Abstract:
An improved portable safety guardrail system which utilizes cast iron bases or welded bases and tubular guardrail sections and gates. The system is designed to meet and exceed OSHA Fall Protection Regulations while having the appeal of being modular and portable with no need for anchoring devices (i.e., anchor bolts, etc.). This invention allows for infinite configuration of a guardrail system to suit the needs of the user.

Description:
CROSS REFERENCES TO CO-PENDING APPLICATIONS 
     None. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention pertains to a safety rail system for providing a protective barrier for blocking access to a hazardous area or for preventing falls from an elevated area. 
     2. Description of the Prior Art 
     Prior art safety rail systems required the user to secure components of the systems by some type of securing method, such as by using anchor bolts or by welding pieces together. One similar prior art system to this invention utilizes cast bases and rail sections. This system uses two post receivers on each cast base to support only two rail sections. In each post receiver are four cast holes spaced 90 degrees from one another. These holes are used to secure the rail sections to the base with some type of securing pin. In contrast, the present invention utilizes a plurality of offset slots instead of holes to provide for infinite positioning. 
     A common prior art system has toe board receiver slots cast into the perimeter of the base itself, creating protrusions. These protrusions could extend up to six inches from the base surface. In contrast, this invention uses removable toe board adapters. By utilizing the adapter method, potential hazards due to protrusions extending from the base are eliminated. One hazard is a potential tip-over of a forklift driving over the protrusion. Another potential hazard is human injury should someone trip over the protrusion and fall. These protrusions also become a nuisance when toe boards are not in use. 
     No known system allows for infinite positioning and in addition has locking gates and removable toe board adapters. The present invention provides for all three of these features inclusive or independent. 
     SUMMARY OF THE INVENTION 
     The general purpose of the present invention is to provide a safety rail system which is intended to be used to cordon off work areas and the like where human safety is an issue. When the cast iron base is coupled to the rail and/or gate sections, it has enough weight, mass and strength to withstand tipping. Thus, the system provides a safe means of protection should one fall against it. It also meets and exceeds OSHA regulations for permanent safety railings. When used on an elevated work surface, optional toe board adapters are added. These adapters enable the system to be in accordance with OSHA regulations pertaining to elevated work areas. 
     The base is the vital component of this invention and enables the system to be as versatile as it is described herein. The base has four post receivers so as to enable as many as four rail sections, latching posts, or gate posts to be incorporated at any one time. Thus, the system has the versatility to have up to four quadrants of work areas to be defined by the base placement. The base also incorporates four symmetrically positioned holes to enable a permanent mount to a surface, via some form of anchor bolts, if desired. 
     Designed into each of the post receivers are strategically positioned slots. These slots will align with two vertically spaced holes in the vertical posts of the rail sections. This alignment will enable the rail sections to be secured to the base at infinite positions along a 360° rotation with some type of locking pin. 
     The rail sections used in this invention come in varying lengths and are comprised of iron tubing with a sufficient wall thickness to withstand the potential force that could be exerted when a person falls against a rail section. It is to be understood that aluminum or another appropriate material may be used in the rail section construction. The rail sections include a rail-locking system that adds additional strength to the entire system, preventing tipping. The vertical posts of each rail section have doughnut-shaped metal pieces (securing rings) welded at equal heights from the bottoms of the posts. The securing rings have precise internal cutouts that enable each rail section to be secured to each other with some type of securing means. A carabiner or locking safety chain would be sufficient to additionally secure the rail sections together. The internal cutouts enable the rail sections to be secured to one another at infinite directions of any rail section that is incorporated in the base at any one time. 
     This invention incorporates a derivative of the rail section. It is a gate assembly that is utilized to access a work area without having to remove locking pins and a rail section to gain access. A coupler is designed to attach and lock a gate post to a base post receiver. This feature is important so it can lock the angle of assembly of the gate post to the base. Without the coupler, the gate post would move within the post receiver slots and then would not align with the gate latching post after moving from its original installation position. 
