WO2017029522A1

WO2017029522A1 - Scaffold board end protector cap

Info

Publication number: WO2017029522A1
Application number: PCT/GB2016/052583
Authority: WO
Inventors: Peter Joseph ROBINSON; Nick ROGERS; Greg JARVIS
Original assignee: Boardeguard Limited
Priority date: 2015-08-20
Filing date: 2016-08-19
Publication date: 2017-02-23
Also published as: GB201514869D0; EP3337940A1

Abstract

A protection device for the end of a scaffold plank or board is described. A scaffold board end protector cap has been developed, the cap comprising a body and a recess; the body having an end face, an upper face, a lower face and side faces extending from the end face, the body extending about the recess and the recess arranged to receive a scaffold board end. A method of manufacture and a scaffold board with protection is also described.

Description

Scaffold board end protector cap

The invention relates to a scaffold board end protector cap, a scaffold board fitted with the end protector cap and a method of manufacturing the .end protector cap. Scaffold boards along with scaffold poles are used to form scaffold towers and support structures and are in regular use on building sites both commercially and in a domestic setting. The boards or planks comprise softwood and are fabricated in a British

Standard size for ease of use and compatibility. However, the boards are prone to damage due to the outdoor exposure they experience in use and the generally harsh environment of a building site. A board can be damaged during board delivery, fabrication of a scaffold structure, packing away or break down of the structure and removing the scaffolding from site and whilst in storage. Damage includes splitting boards, splintering, rot, warping. A damaged board must either be replaced or, if possible, repaired by bracing or, for example, by cutting to remove the damaged portion and provide a board of reduced size. To address the damage issue some plastic boards with plastic end features have been proposed. Many wooden boards feature a stainless steel metal band attached with nails or a metal gripper to the exposed either end of the board. Although the metal band can protect the workforce from splinters and rough wood at the end of the board they also create a hazard and can be unsafe.

As any scaffold installation outside is exposed to weather, in some cases extreme weather and wet conditions, it is common for the boards to split and rot, this alongside the physical manhandling of the boards in use can cause the metal bands to become loose and peel away from the board. In this state the boards rot and decay more swiftly than when complete, leading to more frequent repair, replacement and cut down. As the metal bands are nailed in place, once they become loose the sharp edges of the bands and the nails themselves pose a hazard to the workforce handling the ends of the boards. Injuries can include cuts to hands and shoulders. Any nails or fixings that are lost from the bands or end of the boards are a puncture risk for any vehicles on the building site with pneumatic tyres and could also injure those walking around the site. Despite the aforementioned problems with metal bands they are extensively used on scaffold boards due to their low cost and easy of fitting.

The present invention seeks to improve the existing scaffold end protectors and scaffold boards or planks.

According to an aspect of the present invention there is provided scaffold board end protector cap comprising a body and a recess; the body having an end face, an upper face, a lower face and side faces extending from the end face, the body extending about the recess and the recess arranged to receive a scaffold board end.

The protector cap body forms a band that wraps around the external faces of the scaffold board, the band acting to secure the end protector cap about a scaffold board. The wraparound nature of the cap urges the fibres of the board together and prevents the board from splitting apart.

The upper face is that which, in use, is uppermost on the board when mounted within a scaffold structure and would form the footfall surface presented to the workforce. The lower face is that which, in use, faces away from the workforce and is orientated towards the ground.

The end face is located at a distal end of the scaffold board and is that which, in use, is perpendicular to the upper face and the lower face.

In an embodiment the scaffold board end protector cap comprises accommodation for a fixing member, such that the end protector cap is arranged and secured about a scaffold board. In an embodiment the scaffold board end protector cap comprises a fixing member retainer. The fixings can be screws or nails or other features. The retaining detail is designed to allow the screw or nail to pass by when being inserted but then to act to restrain the fixing from exiting the retaining portion and coming back out of the board. The retainer can be a structure such as a double side lip, sufficiently flexible to allow a screw or nail to be in effect forced past the side lip on fixing, but providing an obstacle to the exit of the fixing screw or nail once inserted. The retaining detail should maintain its function with a board end that has decayed or started to rot. A double side lip can be fabricated with injection moulding techniques and does not require additional side wall depth.

