A cap and stiffener system for a guard rail post

Field of the invention

[001] This invention relates to a roadway guardrail system having a guardrail mounted on supporting posts, as well as to a stiffener for reinforcing a supporting post. The invention can have broader use in other fields (eg, safety barrier systems, fences, guardrails for car parks, warehouses, etc).

Background of the invention

[002] Roadway guardrail systems are known in the prior art. Such systems are typically used to prevent accidents arising from a vehicle leaving the roadway and entering an adjacent hazardous place such as a ditch, etc.

[003] A roadway guardrail system typically includes a plurality of interconnected guardrails mounted to a plurality of spaced apart supporting posts. The supporting posts are spaced along the side of the roadway and are fixed in place.

[004] A variety of supporting posts have been proposed for use in the manufacture of guardrail systems (eg, C-shaped posts, I-beam posts, etc).

[005] Any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates, at the priority date of this application.

Summary of the invention

[006] The present invention provides a stiffener for a post of a guard rail system, the post has a cross sectional shape that includes at least free two ends, the stiffener being adapted to be connected to the post so as to maintain the sectional geometry of the post until a predetermined force is applied to the post.

[007] The stiffener is adapted to prevent the ends from moving towards each other. [008] The stiffener is adapted to prevent the ends from moving away from each other.

[009] The stiffener can include a first portion and a second portion, the first portion having a configuration substantially corresponding to the interior of the post, the second portion having configuration corresponding generally with the free ends and sized to allow inserting the free ends into the second portion of the stiffener. .

[010] The stiffener can have a configuration substantially corresponding to the interior of the post. This configuration substantially corresponding to the interior of the post can be a first portion and there can be present a second portion which is joined to or integrally formed with the first portion, the second portion having configuration corresponding generally with the free ends of the post and sized to allow cooperation between the free ends and the second portion of the stiffener.

[011] The stiffener can be generally planar.

[012] The stiffener can be arranged relative to the post so that a plane of the stiffener is generally perpendicular to a longitudinal axis of the post. Alternatively the stiffener can be arranged relative to the post so that a plane of the stiffener is generally parallel to a longitudinal axis of the post.

[013] The first portion can include: a top, bottom and side panels forming a box like structure with opposed open ends; and a series of webs and cavities which extend between the open ends of the box like structure whereby the cavities are bounded by the webs and or the panels.

[014] The post can include a web, a first flange, and a second flange, and wherein the stiffener can include a plate having a contacting surface, the surface being adapted to abut the flanges.

[015] The stiffener can include a U-shaped formation having a front face, a rear face and a bottom portion.

[016] The U-Shaped formation can further include a side wall extending between the front face and the rear face.

[017] The stiffener can be a hollow core block configured and sized to allow insertion of the block into an open channel of the post.

[018] The block can be adapted to abut the post and the at least two free ends or two of the at least two free ends.

[019] The stiffener can be or include a brace extending between and connected to the at least two free ends of the post.

[020] The stiffener is present in combination with a cap which is adapted to cap off the post.

[021] Alternatively the stiffener is a cap to cap off the post.

[022] The stiffener can be a brace adapted to connect side walls of the post.

[023] The stiffener can be a tubular member.

[024] The stiffener can include means to secure a cap to the post.

[025] The cap can also serves a reinforcing function.

[026] The stiffener can extend along the post in a direction generally parallel to a longitudinal axis of the post.

[027] At least a portion of the stiffener can have a configuration substantially complementary to at least the free ends of the post.

[028] The stiffener can be secured to the post by one or more of the following: bolting; self tapping screws; welding; adhesives; friction fit.

[029] The stiffener can be sized and shaped to allow insertion of the stiffener into the post.

[030] The post can includes at least one embossment and the stiffener is adapted to abut the embossment.

[031 ] The stiffener is adapted to be positioned in conjunction with or in the vicinity of a mounting slot of the post.

[032] The stiffener if combined with or is a cap, can include a groove to receive an upper rim of the post.

[033] A guardrail system including at least one stiffener as claimed in any one of claims 1 to

23.

[034] A guard rail system as claimed in claim 24, wherein one or more of the stiffener is positioned on the post at or near: the base of the post; the earth, the top of the post; an intermediate location between the base and top of the post.

[035] If desired, two or more stiffeners can be used with at least one stiffener cooperating with an upper portion of the post, at least one other stiffener cooperating with a lower portion of the post.

[036] The present invention also provides a method of assembling a guardrail system including: providing a post having in cross-section at least two free ends; attaching a stiffener as described above to the post so as to prevent the ends from moving relative to each other until a predetermined force is applied to the post.

[037] The present invention further provides a capping system for a barrier member, the system adapted to utilise pre-existing apertures in the barrier to secure a cap member in position on the barrier member.

[038] The cap member can include elongated side portions, the side portions having apertures positioned therethrough which when assembled with the barrier member will be aligned with the pre-existing apertures, enabling a pin to be positioned therein.

[039] The capping system can include a bridge member adapted to be pinned to the barrier member, the bridge member providing a means to secure the cap to the barrier.

[040] The bridge member can be reversible so as to be able to be used in a previously installed barrier member or a new barrier member.

[041] The cap can have a cut out portion sized and shaped to accommodate a top flange of a blocking piece.

[042] The capping system can also assist in maintaining the sectional geometry of a post to which it is applied, until a predetermined force is applied.

[043] The present invention further provides a mounting bracket including: a main body portion having first and second ends, the main body portion having a longitudinal axis, a first top flange at the first end, the first top flange extending outwardly from the main body portion; a second top flange at the first end, the second top flange extending outwardly from the main body portion in a direction opposite to that of the first top flange; a first bottom flange at the second end, the second bottom flange extending outwardly from the main body portion in a direction opposite to that of the first top flange; a second bottom flange, the second bottom flange extending outwardly from the main body portion in a direction opposite to that of the first bottom flange; the second flange being axially offset from the first bottom flange; at least one aperture in each the top flange for securing the mounting bracket to a supporting structure; at least one slot in each the bottom flange, the at least one slot being adapted to allow a fastener to pass through, the slot having a surface adapted to contact a body of the fastener, and a threaded sleeve member extending through the main body portion between the first and second ends for attaching an end cap to the main body portion of the mounting bracket.

[044] The bracket can be adapted to fit into a channel of the supporting structure.

[045] The second flange can be axially offset from the first bottom flange a predetermined distance. The predetermined distance can correspond to a height of a connection nut.

[046] The mounting bracket can also assist in maintaining the sectional geometry of a post to which it is applied, until a predetermined force is applied to the post.

_,

5 [047] An end cap assembly including: an end cap, a post, a mounting bracket as described above, connector means for securing the mounting bracket to the post, and means for interconnecting the end cap and the bracket.

[048] The connector can have a snap-on catch means for attaching the mounting bracket to the post to prevent the mounting bracket from moving relative to the post.

[049] The present invention provides a guardrail system including: a supporting post having a cross-sectional shape that includes two ends; a guardrail; a stiffener connected to the supporting post, the stiffener being adapted to prevent the ends from moving relative to each other until a predetermined force is applied to the supporting post.

[050] The stiffener can extend along the supporting post in a direction generally parallel to a longitudinal axis of the post.

[051] The supporting post can have an open channel and the stiffener can be secured to the interior surface of the channel of the supporting post.

[052] The post can be an post having at least one bead which is at least partially tubular, and the stiffener can be adapted to reinforce the at least one bead.

