Patent Publication Number: US-9834939-B1

Title: Portable safety rail system

Description:
The present application is a continuation of U.S. patent application Ser. No. 13/612,292, filed on Sep. 12, 2012, now U.S. Pat. No. 9,376,832, issued Jun. 28, 2016, which claims the benefit of U.S. Provisional Application No. 61/533,587, filed on Sep. 12, 2011, all of which are incorporated herein by reference in their entireties. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to protective barriers for preventing falls or blocking access to a hazardous area. More particularly, the present invention relates to a portable safety rail system. 
     BACKGROUND OF THE INVENTION 
     Safety rail systems are used to provide a barrier around work areas where worker safety is an issue. Examples include construction sites, such as to keep workers from falling off an edge of a roof or falling down uncompleted stairwells and to keep the general public out of the site as well as limiting access at festivals, sporting events, and the like. Such systems must be portable to allow for temporary work to be done while also being sturdy enough to not easily tip over or otherwise accidentally move or dislodge. Portable safety rail systems must also exceed OSHA safety regulations for permanent safety railings. 
     Conventional portable rail systems are modular systems that are assembled on a given job site in accordance with the specific work constraints of the site. As such they must be stored when not in use. Such systems typically utilize tubular railings having horizontal rails extending between vertical posts. The lower ends of the railings are slid into tubular sockets or receptors of bases. Gates that can be opened or closed can also be provided to allow selective passage into and out of the barricaded area. Typically the bases are quite heavy, 40 pounds or more, for example. Storage and transportation of these bases can be problematic as prior bases have not stacked securely and trying to transport them as a stack can be hazardous due to their weight. 
     U.S. Pat. No. 6,554,257 discloses one portable safety rail system that utilizes a plurality of bases into which tubular guardrail sections can be inserted. The system is modular and can be assembled into various configurations of bases, rail sections and gates. The rail sections can be set at any angle from the bases, however, they are unable to rotate once they are locked into place and locking them in place can be difficult because holes in the railings must be properly aligned with slots in the base. In addition, use of a gate requires a number of additional and different parts. Further, the configuration of the bases does not allow them to be stably stacked for transport and storage. 
     As such, it would be advantageous for portable safety rail systems to provide a greater and simpler degree of customizability and a simpler and easier system for transport and storage. 
     SUMMARY OF THE INVENTION 
     A portable safety rail system includes one or more railings inserted into a plurality of rail bases. Each rail base can include a plurality of apertures for receiving end rail posts of railings through a raised hub defining an open region between the bottom of the hub and the surface on which the rail base rests. Each end rail post can have a stop flange that engages an upper surface of hub when inserted therein and an aperture through the end portion that extends into the open region beneath the hub. A pin can be inserted through the aperture in the railing to lock the railing with respect to the rail base, while still allowing the railing to be rotated through 360 degrees of motion even when locked with respect to the rail base. System can also include toe boards that are attached to railings with a mount having an aperture through which railing posts are extended, allowing the toe boards to also be rotated to be aligned with railings. 
     In an embodiment of the invention, a rail base for a portable safety rail system can include an outer base portion that may be shaped as a wheel and that rests on a surface, such as a roof surface, and a central hub connected to the base portion by a plurality of support members, such as spokes, such that the central hub is in a raised position relative to the outer base portion. Raised collars define apertures through each hub for receiving railings of the rail system. The raised position of central hub defines a central open area beneath hub. This allows rail bases to be stacked on top of one another in a stable manner with adjacent base portions resting flush against each other because the hub including raised collars of a rail base below fit within the central open area of the rail base positioned directly above said rail base. 
     In another embodiment of the invention, a gate can be incorporated into portable safety rail system to provide selective access to and from an area. Due to the ability of railings to rotate 360 degrees when locked with rail bases, a standard railing can function as the gate door. A wheel can be added to the end rail post of the railing opposite of the rail base to support the end of the door and allow the door to be easily opened and shut. A latch stand can be attached to an adjacent base to allow the door of the gate to be latched. A first end of the latch can be inserted into an aperture through a collar of the base while a second end can be inserted through an additional aperture in order to prevent rotation of the latch stand so that it provides a secure and stable latching point. 
