated in Figure 8A.

[0107] Figure 9A is an isometric front view of a star cover according to a preferred embodiment of the present invention.

[0108] Figure 9B is a plan view of the star cover illustrated in Figure 9A. [0109] Figure 9C is a front elevation view of the star cover illustrated in Figure 9A.

[0110] Figure 9D is a side elevation view of the star cover illustrated in Figure 9A.

[0111] Figure 9E is a rear view of the star cover illustrated in Figure 9A.

[0112] Figure 9F is a view from the bottom of the star cover illustrated in Figure 9A.

[0113] Figure 9G is an isometric rear view of the star cover illustrated in Figure 9A.

[0114] Figure 10A is an isometric view of a surface protector shim according to a preferred embodiment of the present invention.

[0115] Figure 10B is a plan view of the surface protector shim illustrated in Figure 1 OA.

[0116] Figure I OC is a side view of the surface protector shim illustrated in Figure 10A.

[0117] Figure 10D is an end view of the surface protector shim illustrated in Figure 10A.

[0118] Figure 11A is an isometric view of a spigot cover according to a preferred embodiment of the present invention.

[0119] Figure 1 IB is a front view of the spigot cover illustrated in Figure 1 1 A.

[0120] Figure 11C is a left end view of the spigot cover illustrated in Figure 11 A.

[0121] Figure 1 ID is a plan view of the spigot cover illustrated in Figure 11 A.

[0122] Figure 1 IE is a right end view of the spigot cover illustrated in Figure 1 1 A.

[0123] Figure 12A is an isometric view from the top of a thread safety cap according to a preferred embodiment of the present invention.

[0124] Figure 12B is an exploded isometric view of the thread safety cap illustrated in Figure 12A with preferred thread insert.

[0125] Figure 12C is an isometric view from the side of the thread safety cap illustrated in Figure 12 A.

[0126] Figure 12D is a plan view of the thread safety cap illustrated in Figure 12A.

[0127] Figure 12E is a side view of the thread safety cap illustrated in Figure 12A. [0128] Figure 12F is a sectional side view along line A-A of the thread safety cap illustrated in Figure 12 A.

[0129] Figure 12G is a bottom view of the thread safety cap illustrated in Figure 12A.

[0130] Figure 13 is an assembled view of a tube end cap on a scaffold portion according to a preferred embodiment of the present invention.

[0131] Figure 14 is an assembled view of a star cover used on a scaffold portion according to a preferred embodiment of the present invention.

[0132] Figure 15 is an isometric assembled view of a thread safety cap in use on a scaffold portion according to a preferred embodiment.

[0133] Figure 15A shows the preferred threaded insert on the thread safety cap of the preferred embodiment.

[0134] Figure 15B is a side view of the thread safety cap illustrated in Figure 15.

[0135] Figure 15C is a sectional view of the thread safety cap illustrated in Figure 15A.

[0136] Figure 16 is an assembled isometric view of the surface protector shim of a preferred embodiment in use.

[0137] Figure 17 is an isometric view from above of the coupler midrail adapter in use according to a preferred embodiment.

[0138] Figure 18 is an isometric view from below of the assembly illustrated in Figure 17.

[0139] Figure 19A is a side view of a coupler with midrail adapter according to a preferred embodiment.

[0140] Figure 19B is an end view of the configuration illustrated in Figure 1 A.

[0141] Figure 19C is a plan view of the configuration illustrated in Figure 19A.

[0142] Figure 19D is a plan view of the configuration illustrated in Figure 19B.

[0143] Figure 20 is an isometric view of a scaffold member with spigot cover fitted according to a preferred embodiment.

[0144] Figure 21 is an exploded isometric view of the configuration illustrated in Figure 19 A.

[0145] Figure 22A is an isometric assembled view showing the protective tube fitted to a number of scaffold members according to a preferred embodiment.

[0146] Figure 22B is an isometric view of the protective tube illustrated in Figure 22A. [0147] Figure 22C is a front elevation view of the protective tube illustrated in Figure 22B. DESCRIPTION OF EMBODIMENTS

[0148] According to a particularly preferred embodiment of the present invention, a scaffold safety stillage 10 and system is provided.

[0149] According to the embodiment illustrated, the scaffold safety stillage is provided in one of three preferred configurations illustrated in Figures 2 to 5. The stillage 10 is provided in various configurations and proportions allowing protective component to be provided to a scaffold site in appropriate numbers to allow operators to apply the protective components to the scaffold.

[0150] The stillage 10 illustrated in Figure 1 A is similar to a pallet or skid but with a cage or sides which is specifically tailored to the material or items the stillage is intended to carry. The stillage 10 is substantially square with four equal length sides when viewed in plan.

