Scaffolding stage support extension

A support extension for a scaffolding system to provide additional work area for storage of tools, brackets, trim, lumber, siding or other building materials and particularly to a set of staging insertions configured to match transom support tubing and extend laterally through a transom support and be secured to a staging member.

FIELD OF THE INVENTION

This invention relates to a support extension for a scaffolding system and more particularly to a set of staging insertions configured to extend laterally from a stage support and provide a work area for tool storage, brackets, trim, studs and siding.

BACKGROUND OF THE INVENTION

Scaffolding is a temporary structure designed to support workers, materials and tools during the construction and remodeling of buildings. Scaffolding is structurally comprised of tubes of aluminum, steel or composite materials, couplers and boards or stages that provide a working surface. The couplers are in the form of right angle couplers, putlog or swivel couplers to attach the tubes at end-to-end points using joint pins or by inserting tubes into one another using sleeve joints. Tubes are aligned vertically to form standards that transfer the entire mass of the structure to the ground. The standards rest on base plates that spread the load. A set of two standards are placed in parallel to a second set of two standards with horizontal tubes or ledgers extending between each of the two sets. Staging members may then be directly connected to the standards and/or supported by and upon the ledgers with one or more staging members aligned between each set of two standards.

The spacing of these basic elements within the scaffolding is fairly standard with the maximum bay length, the spacing between each set of two standards being 2.1 m (6.89 ft) or smaller depending upon the load. The scaffolding width is determined by the required work area with the minimum board width allowed being 0.60 m (1.97 ft), but may be up to 0.87 m (2.85 ft). The vertical spacing between the ledgers or lift height is between 2 m (6.56 ft) and 2.7 m (8.86 ft).

The staging may be formed from steel, aluminum or composite material and may be formed as a single unit. The staging member consisting of a top plank for the work surface and two support braces attached along each edge of the plank. It is common practice within the industry, to add additional support and stability to the staging member by integrating transoms extending between the support braces. The transoms may be formed by inserting square or round tubes or metal bars through aligned holes within each of the opposing support braces. To reduce weight and costs of the staging member, the transoms may be hollow piping or square, hexagonal, channel or angled steel or aluminum stock. Each transom bar may be laterally spaced at distances of 0.15 m (0.5 ft) to 0.46 m (1.5 ft) along the staging to provide structural support.

For most scaffolding used on two to three story buildings the board or stage width is between 0.61 m (2 ft) to 0.91 m (3 ft) and pre-constructed staging members with braces and transoms can be procured in standard widths within this range. Each staging unit has a load support rating that limits the weight of workers or materials that may be supported on that staging. Typically, two sets of staging members are used with the first being a main support stage with a higher load rating and the second being a work bench with a lower rating. The main support stage may be attached to a first set of the two standards and extends in a lateral direction along the ledgers. The work bench staging extends parallel to and at a lift height approximately 0.91 m (3 ft) higher than the main support, rising above and behind the work area. A safety net may then be extended from the work bench to the main support to aid in the prevention of workers or materials falling from the scaffolding.

The work area along the main support staging is a limited area for workers to maneuver and for storage of materials, hardware and tools. Efficient work also requires easy access to tools, materials and hardware to fit, align and secure studs, framing, trim board, siding or windows to the building structure. A need exists for a durable safe support storage system to provide more efficient access for workers and that meets the standard requirements and specifications of existing scaffolding elements and structures.

OBJECTS AND SUMMARY OF THE INVENTION

The present invention is a support extension providing workspace for tool and material storage without adding additional staging, board or planking to the scaffolding system. One or more of the support extensions may be affixed to or inserted through the staging portion of the scaffolding. The extensions form a lateral support at every 0.15 m (0.5 ft) to 0.46 m (1.5 ft) of staging and allow material or tools to be straddled along, draped between or hung from one or more of the extensions.

The support extension may be formed of standard steel, aluminum tubing or channel stock or a high-density composite or plastic and is configured in square, round, hexagonal or other shapes to accommodate standard transom shapes and diameters. The support extension is inserted in the hollow diameter of the transom and extends through each of the first and second support braces. One or more openings on one end of the extension allow a joint pin to be inserted through the end of the extension preventing removal of the extension from the brace/transom/stage support. A cap stop or plug surrounds or is inserted through an opening in a portion of the extension preventing insertion of the extension beyond the substantial length of the transom, thus preventing damage to the building siding or windows. A number of openings along the insertion tip of the support extension or a slot for the plug or cap stop may allow for the extension to accommodate different widths of staging by providing for various lengths of insertion through the transom support. A wider staging plank would reduce the length of the cantilever of the support extension but the present invention would be designed to provide a minimal lateral distance of 0.15 m (0.5 ft) to 0.25 m (0.83 ft) in using the extension with a staging plank of a width 0.76 m (2.5 ft) to 0.91 m (3 ft).