     A feature and advantage of embodiments of the present invention is that the railings can be rotated through a 360 degree range of rotation even when locked into place in rail bases. This allows for significantly enhanced customizability of portable rail safety systems that can be configured for any shaped area. 
     Another feature and advantage of embodiments of the present invention is that toe boards can be connected to the system with a mount having an aperture through which a railing post is extended prior to being inserted in hub. This results in the toe boards also being rotatable in a 360 degree range of motion to allow them to be aligned with railings when railings are rotated. Additionally it provides a very robust connection of the toe boards to the railing. 
     A further feature and advantage of embodiments of the present invention is that the railings are locked to the base by inserting a locking pin that only needs to go through the railing. This allows railings to be inserted and locked much more quickly and easily than systems requiring complementary holes in the railings and bases to be aligned. 
     Another feature and advantage of embodiments of the present invention is that the central open region beneath the hub of the rail bases allows the bases to be stacked, when not in use, in a stable manner. This improves the ability of the system to be stored and transported, because it can be done so in a smaller area and in a more stable manner. 
     A further feature and advantage of embodiments of the present invention is that standard railings can function as doors for gates due to the ability of railings to rotate through a 360 degree range of motion. This reduces the number and size of parts needed for the system. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1 a    is an exploded view of a portable safety rail system according to an embodiment of the present invention. 
         FIG. 1 b    is a top view of the portable safety rail system of  FIG. 1   a.    
         FIG. 1 c    is a partial cross-sectional side view of the portable rail safety system of  FIG. 1   a.    
         FIG. 2 a    is a perspective view of a rail base of a portable safety rail system according to an embodiment of the present invention. 
         FIG. 2 b    is a top view of the rail base of  FIG. 2   a.    
         FIG. 2 c    is a bottom view of the rail base of  FIG. 2   a.    
         FIG. 2 d    is a cross-sectional view of the rail base of  FIG. 2 a    taken along the lines  2   d - 2   d  in  FIG. 2   c.    
         FIG. 2 e    is a cross-sectional view of the rail base of  FIG. 2 a    taken along the lines  2   e - 2   e  in  FIG. 2   c.    
         FIG. 3 a    is a side view of a plurality of rail bases of a portable safety rail system according to an embodiment of the present invention. 
         FIG. 3 b    is a cross-sectional view of the rail bases of  FIG. 3 a    taken along the lines  3   b - 3   b  in  FIG. 3   a.    
         FIG. 4 a    is a side view of a portable safety rail system according to an embodiment of the present invention. 
         FIG. 4 b    is a partial perspective view of the portable safety rail system of  FIG. 4   a.    
         FIG. 4 c    is a partial exploded perspective view of the portable safety rail system of  FIG. 4   a.    
         FIG. 4 d    is a partial side view of the portable safety rail system of  FIG. 4   a.    
         FIG. 5 a    is a side view of a portable safety rail system according to an embodiment of the present invention. 
         FIG. 5 b    is a top view of the portable safety rail system of  FIG. 5   a.    
         FIG. 6 a    is a top view of a portable safety rail system according to an embodiment of the present invention. 
         FIG. 6 b    is a perspective view of the portable safety rail system of  FIG. 6   a.    
         FIG. 7  is a side view of a portable safety rail system according to an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
       FIGS. 1 a -1 c    depict the components of a portable safety rail system  100  according to an embodiment of the present invention. Rail system  100  can include a railing  102 , a rail base  104 , a toe board  106  and a toe board mount  108 . As can be seen in the Figures and will be discussed in more detail below, railing  102  can be inserted into rail base  104  and a pin  110  can be inserted into railing  102  to lock the railing  102  against translational movement relative to rail base  104 . As is indicated by the arrow in  FIG. 1 b   , railing  102  can be rotated 360 degrees relative to rail base  104  even after the pin  110  is inserted to secure the railing  102  to the rail base  104 . Toe board mount  108  is captured between the railing  102  and the rail base  104  at one end and secured to toe board  106  at an opposing end. Rail system  100  complies with all applicable OSHA requirements. 