In an embodiment there is at least one opening in the body. The at least one opening is provided in the end face of the body in an embodiment to allow for drainage and air circulation. The openings or holes provide a route for water egress avoiding any build up of, for example, rain water or the back up of any water on the scaffold board as a result of work on site. Drainage is useful to ensure that boards can dry out, avoiding standing water on the boards which could lead to rot. The openings may be of a square shape in an embodiment and in an embodiment can be an elongated or rectangular shape. The elongated shape increases the flexibility of the end cap and allows the end cap to accommodate changes in the shape of the board, for example a warped board. The elongated opening or hole helps prevent deflection of the board if the board is warped. The elongated opening has the effect of reducing tension on the frontmost edge of the board if it is misshapen, in consequence the end cap then sits closer to the board, reducing the risk of the work force tripping and reducing the void space. In an embodiment the scaffold board end protector cap comprises at least one rib member protruding externally from the body and in another embodiment the scaffold board end protector cap comprises at least one rib member protruding internally from the body. The internally protruding rib is orientated towards and within the recess. The rib members are provided for shock absorbing purposes. In an embodiment the rib member is located at the end face, and in addition in an embodiment the rib members are fabricated from a resilient material so as to provide shock absorbency. The shock absorbency is useful when a plank is dropped or suffers an impact at or close to the end face. The ribs dissipate the force of the impact and protect the end of the scaffold board. In an embodiment the upper face of the body of the cap has a shaped portion, the shaping can be a scalloped profile which reduces plastic deformation when the protector cap is fitted to a warped or misshapen board. The scalloped profile therefore broadens the tolerance of the cap fit to boards, and an already damaged or compromised board can still be protected with the end cap. The shaped portion can comprise one or more shapes selected from the range; scalloped, chamfered, indented. The shaped portion provides a gradual change in depth and overall board thickness which helps a worker to adjust to the sensation of reaching the end of the scaffold board. The chamfer reduces the chance of tripping and the scalloped profile provides a snug fit of the protector end cap along the upper surface. The snug fit does not allow for gaps and reduces the build up of building site dirt and debris on the scaffold board and around the protector end cap. The end protector caps are of such dimension that they provide a taper and reduction in thickness of the end protector cap and scaffold board end towards the distal end of the scaffold board. This taper has an effect such that when scaffold boards are stacked, for example when not in use, in storage or in transportation the distal ends of stacked boards are spaced apart and do not touch. The spacing provided by the scaffold board end protector caps on adjacent, stacked boards allows air to flow around the ends of the boards. This means any rain water or spillage can run off or evaporate and the boards remain in a dry state, without being water logged, and are rot free.

In an embodiment the scaffold board end protector comprises signage selected from the range of; colourways, company name, hazard warnings, information, indication of scaffold board orientation. This means a company, such as the scaffolding company, can display its name whilst on a build project and can also use the end caps as an area to display information to the workforce - for example, to promote hazard awareness and safe working. Logos and writing in different orientations mean that the wording is legible any way the board is put down. The name of the company fabricating the scaffold board protector end caps can also be visible.

The scaffold board end protector cap of an embodiment has a depth in the range 70 to 90mm and in an embodiment is 80mm. The depth corresponds to the depth of a scaffold board made to the British Standard and with at least one known dimension the depth can be used as a guide for the location and placement of a scaffold board on and against a scaffold pole. In an embodiment the end cap material is soft plastic. The material of the end cap of an embodiment comprises one selected from the range plastic, polymer, rubber and heat shrunk polymer. The soft plastic embodiment has some elastic properties to allow it to conform to particular board shapes while still retaining the strength and shape of the band provided by the end protector cap, thus avoiding splits in the wood and wood fibres at either end of the scaffold board. In addition, the plastic adds to the shock absorbing nature of the end cap.

In an embodiment the body comprises separate pieces or portions. The faces can be hingedly connected to each other so that the end protector cap can be manufactured in separate parts and can feature hinges or similar fixings to enable the end protector cap to comprise a flat pack assembly for ease of manufacture and shipping.

According to a further aspect of the present invention there is provided a method of manufacture of a scaffold board and scaffold board end protector cap comprising the steps of, (i) preparing the distal ends of a scaffold board; (ii) applying a scaffold end protector cap as claimed in any preceding claim to a distal end of a scaffold board; (iii) heating the scaffold board end protector cap so as to cause shrinking of the cap, and (iv) securing the scaffold board end protector cap to the board.

