Technical Field of the Invention

The present invention relates to safety decking.

Background to the Invention Safety decking systems are used extensively in the building industry. A decking system provides a horizontal platform for workers enabling them to safely access parts of a building site that would otherwise be out of reach. Such decking systems comprise a plurality of square or rectangular panels supported by a plurality of vertical support rods. The vertical rods are of a substantially equal height and are typically provided with base plates to increase the stability of the rod in relation to the ground and/or head plates for enabling secure engagement with the supported panels. The panels may be formed from metal or from a substantially rigid plastic material. Plastic panels are preferred as they are cheaper and relatively lightweight. Additionally, the panels can be readily manufactured in a bright colour, enhancing visibility for workers.

Rather than comprising a single continuous surface, the panels are formed from a number of cross members with gaps therebetween. This has numerous advantages such as reducing weight, allowing visibility through panels, and allowing water to drain away from upper surfaces. These advantages have to be balanced against the disadvantages of panels where gaps are too large or too numerous, including, but not limited to: reduction in load bearing capacity, increased propensity for tools to be lost though the gaps and less secure footing for workers. In known decking systems, lateral stability is ensured mainly by the panels, the relative position of the panels and rods being fixed by the head plates. In some implementations, additional stability may be achieved by securing the rods and/or panels to other structures, such as walls and or scaffolding. Nevertheless, such solutions are still less than optimal.

In respect of known decking systems, rods are provided with a standard length. This allows for the ready construction of a level platform where the ground upon which the rods are supported is level. Where this is not the case, additional effort need to be expended in levelling ground, providing props under rods or cutting rods to length.

It is therefore an object of the present invention to provide a panel for a safety decking system that at least partially overcomes or alleviates the above issues.

Summary of the Invention

According to a first aspect of the present invention there is provided a rod for a safety decking system, the rod comprising: an elongate member having a substantially constant transverse profile, the profile comprising a body portion for providing longitudinal support and a single rail portion, the single rail portion defining two channels for receiving and retaining a locking key.

This therefore provides a rod that is adapted to enable the fitting of crossbars thereto at any desired position by use of a locking key. This enables a decking platform constructed from such rods to have enhanced lateral stability.

The rod may be formed from steel or any other suitable metal. The body portion preferably has a hollow profile. The rail may extend the full length of the rod. In this manner, the rail portion may enable the fitting of a crossbar at any desired location along the rod. The rail portion may be provided at a corner of or an edge of the rod profile.

Each channel may have a lip restricting the width of the channel opening. In particular, where the rail is provided at a corner of the rod profile, the channels may be provided on faces of the rod profile on either side of the corner. The single rail portion may define two perpendicular channels. The rod may comprise only two channels.

The rod may be provided with a secondary rod, the secondary rod operable to be received telescopically within the rod. In such embodiments, the secondary rod may have an outer profile corresponding to the inner profile of the rod. In this manner, the length of the rod may be adjusted. This allows for platforms of differing heights to be erected or for rods to readily compensate for uneven ground.

The rod and secondary rod may be provided with corresponding apertures. Apertures may be provided in the rod near the end farthest from the base plate when the base plate in fitted. Apertures may be spaced along the length of the secondary rod. The apertures formed in the rod may be provided in aligned pairs. The apertures formed in the secondary rod may be provided in aligned pairs. By this construction, the apertures of the rod and apertures of the secondary rod can all be aligned by moving the rods relative to each other into a suitable position.

The rod may be provided with a locking bracket. The locking bracket may comprise one or more arms. An arm of the locking bracket may be sized to extend through the apertures in the rod and secondary rod. In this manner, the locking bracket can be used to maintain the length of the rod. The locking bracket may be made of an elastically deformable material. The locking bracket can therefore provide shock absorbance.

The locking key may comprise a shaft and an offset foot for engaging with the channel. The shaft is preferably an elongate element. The offset foot preferably projects laterally to the axis of a leg projecting from an end of the body and offset with respect to the axis of the shaft. The offset foot preferably has a width corresponding to the width of the leg. In this manner, the offset foot can be inserted into the channel of the rail portion past the lip in a first orientation and rotated to a second orientation where the foot will engage with the lip to prevent withdrawal of the locking key. The locking key may extend perpendicularly from the surface of the rod to which it is releasably fastened. The locking key may additionally comprise a head provided at the end of the shaft distal to the offset foot. The head may comprise a loop or handle. The head facilitates manipulation of the locking key by a worker. The length of the shaft may be determined so as to enable the locking key to fasten a crossbar to the rod. A typical crossbar may comprise an elongate hollow or solid member having opposing aligned apertures or a through bore. Preferably, the shaft is of a width that fits through the opposing aligned apertures or the through bore in a suitable crossbar. Preferably the length of the shaft is greater than the width of a suitable crossbar.