[053] At least a portion of the stiffener can have a configuration substantially complementary to at least a portion of the supporting post.

[054] The stiffener can be sized and shaped to allow insertion of the stiffener into the supporting post.

[055] The stiffener can include a planar surface for securement to the supporting post.

[056] The supporting post can include at least one embossment and the stiffener can be adapted to abut the embossment.

[057] The stiffener can include a mounting aperture adapted to receive a fastener therethrough.

[058] The aperture can be adapted to be aligned with a mounting slot of the supporting post.

[059] The stiffener can be positioned in the vicinity of a mounting slot of the supporting post.

[060] The stiffener can be positioned near a ground line.

[061] The guardrail system can include a first stiffener and a second stiffener, the first stiffener being secured to an upper section of the supporting post, the second stiffener being secured to a lower portion of the supporting post.

[062] Preferably the guardrail system includes a supporting post having an open channel and at least one tubular bead formed on a free edge of the supporting post, and the stiffener includes a first portion and a second portion, the first portion having configuration substantially corresponding to the interior of the open channel of the supporting post, the second portion

having configuration corresponding generally with the tubular bead and being sized to allow inserting the tubular bead into the second portion of the stiffener.

[063] Preferably the first portion includes: a top, bottom and side panels forming a box like structure with opposed open ends; and a series of webs and cavities which extend between the open ends of the box like structure whereby the cavities are bounded by the webs and or the panels.

[064] The guardrail system can include a supporting post having a web, a first flange, and a second flange, and the stiffener can include a plate having a contacting surface, the surface being adapted to abut the flanges.

[065] The stiffener can be welded to the flanges.

[066] The guardrail system can include a supporting post having a web, a first flange, and a second flange, and the stiffener can include an U-shaped bracket having a front face, a rear face and a bottom portion, the arrangement being such that in use the front face and the rear face of the bracket abut the first and second flanges respectively.

[067] The stiffener can include a side wall extending between the front face and the rear face.

[068] Preferably the side wall encloses at least a portion of an open channel of the supporting post.

[069] The stiffener can be a hollow core block configured and sized to allow insertion of the block into an open channel of the supporting post.

[070] The block can be welded to the supporting post.

[071 ] The supporting post can include a web, a first flange, and a second flange, and the block can be adapted to abut the web and the flanges.

[072] The stiffener can be a post cap, the post cap being adapted to restrain edges of the supporting post from movement respective to each other.

[073] Preferably the post cap is detachably secured to the supporting post.

[074] The present invention also provides a method of assembling a guardrail system including: providing a supporting post having in cross-section two ends; attaching a stiffener to the supporting post so as to prevent the ends from moving relative to each other until a predetermined force is applied to the post.

[075] The present invention also provides a method of assembling a guardrail system including: providing a supporting post having an open channel, the post having in cross section two ends; inserting a stiffener into the open channel of the supporting post to prevent the ends from moving relative to each other until a predetermined force is applied to the post .

[076] The method can further include the step of welding the stiffener to the supporting post.

[077] Alternatively, the method can further include the step of releasably securing the stiffener to the supporting post.

[078] The present invention also provides a stiffener for a post, the post having an open channel and two free ends in cross section, the stiffener including a first portion and a second portion, the first portion having configuration substantially corresponding to the interior of the open channel of the post, the second portion having configuration corresponding generally with the free ends and sized to allow inserting the free ends into the second portion of the stiffener.

[079] The first portion can include: a top, bottom and side panels forming a box like structure with opposed open ends; and a series of webs and cavities which extend between the open ends of the box like structure whereby the cavities are bounded by the webs and or the panels. .

[080] The present invention further provides a stiffener for a supporting post, the post including a web, a first flange, and a second flange, the stiffener including a plate having a contacting surface, the surface being adapted to abut the flanges.

[081] The present invention also resides in a stiffener for a supporting post, the post including a web, a first flange, and a second flange, the stiffener including an U-shaped bracket having a front face, a rear face and a bottom portion, the arrangement being such that in use the front face and the rear face of the bracket abut the first and second flanges respectively.

[082] Preferably the stiffener further includes a side wall extending between the front face and the rear face.

[083] The present invention further resides in a stiffener for a supporting post, the stiffener including a hollow core block configured and sized to allow insertion of the block into an open channel of the supporting post.

[084] The supporting post can include a web, a first flange, and a second flange, and the block can be adapted to abut the web and the flanges.

[085] The present invention further provides a stiffener for a supporting post, the stiffener including a brace extending between and connected to end portions of the opposite flanges of the supporting post.

[086] In a further embodiment, the stiffener can be a cap which prevents free ends of a supporting post from moving relative to each other.

[087] The present invention also resides in a stiffener for a post, the post having a cross sectional shape that includes two ends, the stiffener being adapted to be connected to the supporting post to prevent the ends from moving relative to each other until a pre-determined force is applied to the post.

[088] Preferably the stiffener prevents the ends from moving towards each other.

[089] Alternatively, the stiffener prevents the ends from moving away from each other. [090] The present invention provides a capping system for a barrier member, the system being adapted to utilise pre-existing apertures in the barrier to secure a cap member in position on the barrier member.

[091] The cap member can include elongated side portions, the side portions having apertures positioned therethrough which when assembled with the barrier member will be aligned with the pre-existing apertures, enabling a pin to be positioned therein.

[092] The side portions can have different thicknesses.

[093] The system can include a bridge member adapted to be pinned to the barrier member, the bridge member providing a means to secure the cap to the barrier.

[094] The bridge member can be reversible so as to be able to be used in a previously installed barrier member or a new barrier member.

[095] The bridge member can include a mounting bracket including: a main body portion having first and second ends, the main body portion having a longitudinal axis, a first top flange at the first end, the first top flange extending outwardly from the main body portion; a second top flange at the first end, the second top flange extending outwardly from the main body portion in a direction opposite to that of the first top flange; a first bottom flange at the second end, the second bottom flange extending outwardly from the main body portion in a direction opposite to that of the first top flange; a second bottom flange, the second bottom flange extending outwardly from the main body portion in a direction opposite to that of the first bottom flange; the second flange being axially offset from the first bottom flange; at least one aperture in each of the first and second top flanges for locking the mounting bracket onto a supporting structure; at least one slot in each of the first and second bottom flanges, the at least one slot being adapted to allow a fastener to pass through, the slot having a surface adapted to contact a body of the fastener, and a threaded sleeve member extending through the main body portion between the first and second ends for attaching an end cap to the main body portion of the mounting bracket.

[096] The mounting bracket can be adapted to fit into a channel of the supporting structure. [097] The supporting structure can be a supporting post of a "C" cross section.

[098] A top flange can include an abutment surface adapted to abut an inside surface of the supporting post.

[099] A top flange can be adapted to abut a first inside surface of the supporting post and the first bottom flange can be adapted to abut a second inside surface of the supporting post.

[0100] The main body portion of the mounting bracket can have an "I" shaped cross section.

[0101] The second flange can be axially offset from the first bottom flange a predetermined distance.

[0102] The predetermined distance can correspond to a height of a connection nut. Alternatively, the predetermined distance can be slightly higher than a height of the connection nut.

[0103] The flanges can be formed integrally with the main body portion. Alternatively, one or more of the flanges can be attached to the main body portion.

[0104] The present invention also provides an end cap assembly including: an end cap, a supporting member, a mounting bracket as described above, connector means for locking the mounting bracket onto the supporting post, and means for interconnecting the end cap and the sleeve member of the bracket.