     When this invention is used on an elevated work surface, as defined by OSHA regulations, an adapter or receiver for required toe boards is available. Toe boards are intended to keep objects from being kicked over the elevated work surface that may cause injury to someone below. These toe board adapters or receivers slide onto the lower ends of the vertical posts of each rail section and then are lowered onto the toe board. After positioning onto the toe board, the adapters are secured to the rail section with a securing bolt or knob of one&#39;s choice. The toe boards are then secured to the adapter by nails or by a locking pin that is similar to or the same as that used to secure the rail section to the base. Because these adapters are designed to rotate on the vertical post before being locked into place, they can be positioned in any direction so that they follow the in-line path of the rail section itself. 
     This invention comes with an optional number of horizontal cross members or vertical posts that can be welded to the rail sections. This feature enables this portable system to be used in a variety of markets. One example of this feature is the agricultural market. One could specify the requirements of spacing between the horizontal/vertical spacing of the cross members so that animals could not escape from a livestock pen created using this invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Other objects of the present invention and many of the attendant advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, in which like reference numerals designate like parts throughout the figures thereof and wherein: 
     FIG. 1 illustrates a perspective view of a safety rail system, the present invention; 
     FIG. 2 illustrates a top view of a base; 
     FIG. 3 illustrates a side view of the base; 
     FIG. 4 illustrates a front view of two rail sections connected together using rail lock donuts and a securing chain; 
     FIG. 5 illustrates a front view of a gate assembly including a gate section in conjunction with a latching post and a gate post; 
     FIG. 6 illustrates a front view of a gate post and gate section where a locking coupler secures the gate post to a post receiver of a base; 
     FIG. 7 illustrates a cross sectional view of the locking coupler; 
     FIG. 8 illustrates a top view of a rail lock donut; 
     FIG. 9 illustrates a front view of a rail section supported by two bases and incorporating a toe board secured in place by toe board receivers; 
     FIG. 10 illustrates a front view of a toe board receiver; 
     FIG. 11 illustrates a side view of a toe board receiver; 
     FIG. 12 illustrates a perspective view of the safety rail system configured for use in a manufacturing facility; 
     FIG. 13 illustrates a perspective view of the safety rail system constructed around a construction dig site; and, 
     FIG. 14 illustrates a perspective view of a base and rail section depicting how each post receiver has a 360° rotation capacity. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 1 illustrates a perspective view of a safety rail system  10 , the present invention. This illustration shows the safety rail system  10  assembled on a rooftop in a random configuration. The safety rail system  10  is comprised of a plurality of rail sections  12   a - 12   n,  a plurality of bases  14   a - 14   n,  a plurality of rail lock donuts  16   a - 16   n,  a plurality of securing chains  18   a - 18   n,  and a plurality of toe boards  20   a - 20   n  used in conjunction with a plurality of toe board receivers  22   a - 22   n.  Each component will be later described in detail with reference to the following figures. 
     FIG. 2 illustrates a top view of a base  14   a,  and FIG. 3 illustrates a side view of base  14   a.  The bases  14   a - 14   n  weigh between 100-120 lbs. and are cast iron or welded plate and tube to support rail sections  12   a - 12   n  without tipping. Each base  14   a - 14   n  is constructed in the same manner having identical parts including a planar portion  42  with cutouts  40   a - 40   d  on four opposing sides creating built-in handles for transporting it. There is also a centrally located lifting bar  46  which allows the user to hook the bases  14   a - 14   n  to a pulley or a dolly to more easily move the heavy bases  14   a - 14   n.  There are provided holes  38   a - 38   d  which accommodate anchor bolts for securing the bases  14   a - 14   n  to a work surface such as a concrete floor or roof top if permanent mounting is desired. The key feature of the bases  14   a - 14   n  is four post receivers  36   a - 36   d  which extend perpendicularly upward from planar portion  42 . Rail sections  12   a - 12   n  are identical and each includes any number of horizontal rails  23   a - 23   n  connected at their ends to vertical posts  24   a - 24   b.  The vertical posts  24   a - 24   b  are positioned in the post receivers  36   a - 36   n  allowing the rail sections  12   a - 12   n  to be positioned in any position in a 360° range. Each of these post receivers  36   a - 36   d  includes a plurality of slots  44   a - 44   n;  and the vertical posts  24   a - 24   b  of the rail sections  12   a - 12   n  incorporate a plurality of corresponding holes  48   a - 48   n,  as shown in FIG. 4, for receiving locking pins  30  (FIGS. 9) to hold the rail sections  12   a - 12   n  in place in the bases  14   a - 14   n  once the desired position is acquired. Once the rail sections  12   a - 12   n  are secured to bases  14   a - 14   n  at each end, the slots will allow the rail sections  12   a - 12   n  to pivot. Each base  14   a - 14   n  may accommodate a maximum of four rail sections  12   a - 12   n  which can be locked in any position within their range of motion. It is to be understood that the slots  44   a - 44   n  may be substituted with multiple holes at different heights, but holes will not allow the infinite 360° range at which the rail sections  12   a - 12   n  may be locked. The post receivers  36   a - 36   d  can also accommodate a latching post and/or a gate post which will be described with reference to FIGS. 4 and 5. 
