US20080277200A1

US20080277200A1 - Cover insert

Info

Publication number: US20080277200A1
Application number: US11/747,063
Authority: US
Inventors: John Houlihan; Stephen Barlow; George Luchford
Original assignee: Individual
Current assignee: Individual
Priority date: 2007-05-10
Filing date: 2007-05-10
Publication date: 2008-11-13

Abstract

A cover insert for spanning a gap between two boards in a decking, in particular a scaffold decking, to prevent objects from falling through said gap and causing injury comprises first and second substantially parallel side walls (10, 11) for fitting into the gap and a cover portion (7) arranged for covering the space between the side walls. One of the side walls (10) has a pair of laterally extending walls (9, 13) extending outwardly in a direction away from the other of the side walls, the laterally extending walls (9, 13) being spaced apart for receiving an edge of one of the boards. A top one of the laterally extending walls (13), that may be an extension of the cover portion (7), provides a flange that rests on the top of the board on one side of the gap, and the cover portion (7) may also extend on the other side to provide a second flange (14) to rest on the top of the board on the other side of the gap.

Description

FIELD OF THE INVENTION

The present invention relates to a cover insert for substantially closing off gaps in decking, particularly gaps between scaffolding planks.

BACKGROUND OF THE INVENTION

Sixty percent of workers in the construction industry use scaffolding every day. Scaffolding may abut the outside or inside of a building structure in order to provide convenient access to features of the building structure that are above ground level, for construction, maintenance or repair work. Typically, a scaffold comprises three types of tubular element. Upright tubes called standards form two or more vertical planes that are substantially parallel to the surface of the building structure. Horizontal tubes called ledgers lie within a plane formed by the standards and connect consecutive standards together. Horizontal tubes called transoms are supported by the ledgers and are substantially perpendicular to the building structure, connecting two or more planes of standards. These scaffold tubes are fastened together to form a three-dimensional framework. Access to the building structure is provided by decking comprised of parallel boards, such as lengths of plank supported by the transoms.
One of the most common causes of injury to construction workers is falling objects. Scaffolding safety measures include the use of toe boards, as described in U.S. Pat. No. 6,405,830, to prevent small objects from being kicked off the decking, and netting or guard meshes, such as that described in Belgian patent 1000428, for preventing larger objects from falling. Another route by which objects may fall from scaffold decking is through gaps between the planks. Health and safety regulations require that these gaps are minimized, and according to the UK Work at Height Regulations 2005, there should be no gap exceeding 25 mm in any working platform where there is a likelihood of falling objects causing harm.
Gaps are an inevitable consequence of using standards. Where consecutive standards share a plane and are thus linked by a common ledger, and where the decking extends in a direction perpendicular to the structure either side of that plane, then a gap in the decking is left between those standards that is too narrow to be filled by a plank. The minimum width of the gap is equal to the width of the standards at either end. A common solution to this problem is to span the gap with plywood, which is fixed to the decking on either side of the gap with screws. This method is expensive and time-consuming, because a carpenter is needed to cut, pre-drill and fix the plywood to the decking. It is also hazardous, because workers may trip on the plywood edge. Another example of a way of covering such gaps is disclosed in JP2002174027, which shows a cover that extends across the gap and includes a pair of legs that project down into the gap and are biased against the side edges of the scaffolding boards.
The present invention therefore seeks to provide a cover insert, for substantially covering a gap between a pair of generally parallel boards, especially for gaps between planks used on scaffolding, which overcomes, or at least reduces the above-mentioned problems of the prior art.

