AU2016244259B2

AU2016244259B2 - Improvements Relating to Safety Decking

Info

Publication number: AU2016244259B2
Application number: AU2016244259A
Authority: AU
Inventors: Grant Edwards; Peter Horton; Tim Thompson
Original assignee: Buildsafe Equipment Sales Pty Ltd
Current assignee: Buildsafe Equipment Sales Pty Ltd
Priority date: 2015-10-12
Filing date: 2016-10-12
Publication date: 2021-05-20
Anticipated expiration: 2036-10-12
Also published as: AU2016244259A1

Abstract

A temporary decking assembly covering a void gap in the flooring of a building under construction or renovation. The decking assembly comprises a support rail spanning 5 said void gap near a first edge of said void gap, a main deck panel comprising a top sheet portion and underlying longitudinal rails attached to said top sheet portion, and an extension deck panel. The main deck panel is supported at one end so the main deck panel is a distance from said first edge. The extension deck panel spans a portion of said distance. Each longitudinal rail protrudes beyond an end of the top sheet 10 portion to provide a rail support arm. The rail support arms engage with, and are supported by, said support rail. The extension deck panel comprises extension arms which extend beneath said top sheet portion to where they are fastened to said main deck panel. 6/li '-0 Cd cO F U) 10 '-9

Description

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AUSTRALIA

PATENTS ACT 1990

COMPLETE SPECIFICATION STANDARD PATENT IMPROVEMENTS RELATING TO SAFETY DECKING

The following statement is a full description of this invention, including the best method of performing it known to us:

IMPROVEMENTS RELATING TO SAFETY DECKING

Technical Field

This invention concerns safety decking used to provide protection against falls by personnel into a void in a building under construction or renovation.

Background

It is known to use temporary decking as a fall-protection safety measure in buildings under construction where a void exists where a stairway will eventually be located. Such decking may be constructed from panels having a flat solid sheet with supporting side rails affixed on the underside where the side rails have hooks affixed at their ends for locating onto horizontal support rails which are fixed to span the void being covered. A panel of this type is described in our Australian Patent application no. 2012261732 and the contents of that specification are hereby incorporated into the present specification.

Panels are available in a variety of lengths to cater for different void lengths and most are typically about 600mm wide. Narrower 200mm and 300mm wide panels of the same general construction are also used to make up the appropriate width. But the lengths of the panels often do not sufficiently match the size of the void they are used to cover. It is permitted for temporary decking over a void to be a little undersized, and regulations specify a maximum allowable gap at edges of the void platform to allow for this. While the narrower panels allow for good size matching of the decking relative to the width of the panels (so only a small gap is left at the side edges of the void) it is more problematic to cover end gaps (at the end edges of the void) where the panels are shorter than the void being covered. Additional panels can be simply laid over such end gaps but these are easily dislodged and provide a trip hazard.

An aim of the present invention is to provide a better fitting decking assembly which overcomes these problems.

Summary of Invention

Accordingly, in one aspect the invention provides a temporary decking assembly covering a void gap in the flooring of a building under construction or renovation, said decking assembly comprising: - a support rail spanning said void gap near a first edge of said void gap, - a main deck panel comprising a top sheet portion and underlying longitudinal rails attached to said top sheet portion, and - an extension deck panel, wherein: - said main deck panel is supported at one of its ends by said support rail such that said main deck panel is a distance from said first edge, - said extension deck panel spans a portion of said distance, - each said longitudinal rail protrudes beyond an end of the top sheet portion to provide a rail support arm, - said rail support arms engage with, and are supported by, said support rail, and - said extension deck panel comprises extension arms which extend beneath said top sheet portion to where they are fastened to said main deck panel.

Preferably said extension arms engage with and are fastened to respective said longitudinal rails. Preferably said extension deck panel overlies said support rail. Preferably said extension deck's upper face is generally co-planar with said top sheet portion's upper face.

Preferably said main deck panel is supported by a pair of support rails spanning said void gap at respective ends of said main deck panel. Preferably each said extension arm is a continuation of an extension support member on the underside of said extension deck panel and said rail support arms engage with respective said extension support members.

Preferably each said rail support arm defines a hook which hooks over its said engaged support rail. Preferably said deck panel spans substantially the full width or length of said void gap except for said remaining distance.

Preferably: - each said longitudinal rail has a central portion comprising a rigid member of constant cross-section extending for the length of said top sheet portion, and - each end of said central portion has a said rail support arm fastened thereto.