[0105] The top flanges of the mounting bracket can be disposed against an inside surface of the supporting post and a connection bolt can pass through a slot in the second bottom flange and abut against a surface of the slot.

[0106] The present invention also resides in an end cap assembly including: an end cap having an opening therethrough, a supporting post, a mounting bracket, a fastener passing through the opening of the end cap, the fastener being adapted to engage a threaded portion of the mounting bracket to connect the end cap to the supporting post; a connector having snap-on catch means for attaching the mounting bracket to the supporting post to prevent the mounting bracket from moving relative to the post.

[0107] The present invention also provides a method of assembling an end cap, the method including the following steps in any order: (a) inserting a mounting bracket into an open end of a supporting structure; (b) locking the mounting bracket onto an inside surface of the supporting structure; (c) attaching an end cap to the mounting bracket.

[0108] The present invention also provides a connector for an end cap assembly of a guardrail system, the connector including snap-on catch means for locking the connector onto a supporting structure.

[0109] The connector can include: a head portion; and snap-on catch means extending from the head portion; the snap-on catch means including at least one locking projection having a catching element adapted to cooperate in a locking position with a complementary opening of the mounting bracket.

[0110] The catching element can be a lip extending partially around the perimeter of the locking projection in a direction perpendicular to a longitudinal axis of the connector.

[0111] The present invention further resides in an end cap including: a top portion including an open box structure having a closed convex wall at one axial end, and a bottom portion having a pair of generally "C"- shaped opposing side members extending axially from the closed wall and adapted to fit snugly into an end of a supporting post, a tubular sleeve member extending from the closed wall and adapted to receive a fastener therethrough.

[0112] The cap has a cut out portion sized and shaped to accommodate a top flange of a blocking piece.

Brief description of the drawings

[0113] An embodiment or embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0114] Figure 1 is an exploded perspective view of an end cap assembly of a roadway guardrail system, viewed from the curb side;

[0115] Figure 2 is a perspective view of the end cap assembly of Figure 1 ;

[0116] Figure 3 is a top perspective view of an end cap of the end cap assembly of Figure i;

[0117] Figure 4 is a bottom perspective view of the end cap of Figure 3;

[0118] Figure 5 is a perspective view of a mounting bracket of the end cap assembly of

Figure 1;

[0119] Figure 6 is a top perspective view of a connector of the end cap assembly of

Figure 1;

[0120] Figure 7 is a bottom perspective view of the connector of Figure 6;

[0121] Figure 8 is an exploded perspective view of an end cap assembly of a roadway guardrail system, viewed from the curb side;

[0122] Figure 9a is a top perspective view of an end cap of the end cap assembly of

Figure 8;

[0123] Figure 9b is a bottom perspective view of the end cap of Figure 9a;

[0124] Figure 10 is a top view of the end cap of Figure 9a;

[0125] Figure 11 is a front elevation view of the end cap of Figure 9a;

[0126] Figure 12 is a left side view of the end cap assembly of Figure 9a;

[0127] Figure 13 is a right side view of the end cap assembly of Figure 9a;

[0128] Figure 14a is a front perspective view of a connector of the end cap assembly of

Figure 9a;

[0129] Figure 14b is a rear perspective view of the connector of Figure 14a;

[0130] Figure 15 is a side view of the connector of Figure 14a;

[0131] Figure 16 is a top view of the connector of Figure 14a;

[0132] Figure 17 is a rear view of the connector of Figure 14a;

[0133] Figure 18 is a front view of the connector of Figure 14a; and

[0134] Figure 19 is aperspective view of another end cap assembly.

[0135] Figure 20 is a perspective view of a plastic blocking piece and C-section post with an assembled cap;

[0136] Figure 2OA is an exploded view of the assembly of Figure 20;

[0137] Figure 2OB illustrates a top perspective view of the cap of Figures 20 and 2OA;

[0138] Figure 2OC illustrates an underneath perspective view of the cap of Figure 2OB.

[0139] Figure 21 is a schematic top view of a fragment of a roadway guardrail system with a stiffener, wherein the guardrail system is used for curb-side applications;

[0140] Figure 22 is an enlarged sectional view of the supporting post of the roadway guardrail system of Fig. 21;

[0141] Figure 23 is an enlarged cross-sectional view of an assembly including a vertically extending stiffener secured to the supporting post of Fig. 21;

[0142] Figure 24 is a schematic elevation view of the assembly of Fig. 23, viewed from the traffic side;

[0143] Figure 25 is an enlarged cross-sectional view of another post stiffener;

[0144] Figure 26 is a schematic elevation view of the post stiffener assembly of Fig. 25, viewed from the traffic side;

[0145] Figure 27 is an enlarged cross-sectional view of a further post stiffener;

[0146] Figure 28 is a schematic elevation view of the post stiffener assembly of Fig. 27, viewed from the traffic side;

[0147] Figure 29 is a cross-sectional view of the stiffener of Fig. 28 taken along line A-A of Fig. 27;

[0148] Figure 30 is a cross-sectional view of the stiffener of Fig. 28 taken along line B-B of Fig. 27;

[0149] Figure 31 is an enlarged cross-sectional view of a further post stiffener;

[0150] Figure 32 is a schematic elevation view of the post stiffener assembly of Fig.31, viewed from the traffic side;

[0151] Figure 33 is a cross-sectional view of the stiffener of Fig. 31 taken along line A-A of Fig. 11;

[0152] Figure 34 is a cross-sectional view of the stiffener of Fig. 31 taken along line B-B of Fig. 11;

[0153] Figure 35 is an enlarged cross-sectional view of a further post stiffener;

[0154] Figure 36 is a schematic elevation view of the post stiffener assembly of Fig.35, viewed from the traffic side;

[0155] Figures 37 to 39 show preferred location(s) on a post for the use of the post stiffener(s);

[0156] Figure 40 is a cross-sectional view of a further post stiffener;

[0157] Figure 41 is a schematic side view of the post stiffener assembly of Fig. 40;

[0158] Figures 42 to 44 show modified embodiments of the stiffener of Fig. 40;

[0159] Figure 45 is a schematic cross-sectional view of a further post. stiffener assembly for a C-ρost;

[0160] Figure 46 is a schematic cross-sectional view of a further post stiffener assembly for a U-post or C-post;

[0161] Figure 47 illustrates a perspective view of a combination cap and stiffener of a web construction;

[0162] Figure 48 illustrates a perspective view of a combination cap and stiffener to a solid construction;

[0163] Figure 49 illustrates a perspective view of a combination cap and stiffener which extends downwardly from the cap;

[0164] Figure 50 illustrates a perspective view of a combination cap and stiffener having a groove in the under flange of the cap;

[0165] Figure 51 illustrates a schematic cross section of an I-section post, with stiffeners on two sides;

[0166] Figure 52 illustrates a perspective view of a channel or groove on the under flange of a cap;

[0167] Figure 53 illustrates a perspective view of a post stiffener of a tubular construction; and

[0168] Figure 54 illustrates a plate stiffener for horizontal location in a post.

Detailed description of the embodiment or embodiments

[0169] Illustrated in Figures 1 , 2 is a fragment of a roadway guardrail system 10. The guardrail system 10 includes a supporting post 12 of a "C" cross-section to which a guardrail (not shown) and or blocking piece (not shown) can be mounted. Normally, the guardrail system 10 includes a plurality of supporting posts 12. The guardrail system 10 will typically be installed along the side of a roadway to prevent a vehicle from veering off the roadway.