SUMMARY OF THE INVENTION

According to a first aspect of the present invention, there is provided a cover insert for substantially covering a gap between a pair of generally parallel boards, the cover attachment comprising first and second substantially parallel side walls for fitting into the gap and a cover portion arranged for covering the space between the side walls, a first of the side walls having a pair of laterally extending walls extending outwardly therefrom in a direction away from the other of the side walls, the laterally extending walls being spaced apart for receiving an edge of one of the boards.
Preferably, one of said laterally extending walls extends further than the other away from the first side wall. At least one of said laterally extending walls may be provided with means for gripping a surface of said one of the boards. The cover portion preferably includes drainage holes therein and/or may have a non-slip surface.
In one embodiment, a first of the laterally extending side walls comprises a flange extending from a first edge of the first side wall for at least partly overlying a top face of a first of the boards. A first edge of the second side wall is preferably provided with a flange for at least partly overlying a top face of a second of the boards. The cover portion may be substantially coplanar with the or each of said flanges.
In an embodiment, the cover portion is substantially coplanar with one of the laterally extending walls. A second cover portion may extend between the two side walls and be substantially coplanar with the other of the laterally extending walls.
The cover insert as described above may have a predetermined length, which may be between approximately 0.5 m and approximately 3 m, and is preferably any one of the following lengths: 2350 mm, 2050 mm, 1750 mm, 583 mm, 1.3 m, 1.8 m, and 2.5 m.
According to a second aspect, the invention provides a cover attachment system comprising at least one cover insert as described above.
According to a second embodiment, the first and second side walls and the cover portion preferably form a substantially longitudinal channel member.
According to a further aspect, the invention provides a cover attachment system comprising at least one cover insert of the second embodiment and further comprising at least one longitudinal member for fitting between the two side walls into the channel member.
Preferably, the longitudinal member comprises a pair of side elements for fitting into the channel member substantially parallel to the side walls of the cover insert and a main surface extending between the pair of side elements, such that, when in position in the channel member the main surface is substantially coplanar with a top face of the boards.
In a still further aspect, the invention provides a scaffold utilizing a cover attachment system as described above.

BRIEF DESCRIPTION OF THE DRAWINGS

Several embodiments of the invention will now be more fully described, by way of example, with reference to the drawings, of which:

FIG. 1 is a schematic view of a first embodiment of the invention in position covering a gap between planks on a scaffold;

FIG. 2 is a perspective schematic view of the first embodiment of a cover insert;

FIG. 3 is a schematic end view of the embodiment of FIG. 2;

FIG. 4 is a perspective schematic view of a second embodiment of a cover insert according to the invention;

FIG. 5 is a perspective schematic view of a third embodiment of a cover insert according to the invention;

FIG. 6 is perspective view of cover insert forming first part of a fourth embodiment of the present invention;

FIG. 7 is a perspective view of a second part of the fourth embodiment;

FIG. 8 is a perspective view of the fourth embodiment in an assembled state; and

FIG. 9 is a perspective view of a scaffold, having the assembled fourth embodiment of FIG. 8 in position.