Preferably: - said central portion of each longitudinal rail comprises a top flange portion, a bottom flange portion, and a vertical web portion linking said top flange portion to said bottom flange portion. - each said rail support arm fastened to said central portion is so fastened on a first side of said web portion, and - each said extension arm is fastened to its respective said central portion on the second side of said web portion opposite said first side.

Preferably each said extension arm is a continuation of a rigid structural member which extends across the underside of said extension deck panel.

Preferably the height of the portion of said extension arms beneath said top sheet portion is substantially the same as the height said rail support arms extend above said support rail. Preferably each said extension arm bears upon a respective said support rail.

Alternatively the portion of each said extension arm beneath said top sheet portion is shorter than the portion of said rail support arm immediately above said support rail. Said main deck panel may support said extension deck panel clear of said support rail.

A plurality of like said main deck panels and said extension deck panels may be supported by said pair of support rails.

In another aspect the invention provides a combination deck panel for a temporary decking assembly, said deck panel comprising: - a main deck panel portion comprising a main top sheet portion and underlying longitudinal rails attached thereto, and - an extension panel supported from one end of said main panel portion, wherein: - each said longitudinal rail protrudes beyond an end of the main top sheet portion to provide a rail support arm, and - said extension panel comprises: - an extension top sheet portion, and - extension arms which extend beneath said main top sheet portion to engage with and be fastened to said longitudinal rails.

In a further aspect the invention provides a temporary decking assembly wherein a plurality of combination deck panels as defined above are supported by a pair of support rails spanning a void in the flooring of a building under construction or renovation.

Brief Description of Drawings

In order that the invention may be more fully understood there will now be described, by way of example only, preferred embodiments and other elements of the invention with reference to the accompanying drawings where: Figure 1A is a plan view of a void across which is installed a temporary decking assembly according to the prior art; Figure 1B is a plan view of a void across which is installed a temporary decking according to an embodiment of thepresent invention;

Figure 2 is an isometric view looking down on a platform assembly portion as used in a decking assembly according to a first embodiment of the present invention; Figure 3 is an isometric view looking at the underside of the platform assembly 5 portion shown in Figure 2; Figure 4 is a side view of the platform assembly portion shown in Figure 2; Figure 5 is a plan view looking down on the platform assembly portion shown in Figure 2; Figure 6 is a partially exploded view of the portion of the platform assembly portion shown in Figure 2; Figure 7 is a partially exploded view looking at the underside of the platform assembly portion shown in Figure 6; Figure 8 is a side view of the partially exploded platform assembly portion shown in Figure 6; Figure 9 is a plan view of the partially exploded platform assembly portion shown in Figure 5; Figure 10 is a cross-section view through part of the platform assembly shown in Figure 2; Figure 11 is an underside view of a platform assembly portion according to a second embodiment of the present invention; Figure 12 is a side view of the platform assembly portion shown in Figure 11; Figure 13 is a plan view looking down on the platform assembly portion shown in Figure 12; and Figure 14 is a partially exploded view of portion of the platform assembly portion shown in Figure 13.

Discussion of the Prior Art

Figure 1A shows a temporary decking assembly 8 according to the prior art when affixed across a void gap 9 in the flooring 20 of a building under construction. The void gap 9 is due to a void 18 being left to allow for later installation of a staircase. The void 18 is shown adjacent a partly completed interior wall structure 21.

The decking assembly 8 comprises six deck panels 11-16 supported at their respective ends by two support rails 22 and 24 which are in turn supported by four brackets 26-29 securely fastened to the floor structure within the void 18. The support rails 22 and 24 are telescopically adjustable by an internal screw mechanism in order to provide the exact length required to fit between opposing brackets.

The decking assembly 8 illustrated in Figure 1A comprises three wide panels 11-13, two narrower panels 14 and 15 and a wide ladder-access panel 16. The panels 11-15 each have a top sheet portion 30 and a pair of underlying longitudinal side rails 31 and 32 fastened to the top sheet portion. The ladder-access panel 16 differs in that it includes a hinged flap 17 and an access gap 19 which provides ladder access through the decking assembly. The ends of the side rails have the form of respective hooks 34-37 which hook over the respective support rails 22 and 24.

The panels 11-16 are too short to fully cover the void 18. So an end gap 40, comprising end gap portions 41-46, remains beyond the ends of the panels and the support rail 24 and adjacent the end edge 47 of the void 18. Although in many situations a relatively narrow gap is desirable to allow for fitment of plasterboard, an excessively wide end gap 40 needs to be reduced in order to provide the required degree of safety. The regulations within many parts of Australia permit a maximum gap of 100mm at the edge of a temporary platform covering a void. To achieve this while keeping the platform within the void, it would traditionally be necessary to provide a selection of panels having lengths which increment by 100mm. It would be better if voids could be satisfactorily protected using a smaller variety of panel lengths. The present invention provides a means for achieving that need.