[0170] The guardrail system 10 includes an end cap 14 for closing off the longitudinal end of the supporting post 12 and providing a finished appearance to the guardrail system 10. The cap is also useful to cover several otherwise exposed edges which might catch onto workers or pedestrians clothing or skin.

[0171] As shown in Figures 1 and 2, an end cap assembly 16 including a mounting bracket 18 provides means for attaching the end cap 14 to the supporting post 12.

[0172] Referring to Figure 3 and 4, the end cap 14 is a one-piece member of a generally

"C" shaped cross-section. The end cap 14 can be made of plastics or steel or any other suitable material. In a preferred embodiment, the end cap 14 is formed by conventional moulding techniques such as injection moulding.

[0173] The end cap 14 has an upper portion 15 in the form of an open box structure having a closed convex wall 20 at one end. The other end has a bottom portion 17 having a pair of generally "C"- shaped opposing side walls 22.1 and 22.2 extending axially from the closed wall 20. The walls 22.1 and 22.2 are adapted to fit against the peripheral wall of the post 12 so as to close off the longitudinal end of the post 12, with the side wall 22.2 facing the surface 26 of the post 12.

[0174] As best shown in Figures 3, the end cap 14 can have a cut out portion 24 sized and shaped to accommodate a top flange of a blocking piece such as that illustrated in co- pending applications mounted to the supporting post 12. It will be appreciated by those skilled in the art that the guardrail can be directly mounted to the supporting post 12. In such a case no cut out portion 24 is required in the end cap 14.

[0175] Extending from the closed wall 20 in a direction parallel to a longitudinal axis 28 of the end cap 14 is a tubular sleeve member 30 adapted to receive a fastener 32 therethrough. As illustrated in Figure 4, the end cap 14 includes a plurality of reinforcing ribs 34.1, 34.2, 34.3, and 34.4 (not shown) and a plurality of webs 36 connecting the reinforcing ribs 34 with the side walls 22.1, 22.2 and the upper portion 15 of the end cap 14.

[0176] The end cap 14 can be mounted to the supporting post 12 by means of a bridging structure in the form of the mounting bracket 18. Referring to Figure 5, the mounting bracket 18 includes an elongated main body portion 40 extending in a direction generally perpendicular to the longitudinal axis 28 of the end cap 14. Preferably as illustrated in Figure 5, the main body portion has an "I" shaped cross section. It will be appreciated by those skilled in the art that the main body portion 40 can have any other suitable cross section. The mounting bracket 18 can be made of polymeric material or steel or any other suitable material. In one version, the mounting bracket 18 is formed by conventional moulding techniques such as injection moulding.

[0177] A first top flange 42.1 and a second top flange 42.2 are disposed at a first end of the main body portion 40. The flanges 42.1, 42.2 extend outwardly from said main body portion in directions perpendicular to the main body portion 40 of the mounting bracket 18, with the second top flange 42.2 projecting in a direction opposite to that of said first top flange 42.1.

[0178] Each top flange 42.1 , 42.2 includes a mounting aperture 44.1 , 44.2 thereby forming a lateral lug 43.1, 43.2. When overlapped with side surfaces 27.1 and 27.2 of the supporting post 12, the lugs 43.1, 43.2 permit joining of the mounting bracket 18 and the post 12 by making a connection at the common axis through apertures 44.1, 44.2 in the lugs 44 and apertures 46.1, 46.2 provided in the supporting post 12.

[0179] To this end, the end cap assembly 16 includes a connector 48 having a head portion 49 and snap-on catch means in the form of elastically flexible projections 50.1 and 50.2 extending from the head portion 49. It will be appreciated by those skilled in the art that the connector 48 can include any suitable number of flexible projections 50.

[0180] The projections 50.1 and 50.2 are movable between a withdrawal position and a locking position. As best illustrated in Figures. 6 and 7, each projection 50.1, 50.2 is provided

with a lip or barb 52.1 and 52.2 extending radially from its axial end and configured to engage one of the complementary apertures 44.1, 44.2 of the upper flanges 42.1, 42.2 of the mounting bracket 18 to thereby secure the mounting bracket 18 to a port.

[0181] Disposed at a second end of the main body portion 40 of the bracket 18 is a first bottom flange 54. The flange 54 extends in a direction perpendicular to the main body portion 40 and includes an elongated open slot 56 for receiving a connection bolt shown in Figure 2 or 8. The slot 56 terminates with a generally semi-cylindrical surface 58 and has a width which corresponds to, or is slightly wider than the diameter of the connection bolt.

[0182] A second bottom flange 60 extends outwardly from the main body portion 40 in a direction opposite to that of the first bottom flange 54. The second bottom flange 60 is axially offset from the first bottom, flange 54 a predetermined distance H, the distance H being generally equal to the height of a nut 62 engaging a connection bolt 64. Similarly to the first bottom flange 54, the flange 60 includes a semi-cylindrical surface 66 and has a width which corresponds to, or is slightly wider than the diameter of the connection bolt 64.

[0183] Although Figure 5 shows that the flanges 42, 54, and 60 are in the form of thin, substantially flat members, it will be understood by those skilled in the art that the mounting bracket 18 can include any other suitably shaped structures.

[0184] The overall length of the mounting bracket 18 is determined by the spacing between the surfaces 27.1 and 27.2 of the supporting post 12. In general, the bracket 18 is adapted to be slidably received in a channel formed by the surfaces 27.1 and 27.2 of the post 12.

[0185] The mounting bracket 18 further includes a sleeve member 68 extending through the main body portion 40 of the bracket 18 between the lugs 43.1, 43.2 and the flanges 60, 54 respectively. Similarly to the sleeve portion 30 of the end cap 14, the sleeve member 68 is provided with reinforcing members 70 connecting the sleeve member 68 and the main body portion 40 of the bracket 18. The sleeve member 68 has a threaded opening adapted to engage the fastener 32 to thereby connect the end cap 14 to said supporting post 12.

[0186] The sleeve member 68 and flanges 42.1 , 42.2, 54, 60 can be formed integrally with the main body portion 40. Alternatively, one or more of the above-mentioned flanges 42.1, 42.2, 54, 60 and or the sleeve member 68 can be attached to the main body portion 40.

[0187] Although Figures. 1, 2, and 5 illustrate a mounting bracket 18 having a pair of the top ^' flanges and a pair of the bottom flanges, with the flanges extending in parallel directions, it will be understood by those skilled in the art that the mounting bracket 18 can include one or

more flanges extending in a direction(s) different from those of the rest. Similarly, the number of the top flanges and or the number of the bottom flanges can differ from those illustrated in Figures 1, 2, and 5.

[0188] The end cap assembly 16 is assembled as follows. The supporting post 12 is fixed in place by driving the post 12 into the ground (not shown). Alternatively, the post 12 can be placed into a pre-dug post hole (not shown). The mounting bracket 18 is then mounted onto the supporting post 12. To this end, the bracket 18 is positioned within the post 12 such that the contacting surfaces of the flanges 42.1, 42.2 and 60 respectively overlap the surfaces 27.2 and 27.1 of the supporting post 12; the mounting aperture 44.1 is aligned with the mounting opening 46.1 formed in the supporting post 12, and the connection bolt 64 passes through the slot formed in the bottom flange 60.