According to a second aspect of the present invention there is provided a safety decking system comprising a plurality of panels supported by a plurality of rods according to the first aspect of the present invention. The system of the second aspect of the present invention may incorporate any or all features of the first aspect of the invention as desired or as required.

The rods may be connected by one or more crossbars. The crossbars may comprise an elongate solid member having lateral through bores provided at either end. In a preferred embodiment, the crossbars may comprise an elongate hollow member having opposing aligned apertures at either end. In some such embodiments, the crossbars may have a telescopic construction.

The crossbars may be releasably fastened to the rods using one or more locking keys. The crossbars may extend substantially parallel to the rod surface to which they are releasably fastened. Where a rod has a square cross section, the crossbars may extend substantially parallel to the face of the rod to which the crossbar is releasably fastened. Where the crossbars extend parallel to the surface of the rod, only two channels need be machined into the rod for the crossbars to extend in four directions. Extending parallel to the rod is also advantageous in that a locking key can be passed through the apertures or bore in the crossbar in a direction which is perpendicular to the length of the crossbar.

The panels may be substantially square or rectangular. The panels may be formed from a plastic material. The panels are preferably formed from a material of a high visibility colour or is coated in a material of a high visibility colour. In some embodiments, the panels may comprise: an edge member provided at each edge of the panel, one or more parallel interior members running parallel to each edge member, said interior members separated from said edge members by relatively narrow gaps; a central block separated from said interior members by a relatively wide gap, said relatively wide gap bridged by one or more crossbars; and diagonal members connecting the corners at which the interior members meet with the corners at which the edge members meet.

In embodiments where there are multiple interior members, preferably each interior member is separated from each other interior member by relatively narrow gaps.

The members may each comprise an upper planar portion with downwardly projecting ribs at the periphery. Some members may additionally be provided with a central downwardly projecting rib. The provision of such ribs increase the strength of the members whilst not adding excessive mass thus providing a relatively strong and lightweight supporting structure. Similarly to the members, the bars and/or the block may comprise an upper sheet and downwardly projecting ribs at the periphery. The block may additionally be provided with one or more central ribs. The block may further be provided with a honeycomb like support frame on the lower surface of the sheet between the ribs.

The downwardly projecting ribs may be the same height or may be different heights. In some embodiment, there are two different rib heights. In some such embodiments, the outer ribs of the edge members may be of the larger height. In such embodiments, the edge members may also be provided with a central rib of the larger height. In some such embodiments, one peripheral rib of one or more of the bars may be of the larger height. In some such embodiments, the central ribs of the block may be of the larger height. In particular, the peripheral ribs of one or more of the bars aligned with the central ribs of the block may be of the larger height. The upper surface of the edge members, interior members and block may be provided with gripping formations. These may comprise a series of ridges, grooves, projections or the like. This can increase the engagement between worker's footwear and the upper surface thus reducing the trip hazard. The upper surface of the block may be provided with a series or ridges, channels or projections forming text and/or a logo. This can enable the panels to display a message or branding relating to the work site or contractor carrying out the work.

The edge members may be provided with one or more formations for attachment to adjacent panels and/or for attachment to support rods. The formations may be provided in the outer peripheral rib of the edge member. In some embodiments, the formations may additionally be formed in the inner peripheral rib or in the central rib.

The formations may comprise one or more slots for receiving locking pins. The sheet of the edge member may be provided with one or more apertures aligned with the slots. This can enable a worker to readily check whether locking pins are correctly inserted into the slots.

The relatively wide gaps may be of a suitable size to allow standard scaffolding poles to pass through the panel. This can allow the panels to be used in a safety decking system erected alongside or around scaffolding. The rods may be affixed to the panels via base plates. The base plates may be secured to one or more panels using one or more locking pins. The locking pins may be operable to engage with formations for attachment, such as slots, provided in the panels. The secondary rod may be provided with a compensation mechanism. The compensation mechanism may be provided at a distal end of the secondary rod. The compensation mechanism may have inner dimensions suitable to receive the secondary rod and outer dimensions which match the inner dimensions of the pocket. The compensation mechanism may have inner dimensions suitable to receive the secondary rod and outer dimensions which match the outer dimensions of the primary rod. In this manner, base plates having pockets sized to receive the primary rod will be compatible at both primary and secondary rod ends.

The compensation mechanism may be a section of material having the same cross-sectional dimensions as the primary rod. The length of the section may be of the order of the pocket length. The section may protrude beyond the end of the pocket when fitted over the secondary rod. Such a construction allows for ease of insertion into, and removal from, the pocket. The compensation mechanism may be a section of primary rod. In some embodiments, the compensation mechanism may have side walls and an end surface. In such embodiments, the compensation mechanism may comprise a projecting brim. The brim may project outwardly from the base of the side walls. The brim can provide a bearing surface for the base plate when it is fitted over the compensation mechanism. The compensation mechanism may comprise an elastomeric material. In one embodiment, the compensation mechanism may be formed from silicone. The compensation mechanism being made from an elastomeric material provides shock absorbance between the panels and base plates above and secondary rod below. The compensation mechanism may have a plurality of cushioning protrusions. In suitable embodiments, the cushioning protrusions are provided on the end surface. The cushioning protrusions may have any suitable form, including, but not limited to, conical, truncated conical or hemispherical. The compensation mechanism having cushioning protrusions provides shock absorbance between the panels and base plates above and secondary rod below.

The base plates may be secured to the support rods via one or more locking pins. The locking pins may be operable to engage with formations for attachment, such as apertures, provided in the rods. The base plates may further be adapted to be fitted to the lower end of support rods. This can provide a wider and more secure interaction between the ground and the lower end of the support rod.

The locking pins may comprise a shaft and a head. The shaft may be adapted to comprise a tooth on one side. The tooth can engage with the edges of the formations, whether slots or apertures. In addition to engagement, the tooth can provide a tactile feedback to a worker that the pin has been engaged sufficiently. The head may comprise a loop. This allows a worker to readily hold or manipulate the pin securely during insertion or removal.

According to a third aspect of the invention there is provided a compensation mechanism for a secondary rod received telescopically in a primary rod, the compensation mechanism comprising inner dimensions suitable to receive the secondary rod and outer dimensions which match the outer dimensions of the primary rod. By this construction, the compensation mechanism can be used to compensate for the difference in cross section between the primary rod and secondary rod received telescopically therein. The compensation mechanism allows for the secondary rod to be received in components which are sized to receive the primary rod,

The third aspect of the invention may comprise any or all of the features of the first and second aspect of the invention, as desired or as appropriate.

Detailed Description of the Invention

In order that the invention may be more clearly understood one or more embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, of which:

Figure 1 shows (a) a safety decking system according to the present invention,

(b) an expanded detail of the connection between a base plate, support rod and the panels of the safety decking system, (c) an expanded detail of a support rod according to the present invention and a crossbar connected to the support rod, and (d) an expanded detail of a support rod according to the present invention and two crossbars connected to the support rod;

Figure 2 shows (a) a perspective view, (b) a side view (c) a cross-sectional view support rod according to the present invention;

Figure 3 shows a top view of a rod according to the present invention projecting from a base plate; Figure 4 shows a locking key for connecting a crossbar to a rod according to the present invention;

Figure 5(a) shows a compensation mechanism for a secondary rod according to the present invention; Figure 5(b) shows a side view of the compensation mechanism of Figure 5(a);

Figure 5(c) shows a top view of the compensation mechanism of Figure 5(a);

Figure 6 shows a compensation mechanism fitted to a secondary rod; and

Figure 7 shows a compensation mechanism fitted to a secondary rod and with a base plate fitted above. Turning now to figure 1, multiple panels 10 are supported by multiple rods 20 according to the present invention so as to form a safety deck 100. A connection is formed between each support rod 20 and the respective panels 10 via base plates 30. Panels 10 may be supported via base plates 30 (and associated rods 20) at each corner as is illustrated in figure lb. In situations where additional support is required, additional base plates 30 and rods 20 may be provided and attached at other locations. The rods 20 are additionally provided with base plates 30 at their lower ends to provide secure and stable interaction with a ground surface.