[0151] The stillage 10 includes a base platform 11 upon which items or materials placed into the stillage 10 are supported. Normally, this base platform 11 is a grate or grill and is planar.

[0152] The stillage 10 includes four upstanding sidewalls. Normally the upstanding sidewall walls extend upwardly from the edge or periphery of the base platform or substantially adjacent the edge of the base platform. Each of the sidewalls will preferably include a grill or grate extending between the base platform and an upper rail. Alternatively as illustrated in Figure 1 A, a planar lower support frame is provided with a basket shaped grill or grate 12 provided which is attached to the rails 14 and supported by the lower support frame.

[0153] The support frame includes four leg members 13. Preferably, the basket shaped grill or grate 12 is connected or attached to each of the legs 13 over the height of each of the legs 13. A rail 14 extends between the legs 13 at or towards an upper end of each of the legs 13 to form a substantially rectangular frame. Normally, the rail 14 is parallel to the base 11.

[0154] A cap 15 is provided at an upper end of each leg 13 in order to cover the end of the leg 13. Further, a foot 16 is provided on each leg 13 at a lower end. Normally, the foot 16 is enlarged and designed to spread the load of the weight of the stillage including the contents over a larger area than the cross-sectional area of the leg 13. As illustrated, each foot 16 is

substantially circular.

[0155] As seen in Figure 1A, the legs 13 extend below the base platform 11 in order to keep the base platform 11 spaced above the ground surface.

[0156] Each of the support frame members provided including the legs, the rails and any support frame members associated with the base platform are tubular and a circular cross- sectional shape is preferred.

[0157] As illustrated in Figures 1A, 2 and 3, internal dividers 17 may be provided within the stillage 10 in order to divide the internal volume of the stillage into areas. The internal dividers

17 illustrated are frame members provided between the rails 14 of the stillage only.

[0158] The internal dividers 17 will divide the internal volume of the stillage into regular shapes. The configuration of the regular shapes within the internal volume may differ between stillages in order to carry different components and different combinations of components as illustrated.

[0159] The two main types of components provided in stillage according to the present invention are protective tubes 18 and/or storage buckets 19. The configuration and combination of these two types of components will change according to the requirements of the user and therefore, the stillage will normally be provided in different configurations to suit.

[0160] There are three stillage configurations illustrated, the first configuration in Figures 2A to 2D contains all storage buckets for storing protective components to minimise injury or damage to property from exposed scaffold components, the second configuration illustrated in Figures 3 A to 3D including part protective tubes for scaffold components and part storage buckets for storing at least one type of protective component for a scaffold component and the third configuration illustrated in Figures 4A to 4D including all protective tubes for scaffold components.

[0161] Normally, the protective tubes 18 are placed directly into the stillage 10 and the other components are in a storage bucket 19 located in the stillage 10. Normally, the protective tubes

18 are contained within a volume in the stillage (whether a part of the volume of the stillage as illustrated in Figure 3 or the entire volume of the stillage as illustrated in Figure 4) and will normally be laid out substantially parallel to one another in order to increase storage capacity of the stillage. Typically, the protective tubes are sized to fit within the portion in which they are stored with a small clearance typically provided at either end to allow for easy insertion or removal of the protective tubes from the stillage.

[0162] The storage buckets 19 are provided in the stillage with internal dividers 17 such that the internal dividers 17 define a volume or area into which a particularly sized storage bucket can be received to allow security during transport of the stillage.

[0163] Normally, each storage bucket will be a container having one or more sidewalls and a base wall and normally be provided with a lid as illustrated in Figures 5 A to 5F. The storage buckets are also nomially provided with a handle in order to allow removal of the storage bucket from the stillage and also to allow the storage buckets to be carried on site for distribution and/or collection of the protective components stored therein.

[0164] Each storage bucket will normally be sized to allow a single person to carry the storage bucket even when full. The storage bucket will normally be manufactured from a lightweight but relatively strong plastic material in order to reduce weight but be rigid and dimensionally stable.

[0165] The storage bucket may be of any shape, but preferably, the storage buckets will be substantially rectangular in cross-section as illustrated, to allow for easy configuration of the internal volume of the stillage 10 to minimise waste of space in stillage.

[0166] It is particularly preferred that the storage buckets be brightly coloured in order to increase the visibility of storage buckets. A particularly preferred colour is a vivid yellow colour. One or more identification panels 20 may be provided on the storage bucket 19 in order to identify the nature and number of the contents of the storage bucket.

[0167] Normally, different types of protective components are provided in association with the stillage of the present invention. According to the preferred embodiments illustrated, the different types of protective components include surface protector shims 21, thread safety caps 22, coupler midrail adapters 23, star covers 24, spigot covers 25, tube end caps 26 and the protective tubes 18 themselves.

[0168] The coupler midrail adapter 23 illustrated in Figures 6A to 6D is to be used typically where a standard outer diameter scaffold tube 27 needs to be coupled to a smaller dimension tubing member 28 as illustrated in Figures 17 to 19D and 21. This is typically accomplished using a coupler 30 as illustrated in Figures 17 to 21 but Figures 19A to 19D in particular. As illustrated, the coupler 30 is adapted to attach two scaffold tubes of the same dimension together at an angle, normally 90°. The adapter 23 is typically arch shaped having an intrados 31 and an extrados 32 and is fitted into the opening 29 of the coupler 30 in which the smaller dimension scaffold tubing member 28 is located.

[0169] Preferably, the radius of the intrados 31 of the preferred arch configuration is smaller than the radius of the extrados 32. This allows the respective surfaces to abut scaffold components having different radiuses or diameters. As illustrated in Figure 17 and 18, a smaller external diameter member 28 will abut the intrados 31 and then the extrados 32 can be received within a coupler 30 adapted to normally receive a larger diameter member. This allows the same coupler 30 to be used with either the smaller or larger diameter members.

[0170] A side flange 33 is provided on either side extending radially outward from the edges of the extrados 32 in order to receive a coupler portion therebetween to properly locate the adapter by abutting the extrados 32 and the side flanges 33.

[0171] The protective tubes 18 are used to provide a visual warning through the provision of the protective tubes in a bright colour as well as to provide cushioning if accidental impact occurs with a scaffold member. Normally, the protective tube 18 is located around an elongate scaffold tube and normally, substantially along the length of the elongate scaffold tube as illustrated in Figure 22A in particular. Although the protective tube 18 is normally provided in one or more standard lengths, multiple protective tubes can be used to cover an elongate scaffold tube. Preferred dimensions are an inner diameter of approximately 48 mm, an outer diameter of approximately 68 mm resulting in a material thickness of approximately 10 mm and a preferred overall length of between 500 mm and 1000 mm and normally approximately 850 mm.

[0172] Normally, the protective tubes are provided with bright or contrasting colours and a bright yellow is preferred. This will increase visibility of the protective tube. Each protective tube is normally manufactured to be slightly resilient to provide cushioning effect and preferably, a foam material is preferred. It is also particularly preferred that the material used is UV resistant or resist UV degradation.

[0173] As illustrated in Figures 7A to 7G, the protective tube 18 is normally hollow or annular in cross-section with a split 34 along the length of the tube allowing the tube to be opened along its length to receive a scaffold member. A bore 35 is provided through the centre of the tube 18 which is normally approximately equal to the dimension of the scaffold tube to which the protective tube 18 is to be fitted.

[0174] The tube end cap 26 illustrated in Figures 8 A to 8F is resilient to provide some cushioning as well as being resistant to UV degradation. A plastic or rubber material is preferred and foamed low-density polyethylene is particularly preferred. Further, it is again preferred that the tube end cap is brightly coloured in order to increase visibility.

[0175] The tube end cap 26 will has an enlarged head 36 to abut and cover the end of a tube and an insert portion 37 to be received inside the tube as illustrated in Figure 13. The head can have any shape but is normally spherical or rounded to some degree. The head 36 is provided with a peripheral dependent lip 38 in order to define an annular opening 39 into which the end edge of a tube can be received to assist with location of the tube end cap on the tube and minimise the chance of accidental removal.

[0176] The insert portion 37 is shaped and dimensioned to fit within a scaffold tube which is typically of one of a number of standard internal diameters. Typically, the insert portion 37 is resilient in order to allow some deformation of the insert portion 37 during insertion. A number of circumferentially extending fins or ribs 40 are provided on the insert portion 37 and these fins or ribs 40 are deformable at least to a small degree in order to provide an interference or friction fit when inserted but to allow easier removal because of the decrease in contact area between the fins or ribs 40 and the inner surface of the tube.

[0177] The star cover 24 illustrated in Figures 9A to 9G is provided to cover a portion of a scaffold member 41 which is used to mount other components relative thereto as illustrated in Figure 14. The scaffold member 41 normally has a number of triangular portions 42 extending radially from the member 41 which gives the appearance of a "Star shaped portion".

[0178] Again, it is preferred that the star cover 24 is brightly coloured in order to increase visibility. As with other protective components described above, it is preferred that the star cover 24 be slightly resilient to provide a cushioning effect, and resistant to UV degradation.

Therefore, it is again preferred that the star cover 24 is manufactured from a plastic or rubber material and particularly foamed low-density polyethylene although alternative materials could be used.

[0179] Generally, the star shaped portion of the scaffold member 41 is formed by a triangular shaped extensions 42 extending radially from a tube. Typically there are four extensions as illustrated in Figure 14 but there may be more or fewer. The star cover 24 therefore is typically generally triangular in shape. [0180] It is particularly preferred that the star cover 24 have a triangular cover portion 43 with a concentric locator portion 44 provided within the triangular cover portion 43. The cover portion 43 includes a pair of side walls 45 angled relative to one another with a top wall 46 linking the sidewalls and an open bottom. The locator portion 44 extends from an underside of the top wall 46 in order to define a V-shaped recess 47 in the star cover 24 in order to receive a triangular shaped extension 42 on a scaffold member. Typically, the recess 47 is dimensioned to provide a friction or interference fit of the star cover 24 with the extension.

[0181] The surface protector shim 21 illustrated in Figures 10A to 10D is provided to reduce or eliminate damage caused by the impact and fastening of a locking bolt 49 of a scaffold beam clamp 48 to a painted or coated metal beam 50 such as is illustrated in Figure 16. It is to be noted that a scaffold beam clamp 48 is required to be tightened with a minimum torque of 54 N metres and this can cause damage, cracking or flaking of the paint or coat provided on a metal structure.

[0182] A surface protector shim 21 is interposed between the beam 50 and the locking bolts 49. It is preferred that the surface protector shim be a substantially planar blank of material. The shim is normally provided in a bright colour such as yellow to increase visibility of the shim in order to allow both confirmation of its use and location and also to allow easy identification of the shim. Again, it is preferred that the material used be resistant to UV degradation. It is also preferred that the material used be at least somewhat shock and impact absorbing. Plastic is typically preferred and nylon is particularly preferred.

[0183] As illustrated in Figures 10A to 10D, the shim 21 is generally rectangular in shape and between one and 5 mm in thickness. Multiple shims 21 will normally be stored in any storage bucket 19 provided with the stillage 10 of the present invention.

[0184] The spigot cover 25 illustrated in Figures 11 A to 1 IE is provided to cover an end of a scaffold member 41 as illustrated in Figure 20 such that the spigot cover 25 receives the end of the scaffold member entirely and contains the end of the scaffold member within the spigot cover 25.

[0185] The spigot cover is again typically resilient to provide some cushioning as well as being resistant to UV degradation. Again, therefore a plastic or rubber material is preferred and foamed low-density polyethylene is particularly preferred. Further, it is again preferred that the spigot cover is brightly coloured in order to increase visibility.

[0186] The spigot cover 25 will normally be configured as a tubular portion with a partially spherical end. The tubular portion defines an opening 51 therein to for receiving the end of a scaffold member. The spigot cover 25 is typically resilient and therefore, requires some deformation in order to fit the cover over the spigot. Normally this will create an interference or friction fit to hold the spigot cover on the spigot or tube until forcibly removed.

[0187] The thread safety cap 22 illustrated in Figures 12A to 12F is directed towards covering a protruding end of a fastening bolt 52 of a scaffold coupler fitting or accessory 30 which is used to attach two scaffold members 53 to one another. Again, the thread safety cap 22 will normally be at least slightly resilient in order to provide a cushioning effect. The thread safety cap 22 is provided with an external body 54 having an internally threaded insert 55 provided in order to engage with the thread of a protruding fastening component.

[0188] The body 54 can be any shape but is normally rounded or partially spherical. Again, the body 54 is normally brightly coloured for enhanced visibility and is normally manufactured out of a plastic material with polyethylene being preferred and foamed low-density polyethylene being particularly preferred.

[0189] An internally threaded insert 55 is normally provided in the body 54 in order to engage the end of a fastening component. Normally, the body 54 will have a stepped opening with an inner opening of a smaller dimension than an outer opening 56. This allows the internally threaded insert 55 to be inserted into the inner opening and the outer opening 56 being provided to receive or at least partially receive a nut 57 or similar provided on the end of the threaded fastener of the scaffold assembly. Normally, a small clearance gap 58 is provided when sizing the outer opening 56 to provide clearance between the inner surface of the outer opening 56 and any nut 57 to be received therein to minimise or prevent friction with the thread safety cap 22 when attaching or detaching from the threaded fastener.

[0190] The internally threaded insert 55 is internally threaded 59 and has an outer surface which is adapted to be fixed within the body 54. Any mechanism can be used to fix the internally threaded insert 55 within the body 54 and normally an adhesive or similar will be used.

[0191] The stillage is provided containing each of the above in various configurations and proportions allowing protective component to be provided to a scaffold site inappropriate numbers to allow operators to apply the protective components to the scaffold.

[0192] In the present specification and claims (if any), the word 'comprising' and its derivatives including 'comprises' and 'comprise' include each of the stated integers but does not exclude the inclusion of one or more further integers. [0193] Reference throughout this specification to 'one embodiment' or 'an embodiment' means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases 'in one embodiment' or 'in an embodiment' in various places throughout this specification are not necessarily all referring to the same embodiment.

Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[0194] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.