The support extension may include a round or square edge plate or vertical bar that prevents material such as wooden studs, trim board or siding from rolling or sliding off of the extension. The vertical portion may also be a hollow tube allowing tools to be inserted partially in or hung from the extension for safe and easy access. An adhesive wrap or foam cushion may surround a portion of the lateral support extension or the vertical bar or plate. The support extension would not be designed to support the weight of a worker and load ratings with safety warnings and labeling would be important features of the invention.

It is an object of the present invention to form a support extension that is compatible with and meets the standard requirements of common staging and scaffolding boards and platforms.

It is another object of the invention to provide an extended work area for tools, hardware and materials.

It is another object of the invention to form the support extension of standard steel stock, aluminum stock or other light weight materials that match the shapes and dimensions of standard transom supports and staging.

It is another object of the invention to provide lateral support from the staging and a vertical plate or bar preventing materials or tools from rolling or sliding from the support extension.

It is a further object of the present invention to provide the lateral support of the support extension within a safety net.

It is a still further object of the present invention to provide one or more apertures within the support extension to provide for the hanging of tools or hardware from the support.

The present invention is directed to a support extension for a scaffolding system comprising a plurality of lateral extenders dimensionally shaped to conform to a transom support of a stage member and a plurality of locking mechanisms wherein one of the plurality of locking mechanisms affixes to one of the plurality of lateral extenders extended through the transom support securing the extender to the staging member of a scaffolding system

The present invention is also directed to a scaffolding system for supporting workers, tools and materials at a desired height relative to another object, the scaffolding system comprising a plurality of standards supporting a stage upon which the workers may be supported, a plurality of transom supports formed with the stage and defining a plurality of respective passages extending from a first side of the stage to a second side of the stage, and a lateral support having a first portion sized to be received inside the passages defined by the transom supports, the first portion defining a supporting plane upon which materials may be supported adjacent the stage, and the lateral support having a second portion connected to the first portion defining a surface aligned at substantially ninety degrees to the supporting plane.

The present invention is further directed to a method for extending the work area of a scaffolding system comprising dimensionally forming a lateral extender in the shape of a transom port of a staging member, inserting the lateral extender through the transom port, and securing the lateral extender to the staging member. These and other features, advantages and improvements according to this invention will be better understood by reference to the following detailed description and accompanying drawings.

DETAILED DESCRIPTION OF THE INVENT

The elements of one type of scaffolding system10are shown inFIG. 1. The system includes a set of standards12and ledgers16. The standards12are supported on a set of base plates14with the ledgers16extending between the standards12to support the staging18. The vertical distance from the base plate14to the staging18is the base lift Bland the vertical distance between each set of ledgers16is the lift height Lh. The staging18as a single unit or as components is placed between a set of standards12within the bay with the length of the staging18accommodating the bay width Bw. The width of the staging18matches the scaffolding width Sw. The staging member18may be comprised of a first and second brace support22,24that straddles the ledgers16and board or planking20lying across the top of the brace supports22,24. A set of transoms26extend between the first and second base supports22,24providing strength and stability to the staging18. The transoms26are commonly formed from hollow square or round stock of steel or aluminum to reduce the weight of the staging member18. The transom ports28provide an opening for the present invention to be inserted through and extend from. The support extension30of the present invention is configured to match the shape and be slightly smaller in dimension to the transom port28so as to securely fit within and through the port28.

A perspective view of a first embodiment of the support extension30formed from steel or aluminum square stock is shown inFIG. 2. The support extension30comprises a tip32, cantilever34, elbow36and edge bar38or bracket and edge plate40as shown inFIG. 8. The support30may be hollow with an opening42at the end of the edge bar38to allow a tool handle, bracket or other hardware to be inserted and hung over the edge bar38. A bevel44, and or a foam or rubber cushion45may be placed around the edge of the opening42to prevent injury or damage to tools. An opening or recess46, cap stop47(shown inFIG. 3) or slot48(shown inFIG. 4) is positioned along the cantilever34at a distance from the tip end50greater than the scaffolding width Sw. A cap plug or pin54or bolt62is placed through the opening or slot to stop insertion of the support extension at a point greater than the scaffolding width Sw. Along the tip32of the support extension30a locking pin insert opening or recess52is positioned at a distance from the stop pin opening46greater than the scaffolding width Sw. One or more locking pin openings52may be positioned along the tip32of the support extension30to accommodate various scaffolding widths Swand allow for the same extension support30to be used with scaffolding of different dimensions. A locking pin54is shown inFIG. 2and is inserted through the locking pin opening52after installation of the support extension30through the staging transom26. A nail or cap pin (not shown) is inserted through an aperture56on the end of the locking pin54to secure the locking pin54in place and prevent the removal of the support extension30from the transom26without removal of the locking pin54thereby securing the support extension30in place within the transom26.