According to another further aspect of the present invention there is provided a device for manufacturing a scaffold board end protector cap as previously described.

Embodiments of the invention will now be described in detail, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a perspective view of a portion of a conventional scaffold board and of a scaffold board end protector cap according to an embodiment of the invention; Figure 2 is a close up perspective view of the scaffold board end protector cap of Figure 1 ;

Figure 3 is a side view of the scaffold board end protector cap of Figure 1 ;

Figure 4 is a perspective interior view of the scaffold board end protector cap of Figure 1 ; Figure 5a is a side view of the end protector cap of Figure 1 in use with a scaffold pole; Figure 5b is a perspective view of the end protector cap and scaffold pole of Figure 5a;

Figure 6a is a perspective, alternate view, of a portion of the scaffold board and the end protector cap of Figure 1 ; and

Figure 6b is a side view of the scaffold board and scaffold board end protector cap of Figure 1 shown stacked with another scaffold board and scaffold board end protector cap of Figure 1 .

Figure 1 shows a conventional scaffold board 100 having an end 1 , fitted with a scaffold board end protector cap 1 0 of the embodiment. The scaffold board end protector cap 1 0 comprises a body 12 and a recess 14. The body 12 has an end face 16, an upper face 18, a lower face 20 and side faces 22, 24 extending from the end face 1 6. The body 12 is arranged to extend about the recess 14 and the recess 14 is arranged to receive a scaffold board end 1 .

The upper face 18, lower face 20 and side faces 22, 24 depend from and are connected to the end face 1 6. They are broadly arranged perpendicularly to the end face 1 6. The end cap upper face 18, lower face 20 and side faces 22, 24 form a band structure.

Figure 2 and Figure 3 show an embodiment of the end protector cap 10 including a portion 30 suitable for accommodating a fixing member 1 1 . The portion 30 may comprise a fixing member retainer 32 to act to hold and secure the fixing member in place. The fixing member 1 1 is a nail or a screw. Advantageously, the use of longer screws provides additional strength to the boards which prevents splitting.

In addition in a preferred embodiment the end face 16 of the scaffold board end protector cap 10 includes one or more openings 40 located in the end face 16. The openings 40 as illustrated in Figure 4 are oblong or rectangular in shape and are orientated with the long dimension matching the long dimension of the end face. The openings are provided for drainage and air circulation purposes. Longer openings are featured to reduce stress in the portions of the end protector cap 10 that might correspond to warped or misshapen regions of the end of the scaffold board 100.

Another feature of the preferred illustrated embodiment, as seen in Figure 1 and Figure 4 is protruding ribs 50, 52. The ribs or rib members 50, 52 are attached to the end face 16 and may be moulded thereto. The ribs 50, 52 are made from resilient material. Ribs 50 protruding externally to the end face 16 provide cushioning and act as a shock absorbing feature when, for example, the scaffold board 1 00 and end protector cap 10 are dropped or suffer an impact. The ribs 52, located within the recess 14 of the end protector cap 10 provide a cushioning effect between the distal end 1 of the scaffold board 100 and the end protector cap 10, in particular between the end cap body 12 and the scaffold board end 1 . An impact or sudden force exerted on either the body 12 or the scaffold board will likely create less damage that it would do without the rib members 50, 52. Figures 5a and 5b illustrate the depth of 80 mm of the board and end cap and show how the location and structure of the end cap, preferably with a depth of 80 mm, act as a guide to show where to position a scaffold pole. In Figure 5b it is the structure and shape of the end cap 10 give a physical barrier to prevent the scaffold boards 100 slipping off the scaffold pole. In the preferred embodiment the scaffold end protector cap is fabricated from resilient material such as plastic or a polymer.

In the illustrated embodiment the upper face 18 (and lower face 20 may correspond) comprises a shaped region. The shaping can ease the application of the end protector cap 10 to the end 1 of the scaffold board 100. The shaping in Figure 6a can comprise one or more shapes selected from the range; scalloped, chamfered, indented. In addition the end face 16 comprises signage selected from the range of; colourways, company name, hazard warnings, information, indication of scaffold board orientation.