Description of Embodiments of the Present Invention

Figure 1B shows a decking assembly 10 which is the same as decking assembly 8 in Figure 1A except that extension panel portions 62 and 64 have been fastened to the panels 11-16 to form combination deck panels which cover the end gap 40 sufficiently. While the edges 48 and 49 of the main deck panels 11-16 remain at what would have been an unacceptable distance from the end edge 47 of the void 18, the extension panels 62 and 64 span a sufficient portion of that distance to make the decking assembly safe.

Figures 2 to 9 illustrate the structure of a platform assembly 7 comprising a combination deck panel 59 adapted to be used as a replacement for the panel 11 in Figure 1A. The combination deck panel 59 consists of a main deck panel portion 61 and an extension deck panel portion 62 fastened together by a pair of safety-latched D pins 63 which include spring wire latches 57. The main panel portion 61 of the combination deck panel 59 is the same as the basic panel 11, but the panel 61 has been drawn shorter in Figures 2 to 9 than has the panel 11 in Figure 1A so that details of the extension deck panel 62 and its connections can be more clearly shown.

The main deck panel portion 61 comprises a main top sheet portion 30 and underlying longitudinal rails 31 and 32 which are permanently fastened to the main top sheet 30. The fasteners involved are not shown in the drawings in order to reduce complexity. Each end of the rails 31 and 32 has the form of a downwardly directed open-mouthed hook 34-37 which protrudes beyond its respective end of the top sheet portion 30. In use each protruding hook 34-37 engages with, and is supported by, a respective support rail 22 and 24. Each hook therefore functions as a rail support arm because it supports its respective longitudinal rail from the respective support rail 22 and 24.

The extension panel portion 62 is supported from one end of the main panel portion 61.

In Figure 1B the void gap 9 is covered by a temporary decking assembly 10 spanning the void 18 according to one embodiment of the present invention. The decking assembly 10 is the same as the decking assembly 8 shown in Figure 1A except that extension panels 62 and 64 are provided on one end of each of the panels 11-16 in order to cover the end gaps 41-46. Thus three combination deck panels 59 have replaced the three panels 11, 12 and 13 so that the extension panels 62 cover the end gaps 41, 42 and 43 respectively. Similarly, two narrower combination deck panels 60 have replaced the two narrower panels 14 and 15. The extension panels 64 for the narrow panels 14 and 15 are necessarily narrower than the extension panels 62 for panels 11-14.

The extension panels 62 and 64 extend above and thus overlie the support rail 24.

The extension panel 62 described below and as shown in Figures 2-9 is suited to the wider panels. Figures 2-9 show the example of the deck panel 11 connecting with its extension panel 62.

The decking assembly 10 is supported by, and includes, the support rails 22 and 24 which are in turn supported by the brackets 26-29 as in Figure 1A. The support rail 24 extends in a first direction parallel to and near a first edge 47 of the void gap 9. In that position there is a remaining end gap 40 between the first end edge 47 and the top sheet portion 30 of the deck panel. The central portion 51 of each longitudinal rail 31 and 32 is a rigid length of extruded aluminum having a constant cross-section which runs the complete length of the top sheet 30. As most clearly seen in Figure 10, the cross-section of the central portion 51 comprises a top flange portion 65, a bottom flange portion 67 and a vertical web portion 66 linking the top flange portion 65 to the bottom flange portion 67.

The top flange portion 65 includes an upstanding return 69 into which the respective side edge 70 of the top sheet portion 72 is engaged. This provides protection for the edge 70. The top sheet portion may be formed of a structural grade plywood or, more preferably, a partially-hollow composite structure of fibre-reinforced plastics material.

Figure 10 shows a cross-section through the main deck panel portion 61 where it is joined to the extension panel's extension arm 76.

Each hook 34-37 is a component machined from aluminum plate material. At the end of each central portion 51 the respective hook 34-37 is rigidly and permanently fastened by threaded fasteners 38 to the web portion 66 and nests into the channel area 82 bounded by the top flange portion 65, web portion 66 and bottom flange portion 67 on a first side of the web 66. The extended portion of each hook has the form of an inverted open channel which engages around the respective support rail 22 and 24 and whose steeply sloping faces 53 and 54 prevent significant fore and aft movement of the panel relative to the support rail.