[0189] . The connector 48 is then received in the aperture 44.1 of the mounting bracket 18. To this end, the projections 50.1, 50.2 are inserted into the apertures 46.1 and 44.1, and the connector 48 is then pushed in a direction perpendicular to the surface 27.2 of the post 12 until the head portion 49 of the connector 48 is disposed against the substantially vertical surface of the supporting post 12, and the lip 52 engages the flange 42.1 of the mounting bracket 18 to secure the bracket 18 against movement within the supporting post 12. As a result, the mounting bracket 18 is removably attached to the supporting post 12.

[0190] The bottom portion 17 of the end cap 14 is then inserted into the open end of the supporting post 12, with the side wall 22.2 facing the surface 26 of the post 12.

[0191] The fastener 32 passes through the sleeve member 30 of the end cap 14 and engages the threaded sleeve member 68 of the mounting bracket 18. The fastener 32, when tightened, draws the sleeve members 30 and 68 towards one another to thereby releasably secure the end cap 14 and the mounting bracket 18 against relative movement.

[0192] Once the end cap assembly 16 is assembled, a blocking piece (not shown) can be mounted onto the supporting post 12.

[0193] It will be appreciated by those skilled in the art that the mounting bracket is reversible and can be used in a previously installed supporting post or a new supporting post.

[0194] In the system of figures 1 and 2, the end caps 14 and mounting bracket 18, will assist in the post 12 maintaining its sectional geometry, at least at the upper end of the post 12, by preventing, the free ends of the post 12 from moving towards or away from each other in the event of a collision, until such time as a greater force is applied to the upper end of the post 12

than what would be required to cause such relative movement without said end cap 14 and mounting bracket 18 being present. By choosing relatively stronger materials such as steel for the end caps 14 and mounting brackets 18, the sectional geometry will be maintained until an even greater force is applied than for example if plastic materials are used. Further increases in the force can be obtained by replacing the connector 48 with a bolt and nut arrangement.

[0195] Whereas In the system of figures 3 and 4, the end caps 15 (if used without a mounting bracket 18), will assist in maintaining the sectional geometry of the post 12, at least at the upper end of the post 12, from moving towards each other in the event of a collision, until such time as a greater force is applied to the upper end of the post 12 than what would be required to cause such relative movement without said end cap 14 being present. By choosing relatively stronger materials such as steel for the end cap 15, the sectional geometry will be maintained until an even greater force is applied than for example if plastic materials are used. Further increases in the force can be obtained by bolting or welding the end cap 15 into place.

[0196] Illustrated in Figures 8 to 18 is another cap fixing system. Similarly to that described above, the guardrail system 100 includes supporting members being blocking piece 120.1 and supporting post 120.2 of a "C" cross-section to which a guardrail (not shown) can be mounted. The blocking piece 120.1 and supporting post 120.2 are disposed in a generally abutting relationship and connected to each other by means of a bolt 122 and a nut 124.

[0197] The guardrail system 100 includes two end caps being a block cap 140.1 and a post cap 140.2 for closing off the blocking piece 120.1 and supporting post 120.2 respectively. The caps 140.1 and 140.2 are identical.

[0198] Referring to Figures 9a to 13, the end caps 140.1 and 140.2 are each a one-piece member having an open end. The end caps 140.1 and 140.2 can be made of plastics or steel or any other suitable material. Preferably the end caps 140.1 and 140.2 are formed by conventional moulding techniques such as injection moulding.

[0199] Similarly to the end cap 14, the end caps 140.1 and 140.2 have an upper portion

150 in the form of an open box structure having a closed convex wall 200 at one axial end, and a bottom portion 170 in the form of two flanges 220.1 and 220.2 extending axially from the upper portion 150 and adapted to fit against the peripheral wall of the respective blocking piece 120.1 and supporting post 120.2.

[0200] As best illustrated in Figure 9b, the end caps 140.1 and 140.2 include a plurality of reinforcing ribs or webs 340.1, 340.2, 340.3, 340.4, and 340.5 connecting the side walls and the upper portion 150 of the end caps 140.1 and 140.2.

[0201] Referring to Figures 8 and 9, the far side 460 of the post cap 140.2 is secured to the supporting post 120.2 hy means of a pin clip 480. The traffic side 462 of the post cap 140.2 is secured to the post 120.2 by the bolt 122 also securing the blocking piece 120.1 to the supporting post 120.2. The bolt 122 also secures the far side 464 of the block cap 140.1. The traffic side of the block cap 140.1 is secured to the block 120.1 by a TEK screw through the front face of the blocking piece 120.1.

[0202] To this end, each flange 220.1 , 220.2 includes a mounting aperture 440.1 , 440.2 thereby forming two opposed lateral lugs. When overlapped with the side surfaces of the members 120.1 and 120.2, the lugs permit joining of the end caps 140.1, 140.2 and the members 120.1, 120.2 by making a connection at the common axis through apertures 440.1, 440.2 in the flanges and apertures 450 provided in the steel blocking piece 120.1 and the supporting post 120.2.

[0203] As illustrated in Figures 14a-18, a pin clip 480 includes a head portion 490 and snap-on catch means in the form of elastically flexible projections 500.1 and 500.2 extending from the head portion 490. It will be appreciated by those skilled in the art that the pin clip 480 can include any suitable number of flexible projections 50.

[0204] The projections 500.1 and 500.1 are movable between a withdrawal position and a locking position. As best illustrated in Figures 14a and 14b, each projection 500.1, 500.2 is provided with a lip or barb 520.1 and 520.2 extending radially from its external surface and configured to engage one of the complementary apertures 440.1, 440.2 of the flanges 220.1, 220.2 of the end cap to thereby impose a constraint thereon.

[0205] The end cap assembly 100 is assembled as follows. The bolt 122 securing the block 120.1 to the supporting post 120.2 is removed and the two caps 140.1 and 140.2 are placed into position. A pin clip 480 is inserted through the aperture 450.2 to secure the far side 460 of ^■ the post cap 140.2. The traffic side 462 of the post cap 140.2 is secured by repositioning the bolt 122 which also secures the far side 464 of the block cap 140.1. The traffic side of the block cap 140.1 is secured by a TEK screw 500.

[0206] Illustrated in Figure 19 is cap fixing system wherein the guardrail system does not include blocking pieces. The end cap 140 is secured to the supporting post 600 by means of two pin clips 480, with one pin clip being inserted from each side of the post 600 (the far side and the traffic side).

[0207] Illustrated in Figures 20 and 2OA is an assembly similar to that of Figure 8, except that a C- section blocking piece 120.1 is replaced by a polymeric blocking piece 230.1.

[0208] The blocking piece 230.1 hangs over a top edge of the C-section part 120.2 by means of a hook flange 230.2.

[0209] The cap 240.1 as illustrated in Figures 20, 2OA, 2OB and 2OC, is similar to the cap

140.1 and 140.2 and like parts have been like numbered, except that a rectangular bight or cut out 240.2 is formed in one end. The cut out 240.2 allows the hook flange 230.2 to sit therein when the cap 240.1 is placed on the post 120.2. The cap 240.1 is secured to the post 120.2 by a single pin clip 480.

[0210] The caps 240.1, 140.1 and 140.2 can be made from a single mould. As can be seen from Figure 9B, the underside of cap 140.1 includes a rectangular framed portion 500. When it is desired to do a production run of cap 240.1 a generally rectangular insert is placed in the mould, which will occupy the space inside of the framed portion 500, to form the cut out

240.2 of figures 20, 2OA, 2OB and 2OC.

[0211] It will be noted from figure 9B, 11 and 2OC, that the webs 340.4 and 340.5 each have curved portions which act as gusset plates. The gusset is particularly useful when there is only one flange 220.2, as in the case of the cap 240.1, or in the case of caps 140.1 or 140.2 if the flange 220.1 were to break in use. The gusset provides rigidity between the flange 220.2 and the rest of the cap 240.1, 140.1, 140.2 whereby a single anchoring pin 480 will be sufficient to hold a cap onto a post 120.2. A single anchoring pin 480 is used with the cap 240.1 because it is not possible to attach the traffic side of the cap due to the presence of the plastic blocking piece.

[0212] The post caps 140.1 and 140.2 are provided with flanges 220.1 and 220.2 of different thickness, the thicker flange being provided on the far side. The thicker flange is provided for use on the far side so that the thin side can be used on the traffic side of the post, if needed depending on the length of the bolt between the C-section blocking piece and C-section post.

[0213] Preferably the thickness of the thicker flange 220.2 is about 4 mm, while the thinner flange 220.1 is of the order of 1.5 to 2 mm thick.

[0214] The end cap systems of figures 8 to 2OC assist in the post 12 maintaining its sectional geometry, at least at the upper end of the post 12, by preventing the free ends of the post 12 from moving towards each other in the event of a collision, until such time as a greater force is applied to the upper end of the post 12 than what would be required to cause such relative movement without the end caps. Further increases in the force can be obtained by a bolted connection.

[0215] Illustrated in Figs. 21, 22 is a fragment of a roadway guardrail system 910. The guardrail system 910 includes a guardrail 912 in the form of a "W" beam supported by a supporting post 914. A spacer member 915 is provided between the supporting post 914 and the guardrail 912. As shown in Fig. 21, the spacer member 915 can have a cross-section similar to. the supporting post 914. The guardrail 912, if desired, can be directly mounted to the supporting post 914.

[0216] It will be appreciated by those skilled in the art that the guardrail system 910 may include one or a plurality of interconnected guardrails 912 mounted on a plurality of supporting posts 914. The guardrail system 910 will typically be installed along the side of a roadway to prevent a vehicle from veering off the roadway.

[0217] As shown in Fig. 22, the supporting post 914 has a generally channel shaped configuration and includes a web 916 and flanges 918.1, 918.2 extending in a direction generally perpendicular to the web 916. Free edge portions 919.1, 919.2 of the flanges 918.1, 918.2 are turned inwardly to form edge folds shown, as open-section beads or edge curls 920.1, 920.2. The beads 920.1 , 920.2 extend along each free edge 919.1 , 919.2 and have a generally elliptical, . preferably circular, cross-section. The beads 920.1, 920.2 are turned inwardly an angular amount of about 270 degrees from the respective flange 918.1, 918.2, with the gap between the bead and the respective flange being of an angular amount about 90 degrees. If desired, the beads 920.1, 920.2 can be closed.

[0218] The web 916 of the supporting post 914 is provided with a reinforcing rib or embossment 922 protruding outwardly, away from the cross-section of the post 914. Similarly, the flanges 920.1 and 920.2 have reinforcing ribs or embossments 924.1, 924.2 respectively. The embossments 924.1 , 924.2 protrude inwardly, toward the interior of the cross-section of the supporting post 914.

[0219] As shown in Fig. 21, the guardrail system 910 further includes a reinforcing member or stiffener 917 secured to the supporting post 914 for the purpose of reinforcing a section of the post 914.

[0220] Stiff eners of various configurations will now be described with reference to the rest of the figures.

[0221] As shown in Figs. 23 and 24, a sub-assembly of the guardrail system includes a supporting post 914 and apair of stiffeners 930 and 930.1. Each stiffener 930, 930.1 is formed with a configuration and dimensions compatible with the configuration of the supporting post 914.

[0222] The stiffeners 930, 930.1 are an elongated reinforcing members positioned within the channel of the supporting post 914 and can be secured to the supporting post 914 by a variety of securing mechanisms or fasteners (not shown). Examples of such securing mechanisms or fasteners which can be used include bolts, TEK or self tapping screws, adhesives, friction fitting, welding if the stiffener is made of metal. The most preferred form of fixing is a bolted construction. To this end, the reinforcing members 930, 930.1 are provided with mounting apertures 931.1, 931.2 respectively.

[0223] As illustrated in Fig. 24, a first stiffener - the stiffener 930.1 - is placed at a region of high stress (eg, near a ground line 932). A second stiffener - the stiffener 930 - is placed in the vicinity of an elongated mounting opening 934 extending in a direction parallel to the longitudinal axis of the supporting post 914. The opening 934 is adapted to receive a fastener (eg, post bolt, not shown) therethrough to secure the stiffener 930.1, the guardrail 912 and or the spacer member 915 to the supporting post 914. In a preferred embodiment of the present invention, each stiffener 930, 930.1 extends for 215 mm along the length of the supporting post 914.

[0224] In some applications, the stiffener 930 can be sized so as to extend for the entire length of the supporting post 914, thus obviating the need for stiffener 930.1.

[0225] As shown in Fig. 23, the stiffeners 930, 930.1 are shaped generally complementary to the shape of the internal surfaces of the supporting post 914 and include a first portion 936 and a second portion 938. The first portion 936 has a configuration corresponding generally with the inside surface of the supporting post 914. The first portion 936 is dimensioned and shaped to fit into the channel of the supporting post 914, whilst the second portion 938 has a configuration corresponding generally with the configuration of the beads 920.1, 920.2 and is adapted to fit around the beads 920.1, 920.2 of the supporting post 914.

[0226] The first portion 936 of the stiffeners 930, 930.1 is in the form of a box like or web structure with opposed open ends. The stiffeners 930, 930.1 include a sleeve member 944 and a plurality of webs 946 connecting the sleeve member 944 with the side walls of the stiffener 930, 930.1.

[0227] The second portion 938 of the stiffeners 930, 930.1 includes a generally planar wall portion 940. The free edges of the wall portion 940 are formed so as to turn inwardly and terminate in reinforcing rod-shaped structures 942 that can be positioned within the beads 920.1, 920.2 to provide reinforcement, whereby the cross section of the post 914 is assisted to maintain its sectional geometry until a predetermined force is applied, so that the post will not fail until a

force greater than the force to change the sectional geometry without such a stiffener has been applied..

[0228] The stiffeners 930, 930.1 are preferably made of plastics or polymeric material.

More preferably, the stiffeners 930, 930.1 are moulded from a thermoplastic material. It will be appreciated by those skilled in the art that the stiffeners 930, 930.1 can be made of any material capable of providing reinforcement to the supporting post 914 (eg, metal) and can be made hollow or webbed to conserve plastic. If desired it could be solid.

[0229] A further embodiment of a post and post stiffener arrangement is shown in

Figures 25 and 26. Similarly to the embodiment illustrated in Figs. 23, 24, the supporting post 914 is provided with two stiffeners 950 and 950.1. The locations of the stiffeners 950, 950.1 are similar to those illustrated in Fig. 24.

[0230] The stiffeners 950, 950.1 are in the form of generally rectangular plate members having two opposing side surfaces 952 and 954. As best illustrated in Fig. 25, the surface 952 of the stiffeners 950, 950.1 abuts the internal surfaces of the edge portions 919.1, 919.2 of the flanges 918.1, 918.2 of the supporting post 914. The stiffeners 950, 950.1 are welded to the supporting post 914 with two continuous welds 956.1, 956.2 extending in a generally vertical direction for the entire length of the stiffeners 950.1, 950.2. It will be appreciated by those skilled in the art that the stiffeners 950.1, 950.2 can be made of any material capable of being welded to the supporting post 914. Alternatively the stiffeners 950 can be glued or bolted to the supporting post 914.

