FIELD OF THE INVENTION

The invention generally relates to a scaffold system suitable for use with low to medium height brick wall construction as is frequent in the brick and block laying industry.

BACKGROUND

A scaffold is a temporary or movable platform for workers (as bricklayers, painters, or miners) to stand or sit on when working at a height above the floor or ground. In the brick or block laying industry, a scaffold is typically used to construct brick or block walls higher than a person may comfortably reach. A scaffold used in the in the brick and block laying industry is generally desired to allow a worker to build a wall a height of one or two stories.

One form of scaffold system is shown in Figure 1 which is known as an H-frame scaffold and constructed from many interlinking members. This scaffold system is generally designed to support a person only, and is not designed to support masonry work, such as large brick or block loads that may be desired to be stacked upon it. Figure 2 shows a scaffold system generally designed for use with residential buildings. This scaffold system is multi-purpose and generally set up for builders to do the facia, soffit also suits painters and is expected to be used also by the brick layer. However, the scaffold is not wide enough for bricks and a brick layer. A further disadvantage is that the scaffold system must be erected too far away from the building for a brick layer to comfortably lay bricks, which may lead to injury.

Figure 3 and Figure 4 shows other examples of scaffolding systems which are readily available for hire, comply with health and safety regulations when constructed correctly. However these scaffolding systems are not suitable for masonry work as they will not handle being loaded with materials using for brick and block wall construction. Further, the scaffolding systems shows are limited to a small working area of around 3 to 4 metres in width. The work space required to erect brick and block walls vary in length, however they are generally much wider than 3 to 4 metres that a typical scaffold section will span. It is cumbersome to build a wall in the 3 to 4 m increments as these scaffolding systems allow, especially as the scaffold would need to be disassembled, moved across a wall face to a new location then reassembled. Often reassembly requires further checks and certification by a safety officer before it is allowed to be used again. Figure 5 shows a typical scaffolding system broken down for transport. Typically, at least two trailer loads, and usually a truck is required to transport even a basic scaffold system.

The abovementioned scaffolds are connected using many bolts/fasteners, each requiring individual attention for assembly. Bolt ends can protrude into working space and snag workers.

The brick and block wall building industry therefore has a desire for a low height scaffold that can be easily constructed and deconstructed, easily transported, and provides the strength required to handle the load of wall materials. The brick and block wall building industry has made some effort to address these desires and one of the most common practices in brick or block laying is the use of a "pallet scaffold" as shown in Figure 6 and Figure 7 which is a low height scaffold assembled from shipping pallets. A pallet scaffold is highly convenient for a bricklayer as pallets are readily available on a building site and can be utilised to erect a temporary scaffold in order to complete brick or block walls to the desired height of one to two stories. The pallet scaffold avoids the need to hire or purchase conventional scaffolding and avoids time wasted assembling the scaffold. However, it is generally accepted that a pallet scaffold evokes safety concerns and is typically forbidden as contrary to health and safety laws.

The object of the invention to go at least some way toward improving upon the scaffold systems of the prior art, or which at least provides the public with a useful choice.

In this specification, where reference has been made to external sources of information, including patent specifications and other documents, this is generally for the purpose of providing a context for discussing the features of the present invention. Unless stated otherwise, reference to such sources of information is not to be construed, in any jurisdiction, as an admission that such sources of information are prior art or form part of the common general knowledge in the art.

SUMMARY OF THE INVENTION

In one aspect the invention consists in a scaffold system comprising :

a base level scaffold structure comprising :

at least two H-frame base level structures that comprise:

at least two posts for vertical orientation and interconnection by at least one support member spanning between at least two of the at least two vertically orientated posts; at least two of the posts for vertical orientation connectable to a further support member adapted to span between two of the at least two base level structures to thereby arrange the at least two base level structures to define a substantially square or rectangular footprint; and

wherein the base level structures are adapted to attach to a first level scaffold structure; and

the first level scaffold structure comprises:

a sidewall structure comprising a set of posts for vertical orientation and adapted to connect to vertically orientated post of the base level to form corners of the sidewall structure; and

a side rail structure adapted to span between the set of posts in the sidewall structure.