The extension deck panel 62 comprises a top sheet portion 72 securely fastened by fasteners 78 to a pair of side rails 73 and 74 beneath. The side rails 73 and 74 function as extension support members. Portions of the side rails 73 and 74 extend as extension arm portions 76 and 77 beyond the top sheet portion 72 and below the plane of the top sheet portion 72.

Each extension arm is therefore a continuation of the extension side rail which acts as a rigid structural member when extending across the underside of the extension panel.

Each extension side rail 73 and 74 and its extension arm portion 76 and 77 is formed integrally from a single length of rigid aluminum extrusion of constant cross section. But the extruded length is machined to produce a different cross-section between, on one hand beneath the top sheet portion 72 and, on the other hand, the extension arm portion. As can be discerned from Figures 7 and 10, the cross-section of the un machined extrusion has an upper flange portion 86 and a lower sideways-oriented channel portion 88 which is joined to the upper flange portion 86 by a connecting web portion 90. The flange portion 86 is machined away from the extrusion where the extension arm 76 engages with the longitudinal side rail 31. The channel portion 88 and web portion 90 are machined away from the extrusion where the flange portion 86 is affixed to the top sheet portion 62. Beneath the extension panel's top sheet 72, the upper flange 86 is permanently fastened by the fasteners 78 to the top sheet 72.

To assemble the combination deck panel 59, the extension arms 76 and 77 of the extension panel are slid beneath the top sheet portion 30 of the main deck panel and into respective channel areas 83 of a central portion 31 and 32 where each extension arm is then bounded by a top flange portion 65, web portion 66 and bottom flange portion 67, but on the opposite side of the web portion 66 than is the hook 34 at that end of the longitudinal rail. Each extension arm 76 and 77 is then fastened by a fastening pin 63 through the arm and adjacent web portion 66. Each extension arm is therefore separated from its closely adjacent hook by a web portion of the longitudinal rail.

The extension arm portions 76 and 77 are therefore shaped so at their protruding end they are deep enough (vertical dimension) to substantially fill the height of the channel area 83 but where they pass over the support rail 24, which is beneath the top sheet portion 72, they have substantially the same depth as the adjacent hook so the arm portions bear against the support rail 24 alongside the adjacent hook.

In an alternative configuration, the channel area 83 supports the extension arm portions 76 and 77 so the extension arms do not contact the support rail. In this situation, the main deck panel supports the extension deck panel clear of the support rail.

Safety regulations treat the width of a gap of concern as the distance from the support rail 24 to the void edge 47 rather than the distance from the upper sheet 30 to the void edge 47. This is because although the support rail is lower than the upper sheet, it still provides a fall barrier. Accordingly, as the rail extends for about 85mm beyond the edge of the upper sheet, fitment of an extension panel 62 having a top sheet portion of 600 x 185mm provides only an additional 100mm of gap coverage. An advantage of the present invention is that an extension panel may be attached at either one or both ends of a main panel, so providing an overall increase in coverage of either 100mm or 200mm respectively. So with the present invention, a suitable set of components for construction of decking assemblies of the type described in any size desired may be provided by a selection of panels sized with length increments of 300mm. In that way acceptable covers can be assembled for any length of void while allowing a substantial reduction in the variety of lengths which need to be available in order to satisfy the regulations.

Figures 11 to 14 illustrate an alternative combination deck panel 159 which shares most features with the panel 59 described above. The main difference is that each end 191 and 192 of the top sheet portion 130 of the main deck panel 161 and each end 193 and 194 of the top sheet portion 172 of the extension panel 162 includes a respective edge strip 195. Each edge strip 195 is the same and is formed from an aluminium extrusion comprising a channel-shaped end 196 and a textured tread end 197. The channel shaped ends 196 surround and mate neatly with corresponding respective panel edges 198 of the top sheet portion 130 and corresponding respective panel edges 199 of the top sheet portion 172, and are fastened thereto by rivets 200. The textured tread ends 197 of the edge strips 195 in use extends outwards from the respective top sheet edges 198 and 199. The edge strips protect the edges of the panels from damage and also provide a roughened surface which reduces the potential for accidental slipping of workers using the decking assembly.

In this specification reference to the length of a panel or an extension panel or a void means the distance in the direction adopted by the longitudinal rails 31 and 32. Thus an extension panel will commonly have a shorter length than its width.