[0231 ] The stiffeners 950, 950.1 preferably extend for 150 mm along the length of the supporting post 914.

[0232] Illustrated in Figures 27 to 30 is a stiffener 960 which is in the form of a welded frame structure (but could be cast if desired) including a side wall 960.1, a front face 960.2, a rear face 960.3, and a bottom panel 960.4. As best illustrated in Figs. 29 and 30, the front face 960.2 and the rear face 960.3 are provided with mounting slots 962.2 and 962.1 respectively. It has been found that that the plate thickness of 1/4" is suitable for the purpose of increasing torsional rigidity with open channel guardrail posts 914 and maintaining the sectional geometry as described above.

[0233] The stiffener 960 is dimensioned and shaped to fit into the channel of the supporting post 914 so that, in use, the front face 960.2 and the rear face 960.3 abut against the embossments 924.1, 924.2 respectively.

[0234] A modified form of the stiffener 960 is shown in Figs. 31 to 34. The stiffener 970 is in the form of U-shaped bracket including a body 976, a first flange 972 extending in perpendicular relation from one end of the body 976 and a second flange 974 extending from the opposite end of the body 976. The first flange 972 and the second flange 974 are provided with mounting slots 978.1, 978.2 respectively. The stiffener 970 has external dimensions generally similar to the stiffener 960 in the embodiment shown in Figures 27 to 30. In a preferred embodiment, the U-shaped bracket 970 is made of steel, however any other suitable material can be used. Preferably, the bracket 970 is made of a sheet material.

[0235] The post stiffeners 960 and 970 of figures 27 to 30 and 31 to 34 are illustrated as having a height H greater than the depth D. The height H is selected so as to position base plates 960.4 and 976 at a desired location on the post.

[0236] By making the height H equal to the depth D, the stiffeners 960 and 970 can be utilised in a number of orientations, so that for example the base plate 976 will prevent beads 920.1 an d920.2 moving towards or away from each other, while keeping the internal volume of the post 14 open, i.e. water can pass from the top to the bottom.

[0237] In one arrangement the plates 976 and 960.4 are at 90 degrees to the longitudinal axis of the post 914, while in another arrangement, the plates 976 and 960.4 can be parallel to the longitudinal axis of the post 914, and will operate in a similar fashion to the stiffener 950 of figures 25 and 26, but using a bolted connection instead of welding.

[0238] The roadway guardrail system 910 and the stiffeners of figures 27 to 34 can be assembled as follows. The supporting post 914 is fixed in place by driving the post 914 into the ground (not shown). Alternatively, the post 914 can be placed into a pre-dug post hole (not shown). The stiffener 960 or 970 is then mounted on the supporting post 914 so that the mounting bore formed in the stiffener will be aligned with the mounting opening 934 formed in the supporting post 914.

[0239] Similarly, the mounting opening (not shown) formed in the guardrail 912 is aligned with the mounting opening 934 of the supporting post 914.

[0240] A post bolt (not shown) extends through the mounting opening of the guardrail

912, the mounting opening 934 of the supporting post 914, and the mounting apertures of the stiffener 960 or 970, and to releasably secure the guardrail 912, the stiffener 960 or 970, and the supporting post 914 against relative movement. To this end, the head of the bolt is disposed against the substantially vertical surface of the guardrail 912. A nut (not shown) engaging the threaded portion of the bolt is disposed against the substantially vertical surface of the supporting

post 914 or the stiffener to secure the bolt against movement within the opening 934. Once the guardrail system is assembled and before the full tightening of the assembly, the desired height of the guardrail 912 can be further adjusted by knocking the guardrail in a generally vertical direction.

[0241] Illustrated in Figures 35 and 36 is a stiffener 980 which is in the form of a hollow core block or tube welded to the supporting post 914 with welds 982. Similar to the embodiments described above, the stiffener 980 is sized to abut one or more internal surfaces of the open channel of the supporting post 914. As shown in Fig. 36, the stiffener 980 is attached to an upper portion of the supporting post 914 in the vicinity of the mounting slot 934.

[0242] If desired the stiffener 80 of figures 35 and 36 can be solid block. A bolt hole or other fixing means can be provided. The solid block could be made of wood or polymeric material and can be held in place by a self tapping screw through the free ends of the post into, the block.

[0243] As mentioned earlier in this specification, the number and position(s) of the stiffener(s) along the length of the supporting post 914 can be chosen to suit the conditions of use. Preferred locations of stiffeners 1000 (which can be any of those described above or below) are illustrated in Figures 37 to 39. In figure 37, two stiffeners are used , one near the base, and one near the top of the post 914. In figure 18 only one stiffener 1000 is used near the base and in Figure 19 only one is used near to the top of the post 914. If desired more than two stiffeners could be used on a single post

[0244] Illustrated in Figures 40 to 44 is a stiffener 1020 which is in the form of a brace ( which can transmit to some degree both tensile and compressive forces) extending between and connected to the end portions 919.1, 919.2 of the flanges 918.1, 918.2 of the supporting post 914. As best shown in Fig. 41, the stiffener is connected to a lower portion of the supporting post 914 near a ground line.

[0245] As illustrated in Figs. 42 to 44, the stiffener 1020 includes two opposite end portions 1022.1, 1022.2 and a middle portion 1024 extending therebetween. The shape of the end portions 1022.1, 1022.2 of the stiffener 120 is generally complementary to the shape of beads 920.1, 920.2 of the supporting post 914.

[0246] As illustrated in Figs. 42, 43, the cross-section of the middle portion 1024 increases gradually toward the connecting portions 1022.1, 1022.2. In. an alternative embodiment illustrated in Fig. 44, the middle portion 1024 includes two generally parallel walls 1024.1 and 1024.2.

[0247] The stiffeners of figures 42 to 44 preferably can undergo or transmit both tensile and compressive forces to assist the sectional geometry to maintain its shape until a force greater than the force needed to change the sectional geometry without such a stiffener is applied.

[0248] It will be appreciated by those skilled in the art, that a C-post 914 can be provided with a stiffener 1030, as is illustrated in Fig. 45. Similarly to the stiffener 1020, the stiffener 1030 extends between the flanges 918.1, 918.2 of the supporting post 914 and includes two opposite end portions 1032.1, 1032.2 adapted to engage and interlock the end portions 919.1, 919.2 of the post 914.

[0249] Illustrated in Fig. 46 is a stiffener 1040 which is attached to an U-post 914. The stiffener 1040 can be secured to the flanges 918.1, 918.2 of the supporting post 914 by fastener(s) (not shown).

[0250] As mentioned earlier, the position(s) of the stiffener(s) along the length of the supporting post 914 can be chosen to suit the conditions of use. In particular, a stiffener in the form of a post cap and or a mounting bracket can be attached to an upper portion of the supporting post 12 or 914 so as to perform two functions: firstly to shield the sharp edges of the supporting post 12 or 914 and or blocking piece (not shown); and secondly to provide additional sectional geometry maintenance to the supporting post 12 or 914.

[0251 ] Such post caps are discussed above, and can be secured in place by bolts and nuts.

