AU2019238568A1

AU2019238568A1 - Safety cap device

Info

Publication number: AU2019238568A1
Application number: AU2019238568A
Authority: AU
Inventors: Ante MIHALJEVIC; Davor Mihaljevic
Original assignee: Kraljevic Mathew; Mirza David
Current assignee: Mihaljevic Ante
Priority date: 2018-03-22
Filing date: 2019-03-19
Publication date: 2020-09-17
Anticipated expiration: 2039-03-19
Also published as: AU2021221924A1; AU2019238568B2; WO2019178638A1; AU2021221924B2

Abstract

A safety cap device (10) includes a cap (20) having an internal receptacle (40) configured to receive a rebar or other construction element, the cap (20) having a first engagement formation (80). The safety cap device (10) including a mounting bracket (30) having a recess (100) configured to receive the cap, the mounting bracket having a second engagement formation (130), an upper portion of the mounting bracket (30) including a support bracket (140) configured to support a length of timber or another such rigid element. The first engagement formation (80) and second engagement formation (80) are engageable to selectively secure the cap (20) to the mounting bracket (30).

Description

Safety cap device

Technical Field

[0001] The present disclosure relates to a safety cap device. In particular, the present invention relates to a safety cap device for use on construction sites. However, it will be appreciated that the safety cap device may be used in other applications.

Background of the Invention

[0002] During construction with concrete, reinforcing steel bars (also called rebars) are generally placed within the concrete to greatly increase the tensile strength of the concrete once cured. The amount of steel used and the bar diameter and placement vary depending on site specific factors in accordance with engineering specifications for the site.

[0003] It is common practice for steel reinforcing bars (rebars) to project out of a concrete slab during construction. This is typically done to provide a structure to tie other rebars or steel reinforcing for placement within elements such as walls which are constructed subsequent to the slab. However, during the construction process, there are often long periods between the base slab being poured and the walls being erected. In this intervening period of time, the vertical rebars are exposed, and provide a significant risk to workers.

[0004] Due to the relatively small diameter of the rebars, and the fact that they are extremely rigid and often extremely sharp from cutting, they pose a significant risk to workers in the event that a worker falls on one of the rebars from above. Such impalement injuries are common, and have resulted in many fatalities on construction sites around the world.

[0005] In recent years, many developed countries have adopted building regulations which mandate that exposed rebars must be covered or capped to reduce the risk of serious workplace injuries, such as impalements resulting from workers falling on the exposed rebar ends.

[0006] The adoption of such mandatory capping regulations has resulted in a significant decrease in worksite injuries. However, the caps are typically in the form of plastic caps which sit over the end of each rebar. Whilst the caps reduce the risk of minor injuries, there is still a risk that a person falling onto the cap may be injured or even killed, as the capped bar is still extremely rigid from above, and the surface area of the cap is still reasonably small. As such, the introduction of mandatory rebar capping does not completely obviate the risk of injury or death via impalement. It should be noted that standard rebar caps do not provide and are not designed for impalement protection, and they only protect against minor injuries.

[0007] In some instances, the thickness of the cap is not sufficient, and a person falling onto and landing on the cap may cause the cap to rupture, exposing the rebar. This problem can also arise as the caps become affected by sunlight which may degrade certain polymers over time, resulting in increased brittleness or reduced cap strength.

[0008] In recent years, several products have been released which provide an alternative to traditional plastic caps. One such system is sold under the brand CARNIE CAP™. The CARNIE CAP™ is a plastic cap which is intended to be fitted over rebars and has an upper support platform for holding a length of timber, such as a length of 90mm x 45mm timber.

In use, when a row of rebars are projecting from a slab, a worker will install the CARNIE CAP™ on every rebar end, or intermittently, for example, every 2, 3, 4 or more rebar ends. A length of timber is then seated on the support platform, such that the timber covers the exposed ends of the rebars. This provides fall protection for a worker working in the vicinity of the CARNIE CAP™ installation.