Whilst the above description includes the preferred embodiments of the invention, it is to be understood that many variations, alterations, modifications and/or additions may be introduced into the constructions and arrangements of parts previously described without departing from the essential features or the spirit or ambit of the invention.

It will be understood that where in this specification a decking assembly is described as covering a void gap, it is not intended to mean that a 100% filling of the void gap is necessarily achieved. Small gaps are permitted as provided for by the relevant safety regulations.

It will also be understood that where the word "comprise", and variations such as "comprises" and "comprising", are used in this specification, unless the context requires otherwise such use is intended to imply the inclusion of a stated feature or features but is not to be taken as excluding the presence of other feature or features.

The reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that such prior art forms part of the common general knowledge.

Claims

The claims defining the invention are as follows

1. A temporary decking assembly covering a void gap in the flooring of a building under construction or renovation, said decking assembly comprising: - a support rail spanning said void gap near a first edge of said void gap, - a main deck panel comprising a top sheet portion and underlying longitudinal rails attached to said top sheet portion, and - an extension deck panel, wherein: - said main deck panel is supported at one of its ends by said support rail such that said main deck panel is a distance from said first edge, - said extension deck panel spans a portion of said distance, - each said longitudinal rail protrudes beyond an end of the top sheet portion to provide a rail support arm, - said rail support arms engage with, and are supported by, said support rail, and - said extension deck panel comprises extension arms which extend beneath said top sheet portion to where they are fastened to said main deck panel.

2. A temporary decking assembly according to claim 1 wherein said extension arms engage with and are fastened to respective said longitudinal rails.

3. A temporary decking assembly according to Claim 1 or 2 wherein said extension deck panel overlies said support rail.

4. A temporary decking assembly according to any one of the preceding claims wherein said extension deck's upper face is generally co-planar with said top sheet portion's upper face.

5. A temporary decking assembly according to any one of the preceding claims wherein said main deck panel is supported by a pair of support rails spanning said void gap at respective ends of said main deck panel.

6. A temporary decking assembly according to any one of the preceding claims wherein each said extension arm is a continuation of an extension support member on the underside of said extension deck panel and said rail support arms engage with respective said extension support members.

7. A temporary decking assembly according to any one of the preceding claims wherein each said rail support arm defines a hook which hooks over its said engaged support rail.

8. A temporary decking assembly according to any one of the preceding claims wherein said deck panel spans substantially the full width or length of said void gap except for said remaining distance.

9. A temporary decking assembly according to any one of the preceding claims wherein: - each said longitudinal rail has a central portion comprising a rigid member of constant cross-section extending for the length of said top sheet portion, and - each end of said central portion has a said rail support arm fastened thereto.

10. A temporary decking assembly according to claim 9 wherein: - said central portion of each longitudinal rail comprises a top flange portion, a bottom flange portion, and a vertical web portion linking said top flange portion to said bottom flange portion. - each said rail support arm fastened to said central portion is so fastened on a first side of said web portion, and - each said extension arm is fastened to its respective said central portion on the second side of said web portion opposite said first side.

11. A temporary decking assembly according to any one of the preceding claims wherein each said extension arm is a continuation of a rigid structural member which extends across the underside of said extension deck panel.

12. A temporary decking assembly according to any one of the previous claims wherein the height of the portion of said extension arms beneath said top sheet portion is substantially the same as the height said rail support arms extend above said support rail.

13. A temporary decking assembly according to any one of the preceding claims wherein each said extension arm bears upon a respective said support rail.

14. A temporary decking assembly according to any one of claims 1 to 11 wherein the portion of each said extension arm beneath said top sheet portion is shorter than the portion of said rail support arm immediately above said support rail.

15. A temporary decking assembly according to claim 14 wherein said main deck panel supports said extension deck panel clear of said support rail.

16. A temporary decking assembly according to claim 5 wherein a plurality of like said main deck panels and said extension deck panels are supported by said pair of support rails.

17. A combination deck panel for a temporary decking assembly, said deck panel comprising: - a main deck panel portion comprising a main top sheet portion and underlying longitudinal rails attached thereto, and - an extension panel supported from one end of said main panel portion, wherein: - each said longitudinal rail protrudes beyond an end of the main top sheet portion to provide a rail support arm, and - said extension panel comprises: - an extension top sheet portion, and - extension arms which extend beneath said main top sheet portion to engage with and be fastened to said longitudinal rails.

18. A temporary decking assembly wherein a plurality of combination deck panels according to claim 17 are supported by a pair of support rails spanning a void in the flooring of a building under construction or renovation.