     FIG. 4 illustrates a front view of two rail sections  12   a - 12   n  connected together using rail lock donuts  16   a - 16   n  and a securing chain  18   a,  and FIG. 5 illustrates a front view of a gate assembly which includes a gate section  32   a  in conjunction with a latching post  28   a  and a gate post  34   a.  Each gate section  32   a - 32   n  includes any number of horizontal rails  25   a - 25   n  connected at their ends to vertical posts  26   a - 26   b.  A plurality of latching posts  28   a - 28   n  and a plurality of gate posts  34   a - 34   n  may be used in any configuration. Illustrated in these figures are the holes  48   a - 48   n  which were mentioned in connection with the previous figures. The latching post  28   a  and the gate post  34   a  also incorporate holes  48   a - 48   n  identical to those in the vertical posts  24   a - 24   b  of the rail sections  12   a - 12   n  and these holes serve the same purpose. Also illustrated are hinges  50   a - 50   n  which are secured to the gate post  34   a  in at least two positions. The opposite ends of hinges  50   a - 50   n  secure to the vertical post  26   b  of gate section  32   a,  creating a pivoting gate. The gate section  32   a  also has a gate latch  52  secured on the vertical post  26   a  opposite hinges  50   a - 50   n.  The gate latch  52  provides a locking means for the gate section  32   a.  In the configuration illustrated in FIG. 5, only the gate post  34   a  and the latching post  28   a  are secured to bases  14   a - 14   n  (not illustrated) and gate section  32   a  is suspended between them, creating the operational gate. Both the latching post  28   a  and the gate post  34   a  are locked in position using a locking coupler  54  which will be described with reference to FIGS. 6 and 7. It is necessary to lock the gate post  34   a  in position using the locking coupler  54  to prevent pivoting, keeping hinges  50   a - 50   n  in position. 
     FIG. 6 illustrates a front view of a gate post  34   a  and gate section  32   a  where locking coupler  54  secures gate post  34   a  to post receiver  36   a  of base  14   a,  and FIG. 7 illustrates a cross sectional view of locking coupler  54 . Illustrated in particular is the configuration of the safety rail system  10  components when a gate is needed and the locking coupler  54  is used. Also illustrated are a set of holes  56   a  and  56   b  which lock the gate post  34   a  to the locking coupler  54  and a hole  58  which allows the locking coupler  54  to be secured to post receiver  36   a  of base  14   a  by a securing knob, bolt or other suitable device. 
     FIG. 8 illustrates a top view of a rail lock donut  16   a.  Illustrated in particular is a hole  60  whereby the rail lock donut  16   a  is secured to vertical post  24   a  or  24   b  of rail section  12   a,  and slots  62   a - 62   b  which accommodate securing chains  18   a - 18   n,  as illustrated in FIGS. 1 and 4. 
     FIG. 9 illustrates a front view of a rail section  12   a  supported by two bases  14   a - 14   n  and incorporating a toe board  20   a  secured in place by toe board receivers  22   a - 22   n,  where all numerals correspond to those elements previously described. With further reference to FIGS. 10 and 11, the use of the toe board will now be described in detail. 