     Railing  102  can be formed from a plurality of tubular rails, including vertical end rail posts  112 , top rail  114  and one or more support rails  116 . In one embodiment, railing  102  is formed from steel. Railing  102  can further include a stop flange  118  along one or both of vertical end rail posts  112  that forms a ledge. In one embodiment, stops configured as stop flanges  118  can be welded onto end rail posts  112 . Below stop flange  118 , end rail posts  112  of railing  102  can further include a pin insertion aperture  120  extending through end rail post  112 . The tubing may generally be steel and the diameter may be 1 inch to 3 inches. Alternatively other metals such as aluminum may be practical. The stops may be welded two to six inches from the tip end  121  of each railing end post. 
     Referring now to  FIGS. 2 a -2 e   , further detail of a rail base  104  according to an embodiment of the present invention can be seen. Rail base  104  can include an outer base portion  122  and a central hub  124  connected by a plurality of support members  126 . Post receiving portion configured as a hub  124  can include a plurality of collars  128  defining rail receiving apertures  130  extending through hub  124  and one or more additional apertures  132 , each receiving aperture  130  defining a vertical axis  131  that passes through the respective post receiving portion. As can be seen most clearly in  FIGS. 2 d  and 2 e   , the hub  124  comprising a hub plate  133  including a side edge  135  and a planar lower face  136  that is downward facing, the side edge  135  and receiving apertures  130  being coterminous with the planar lower face  136 . The base portion  122  can be adapted to rest on a surface with support members  126  extending at an angle upwardly to hub  124  so that hub  124  is elevated relative to base portion  122  forming an open region  134  between the hub  124  and the surface upon which base portion  122  rests. Open gaps  134   a  are also present between support members  126  as they extend from base portion  122  to hub  124 . In one embodiment, rail bases  104  can be formed from cast iron. 
     Rail bases  104  can be stacked on top of each other as shown in  FIGS. 3 a  and 3 b   . Open areas  134  underneath hubs  124  allow adjacent base portions  122  of rail bases  104  to rest on top of each other with collars  128  of a rail base  104  below fitting into open area  134  of a rail base  104  above while also allowing the bottom surface  137  of the base portion  122  of the rail base  104  above to rest flush on the top surface of the base portion  122  of the rail base  104  below. This provides a stable stack that is not prone to tipping and is not possible with standard rail bases that do not incorporate open areas  134 . Stably stackable rail bases  104  provide for significantly easier shipment and storage of rail bases  104 . Each base has an upper seating surface  135  for receiving the bottom or lower seating surface  137  of another base. For each base the distance d 1  between the lower seating surface and upper seating surface defines an effective stacking height and each base has a height d 2 . The stacking height in particular embodiments is less that 80% of the height, in particular embodiments it is less than 70% of the height and in particular embodiments is less than 60% of the height. The ratio of the stacking height to the height provides a measurement of the nesting of the bases when stacked with the lower the ratio the greater the nesting and correspondingly the greater the stability of the stacked bases. 
     The bases may be made of cast iron and weigh between 40 pounds and 100 pounds. The bases may have a diameter of from 12 inches to 30 inches. 
     Referring again to  FIGS. 1 a -1 c    and to  FIGS. 4 a -4 d   , the details of how components of safety rail system  100  fit together can be seen. Rail engagement portion  138  of toe board mount  108 , which has an aperture  140  therethrough, can rest on a collar  128  of rail base  104 . End portion  113  of end rail post  112  of railing  102  can be inserted through the aperture  130  through hub  124  at collar  128  (and through aperture  140 ) until the stop flange  118  of the railing  102  engages the collar  128 , capturing the rail engagement portion  138  of the toe board mount therebetween. Stop flange  118  also serves to ensure that the end rail post  112  is not over-inserted and that the aperture  120  through the end rail post  112  is in open region  134 . The pin  110  is then inserted through the aperture  120  to secure the railing  102  to the rail base  104 . Aperture  120  can be accessed to insert pin  110  due to the open area provided by both open area  134  beneath hub  124  and the gaps  134   a  between support members  126 . Insertion of pin  110  does not require any specific alignment of railing  102  and rail base  104  because the pin  110  only goes through the railing  112  below the hub  124 , so the process of insertion and locking is simplified. The toe board  106  is secured to a bracket  142  of toe board mount  108  by, for example, mechanical fasteners either before or after railing  102  is secured to rail base  104 . Toe board  106  serves to keep objects from being kicked or otherwise accidentally knocked under the rail system  100 , and, in many uses of rail system  100 , subsequently off of an elevated surface onto the public or other area below. 