In some embodiments, the first level scaffold structure is telescopically received in an opening in the base level scaffold structure.

In some embodiments, the posts for vertical orientation in the base scaffold level comprise at least a hollow extrusion at an upper region, and the posts of the sidewall structure of the first level scaffold structure are adapted to be received within the hollow extrusion at the upper region of the posts for vertical orientation in the base scaffold level.

In some embodiments, the side rail structure comprises a member adapted to span between at least two posts of the sidewall structure of the first level scaffold structure, the opposing ends of the member comprising an open or closed end channel shaped complementary to the profile of the posts of the sidewall structure.

In some embodiments, the posts for vertical orientation of the first level scaffold structure further comprise a collar at least partially encircling an outer surface of each post vertically positioned so as to vertically locate the members of the side rail structure.

In some embodiments, the posts for vertical orientation of the base level scaffold structure each comprise one or more flanges forming points of attachment for a support member.

In some embodiments, the scaffold system further comprises floor members adapted to span between two or more base level structures, the floor members comprising at least one board longitudinally flanked by at least one extrusion that having at least two substantially perpendicular sides. In some embodiments, the floor members further comprise a hook located at longitudinally opposed ends, the hook adapted to fasten to the base level structures.

In some embodiments, the scaffold system further comprises a ladder adapted to span between the position of the floor members and a surface upon which the scaffold system is assembled.

In another aspect the invention consists in a scaffold system comprising :

a base level H-frame scaffold structure comprising :

at least two base level structures each having at least two vertically arranged posts interconnected by at least one support member, two of the at least two base level structures interconnected by a further support member to thereby arrange the two base level structures to define a substantially square or rectangular footprint; and

a first level scaffold structure comprising :

a sidewall structure comprising :

a set of vertically arranged posts positioned above and connecting with the vertically positioned posts of the base level structure to thereby form corners of the sidewall structure;

a plurality of side rails adapted to span between vertically arranged posts of the sidewall structure.

In some embodiments, the vertically arranged posts of the first level scaffold structure are telescopically received in an opening in the vertically arranged posts of the base level scaffold structure.

In some embodiments, the side rail structure comprises a plurality of members adapted to span between at least two posts of the sidewall structure of the first level scaffold structure, each opposing end of each member comprising an open end channel shaped complementary to the profile of the posts of the sidewall structure.

In some embodiments, the vertically orientated posts of the first level scaffold structure further comprise a collar at least partially encircling an outer surface of each post positioned so as to vertically support the side rails.

In some embodiments, the vertically orientated posts of the first level scaffold structure further comprise a collar at least partially encircling an outer surface of each post positioned so as to align the depth of telescopic overlap with the vertically arranged posts of the base level scaffold structure.

In some embodiments, the vertically orientated posts of the base level scaffold structure each comprise one or more flanges forming points of attachment for a support member.

In some embodiments, the scaffold apparatus further comprises floor members adapted to span between two or more base level structures, the floor members comprising at least one board longitudinally flanked by at least one extrusion that having at least two substantially perpendicular sides.

In some embodiments, the floor members further comprise a hook located at

longitudinally opposed ends, the hook adapted to fasten to the base level structures.

In some embodiments, the scaffold apparatus further comprises a ladder adapted to span between the position of the floor members and a surface upon which the scaffold system is assembled.

In another broad aspect the invention consists in a scaffold system comprising a set of components adapted for assembly to a scaffold section, the components comprising : at least two frame components, each comprising :

at least two vertical members separated by at least two interconnecting members, the at least two vertical members comprising a socket;

two or more brace components adapted to span between and connect to the two side frame components;

at least four corner pole components, each adapted to connect with the socket of a vertical member; and

a plurality of support rail components adapted to span between two pole components. In some embodiments, the plurality of support rail components comprise an open end adapted for engagement with the pole components.

In some embodiments, the one or more hand rail components comprise one or more lengths adapted to span the width and/or length of the scaffold section.

In some embodiments, the one or more hand rail components comprise a first length adapted to span the width of the scaffold section, and a second length adapted to span the length of the scaffold section. In some embodiments, the pole components are adapted to telescopically connect with the socket of the frame components

In some embodiments, the pole components comprise a plurality of collars comprising at least a first collar located about the lower region of the pole and adapted to control the depth of telescopic engagement with the socket; and a further collar located about an upper region of the pole and adapted to vertically support rail components. In some embodiments, one of the interconnecting members is adapted to vertically support a plank.