DETAILED DESCRIPTION OF THE DRAWINGS

Thus, FIGS. 1-3 show a first embodiment of a cover insert for spanning a gap between planks on a scaffold. As explained above and shown in FIG. 1, a scaffold 1 typically comprises upright tubes called standards 2 and horizontal tubes called transoms 3 which support a decking formed by parallel boards, such as lengths of plank 4. Where the planks 4 abut the standards 2, a gap 5 is formed between the planks 4 due to the planks 4 being longer than the spacing between the standards 2, which may be 1.8 m, as shown, according to common practice in the industry in the United Kingdom. The gap 5 therefore has a width substantially the same as the diameter of the standards 2, which is commonly 50 mm. According to a first embodiment of the present invention, the gap 5 is covered between the standards 2 using several, in this case, three cover inserts 6. The cover inserts are therefore approximately 583 mm in length, the distance between the standards being 1.75 m.
As best shown in FIGS. 2 and 3, each of the cover inserts 6 includes a top surface element 7, a channel portion 8 and a laterally extending wall 9 parallel to the top surface element 7. The channel portion 8 is formed of a pair of longitudinal side walls 10 and 11 connected at their top edges by the top surface element 7 which therefore spans between them and a subsidiary cover portion 12 that extends between the bottom edges of the side walls 10 and 11. The top surface element 7 extends laterally on either side of the side walls 10 and 11 in the form of side flanges 13 and 14. In this embodiment, the surface element 7 also extends longitudinally beyond each end of the channel portion 8 to provide end flanges 15 and 16 at each end. The laterally extending wall 9 is arranged to extend further away from the channel portion 8 than the side flange 13, as best seen in FIG. 3.
Side flange 13 and laterally extending wall 9 thus define a space, together with side wall 10, for receiving an edge of a plank 4. The cover insert 6 can be located in position even when the planks are already in place because the laterally extending wall 9 is wider than side flange 13, thus allowing the laterally extending wall 9 to be inserted through the gap 5 and rotated under the plank 4 so that the edge of the plank passes into the space between the laterally extending wall 9 and the side flange 13 until the two side flanges 13 and 14 come to rest on the top surface of the two planks adjacent the gap. The laterally extending wall 9 is also provided with gripping means, such as raised triangular teeth that will bite into the plank 4 and prevent sideways movement between the plank and the cover insert 6.
The top surface element 7 of cover insert 6 is provided with drainage holes 17 to allow liquid, for example rain, to drain through. The top surface element 7 may also be provided with non-slip characteristics to reduce the chances of users from slipping on the cover insert. The non-slip characteristics may include surface shaping to reduce its slipperiness, or may be provided by a rubber mat attachment (not shown). The top surface element 7 may also include advertising space to enable the manufacturer thereof (or others) to include trade marks or other messages, for example warning messages, thereon.
FIG. 4 shows a second embodiment of a cover insert 6, similar to the first embodiment, but where the cover insert may be more easily made out of a single sheet of strip metal, for example, with the same elements as those of the first embodiment having the same reference numerals. In this case, all the portions can be formed by folding over an appropriately-sized sheet of metal, for example steel. As can be seen, the top surface element 7 is connected to the outer edges of side flanges 13 and 14, which are themselves formed by folding at the top edges of side walls 10 and 11. However, the subsidiary cover portion 12 and end flanges 15 and 16 (of the embodiment of FIGS. 2 and 3) do not exist in this embodiment, so that the end walls 10 and 11 extend to the ends of the cover insert 6. The cover portion 7, in this embodiment is slightly convex to allow run-off of water, rather than having drainage holes provided.
FIG. 5 shows a third embodiment of a cover insert 6, again similar to the first embodiment, with the same elements as those of the first embodiment having the same reference numerals. In this case, however, as in the second embodiment, there are no end flanges, so that the channel portion 8 extends to the ends of the cover insert. The cover portion 7 is shown, in this embodiment, with a “diamond” gripping surface. It will be apparent that many of the features from the different embodiments can be mixed and matched as required.
An advantage of these embodiments of the invention is that the cover inserts may be manufactured in various lengths suitable for use with different types of scaffolding. For example, they can be made of any length between about 5 cm and 10 m, preferably between about 50 cm and about 5 m. With traditional scaffolding, for example, 2350 mm lengths could be used for light duty scaffolds, 2050 mm lengths for general purpose scaffolds, 1750 mm lengths for heavy duty scaffolds and 583 mm lengths for any application. With system scaffolding, 1.3 m, 1.5 m or 2.5 m lengths could be used.
FIGS. 6-9 show a further embodiment of the invention. In this embodiment, there is provided a cover attachment system formed of one or more cover inserts 6, similar to those of the first embodiment, with the same elements as those of the first embodiment having the same reference numerals, and a longitudinal member 18 for fitting into the cover insert. As shown in FIG. 6, the cover insert 6 of this embodiment does not include the cover portion 7 at the top, but only the subsidiary cover portion 12 so as to define the channel portion 8 without a top. In this case, however, the side walls 10 and 11 are provided, on their inner faces, with a longitudinally extending clipping rim 22 adjacent the subsidiary cover portion 12.
As shown in FIG. 7, longitudinal member 18 comprises a cover portion 19 and two sides 20 and 21. A clip 23 is provided on the outer face of each side 20 and 21 to securely engage the longitudinal member to the channel portion 8. The clip 23 may comprise a rim on the bottom edge of each side 20 and 21 of the longitudinal member 18 to engage with the clipping rim 22 on each of the side walls 10 and 11 of the cover insert 6.
FIG. 8 shows the longitudinal member 18 in position within the channel portion 8 of cover insert 6 with the clip 23 of the longitudinal member 18 having engaged with the clipping rim 22 of the cover insert 6 so as to substantially retain the longitudinal member 18 within the channel 8, whilst allowing relative longitudinal movement thereof. In the view of FIG. 8, of course, the orientation of the cover insert 6 has been reversed compared to that of FIG. 6. As can be seen, the longitudinal member 18 is of a height such that, when in position in the channel portion 8, the cover portion 19 is substantially coplanar with the side flanges 13 and 14 of the cover insert 6. FIG. 9 shows this embodiment in position covering a gap in a scaffold decking, wherein the ends of two longitudinal members 18 abut each other within the channel portion 8 of a cover insert 6, such that the members 18 lie in series and the inserts 6 are spaced to hold the members 18 in position. According to this embodiment, three members in series would have a total length of 1750 mm.
The cover insert may be made using various materials, and should be able to bear weights at least as great as those borne by the surrounding decking. The cover inserts should preferably be light, flame-retardant, partially flexible, quick and easy to install, portable and re-usable.
The drainage holes may be of 2 mm diameter to facilitate drainage of rain water and reduce wind uplift forces.
In use, embodiments of the present invention preferably span gaps of 50 mm width in a decking. Use of the invention is not limited to gaps between standards, because the invention is suitable for spanning gaps with other origins in a decking. By spanning such gaps, the likelihood of objects falling from the decking is reduced and safety is improved.
It will be appreciated that although only a few particular embodiments of the invention have been described in detail, various modifications and improvements can be made by a person skilled in the art without departing from the scope of the present invention. For example, although it is envisaged that the boards, or planks, in the preferred embodiment, are made of wood, it will be apparent that the invention will work with boards made of plastic or any other material, and that the thickness of the particular boards or planks is immaterial, provided the cover insert is made to fit the particular thickness of the boards with which it is to be used.