An alternative to a locking pin as shown inFIG. 3is a locking cap58with a detent59and recess60. The locking cap58may be slid over the tip of the support extension30after inserting the support extension30through the transom26. By applying pressure to the detent59and then releasing pressure at one of the one or more recess ports60the support extension30may be locked in place within the transom26. A cap stop47may also implore a detent59and one or more recess ports60to prevent the extension support30from being inserted beyond a minimal distance through the scaffolding thereby preventing damage to a wall or building structural surface. The position of one or more of the recess ports60of the locking cap58are at a distance from the recess ports60of the cap stop47greater than the scaffolding width Swas described above. In a further embodiment, as shown inFIG. 4a slot48through the cantilever34may allow adjustment of a bolt62extended through the slot48of the support extension30to prevent the support extension30from being inserted to far through the transom26of the staging member18. The bolt62may be tightened using a nut and washer. A slot48through the tip32of the support extension30may also be applied to lock the support extension30in place within the transom26using the bolt and nut assembly. The cantilever34and edge bar38of the support extension30may be surrounded with a wrap adhesive, foam cushion or rubber grip solution64that is glued, sprayed or rolled onto the support extension30to protect scratching or damage to materials or tools placed along or supported by the support extension30.

The support extension30may be formed from a single piece of square stock cut to a length between 0.81 m (2.67 ft) and 1.22 m (4 ft). For a piece cut to 0.91 m (3 ft) a measurement of 0.25 m (0.83 ft) is taken from either end of the square stock and an elbow36and a vertical edge bar38are formed by folding the material at this point. The elbow may be at 90° as shown inFIGS. 2-4, or be at an angle of approximately between 60° and 90° as shown inFIG. 5. The formation of the elbow36at an angle smaller than 90° provides for a narrower region to slide and secure trim or siding material against. The elbow36and vertical edge bar38may also be formed by making two cuts in the material each approximately at a 45° angle at or near the measured point and having the cuts intersect without cutting through the material. The cut portion of the material is removed and the piece is folded to form the vertical edge bar38. An angle bracket39may then be welded to each side of the support extension30at the elbow36to hold the position of the vertical edge bar38as shown inFIG. 3.

In either embodiment as shown inFIG. 6, the tip32of the support extension30is aligned with and slid into the transom port28to or near the point of contact of the cap stop47with the brace support22so that the tip32extends partially from the transom port28of the opposing brace24as shown inFIG. 7. A locking pin54or locking cap58is secured to the tip32of the support extension30preventing removal of the extension30from the transom port28without removal of the locking pin54or cap58. One or more support extensions30may be installed along the staging18to accommodate and support the length of a building material64such as lumber, trim or siding, or to provide improved access to tools66or hardware. The support extension allows building materials, tools and hardware to be removed from the boards or planking work surface20of the staging18improving safety as workers are not mis-stepping or weaving in trying to avoid laid out tools or material as they maneuver along the work surface. Work efficiency is also improved as stretching or overreaching for misplaced tools is avoided. The support extension30may be installed from the work surface by sitting or kneeling perpendicularly to the work surface20and inserting the support extension30into the transom port28. By rotating around to the opposing brace, the locking cap58or pin54may also be easily installed securing the support extension30in place. A safety net (not shown) would hang below and under the staging member18and would not be interfered by the installation of one or more the support extensions30. The net would also provide a catching surface if a support extension30, cap58or pin54was accidentally dropped during installation.

Further embodiments of the support extension are shown inFIGS. 8-10. As shown inFIG. 8, steel or aluminum square stock could be used, but instead of forming an elbow by folding the stock, an edge plate40may be affixed to the square stock68using a collar bracket70. The edge plate40would provide a larger surface area to help prevent dropping of material from the support extension and allow a larger load of material to be supported. A warning label80may be affixed to the cantilever clearly denoting that the support extension is not intended to support the weight of a worker and should not be stepped or stood upon. Similarly, the embodiments ofFIGS. 9 and 10show the use of round stock76with a square edge plate40or round edge plate78using a collar bracket70. The use of standard materials that require only the attachment of a plate and bracket greatly reduces the manufacturing costs and tooling mechanisms needed to produce the present invention. The plate attachment40may be in a square or rectangular configuration as shown inFIG. 9or a round plate78as shown inFIG. 10. The openings or recess ports for a stop pin, plug or cap and a locking pin, plug or cap are similar to those features as described above. The material selected and shape of the support extension is determined by the standard dimensions and shape configurations of the staging transoms26. Channel stock, I-Bar, hexagonal, triangular or other shapes may be used, with the formation of an edge bar or plate dependent upon the material selected. The support extension may also be of composites of ceramic or plastics or other materials that can provide the lateral strength and required support of the weight of the building materials used. None of the presented embodiments are intended to in any way limit the scope of the present invention.