In use, the band structure of the end face 16, upper face 18, lower face 20, side faces 22, 24 wraps around a scaffold board end. A fixing member 1 1 acts to hold the scaffold board end 1 in place within the scaffold board end protector cap 10. In use, the fixing member 1 1 is held in place in a fixing member retainer 32 located in an accommodation region 30.

In use the shaped region of the upper face 18, acts to separate adjacent stacked scaffold boards 100 fitted with scaffold board end protector caps 10, 10' so that the boards drain and dry out and whereby air circulation is allowed around the board ends. A first end protector cap 1 0 has upper face 18 and lower face 20, a second end protector cap 10' has upper face 1 8' and lower face 20'. A spacing is provided between the lower face 20 and the upper face 18' as illustrated in Figure 6b.

Various modifications may be made to the described embodiments without departing from the scope of the present invention. The body may be of an alternative shaping and may comprise any suitable material and may be of varying length and thickness.

Alternative forms of construction may be considered. The drainage openings holes may be in any face. The shock absorbing ribs may be located anywhere on the end cap, and may be of any size. The faces can be separate pieces or manufactured in separate parts. They can feature hinges or similar fixings to enable the end protector cap to comprise a flat pack assembly for ease of manufacture and shipping. The end face can comprise signage selected from the range of; colourways, company name, hazard warnings, information, indication of scaffold board orientation.

Claims

1 . A scaffold board end protector cap comprising a body and a recess; the body having an end face, an upper face, a lower face and side faces extending from the end face, the body extending about the recess and the recess arranged to receive a scaffold board end.

2. A scaffold board end protector cap as claimed in claim 1 , further comprising

accommodation for a fixing member, such that the end protector cap is arranged and secured about a scaffold board.

3. A scaffold board end protector cap as claimed in claim 2, further comprising a fixing member retainer.

4. A scaffold board end protector cap as claimed in any one of claims 1 , 2 or 3, further comprising at least one opening in the body.

5. A scaffold board end protector cap as claimed in claim 4, wherein the at least one opening is provided in the end face allowing for drainage and air circulation.

6. A scaffold board end protector cap as claimed in any preceding claim, further

comprising at least one rib member arranged to protrude externally from the body.

7. A scaffold board end protector cap as claimed in any preceding claim, further

comprising at least one rib member arranged to protrude internally from the body, towards and within the recess

8. A scaffold board end protector cap as claimed in claim 6 or claim 7, wherein the rib member is located at the end face.

9. A scaffold board end protector cap as claimed in any one of claims 6, 7 or 8, wherein the rib members are fabricated from a resilient material so as to provide a shock absorbing function.

10. A scaffold board end protector cap as claimed in any preceding claim, the upper face of the body of the cap having a shaped portion, and wherein the shaped portion comprises one or more shapes selected from the range; scalloped, chamfered, indented.

1 1 . A scaffold board end protector cap as claimed in any preceding claim, wherein the end face comprises signage selected from the range of; colourways, company name, hazard warnings, information, indication of scaffold board orientation.

12. A scaffold board end protector cap as claimed in any preceding claim having a depth in the range of 70 to 90mm, preferably 80mm.

13. A scaffold board end protector cap as claimed in any preceding claim, wherein the end cap material comprises one of; plastic, polymer, rubber.

14. A scaffold board end protector cap as claimed in any preceding claim, wherein the end cap material comprises heat shrunk polymer material.

15. A scaffold board end protector cap as claimed in any preceding claim, wherein the body comprises separate portions with faces hingedly connected to each other.

16. A method of manufacture of a scaffold board and scaffold board end protector cap as claimed in any preceding claim comprising the steps of, (i) preparing the distal ends of a scaffold board; (ii) applying a scaffold end protector cap as claimed in any preceding claim to a distal end of a scaffold board; (iii) heating the scaffold board end protector cap so as to cause shrinking of the cap, and (iv) securing the scaffold board end protector cap to the board.

17. A scaffold board end protector cap manufactured as claimed in claim 16.

18. A scaffold board comprising a scaffold board end protector cap as claimed in any one of claims 1 to 15, or claim 17.

19. A device for manufacturing a scaffold board end protector cap as claimed in any preceding claim.

20. A scaffold board end protector cap as hereinbefore described with reference to the accompanying drawings.