[0009] Furthermore, the CARNIE CAP™ obviates the need to cap every single rebar in a row, as the installed timber on the support platform covers the exposed bar ends. Once the timbers are in position, they can be secured to the individual CARNIE CAP™ covers with nails or screws, to prevent the timbers from being removed.

[0010] The CARNIE CAP™ provides a significantly larger surface area from above, hence a reduced risk of impalement if a worker falls on the timber from above. However, a disadvantage of the CARNIE CAP™ system is that the caps tend to be damaged after one or more usages due to wear and tear on the internal fins, in particular on account of the engagement with the rebar. This limits the ability to reuse the caps, hence resulting in a higher cost per use.

[0011] A product sold under the brand WISABLOCK™ offers a similar solution, but with the timber receiving portion defining a rectangular enclosure. This negates the requirement to secure the timbers with fasteners, which may be timesaving. However, the timber must be installed in a direction extending parallel to the row of rebars. In some applications, for example where there is an adjacent wall or other structure, this may result in the installation being difficult and time consuming. This arrangement can also be difficult to install in vertical applications, especially where there are space limitations defined by the floor, ceiling and walls. The WISABLOCK™ does not provide a fastener or other means to secure the timber. As such, the timber cross-member is free to move, and may unintentionally slide.

[0012] As with the CARNIE CAP™, the WISABLOCK™ tends to be damaged after one or more uses after engagement with the rebar. This limits the ability to reuse the cap, hence resulting in higher cost per use.

[0013] Another product is marketed under the brand ReACTer Cap™. This system uses an individual flared cap for each rebar, or intermittent rebars in a row. An elongate plastic member is then secured to the flared caps by way of a channel formed in the elongate plastic member. A disadvantage of this system is that the elongate plastic members must be installed in a direction extending parallel to the row of rebars. In some applications, for example where there is an adjacent wall or other structure, this makes the installation difficult. Furthermore, the small tolerance between the flared caps and the channel in the elongate plastic member renders the system difficult to use if either of the components is damaged from wear and tear. In addition, the elongate plastic members must be cut to suit site specific dimensions, meaning that the life of the elongate plastic members may be limited to a small number of installations, hence increasing the cost per use.

Object of the Invention

[0014] It is an object of the present invention to substantially overcome or at least ameliorate one or more of the above disadvantages, or to provide a useful alternative.

Summary of the Invention

[0015] In a first aspect, the present invention provides a safety cap device comprising: a cap having an internal receptacle configured to receive a rebar or other construction element, the cap having a first engagement formation; and

a mounting bracket having a recess configured to receive the cap, the mounting bracket having a second engagement formation, an upper portion of the mounting bracket including a support bracket configured to support a length of timber or another such rigid element;

wherein the first engagement formation and second engagement formation are engageable to selectively secure the cap to the mounting bracket.

[0016] The first engagement formation includes an upwardly extending flange and the second engagement formation includes an annular projection. [0017] An outer surface of the cap preferably includes at least one longitudinally extending spine, and an internal surface of the recess preferably has at least one corresponding longitudinally extending channel.

[0018] There are preferably four spines and four channels.

[0019] There are preferably two upwardly extending flanges, each extending around a portion of the perimeter of the cap.

[0020] The internal receptacle preferably includes elastically or plastically deformable ribs configured to engage with the rebar or other construction element.

[0021] The support bracket preferably has a base and two generally perpendicular arms.

[0022] At least one of the two perpendicular arms preferably includes a fastener receiving hole.

[0023] The first engagement formation preferably includes a male thread and the second engagement formation preferably includes a corresponding female thread.

[0024] The cap preferably has a polygonal cross-sectional profile when viewed in a plane extending perpendicular to a longitudinal axis and the mounting bracket recess preferably has a corresponding polygonal cross-sectional profile.

[0025] The first engagement formation preferably includes a first aperture formed in the cap and the second engagement formation preferably includes a corresponding second aperture formed in the mounting bracket, the first and second apertures being configured to receive a pin.