     FIG. 10 illustrates a front view of a toe board receiver  22   a,  and FIG. 11 illustrates a side view of a toe board receiver  22   a.  Each toe board receiver  22   a - 22   n  includes a sleeve  64  which is slid upwardly over and about the bottom of vertical post  24   a  or  24   b  of rail section  12   a  prior to securing rail section  12   a  to base  14   a.  Each sleeve  64  has a nut  74  welded to the outside over a hole, not illustrated, in the sleeve  64 , where an L-bolt  76  or the like is screwed through the sleeve  64  and frictionally engages vertical post  24   a  or  24   b.  The sleeve  64  may also be bolted or welded, if necessary or so desired. There is a board receiver bracket  66  connected at an angle to the sleeve  64  by shaft  68 . The board receiver bracket  66  is straddled over toe board  20   a  and appropriately secured thereto through holes  70   a  and  70   b  by a bolt, securing pin or other appropriate means. Each rail section  12   a - 12   n  should include two toe board receivers  22   a - 22   n  and one toe board  20   a - 20   n,  as illustrated, to prevent materials from being kicked off an elevated work area using the safety rail system  10 . 
     FIG. 12 illustrates a perspective view of the safety rail system  10  configured for use in a manufacturing facility, where all numerals correspond to those elements previously described. It defines the use for the four post receivers  36   a - 36   d  that are incorporated into the bases  14   a - 14   n.  Unlimited work areas can be defined with this set-up or one similar to it. Also illustrated is how the gate sections  32   a - 32   n  are used in conjunction with the rail sections  12   a - 12   n.  These gate sections  32   a - 32   n  allow access to the work areas by workers or a forklift, for example. When the gate sections  32   a - 32   n  are not in use, they are closed. When closed, these gate sections  32   a - 32   n  create a safe barrier just as the solid rail sections  12   a - 12   n  would. This illustration shows work areas configured in squares, but it is to be understood that the safety rail system  10  can be configured in any shape needed. 
     FIG. 13 illustrates a perspective view of the safety rail system  10  constructed around a construction dig site  78 . This configuration allows the safety rail system  10  to follow the various angles that are created by the edge of the dig site  78  and still be secured in position by the locking pins  30  (FIG. 9) at any of the angles shown, as well as an infinite number of angles not shown. 
     FIG. 14 illustrates a perspective view of a base  14   a  and rail section  12   a  depicting how each post receiver  36   a - 36   d  has the capability to be secured by a locking pin  30  (FIG. 9) to a rail section  12   a - 12   d  in a 360° range when utilizing the slots  44   a - 44   n  in the post receivers  36   a - 36   d.  A plurality of holes at different horizontal planes may be substituted for the plurality of slots  44   a - 44   n,  but the holes would limit the direction the rail sections  12   a - 12   n  could be positioned and not allow the infinite positioning that slots  44   a - 44   n  provide. 
     MODE OF OPERATION 
     With reference to FIGS. 1-14, the mode of operation is now described, where all numerals correspond to those elements previously described. The portable safety rail system  10  is comprised of a number of components. The rail sections  12   a - 12   n  come in varying lengths. Secured to the vertical posts  24   a - 24   b  of a rail section  12   a  is a rail-lock donut  16   a - 16   n.  These rail lock donuts  16   a - 16   n  are secured at equal heights on all rail sections  12   a - 12   n  by welding or other appropriate means. When the rail sections  12   a - 12   n  are secured in position and the rail lock donuts  16   a - 16   n  are coupled with a securing chain  18   a - 18   n,  added strength is given to the system should a rail section  12   a - 12   n  start to tip over. A carabiner or other suitable device may be substituted for the securing chains  18   a - 18   n.  The tipped-over rail section  12   a - 12   n  would then try to drag the next attached rail section  12   a - 12   n  with it and so on. The overall weight will prevent the safety rail system from tipping over. The rail lock donut  16   a - 16   n  is designed so it too can accommodate the infinite directions available to the rail sections  12   a - 12   n  as they are turned in the post receivers  36   a - 36   d  of bases  14   a - 14   n.    
     The gate assemblies for the safety rail system  10  are unique in design. A gate assembly is comprised of four major components: namely, one of the gate sections  32   a - 32   n,  one of the latching posts  28   a - 28   n,  one of the gate posts  34   a - 34   n,  and a locking coupler  54 . The latching post  28   a  is where a gate latch  52  will secure the gate section  32   a  so to not swing to and fro. The gate section  32   a  connects via hinges  50   a - 50   n  to the gate post  34   a.  The gate sections  32   a - 32   n  also have the capability to have infinite positions for placement and when the desired direction is found, the locking couplers  54  can easily lock the gate sections  32   a - 32   n  into position so they will not move. The locking coupler  54  is made of a lightweight metal such as aluminum. It is machined half way through to be the outside diameter of a gate post  34   a - 34   n . The locking coupler  54  has holes  56   a - 56   b  for a securing means such as a spring pin or bolt that can be installed on the gate post  34   a - 34   n  so that the gate post  34   a - 34   n  cannot be removed. The lower interior of the locking coupler  54  is machined tapered to fit the tapered post receiver  36   a - 36   d,  or if tubing is used, it would not need to be tapered. It also has a hole  58  so that a knob can be screwed into the hole and against the post receiver so that the gate post  34   a - 34   n  will not rotate when mounted into position. 