If plastic caps are used, the opposite side of the cap can be secured with a TEK screw. Steel blocks are capped by securing one side of the cap with the block bolt and nut, while an opposite side can be secured with a TEK screw.

[0252] Illustrated in figures 47 to 51, are stiffeners and post caps in combination.

[0253] In figure 47 is a post cap 1200 having a cap head 1201 which includes an under flange 1205 and a body 1202 which extends away from the cap head 1201. The under flange 1205, will prevent the cap head 1201 from entering wholly within a post such as post 12. The cap body 1202 has a hollow webbed construction so as to minimise material required for manufacture. Central reinforcing webs 1203 and the thickness of the side walls 1204 will determine the magnitude of compressive forces which can be applied to the post cap 1200, before it will change shape, and thus the post into which it is inserted may change its shape. If a greater force to cause collapse of the body 1202 is required then the webs 1203 and side walls 1204 can be increased in thickness. The post cap 1200 can be manufactured from polymeric or metallic materials, depending upon the amount of compressive force the post cap 1200 is to bear before changing its shape.

[0254] Illustrated in figure 48 is a post cap 1220, which is similar to that of figure 47, and like parts have been like numbered. The post cap 1220 differs from the post cap 1200, by the body 1202 being of a solid construction.

[0255] Illustrated in figure 49 is a post cap 1260, which has a cap head 1201 and a cap body 1202, which is constructed similarly to that of the post cap 1200 of figure 47, and like parts have been like numbered. The post cap 1260 also includes an elongated stiffener 1262, which operates in a manner similar the stiffeners of figures 40 to 46, except that the stiffener 1262 will only prevent the free ends of the post into which it is inserted from moving towards each other, for the length of the stiffener 1262. Thus the stiffener 1262 will only maintains the sectional geometry with respect to compressive forces, unless the free ends 1264 and 1266 of the stiffener 1262 are secured to the free ends of the post to which it is connected. This can be done by bolting, self tapping screws, adhesives, welding or any appropriate connection means.

[0256] Illustrated in figure 50 is a post cap 1280 similar to that of figure 49, and like parts have been like numbered. The post cap 1280 differs from post cap 1260 by the presence of a channel or groove 1282 which is located within the cap head 1201. The groove 1282 receives the upper rim of a post such as the post 12 of figure 1. The groove 1282 also prevents the post cap 1280 from wholly entering the post. Once inserted into.a post, the groove 1282 will receive the upper rim of the post, and the outer wall 1284 will, for the upper portion of the post, prevent the free ends of the post from moving away from each other, while the rest of the construction will prevent the free ends from moving towards each other, until a sufficient force is applied.

[0257] Illustrated in figure 51 is a post cap 1290 similar to that of figure 50, and like parts have been like numbered. The post cap 1290 differs from the post cap 1280 in that the stiffener 1262 includes free ends 1265 and 1267 which have a wrap around configuration, to thereby capture the free ends of a C-section or Charlie post and thereby to prevent, along a greater length of the upper part of the post, the free ends of the post from moving away from each other, until a sufficient force is applied.

[0258] Illustrated in figure 52 is an I-section post, having on its opposed free ends stiffeners 1040, such as that illustrated in figure 46. The stiffeners 1040 can be secured by any previously described means to the free ends of the I-section post, but the most preferred means is for a friction fit, so that assembly by tapping into place with a hammer can be easily effected.

[0259] Illustrated in figure 53 is a post stiffener 1230, which will operate, in some respects, in a similar manner to the mounting bracket 18 described above. The stiffener 1230 is a hollow cylindrical spacer, which is of a length designed to fit within the two opposed sides of a

post. By first locating the hollow 1232 so that it is aligned with respective holes through the sides of a post and then threading a both through first one hole, then the hollow 1232 of the stiffener and then the second hole, the stiffener 1230 can be secured in place with a nut. The bolt the spacer and the nut can then perform the task of maintaining the section geometry until a predetermined force is applied. The bolt, stiffener and nut will resist forces tending to move the free ends of the post away from each other, in the vicinity of the stiffener 1230, as well as those forces tending to move the free ends of the post towards each other.

[0260] Illustrated in figure 54 is plate stiffener 1300 which has a profiled periphery 1302, which will allow the plate stiffener 1300 to fit within the confines of the internal portions of the post 914 of figure 22, when the plate stiffener 1300 is generally perpendicular to the longitudinal axis of the post. The plate stiffener 1300 has a relatively simple shape, but can be less complex by being rectangular in shape, or more complex, by for example having a peripheral shape which is similar to the outer periphery of the 930, which will then provide means to engage the bead of the post 914 of figure 22.

[0261] The thickness of the plate stiffener 1300 an be sized according to the amount of stiffening that is desired, but it is expected that a thickness in the range of 3mm to 25mm should be sufficient for most applicants.

[0262] If the method of securing of the plate stiffener 1300 to the post is by friction

(between the edges of the stiffener 1300 and the internal surfaces of the post 914) or welding or adhering into place then the thickness can be kept to a minimum. However, by increasing the thickness to of the order of 10mm to 25 mm or greater, means that the plate stiffener can be secured to the post by TEK or self drilling and tapping screws which pass through the outer wall of the post 914 and into the post stiffener 1300.

[0263] The stiffener 1300 can be made in different peripheral shapes to be accommodated in different shape posts. If desired the stiffener 1300 could be combined with the stiffeners 1030, 1040 and the other stiffeners which engage the free ends of the posts, so as to produce a stiffener which is similar to stiffener 940 of figure 23, so that the combined stiffener is capable of interacting and holding the free ends while at the same time providing internal support for the walls of the post.

[0264] While the systems of figures 47 to 51 are illustrated as being for use with a C- section or Charlie post, it will be understood that appropriate suitable modifications will be required for use with the beaded post 914 of figure 22, so as to accommodate the turned or beaded free ends.

[0265] In some instances, it may be desirable to use uniformly spaced stiffeners. For other applications, a stiffener can extend for substantially the entire length of the supporting post. Similarly, the extent of the overlap between the external surface of the stiffener and the surface of the supporting post 14 can be changed to suit particular applications.

[0266] It will be appreciated by those skilled in the art that the stiffener(s) can be formed integrally with the supporting post 914.

[0267] The stiffener(s) described in this specification prevent the ends and walls of a supporting post from moving relative to each other until a predetermined force is applied to the supporting post. In a preferred embodiment, the stiffener(s) described above either prevents the ends of the supporting post from moving towards each other, hi other embodiments, the stiffener(s) prevents the ends of the supporting post from moving away from each other. It will be appreciated by those skilled in the art, that some stiffeners can perform both functions. It will be further appreciated that a supporting post provided with such stiffeners is capable of withstanding a higher load before failure.

[0268] The stiffener(s) provide reinforcement both in terms of structural rigidity (eg, torsional rigidity) and energy absorption capability. It will be further understood that in some cases the use of stiffener(s) can improve the sectional properties of the supporting post (eg, the moment of inertia).

[0269] Where ever it is used, the word "comprising" is to be understood in its "open" sense, that is, in the sense of "including", and thus not limited to its "closed" sense, that is the sense of "consisting only of. A corresponding meaning is to be attributed to the corresponding words "comprise", "comprised" and "comprises" where they appear.

[0270] It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text. All of these different combinations constitute various alternative aspects of the invention.

[0271 ] While particular embodiments of this invention have been described, it will be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and , examples are therefore to be considered in all respects as illustrative and not restrictive, and all modifications which would be obvious to those skilled in the art are therefore intended to be embraced therein.