[0026] In a second aspect, the present invention provides a method of covering a plurality of exposed rebar ends, the method includes the steps of:

placing a first cap having an internal receptacle on a first rebar end, the first cap having a first engagement formation;

placing a second cap having an internal receptacle on a second rebar end, the second cap having a first engagement formation;

securing a first mounting bracket to the first cap, the first mounting bracket having a recess configured to receive the first cap, the first mounting bracket having a second engagement formation,

securing a second mounting bracket to the second cap, the second mounting bracket having a recess configured to receive the second cap, the second mounting bracket having a second engagement formation, placing a length of timber or another such rigid element between and in abutment with the first mounting bracket and the second mounting bracket;

wherein the first engagement formations and second engagement formations are engageable to selectively secure the first cap to the first mounting bracket, and the second cap to the second mounting bracket.

Brief Description of the Drawings

[0027] A preferred embodiment of the invention will now be described by way of specific example with reference to the accompanying drawings, in which:

[0028] Fig. 1A is a top view of a cap according to a first embodiment of the invention;

[0029] Fig. IB is a top view of a cap according to a second embodiment of the invention;

[0030] Fig. 2A is a side view of the cap of the first embodiment;

[0031] Fig. 2B is a side view of the cap of the second embodiment;

[0032] Fig. 3A is a bottom view of a cap according to the first embodiment;

[0033] Fig. 3B is a bottom view of a cap according to the second embodiment;

[0034] Fig. 4 is a top view of a mounting bracket of the invention;

[0035] Fig. 5 is a front view of the mounting bracket of Fig. 4;

[0036] Fig. 6 is a cross-sectional front view of the mounting bracket of Fig. 4;

[0037] Fig. 7 is an end view of the mounting bracket of Fig. 4;

[0038] Fig. 8 is a bottom view of the mounting bracket of Fig. 4;

[0039] Fig. 9a is a side view of an embodiment of a mounting bracket according to a further embodiment of the invention;

[0040] Fig. 9b is a side cross-sectional view of a cap according to the embodiment of Fig. 9a; and

[0041] Fig. 10 depicts the cap and mounting bracket with cross-members in situ.

Detailed Description of the Preferred Embodiments

[0042] A safety cap device 10 is disclosed herein. The device 10 is a two part system which includes a cap 20 and a mounting bracket 30, which are separately formed. Advantageously, the cap 20 is disposable and can be replaced when it becomes damaged or worn during use, for example by the end of a rebar. In this manner the user can replace the caps 20 as necessary and reuse the mounting brackets 30.

[0043] The cap 20 and the mounting bracket 30 may be provided to the consumer separately for assembly on site (or elsewhere). Alternatively, the cap 20 and the mounting bracket 30 may be provided pre-assembled.

[0044] In some scenarios, the caps 20 can be used in isolation, for example as a single rebar minor-injury protector.

[0045] The cap 20 is designed to fit over and engage with a steel bar such as deformed or threaded rebar. In the first embodiment depicted in Figs. 1A, 2A and 3A, the cap 20 has an internal receptacle 40 adapted to receive rebars being between 24mm and 36mm in diameter. In contrast, the embodiment of the cap 20 depicted in Figs. IB, 2B and 3B, the caps are suitable for use with smaller rebars being between 10mm and 20mm in diameter.

In this way the caps 20 can be chosen to suit the specific rebar dimensions used on a given construction site. Flowever, in another embodiment, the caps 20 may be suitable for use with rebars from 10mm through to 36mm.

[0046] It will be appreciated that whilst the device 10 is described and depicted as a two part system, it may alternatively be provided as a three part system, including an adaptor that is inserted into to mounting bracket 30 if the small diameter cap 20 of Figs. IB, 2B and 3B is used.