Claims

1. A cover insert for substantially covering a gap between a pair of generally parallel boards, the cover attachment comprising first and second substantially parallel side walls for fitting into the gap and a cover portion arranged for covering the space between the side walls, a first of the side walls having a pair of laterally extending walls extending outwardly therefrom in a direction away from the other of the side walls, the laterally extending walls being spaced apart for receiving an edge of one of the boards.

2. A cover insert according to claim 1, wherein one of said laterally extending walls extends further than the other away from the first side wall.

3. A cover insert according to claim 1, wherein at least one of said laterally extending walls is provided with means for gripping a surface of said one of the boards.

4. A cover insert according to claim 1, wherein said cover portion includes drainage holes therein.

5. A cover insert according to claim 1, wherein said cover portion has a non-slip surface.

6. A cover insert according to claim 1, wherein a first of the laterally extending side walls comprises a flange extending from a first edge of the first side wall for at least partly overlying a top face of a first of the boards.

7. A cover insert according to claim 1, wherein a first edge of the second side wall is provided with a flange for at least partly overlying a top face of a second of the boards.

8. A cover insert according to claim 6, wherein said cover portion is substantially coplanar with the or each of said flanges and/or with one of the laterally extending walls.

9. A cover insert according to claim 7, wherein said cover portion is substantially coplanar with the or each of said flanges and/or with one of the laterally extending walls.

10. A cover insert according to claim 8, further comprising a second cover portion extending between the two side walls and being substantially coplanar with the other of the laterally extending walls.

11. A cover insert according to claim 9, further comprising a second cover portion extending between the two side walls and being substantially coplanar with the other of the laterally extending walls.

12. A cover insert according to claim 1, having a predetermined length, which may be, for example, between approximately 0.05 m and approximately 10 m.

13. A cover insert according to claim 12, wherein the predetermined length of the insert is any one of the following lengths:

2350 mm;

2050 mm;

1750 mm;

583 mm;

1.3 m;

1.8 m; and

2.5 m.

14. A cover attachment system comprising at least one cover insert according to claim 1.

15. A cover insert according to claim 1, wherein the first and second side walls and the cover portion form a substantially longitudinal channel member.

16. A cover attachment system comprising at least one cover insert according to claim 15 and further comprising at least one longitudinal member for fitting between the two side walls into the channel member.

17. A cover attachment system according to claim 16, wherein said longitudinal member comprises a pair of side elements for fitting into the channel member substantially parallel to the side walls of the cover insert and a main surface extending between the pair of side elements, such that, when in position in the channel member the main surface is substantially coplanar with a top face of the boards.

18. A cover attachment system according to claim 16, further comprising means for fastening the longitudinal member to the channel member.

19. A scaffold utilizing a cover attachment system according to claim 14.

20. A scaffold utilizing a cover attachment system according to claim 16.