In some embodiments, a plurality of scaffold sections are adapted for connection in a sequence, and adjacent sections share a frame component.

In some embodiments, a base level of the scaffold is assembled from the frame components and the brace components, and the first scaffold level is assembled from the pole components and the support rail components; and wherein the first level is telescopically received by the base level.

In some embodiments, the vertical members comprise one or more mounting flanges adapted to facilitate attachment to the brace components.

In some embodiments, the support rail components further comprise a plurality of floor rail components adapted to span between two adjacent frame components.

In some embodiments, the vertical members comprise a receptacle positioned on an outer, upper region thereof, and the floor rail components have a downwardly disposed member adapted for engagement with the receptacle.

In some embodiments, the some of the plurality of support rail components are adapted to span between the floor support components.

In some embodiments, the vertical members comprise a receptacle located on opposing sides thereof, and with a relative vertical offset.

In another broad aspect the invention consists in a scaffold system comprising a set of components adapted for assembly to a scaffold section, the components comprising : at least two frame components, each comprising :

at least two vertical members separated by at least two interconnecting members, the at least two vertical members comprising a socket;

two or more brace components adapted to span between and connect to the two side frame components;

at least four corner pole components, each adapted to connect with the socket of a vertical member; and

a plurality of support rail components adapted to span between two pole components; wherein the support rail components further comprise a plurality of floor rail components adapted to span between two adjacent frame components; and

wherein the vertical members further comprise a receptacle positioned on an outer, upper region thereof, and the floor rail components have a downwardly disposed member adapted for engagement with the receptacle.

In another broad aspect the invention consists in a method of assembling a scaffold for low level brick and block wall construction, the scaffold comprising a set of components adapted for assembly to a scaffold section, the components comprising :

at least two frame components, each comprising :

at least two vertical members separated by at least two interconnecting members, the at least two vertical members comprising a socket;

two or more brace components adapted to span between and connect to the two side frame components;

at least four corner pole components, each adapted to connect with the socket of a vertical member; and

a plurality of support rail components adapted to span between two pole components; wherein the method comprises:

attaching the brace components to the frame components to establish a base level of the scaffold;

attaching the corner poles to the frame components;

attaching the support rail components to the poles.

In another broad aspect the invention consists in a method of construction a scaffold system adapted to support low level brick and block wall construction comprising :

providing a base level scaffold structure comprising :

arranging a rectangular footprint defined by two base level scaffold structures, the structures comprising two vertically arranged posts interconnected by at least one support member;

interconnecting the two base level scaffold structures with a plurality of cross members; arranging a first level scaffold structure comprising :

telescopically inserting a side wall post to and for each vertically arranged post of the base level structure, the post comprising an exterior profile complementary to an interior profile of the vertically arranged post of the base level structure, and a collar at least partially extending around the exterior thereof to set the telescopic depth thereof; and attaching one or more a side rails between two side wall posts, the side rails comprising a member adapted to span between at least two posts of the sidewall structure of the first level scaffold structure, each opposing end of each member comprising an open end channel shaped complementary to the profile of the posts of the sidewall structure.

In some embodiments, the method further comprises laying floorboards between two or more base level structures, the floor members comprising at least one board

longitudinally flanked by at least one extrusion that having at least two substantially perpendicular sides.

In some embodiments, the method further comprises arranging floor members adapted to span between two or more base level structures, the floor members comprising at least one board longitudinally flanked by at least one extrusion that having at least two substantially perpendicular sides.

The following embodiments may relate to any of the above aspects. Other aspects of the invention may become apparent from the following description which is given by way of example only and with reference to the accompanying drawings.

As used herein the term "and/or" means "and" or "or", or both.

As used herein "(s)" following a noun means the plural and/or singular forms of the noun. The term "comprising" as used in this specification means "consisting at least in part of". When interpreting statements in this specification which include that term, the features, prefaced by that term in each statement or claim, all need to be present but other features can also be present. Related terms such as "comprise" and "comprised" are to be interpreted in the same manner.

This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described by way of example only and with reference to the drawings in which :

Figure 1 shows a generic H-frame scaffold and constructed from many interlinking members.

Figure 2 shows a scaffold system generally designed for use with residential buildings. Figure 3 shows an example of scaffolding systems which are readily available for hire, comply with health and safety regulations when erected correctly, and are often supplied by a client for the purpose of brick and block laying.

Figure 4 shows an example of scaffolding systems which are readily available for hire, comply with health and safety regulations when erected correctly, and are often supplied by a client for the purpose of brick and block laying.

Figure 5 shows a typical scaffolding system broken down for transport.

Figure 6 shows a pallet scaffold.

Figure 7 shows another view of the pallet scaffold.

Figure 8 shows a first embodiment of the scaffold.

Figure 9 shows a partial exploded view of the first embodiment of Figure 8.

Figure 10 shows view of the hand rail member.

Figure 11 shows a view of the vertical poles.

Figure 12 shows an exploded view of reinforced planks to complement first embodiment Figure 13 shows a second embodiment showing an H frame with a pair of receptacles positioned on opposing sides at unequal heights.

Figure 14 shows a floor side beam having downwardly disposed engaging tines adapted for engagement with the hoops of the H frame.

Figure 15 shows side view of planks positioned on the floor side beams.

Figure 16 shows a supported floor.

Figure 17 shows an additional component alternative to the component shown in Figure 14 having a receptacle for receiving a vertical post as shown in Figure 11. Figure 18 shows a door mounted to a vertical post midway along the side of the scaffold.

Figure 19 shows a scaffold disassembled for transport. DETAILED DESCRIPTION

It is desirable to have a scaffold designed to particularly suit masonry work, such as construction of a brick or block wall, a scaffold that is easy to transport, a scaffold that is quick and easy to assemble and disassemble, can handle the load requirements of brick and block layers, and meet health and safety requirements. It is further desirable to have a scaffold that has segments easily connected together to suit the length of each individual wall.

Figures 8 to 19 show exemplary embodiments and components of a scaffold system that address these desired features and provide a scaffold focussed on the specific needs of brick and block layers.

The preferred material for the scaffold structure components is steel. However, other metal materials such as aluminium, alloys, composites, or individually selected components made of different materials may be used where wall thicknesses are appropriately selected to bear desired loads and withstand inevitable wear and tear that occurs in the trade. A steel structure is robust and meet the demands of the trade, yet is still light enough to be easily assembled.

Exemplary embodiments of the scaffold described herein also meet with health and safety criteria, and is supported by a PS4 review to ensure the system is specified to support the loads required for brick and block laying when erected correctly and used in conjunction with the strengthened planks which are described in detail below.

Exemplary embodiments of the scaffold will ultimately reach block work construction heights of approximately 3.6 metres. Some embodiments include an additional lift to suit the concrete pump operator for block fill. However, in some embodiments, the height of the structure can be extended by stacking one layer of the structure on top of another layer.

Exemplary embodiments of the scaffold system comprise segments which can be assembled to stand independently, or be connected together to adjacent segments in order to span various lengths of masonry construction. Figure 8 shows a view of an assembled preferred scaffold according to one embodiment. The scaffold comprises a base level scaffold section 10 and a first level scaffold section 20. The scaffold system is constructed from five component types, these are:

• frames 10

• cross braces 15

• vertical poles 21

• longitudinal rails 23; and

• lateral rails 26.

Figure 9 shows the scaffold components of Figure 8 in a partial exploded form.

It should be noted that the longitudinal and lateral rails are required for a scaffold of rectangular form. Where the scaffold is of a square form, for example, a rail of merely one length would be required.

The base level scaffold section 10 is constructed from a pair of side frames 10. Each side frame 10 comprises at least two vertically arranged posts 11 separated and located by one or more interconnecting members 14. In the first embodiment, at least one interconnecting member 14 is located at the upper region of the vertical posts 11 so as to provide vertical support for planks. Each frame 10 may have any number of vertical poles 11 supported by any number of interconnecting members 14. However, it is most efficient to have two vertical poles 11 supported by two interconnecting members 14, a first located at or near the bottom of the poles 11 and another located at or near the top.

In some embodiments, the interconnecting members 14 are at least located at upper and lower regions of the vertically arranged poles 11. However, the interconnecting members 14 may be located anywhere on the vertical poles although it is particularly advantageous that a side member 14 is located at or near the top of the vertical poles 11 so as to provide a surface upon which a floor can be supported .

In preferred forms, each frame 10 is unitary where the two vertical poles 11 are integrally formed in a fixed relationship by fusing the vertical poles 11 and

interconnecting members 14. For example, the vertical poles 11 and interconnecting members are made of metal extrusion and welded together. In this way, an H-frame is formed. A number of cross-brace components 15 are arranged to located and provide relative stabilisation of each frame 10. The cross brace components 15 are separable from the frames 10. For example, the cross brace components could be bolted to the frame by providing an aligned aperture on each cross brace components and the frame, or a flange 9 as depicted attached to the frame, so that a fastener may pass through to lock these components together. A preferred fastener is an antiluce fastener which allows quick connection and disconnection of such components.

In preferred embodiments, the cross member 15 is arranged to span from the top of a vertical pole 11 on one H-frame, to the bottom of a vertical pole 11 of an adjacent H- frame. As many cross members 15 may be used as desired for the stability required. However, the most efficient arrangement is two cross members 15 arranged in an X- pattern on each of a front set of vertical poles and a rear set of vertical poles.

The first level scaffold section 20 is constructed from the components of vertical poles 21, the longitudinal rails 23, and lateral rails 26. The corner posts 21 are configured to connect with the vertical poles of the frames 10 and also vertically support the lateral 26 and longitudinal rails 23. The vertically arranged corner posts 21 form allow the formation of a sidewall structure where rails 23, 26 are assembled to span between at least some of the set of corner posts, thereby forming the sidewall structure to the first scaffold level.

Figure 10 shows a detailed view of an exemplary corner post 21 and top section of the vertical post 11 of the base level section 10. The post 21 is telescopically received in an aperture 8 of the vertical post 11. The telescopic engagement is preferably facilitated by selection of metal extrusions where the outside dimensions of the frame post 11 closely matches and is complementary in shape to the outside dimensions of the post 21. To control the depth of telescopic engagement between the two posts, the upper post 21 is preferably provided with a collar 23. The collar is located at a height from the base of the post that corresponds to the desired depth of telescopic engagement. The collar may formed, for example, by the use of an off-cut material of the base level vertical post 11. The collar may be attached to the post 21 by a weld or other known attachment options.

The upper level corner posts 21 may have several collars. For example, Figure 10 shows two additional collars 24, 25 spaced above the lowermost depth control collar 23. Upper collars are used to vertically support one or more side rail members 22 that may be arranged to span between corner posts 21 as shown in Figure 8. Figure 11 shows a partial view of the end of what may be the lateral or longitudinal rail member components 23, 26. The rail members feature an open channel 7 disposed at each end. The open channel 7 advantageously allows a side rail member to be dropped into place at an initial angled engagement with one of the corner posts 21, then rotate down to engage with an opposing corner post. The side rails may alternatively feature closed channel on at least some side rail members. For example, lower side rail members for engaging mid-level collars 24 may feature open channel sections, while top level side rails may have closed channel sections for engaging top positioned collars 25. It is typical for wooden boards to be used to form a floor for scaffold use. However, for brick and block work, the loads placed on the boards may present a safety hazard .

Figure 12 shows an exploded view of an improved floor board member 32 constructed from a board section 30 supported by an angle or U-section extrusion 31 at least partially cladding the outer edges of the board 32. The extrusion can be attached to the board 32 using fasteners. The extrusion cladding 31 acts to support the board 32 to minimise flexing of the board and improve the load carrying ability. The extrusion cladding 31 also allows a strong floor to be assembled. A number of boards can be laid to the top surface of the base level scaffold structure in order to provide a floor that is able to support the loads associated with brick and block work.

Figure 13 shows a frame post component 11 according to another embodiment. The scaffold system is constructed from six component types, these are:

• frames 10

• cross braces 15

• vertical poles 21

• floor rails 4

• longitudinal rails 23; and

• lateral rails 26. It should be noted that the longitudinal and lateral rails are required for a scaffold of rectangular form. Where the scaffold is of a square form, for example, a rail of merely one length would be required.

The frame post component of this embodiment features receptacle 6 located on opposing sides of the frame and at a vertical height differential. The receptacle 6 are configured to receive a portion of a floor rail 4 shown in Figure 14. The floor rail 4 has a longitudinally extending member 4 and a hook or otherwise downwardly protruding portion 5 at each extent of the member 4. The downward protrusion is configured for engagement with the receptacle 6 of the vertical member 11. In this way, floor rails can be hung from the vertical poles 11 that are arranged as part of the base level of the scaffold.

The receptacle 6 are vertically offset such that the floor rails are also vertically offset. When building a series of scaffold sections, one scaffold section is arranged such that the vertical height of the receptacle of that section match. This ensures the floor rails are assembled level, and also that alternating scaffold sections have alternating floor rail heights. The vertical offset of the receptacle 6 is such that a layer of planks is allowed to extend out the sides of a section of scaffold without impeding the planks on adjacent sections.

Figure 15 shows a side view of the vertical posts 11, receptacle 6, planks 30 and floor rails 4. On the right side the planks are supported at a lower level, and the left side at an upper level. The planks at each level may extend into the region of the next scaffold section. The primary advantage of this arrangement is that any plank or board may be used to form a floor of the scaffold. Planks are often abundant on building sites and may be of a variety of lengths. A plank of any length may therefore be utilised. A uniform floor surface is easily created by layering planks on top of the lower level of planks thereby filling any gaps.

Figure 16 shows lateral floor support members 3 arranged to span between parallel floor rails 4. The members 3 help to support the floor surface from sagging and may be used as desired depending on what stiffness of plank is used to construct the floor.

Advantageously, the floor support members 3 are the same component as used for the lateral hand rail, therefore minimising the provisional of extra component types from the scaffold construction.

Figure 17 shows additional or alternative side rail component 40 to the component shown by Figure 14. The rail 40 has a receptacle 41 for receiving a vertical corner post 11. Post positioned midway to allow scaffolding sections to be constructed extending at right angles to existing scaffold sections; or a feature such as a closable door to be positioned along the side of the scaffold - for example, where stairs or a ladder are provided to allow easy access to the first scaffold level. Figure 18 shows a door mounted to a vertical post midway along the side of the scaffold.

Transportation of exemplary embodiments of the scaffold system is also improved.

Figure 19 is an image of the scaffold of Figure 8 dismantled to illustrate the

advantageous compact nature of the disassembled components. Enough parts to build at six frame segments of the scaffold - typically enough to span 30 linear metres and reach a mid-floor height of 3.6 metres to enable complete construction of a brick or block wall in a domestic application, and allow access for a concrete pump operator. Trucks or oversize trailers are no longer required.

The above described embodiments enable must faster operation compared to scaffold systems of the prior art. In one example, a test masonry retaining wall was completed in two days including block fill. Using scaffold systems of the prior art would require up to a seven days to complete because there is no scaffold suitable to hire or purchase that can be assembled as quickly and efficiently and is fit for the purpose of brick and block wall construction.

Further, scaffold systems of the prior art are typically assembled and disassembled by a scaffolding hire company. During the assembly and disassembly process, which can take several days alone, masonry workers must work on other jobs elsewhere and may only visit a site for work once the scaffold is assembled. This means jobs must be overlapped carefully in order to minimise downtime. However, it is frequently the case that scaffold hire companies cause delays for a variety of reasons. These delays may result in one or two days where a one masonry job is completed by the next job is not able to be started. The scaffold embodiments of the invention have proven that by supplying and erecting our own scaffold quickly and easily significantly reduces the time frame of the job, minimises or avoids job overlap, and ultimately saves time and cost.

Furthermore, the exemplary embodiments can be assembled easily by a single person if necessary.

Where in the foregoing description reference has been made to elements or integers having known equivalents, then such equivalents are included as if they were individually set forth. Although the invention has been described by way of example and with reference to particular embodiments, it is to be understood that modifications and/or improvements may be made without departing from the scope of the invention as set out in the claims.