[0047] Referring to the bottom view in Figs. 3A and 3B, the internal receptacle 40 within the caps 20 includes three longitudinally extending ribs or spines 50. The spines 50 are elastically or plastically deformable when a rebar is inserted into the base of the cap 20, and the amount of deflection required depends on the diameter of the rebar. For example, with larger diameter rebars, more deformation of the spines 50 is possible, such that the available clear diameter of the receptacle 40 is increased. In contrast, when a smaller diameter rebar is used, less deformation of the spines 50 is required. In this manner, the elastic or plastic deformable nature of the spines 50 provides for adjustability of the available diameter of the receptacle for receiving a rebar. Furthermore, the spines 50 permit engagement with other building products such as star pickets.

[0048] It will be appreciated that an alternative engagement may be adopted between the cap 20 and the rebar, such as a taper, a hexagonal shaped receptacle 40, a polygonal shaped receptacle, rubber O-rings positioned in the receptacle 40, an internal screw thread, or a deformable rubber insert. Alternatively the cap 20 may be fabricated with a tubular receptacle 40, from an elastically deformable rubber or other such material, so that the cap 20 can deform to grip the rebar in the receptacle 40, and also externally deform, if required, to engage the mounting bracket 30.

[0049] The distal end of each cap 20 includes a cover 60 which sits over the end of the rebar. The cover 60 may also be provided with a steel or other such reinforcement plate (not shown) and located within the cover 60.

[0050] Referring to Figs. 1A and IB, the caps 20 include longitudinally extending external ribs 70. In the embodiment shown, there are four ribs evenly spaced around the

circumference of the cap 20. However, it will be appreciated that one, two, three, five or more ribs 70 may alternatively also be used. In alternative embodiment, another system may be used to prevent the cap 20 from rotation relative to the mounting bracket 30. For example, the exterior surface of the cap 20 may be triangular, hexagonal, pentagonal, square in cross-section (or some other polyhedron), and sized to fit snugly within a correspondingly shaped receptacle formed in the mounting bracket 30. In this embodiment, the exterior surface of the caps 20 is complimentary with the interior surface of the mounting bracket 30, and preferably not round, to prevent rotation.

[0051] Importantly, the spines 50 extend parallel with a longitudinal axis of the caps 20 (corresponding with the longitudinal axis of the rebar). In this way, the spines 50 maximise the engagement along the length of the end portion of the rebar. In this manner, the spines are parallel and non-tapered, such that the cross-sectional area of the internal receptacle 40 (the space which receives the rebars) has a constant cross-sectional area when viewed through a plane which is perpendicular to the longitudinal axis.

[0052] As shown in Figs. 2A and 2B, a proximal end of the cap 20 includes a first engagement formation in the form of an upwardly extending flange 80.

[0053] Referring to Figs. 4 to 8, the mounting bracket 30 is shown in isolation. Importantly, a single mounting bracket 30 can be used interchangeably with the caps 20 of either of the first and second embodiments.

[0054] The mounting bracket 30 has a recess or cylindrical bore 100. The recess 100 is sized to receive the cap 20 of either of the first and second embodiments. A circumferential internal wall of the recess includes four longitudinally extending channels 110. The channels 110 correspond with the longitudinally extending external ribs 70 of the caps 20. As such, the engagement between the longitudinally extending channels 110 and the ribs 70 prevents or at least inhibits rotation of the mounting bracket 30 relative to the cap 20. [0055] It will be appreciated by those skilled in the art that the longitudinally extending channels 110 and longitudinally extending external ribs 70 may be made in the contrary sense to what is described above. That is, the male and female portions may be formed on either of the mounting bracket 30 or the cap 20.

[0056] The mounting bracket 30 has a second engagement formation in the form of an annular projection or lip 130 configured to engage with the upwardly extending flange 80. When the annular projection 130 engages with the upwardly extending flange 80, the cap 20 is secured to the mounting bracket 30. However, it will be appreciated that other engagement formations between the mounting bracket 30 and the caps 20 may be envisaged.

[0057] In some embodiments, the mounting bracket 30 may be provided to support ancillary devices such as reflectors, lights, or mounting points for securement of such ancillary features. For example, the cap 20 may be configured to engage with a sign or sign post, a light, a reflector, or any other item commonly deployed on a construction site.

[0058] In the embodiment shown in the drawings, the flange 80 extends around a portion of the circumference of the cap 20. This assists to enable a user to separate the flange 80 from the annular projection 130 when it is desired to separate the cap 20 from the mounting bracket 30.

[0059] Referring to the top view of Fig. 4, the timber support bracket 140 of the mounting bracket 30 is chamfered to prevent or at least reduce the risk of minor injuries.

[0060] The timber support bracket 140 of the mounting bracket 30 is sufficiently wide that it provides a bearing surface which enables two pieces of timber to be positioned end-to-end on the support bracket 140. This provides cost savings, as it removes the requirement to have a separate cap 20 and mounting bracket 30 located at the end of each timber.

[0061] As depicted in Fig. 7, fastener securement holes 150 are located in the side of the timber support bracket 140. The fastener holes 150 are configured to receive screws or nails. The holes 150 may be arranged diagonally as shown in Fig. 7. Alternatively, the holes 150 may be arranged laterally spaced, as depicted in Fig. 10, such that there are two holes 150 positioned on a generally horizontal plane, which may be more suitable for joining timbers end to end. Alternatively, there may be four holes located in a square formation, such that the user chooses which holes are most appropriate for a given timber profile. Fig. 10 graphically depicts the scenario where two cross-member timbers 155 are arranged end to end. However, in other scenarios, the mounting bracket 30 supports the end of a single cross-member 155, or an intermediate portion of a single cross-member 155.

[0062] The timber support bracket 140 is preferably around 105mm wide and suited to receive 100mm x 45mm timber. However, it will be appreciated that the timber support bracket 140 may be fabricated in different sizes.

[0063] In one embodiment, not shown, the base of the timber support bracket 140 may include a plurality of upwardly extending projections or protrusions. The projections are intended to deflect or deform under load. This feature provides impact energy absorption, and may assist to reduce injuries resulting from a person falling on the timber.

[0064] Whilst the safety cap device 10 is described with respect to a timber safety barrier, it will be appreciated that other materials such as various polymers may alternatively be used to provide the platform between adjacent mounting brackets 30.

[0065] Whist the cap 20 and mounting bracket 30 are described herein employing a snap fit type engagement, it will be appreciated by those skilled in the art that other engagement arrangements may be possible. For example, a threaded engagement or some alternative means to engage the cap 20 with the mounting bracket 30 may be used.

[0066] For example, in the embodiment depicted in Figs. 9a and 9b, the mounting bracket 30 includes an aperture 180 which extends through to the recess 100. Referring to Fig. 9b, the cap 20 includes a corresponding button or protrusion 185 which is resiliently biased, and the button 185 is configured to extend at least partially into the aperture 180. For example, the button 185 may be defined by a small protrusion which is connected to a resilient arm, so that it can be pushed and deflected radially inwardly. Alternatively, the button 185 may be seated on a spring or other structure which biases the button radially outwardly. The button 185 and aperture 180 interact to secure the cap 20 to the mounting bracket 30, to prevent or at least inhibit rotation or axial movement. In this embodiment, a user may separate the cap 20 from the mounting bracket 30 by pressing the button. This separation process may be performed with the aid of a tool.

[0067] Alternative engagement formations between the cap 20 and the mounting bracket 30 are envisaged, such as a bayonet type fitting.

[0068] In an alternative arrangement, a pin or other such fastener may be inserted through a hole formed in the wall of the mounting bracket 30, to engage with a

corresponding hole or notch formed on the outer surface of the cap 20. [0069] In each arrangement, first and second engagement formations are used to prevent the mounting brackets 30 rotating or moving longitudinally relative to the cap 20.

[0070] Advantageously, the caps 20 and the mounting bracket 30 are selectively separable. This is favourable, as the caps 20 generally have a shorter working life, due to wear and tear on the spines 50. The separation permits the caps 20 to be replaced once damaged whilst the mounting brackets 30 are reused.

[0071] In some scenarios, the caps 20 may be used on their own, without the mounting bracket 30. For example, when there is no risk of workers falling on the rebars, the caps can be used in isolation to provide protection against minor injuries.

[0072] The caps 20 and mounting brackets 30 may be fabricated from polypropylene or another suitable polymer.

[0073] The caps 20 and mounting brackets 30 are preferably fabricated from a material which is brightly coloured or fluorescent to ensure the caps 20 and mounting brackets 30 are visible and prominent on the construction site.

[0074] Advantageously, the cap 20 enables the end of the rebar to be seated at (or at least close to) the base of the internal receptacle 40. Accordingly, the gap between the underside of the timber and the top of rebar is considerably less than in other fall prevention systems, therefore providing protection against a person being able to insert a part of their body or unintentionally make contact with the exposed rebar due to the timber being further away.

[0075] In a further embodiment not shown in the drawings, the safety cap device 10 includes a cap 20, a mounting bracket 30 and also an additional insert to accommodate different diameter rebars.

[0076] Advantageously, unlike the CARNIE CAP™ and WISABLOCK™ products described in the background, the entire safety cap device 10 does not need to be discarded once the internal fins become worn or damaged. In the CARNIE CAP™ and WISABLOCK™ products, the entire system is discarded when the fins become damaged, which increases the cost per use.

[0077] Advantageously, the cap 20 and mounting bracket 30 are prevented from rotation by the first and second engagement formations.

[0078] Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

Claims

The claims defining the invention are as follows:

1. A safety cap device comprising:

a cap having an internal receptacle configured to receive a rebar or other construction element, the cap having a first engagement formation; and

2. The safety cap of claim 1, wherein the first engagement formation includes an upwardly extending flange and the second engagement formation includes an annular projection.

3. The safety cap of either of the preceding claims, wherein an outer surface of the cap includes at least one longitudinally extending spine, and an internal surface of the recess has at least one corresponding longitudinally extending channel.

4. The safety cap of claim 3, wherein there are four spines and four channels.

5. The safety cap of claim 2, wherein there are two upwardly extending flanges, each extending around a portion of the perimeter of the cap.

6. The safety cap of any one of the preceding claims, wherein the internal receptacle includes elastically or plastically deformable ribs configured to engage with the rebar or other construction element.

7. The safety cap of any one of the preceding claims, wherein the support bracket has a base and two generally perpendicular arms.

8. The safety cap of claim 7, wherein at least one of the two perpendicular arms includes a fastener receiving hole.

9. The safety cap of claim 1, wherein the first engagement formation includes a male thread and the second engagement formation includes a corresponding female thread.

10. The safety cap of claim 1, wherein the first engagement formation and the second engagement formation are defined by a bayonet type fitting.

11. The safety cap of claim 1, wherein the first engagement formation includes a resiliently biased protrusion associated with the cap, and the second engagement formation includes an aperture formed on the mounting bracket adapted to receive the protrusion.

12. The safety cap of any one of claims 1 to 8, wherein the cap has a polygonal cross-sectional profile when viewed in a plane extending perpendicular to a longitudinal axis and the mounting bracket recess has a corresponding polygonal cross-sectional profile.

13. The safety cap of claim 1, wherein the first engagement formation includes a first aperture formed in the cap and the second engagement formation includes a corresponding second aperture formed in the mounting bracket, the first and second apertures being configured to receive a pin.

14. The safety cap of any one of the preceding claims, wherein the cap and/or mounting bracket are fluorescent, luminescent or reflective.

15. The safety cap of any one of the preceding claims, wherein the cap and/or mounting bracket includes battery or electrically powered light source.

16. The safety cap device of any one of the preceding claims, wherein the mounting bracket is configured to support an ancillary item such as a light or sign.

17. A method of covering a plurality of exposed rebar ends, the method includes the steps of: placing a first cap having an internal receptacle on a first rebar end, the first cap having a first engagement formation;

securing a second mounting bracket to the second cap, the second mounting bracket having a recess configured to receive the second cap, the second mounting bracket having a second engagement formation,

placing a length of timber or another such rigid element between and in abutment with the first mounting bracket and the second mounting bracket;