     Although this invention was designed for manufacturing facilities, construction sites, and animal pens, it can be used on elevated work surfaces and meets or exceeds OSHA&#39;s regulations for fall protection on an elevated work surface. This invention has optional toe board receivers  22   a - 22   n  which are slid over and about the bottoms of each of the vertical posts  24   a - 24   b  of the rail sections  12   a - 12   n.  A toe board  20   a - 20   n,  that meets OSHA&#39;S standards, can be secured to the board receiver bracket  66  and secured with a screw, bolt or locking pin. Once in place, the toe board receiver  22   a - 22   n  can be secured to the rail section by tightening the L-bolt  76  against the post receivers  36   a - 36   d  of bases  14   a - 14   n.  This device was also designed to have infinite directional movement before securement. No matter what position the base  14   a - 14   n  is in when the rail section  12   a - 12   n  is installed and secured, the toe board receivers  22   a - 22   n  will always be able to follow the run of the rail sections  12   a - 12   n.    
     The bases  14   a - 14   n  are of a cast iron design or welded design to meet the weight requirements. They have enough weight that when varying lengths of rail sections  12   a - 12   n  or gate sections  32   a - 32   n  are secured to the post receivers  36   a - 36   d,  the safety rail system  10  can withstand a minimum of 250 pounds of pressure from any angle. This feature allows the system to be in compliance with OSHA&#39;s Fall Protection Regulations. Each of the bases  14   a - 14   n  has four post receivers  36   a - 36   d  which allow the bases  14   a - 14   n  to accommodate as many rail sections  12   a - 12   n,  thus creating a maximum of four quadrants emanating from each base  14   a - 14   n.  The post receivers  36   a - 36   d  have strategically positioned slots  44   a - 44   n  that enable the rail section  12   a - 12   n  to be positioned in infinite directions while setting up another base  14   a - 14   n  at the end of the rail section  12   a - 12   n.  When the rail section  12   a - 12   n  is placed into the desired position, bolts or locking pins  30  are installed through the slots  44   a - 44   n,  into the holes  48   a - 48   n  on the vertical posts  24   a - 24   b  of rail sections  12   a - 12   n.  One type of locking pin is a clevis pin with a hole at one end for a lynch pin with a ball detent. A double ring with a lanyard can connect between a top of the clevis pin and the lynch pin for operator convenience. This secures the rail sections  12   a - 12   n  in place. 
     Various modifications can be made to the present invention without departing from the apparent scope hereof. 
     SAFETY RAIL SYSTEM 
     PARTS LIST 
       10  safety rail system 
       12   a-n  rail sections 
       14   a-n  bases 
       16   a-n  rail lock donut 
       18   a-n  securing chain 
       20   a-n  toe boards 
       22   a-n  toe board receivers 
       23   a-n  horizontal rails (of rail sections) 
       24   a-b  vertical posts (of rail sections) 
       25   a-n  horizontal rails (of gate sections) 
       26   a-b  vertical posts (of gate sections) 
       28   a-n  latching posts 
       30  locking pin 
       32   a-n  gate sections 
       34   a-n  gate posts 
       36   a-d  post receivers 
       38   a-d  holes 
       40   a-d  cutouts 
       42  planar portion 
       44   a-n  slots 
       46  lifting bar 
       48   a-n  holes 
       50   a-n  hinges 
       52  gate latch 
       54  locking coupler 
       56   a-b  holes 
       58  hole 
       60  hole 
       62   a-b  slots 
       64  sleeve 
       66  board receiver bracket 
       68  shaft 
       70   a-b  holes 
       74  nut 
       76  L-bolt 
       78  dig site