In some instances such additional base plates 30 and rods 20 may be used instead of base plates 30 and rods 20 at the corners. This might be necessary where the ground beneath a corner is unsuitable for supporting a rod. This might be due to this particular area being uneven, soft or having a loose surface layer. The panels 10 are typically moulded from a substantially rigid plastic material and may be square (as shown in figure 1) or rectangular as required or desired. The upper surface of the panels 10 may be provided with gipping formations such as ridges, grooves, projections or the like. This can increase engagement between a worker's footwear and the upper surface.

In the example of figure la, the panels 10 comprise edge members 11 along each edge and interior members 12 separated from edge members 11 and the other interior members 12 by relatively narrow gaps 16. The panel 10 comprises central block 13 separated from the inner most interior members 12 by relatively wide gaps 17. The narrow and wide gaps 16, 17 are bridged by a plurality of cross-struts 15. In addition, the panel 10 is provided with corner members 14 which connect the corners where edge members 11 meet to the corners where interior members 12 meet.

The edge members 11 are provided with aligned apertures (not shown) connected by slots (not shown) adapted to retain locking pins. This enables the base plates 30 to be connected to the panels 10 by use of suitable locking pins.

The rods 20 are connected together by crossbars 50. The crossbars provide lateral support to the decking system 100. The crossbars 50 are fastened to the rods 20 using locking keys 40 as will be described further below. The crossbars are typically elongate hollow members. As is shown in figure 1, the crossbars 50 may be formed of two (or more) elements connected telescopically. This allows crossbars to be adapted to fit a required spacing between rods. In a preferred embodiment, the telescopic connection may be biased to extend the length of the crossbars 50 The crossbars 50 are provided with opposing aligned apertures through which a locking key 40 can be inserted.

As is shown in figure 2, the support rod has an elongate hollow profile. The profile comprises a body portion 21 and a rail 22 for receiving and retaining a locking key 40. In the present example, the support rod 20 has a substantially square profile, but the skilled man will appreciate that other profile shapes are also suitable.

The rail 22 defines a pair of channels 23, each channel 23 having a lip 24 that restricts the width of the channel opening. The skilled man will appreciate that in other examples, the rail 22 may be configured to provide only a single channel 23 or indeed more than two channels 23.

The rod 20 is comprised of a primary rod 20a and a secondary rod 20b, the secondary rod 20b adapted to fit telescopically within the primary rod 20a. This enables the length of the rod 20 to be adjusted enabling compensation for uneven ground or the like. Nevertheless, the skilled man will appreciate that a rod may comprise a single rod or more than two rods as required or desired.

The primary rod 20a and secondary rod 20b may be provided with a series of corresponding apertures 25. In order to maintain the desired length of the rod 20 one arm 61 of a locking bracket 60 can be inserted through aligned apertures in rods 20a, 20b. The locking bracket 60 may comprise two arms 61, 62 projecting from either end of a body 64. In this manner the locking bracket 60 will fall in use into a position where the arm 62 not projecting through the apertures 25 will rest against the exterior of the rod 20a. The end 63 of arm 62 may be kinked so as to help retain the bracket 60 in position. The locking bracket 60 is typically also provided with a handle 65 to facilitate removal by a worker. The locking bracket 60 may be formed of an elastically deformable material. This provides shock absorbance to force applied from the panels above.

Each support rod 20 is provided with a plurality of apertures 29 at each end. The apertures 29 are adapted to receive and retain locking pins used to connect the rods 20 to base plates 30.

The base plates 30 comprise a central plate 31 with a series of legs 32 projecting from each corner of one side of the plate. Each leg 32 ends in a foot 33 comprising a surface substantially parallel to the plate 31. Projecting on the opposite side of the plate 31 to the feet 32 are shoulders 34 and a pocket 35. The mutually perpendicular orientation of the main plate 31 and the surfaces machining up legs 32 and shoulders 34 provide the base plate 30 with structural rigidity under shear forces. The feet 33 provide engagement with the ground when the base plate 30 is fitted to the lower end of a rod 20 and support for the panels 10 when fitted to the upper end of a rod 20. The legs 32 support the feet 33 in either position.

The pocket 35 is comprised of projecting walls adapted to receive support rod 20. Accordingly, the pocket 35 thus has a cross-section corresponding to either the primary rod 20a or secondary rod 20b cross-section. Alternatively, the pocket 35 has a cross-section corresponding to the primary rod 20a cross section and a compensation mechanism is used to compensate for the difference at the secondary rod 20b end, as will be described in greater detail below. The pocket 35 is additionally provided with apertures 39. A locking pin (not shown) can be inserted through apertures 39 on opposing sides of pocket 35 and apertures 29 on opposing sides of a support rod 20 inserted into the pocket 35. This locks the support rod 20 into position within the pocket 35.

Turning now to figure 4, additional details of locking key 40 are shown. In particular, the locking key 40 comprises a shaft 41 and a head 42. The head 42 comprises a loop or handle which facilitates manipulation of the locking key 40 by a worker.

The shaft 41 is provided with an offset foot 43 for engaging with the channel. The offset foot 43 projects laterally to the axis of a leg 44 projecting from an end of the shaft 41 and is offset with respect to the axis of the shaft 41. The length of the shaft 41 is selected so as to enable the locking key 40 to fasten the crossbar 50 to the rod 20. In this context, the shaft 41 is of a width that fits through the opposing aligned apertures in the crossbar 50 and of a length that is greater than the width of the crossbar 50.

In use, the shaft 41 is inserted through a crossbar 50 such that the offset foot 43 projects from one side of the crossbar 50 and the head 42 projects from the other side of the crossbar 50. This enables the offset foot 43 is inserted into the channel 23 of the rail 22 at a desired location along a rod 20. The foot 43 is orientated such that it can pass the lip 24. The foot 43 can then be rotated to a second orientation (as shown in figure 3) where the foot 43 will engage with the lip 24 to prevent withdrawal of the locking key 40 from the channel 23 by pulling on the head 42. To unfasten the locking key 40 it can be rotated back to a position where the foot 43 can be withdrawn past the lip 24. In this context, the orientation of the loop comprising the head 42 can provide a worker with visual confirmation of the orientation of the locking key 40. As the rail 22 (and hence channel 23 and lip 24) extends along substantially the full length of road 20a, it is possible to fasten a crossbar to the rod 20a at any desired location.

The tooth 43 can engage with the edges of slots 181 or apertures 21, 39, 182 as required. In addition to engagement, the tooth 43 provides tactile feedback to a worker that the pin 40 has been engaged sufficiently. The shaft 45 may be solid or may, as is shown best in figure 6b comprise an internal channel 45. The internal channel 45 reduces the weight of the pin 40.

As previously mentioned, if the base plates are designed to have a pocket 35 having a cross-section corresponding to that of the primary rod 20a, a compensation mechanism must be used to account for the difference at the secondary rod 20b end. if necessary, a piece of primary rod (not shown) can be used as a compensation mechanism, the piece of primary rod having apertures formed in its side which align with apertures 39 formed in the pocket 35 of a base plate 30 when the base plate 30 is fitted. A locking pin can then be used to releasably attach the base plate 30, piece of compensatory primary rod and secondary rod 20b together.

An alternative compensation mechanism is shown in Figure 5. As can be seen in Figure 6, the end of the secondary rod 20b receives a compensation mechanism in the form of a cap 70 which compensates for the difference in cross section. The cap 70 comprises side walls 71, a closed end surface 72 and an open face 76 at one end. The cap 70 is formed from elastomeric material and has inner dimensions sized to receive the secondary rod 20b with a tight but sliding fit. The outer dimensions of the cap 70 are sized to slot into the pocket 35 of the base plate 30 with a tight but sliding fit. A plurality of conical cushioning protrusions 73 formed on the end surface 72 of the cap 70 contact the inner surface of the pocket 35 which is parallel to the base plate 30. An outwardly protruding brim 74 formed about the sides of the lower end of the cap 70 provides a bearing surface for the base of the base plate 30 when the cap 70 is received in the pocket 35. As illustrated in Figure 7, the cap 70 sits between the secondary rod 20b and the base plate 30 and, whilst compensating for the difference in cross-section, also acts as a shock absorber between the two components. The protrusions 73 provide additional shock absorbance as they are readily compressed.

Apertures 75 formed in the side walls 71 of the cap 70 align with the end apertures 29 of the secondary rod 20b and with the apertures 39 of the pocket 35 when the cap 70 is in place. In this manner, a locking pin can be passed through the apertures 75, 29, 39 and used to secure the components together. The above embodiments are described by way of example only. Many variations are possible without departing from the scope of the invention as defined in the appended claims.