     The single securing point that constrains the railing  102  translationally but not rotationally relative to the rail base  104  allows the railing  102  to have 360 degrees of rotation relative to the rail base even while they are secured together. This provides simplified adjustment capability relative to the prior art, which requires rotation of the railing prior to securing to the base and alignment of openings in both the railing and the base. In addition, the aperture  140  through rail engagement portion  138  of toe board mount  108  allows toe board mount  108 , as well as toe board  106 , to similarly be rotated through 360 degrees of rotation. 360 degree positioning provides increased flexibility in assembling portable security rail systems  100 , which can be beneficial in adjusting the system to a specific situation, such as assembling the system around obstacles or in a curved manner. 
       FIGS. 5 a -5 b    depict a portable safety rail system  100  having a plurality of rails  102  and rail bases  104  in a typical usage configuration. Safety rail system  100  is positioned on an elevated surface  10  to prevent people and objects from falling off of a front edge  12  and side edges  14  of surface  10 . Rail system  100  is assembled on site and set up to fit the specific geometry of the surface  10 . As can be seen in the Figures, the safety rail system  100  configured for this specific surface  10  utilizes five rail bases  104  and four railings  102 . System  100  also includes toe boards  106  to prevent objects from rolling off of surface  10 . Depending on the positioning of each rail base  104  within system  100 , each rail base has one or two, and can have up to four, railings  102  inserting into collars  128  of rail bases. Referring now to  FIGS. 6 a  and 6 b   , another typical configuration of a portable safety rail system  100  is depicted. In this embodiment, system  100  is used to prevent access to an area  20 . System  100  can be advantageously used to provide a barrier for and prevent access to curved and non-uniformally shaped areas due to the ability of railings  102  to be rotated within rail bases  104  through 360 degrees of rotation. In fact, in the hexagonally configured example in  FIGS. 6 a  and 6 b   , each railing  102  extends from each of its rail bases  104  at a different angle than the adjacent railing  102  that shares the same rail base  104 . The toe boards and toe board mounts are illustrated in  FIG. 5 a    connected. In embodiments the portable rail system may include preassembled, such as by welding, toe boards with the toe board mounts already attached. 
       FIG. 7  depicts a further embodiment of the present invention that includes a gate  150 . Gates  150  are useful in situations where selective access to and from the barricaded site is necessary or desired. Advantageously, door  152  of gate  150  can be a standard railing  102  with the same basic structure as all of the other railings  102  in the system, so an additional gate door does not need to be purchased and brought with the system  100  each time it is used. To utilize a railing  102  as a door  152  for a gate  150 , the railing  102  is inserted and locked into the collar  128  of a rail base  104  as described previously. A wheel  154  can be attached to the end portion  113  of the opposite end rail post  112  of the railing  102  to aid in opening and closing the gate door  152  and to provide stability to door  152 . Due to the ability of railings  102  to be rotated through a 360 range of motion even when locked into place in rail bases  104 , gate door  152  can be opened to allow entry or exit through the entire distance between adjacent rail bases  104 . A latch stand  158  can be positioned on an adjacent rail base  104  having a first latch portion  160  that cooperates with a second latch portion  156  on door  152  to allow the door  152  to be selectively latched and/or locked. A first leg  162  of latch stand  158  can be inserted into a collar  128  of rail base  104  and locked with a pin similar to how railings  102  are inserted and locked in place. A second leg  164  of latch stand  158  can be inserted into an additional aperture  132  positioned in rail base  104 , as, for example can be best seen in  FIGS. 2 b  and 2 c   . By inserting the second leg  164  into the aperture  132 , the latch stand  158  is prevented from rotating, allowing the latch stand  158  to provide a stable latching source for the gate door  152 . 
     The present invention may be embodied in other specific forms without departing from the spirit of any of the essential attributes thereof. Therefore, the illustrated embodiments should be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention.