US20100314199A1

US20100314199A1 - Fall Protection Systems

Info

Publication number: US20100314199A1
Application number: US12/706,423
Authority: US
Inventors: Rafael Martinez; Joseph A. Martinez; James Harrison
Original assignee: Individual
Current assignee: Individual
Priority date: 2005-07-07
Filing date: 2010-02-16
Publication date: 2010-12-16

Abstract

In one embodiment, a fall protection system including a J-shaped stanchion that attaches to a roof truss (or rafter) in such a manner as to enable the entire girth of the roof truss overhang (or rafter) to be the sole support for the stanchion. The stanchion is designed to bend below the fascia and return up above the roof surface where successive stanchions similarly attached are connected via a fall protection guardrails providing fall protection for all workers. This single point of attachment allows the carpenters to attach the stanchions prior to hoisting the trusses onto the roof bearing walls. As soon as the trusses are properly braced, the guardrails can be hoisted and secured. In another embodiment, the disclosure includes a combination fall protection and catwalk system for above-ground floors. In another embodiment, the disclosure includes a fall protection system for reroofing applications.

Description

CROSS-REFERENCE TO RELATED INVENTIONS

This application is a continuation-in-part of U.S. application Ser. No. 11/329,404, filed Jan. 10, 2006, which is a continuation-in-part of U.S. application Ser. No. 11/177,009, filed Jul. 7, 2005, the disclosures of which are hereby incorporated by reference herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention
This invention relates to fall protection devices and systems which are attached to roofs or other structures under construction. More particularly, this invention relates to fall protection devices and systems which are mounted on trusses or rafters of structures under construction or to the roofs of existing structures. This invention also relates to fall protection devices and systems for above-ground floors or decks under construction.
2. Description of the Background Art
The Occupational Safety and Health Act mandates that every trade who must build or stand on a roof surface should have fall protection. At the very minimum a slide guard should be in place to protect the worker. The minimum slide guard is described as a two by four nominal dimension member secured on its edge to the roof below the worker to arrest his possible slide. Many trades must stand on a sloped roof to accomplish their work. Tradesmen include framing carpenters and roofers. For multi-storied structures, other tradesmen may include window installers, house wrap installers, siding installers, exterior trim carpenters, soffit installers, lathers and stucco crews.
In practice, the framing carpenter installs a slide guard on the roof surface, but it is often promptly removed when the framing is finished since it becomes an obstacle to some subsequent trades. Moreover, the guards are seldom replaced. There therefore exists a need to overcome the shortcomings of conventional fall protection devices.
Prior art fall protection devices include stanchions which attach to a truss below the roof line and to the fascia to dip down below the fascia and then up above the roof. Thus, the prior art cannot be employed in buildings designed with no fascia. Further, even though the buildings are designed with fascia, damage may occur where the fascia is the finished product. Still further, where the roofing requires a metal eave drip to the fascia to be installed before roofing, the connection to the fascia may have to be removed, thus rendering the prior art inoperable. Finally, the prior art cannot be properly attached until the fascia is constructed. Hence, there has existed a need for a fall protection device that does not require a mechanical attachment to fascia.
Representative prior art include U.S. Pat. Nos. 6,345,689; 5,221,076; 5,353,891; 5,573,227; 5,570,559; 4,666,131; 5,067,586; 4,669,577; 3,901,481; and 4,359,851.
Therefore, it is an object of this invention to provide an improvement which overcomes the aforementioned inadequacies of the prior art devices and provides an improvement which is a significant contribution to the advancement of the fall protection art.
Another object of this invention is to provide a fall protection system that attaches to a roof truss at a single point in such a manner as to extend below the fascia and return up above the roof surface such that the carpenters may attach the stanchions prior to hoisting the trusses onto the roof-bearing walls, or immediately thereafter, and then install the guardrails such that the workers are protected throughout the entire construction process.
Another object of this invention is to provide a fall protection system having various constructions for connecting the J-shaped stanchions to a roof truss, optionally including a separate attachment bracket that may be pre-installed onto the truss during fabrication of the truss at the factory to which the J-shaped stanchion is then removably connected during assembly on the job site.
Another object of this invention is to provide a fall protection system which is economical to manufacture while supporting the minimum impact of two hundred pounds (200 lbs.) required by OSHA for a slide guard or guard rail.
Another object of this invention is to provide a fall protection system including a J-shaped stanchion that is extendible to allow additional rows of guard rails to be installed.
Another object of this invention is to provide a fall protection system for reroofing a structure.
Another object of this invention is to provide a combination fall protection/catwalk system along the edge of a structure such as an above-ground floor.
The foregoing has outlined some of the pertinent objects of the invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the intended invention. Many other beneficial results can be attained by applying the disclosed invention in a different manner or modifying the invention within the scope of the disclosure. Accordingly, other objects and a fuller understanding of the invention may be had by referring to the summary of the invention and the detailed description of the preferred embodiment in addition to the scope of the invention defined by the claims taken in conjunction with the accompanying drawings.

SUMMARY OF THE INVENTION

For the purpose of summarizing this invention, one embodiment of this invention comprises a fall protection system including a J-shaped stanchion which attaches to a roof truss (or rafter) in such a manner as to enable the entire girth of the roof truss overhang (or rafter) to be the sole support for the stanchion. The J-shaped stanchion is designed to exceed the 200 pound minimum impact currently required by OSHA for a slide guard or guardrail. The J shape of the stanchion is configured to extend below the fascia and return up above the roof surface. During assembly, a plurality of stanchions is attached along the roof line. Horizontal fall protection guardrails are then connected to the upstanding stanchions thereby providing fall protection for workers. Notably, the single point of attachment to the trusses along the roof line allows the carpenters to attach the stanchions prior to hoisting the trusses onto the roof bearing walls. As soon as the trusses are properly braced, the guardrails can be hoisted and installed. Furthermore, the trusses may optionally be fabricated with a separate attachment bracket to which the J-shaped stanchion is removably connected. This feature of the preferred embodiment has the potential of protecting workers during the entire construction process of the structure which involves working on the roof. When all workers are safely off the roof, the stanchions may be easily removed and reused.
Another embodiment of this invention comprises a truss plate affixed to the upper surface of a roof being reroofed, allowing the J-shaped stanchion to then removably attached to the truss plate.
Another embodiment of this invention comprises a catwalk bracket affixed to the wall of a structure, to support a catwalk plank and the J-shaped stanchion
The foregoing has outlined rather broadly the more pertinent and important features of the present invention in order that the detailed description of the invention that follows may be better understood so that the present contribution to the art can be more fully appreciated. Additional features of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:

FIG. 1 is a perspective view of the fall protection system of the invention including a J-shaped stanchion guardrail member and attachment bracket;

FIG. 2 is a side view of FIG. 1 attached to a truss of a building with a square cut fascia;

FIG. 3 is a side view of FIG. 1 attached to a truss of a building with a plumb cut fascia;

FIG. 4 is a perspective view of three stanchion guardrail members shown in FIG. 1 attached to the trusses of a building with the horizontal guardrail installed;

FIG. 5 is a perspective view of another embodiment of a the fall protection system of the invention with a removable extended stanchion;

FIG. 6 is a perspective view of another embodiment of the fall protection system of the invention with a permanent extended stanchion;

FIG. 7 is a perspective view of a lock bracket that may be employed in combination with the fall protection system of the invention to more securely lock the attachment bracket to the truss;

FIG. 8 is a perspective view of the fall protection system of the invention shown in phantom with the lock bracket mounted in position on the attachment bracket for locking the attachment bracket into position with the truss;

FIG. 9 is a side elevational view of another embodiment of the invention employing another type of coupler allowing a stanchion extension composed of a plank to be connected to the end of the stanchion; and

FIG. 10 is a perspective view of another embodiment of the fall protection system of the invention having an attachment bracket composed of a center web with a multiplicity of punched barbs extending therefrom (preferably on both sides), that dig into the truss when the attachment bracket is installed;

FIG. 11 is a perspective view of another embodiment of the fall protection system of the invention having an attachment bracket with pointed upper members to facilitate insertion between the rafter and the already-installed plywood;

FIG. 12 is a perspective view of another embodiment of the invention in which the attachment bracket is removably connected to the J-shaped stanchion allowing the attachment bracket to be first installed to the truss, the truss erected, and the J-shaped stanchion connected thereto;

FIG. 13 is a perspective view of an attachment bracket of another embodiment of the fall protection system of the invention having a multiplicity of barbs formed in its center web for connection to the truss;

FIG. 14 is a perspective view of an attachment bracket of another embodiment of the fall protection system of the invention particularly designed to be pre-installed at the during factory fabrication of the truss;

FIG. 15 is a perspective view of a J-shaped member employed as a support for another device such as a satellite dish;

FIG. 16 is a perspective view of a J-shaped member having a hook at its end which may be employed for supporting objects such as Christmas ornaments, plants, etc.;

FIG. 17 is a perspective view of a J-shaped member having an upstanding member serving as a flag pole;

FIG. 18 is a side view of a J-shaped member which may be employed as a support for an object such as a basketball hoop;

FIG. 19 is a top perspective view of a roof truss bracket that is intended to be nailed on the roof to be reroofed;

FIG. 20 is bottom perspective view of FIG. 19;

FIG. 21 is a perspective view of a J-shaped stanchion having a J-shaped truss attachment bracket with a T-bar that removably engages into the roof truss bracket.

FIG. 22 is a cross-sectional view of the roof truss bracket and J-shaped truss attachment bracket removably assembled together;

FIGS. 23A&B are a top perspective views of a combination fall protection/catwalk bracket that is intended to be nailed to the wall of the above-ground floor and tied to the floor by a tie strap, to which a catwalk plank may then be mounted thereon and to which the J-shaped stanchion may then be removably connected;

FIGS. 24A&B are bottom perspective views of FIG. 23;

FIG. 25 is an exploded perspective view of the combination fall protection/catwalk bracket being affixed to the wall of the structure;

FIG. 26 is a perspective view of the J-shaped stanchion having an attachment bracket for connection to the combination fall protection/catwalk bracket;

FIG. 27 is an exploded perspective view of the attachment bracket of the J-shaped stanchion being connected to the combination fall protection/catwalk bracket;

FIG. 28 is a perspective view of a pair of J-shaped stanchions affixed to the wall of an above-ground floor showing the manner in which the catwalk plank is inserted into position on top of the upper plate and under the edge plate of the combination fall protection/catwalk bracket; and

FIG. 29 is a perspective view of the assembled combination fall protection/catwalk system of the inventions with the guard rails installed.

Similar reference characters refer to similar parts throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the drawing of FIG. 1, a J-shaped stanchion 1 includes a truss attachment bracket 2 in a preferred J shape comprised of center web 2C to which an upper rear flange 2A, upper front flange 2B and lower flange 2D, formed of flat stock steel are secured by weld 16. The J-shaped formed of square stock tubing and bent 180 degrees is preferably affixed to the lower flange 2D by weld 16. Also preferably, two slide arrest guardrail brackets 3, formed of flat stock steel and bent so as to accept a nominal 2′.times.4″ plank (or higher) horizontal slide arrest guardrail 5 (see FIG. 4) is affixed to the stanchion 1 by weld 16 on the upper portion thereof above the roof line at its side 17 to face roof-ward.
Referring next to FIG. 2, the stanchion 1 and the attachment bracket 2 are shown mounted to a structure or building 15 with square cut fascia 6. The attachment bracket 2 is preferably fastened by nailing, screwing, welding, strapping, gluing, bolting, or any known equivalent to either side of the truss 11. Where nails, bolts, screws, bolts, and their fastener equivalents are used to secure the attachment bracket 2 to the roof truss 11, they are inserted through the orifices 4 in the center web 2C of the attachment bracket 2 and into the adjacent truss 11.
Stanchions 1 are respectively installed on respective roof trusses 11 along the horizontal roof edge 18. The strength of this attachment is due to the envelopment of the roof truss 11 between the upper rear flange of attachment bracket 2A, the upper front flange of attachment bracket 2B and the lower flange of attachment bracket 2D adjacent the center web 2C causing the entire truss 11 to react as one with stanchion 1 on impact. The lower portion of the stanchion 1 is bent 180 degrees from its end 17 such that the guardrail brackets 3 are perpendicular to the plane of the roof regardless of the roof pitch.
Referring next to FIG. 3, the stanchion 1 and the attachment bracket 2 are shown mounted to a structure or building 15 with plumb cut fascia 6. Note that the J shape of the stanchion 1 provides adequate clearance for the fascia 6.
Referring next to FIG. 4, the stanchions 1 are installed along horizontal roof edge 18 and then the guardrails 5 are installed into the respective guardrail brackets 3. As shown, when two stacked guardrail brackets 3 are employed on the stanchion 1, the guardrails 5 overlap adjacent guardrails 5 at their ends.
Referring next to FIG. 5, the stanchion 1 is extendable by a removable stanchion extension 1A coupled to the stanchion by a coupler 20. Guardrail brackets 19, similar in construction to brackets 3, comprise flat stock steel bent so as to accept a nominal 2.times.4 plank (or higher) slide arrest guardrail 5 (see FIG. 4), and are welded 16 to the upper portions of the extension 1A to face roof-ward.
FIG. 6 illustrates an alternative embodiment of the invention illustrated in FIG. 5 in which the stanchion extension 1A is integrally formed with the stanchion 1.
Referring now to FIG. 7, the invention also comprises a lock bracket 21 composed of a strip of steel bent in a generally L-shaped configuration. The shorter leg 21A of the L-shaped configuration comprises an inwardly turned end 22 that defines space 23 between it and the balance of the shorter leg 21A.
As shown in FIG. 8, the lock bracket 21 is dimensioned to be installed after the attachment bracket 2 is mounted to the truss 11 whereby the lock bracket 21 more securely holds the attachment bracket 2 in position. More particularly, as shown in FIG. 8, once the attachment bracket 2 is affixed to the end of the truss 11 with, for example, nails through orifices 4, the space 23 of the lock bracket 21 allows it to be slid onto the lower flange 2D from the inward side of the mounting bracket 2 to the underside of the lower flange 2D with the end 22 overlapping one side thereof When slid downwardly to meet the stanchion 1, the 2.times.6 plank of the truss 11 is captured between the web member 2C and the longer side 21B of the L shape of the lock bracket 21. The lock bracket 21 fully captures the truss 11 to prevent any loosening of the fasteners that secure the attachment bracket 2 to the truss 11.
Referring now to FIG. 9, in lieu of the stanchion extension 1A previously described above, another type of extension may comprise a wood plank 25 such as a 2.times.4 plank which is coupled to the end of the stanchion 1 by a tubular coupler 26 that conforms at its one end to the outer circumference of a nominal sized plank 25 and its other end to the upper end of the stanchion 1. As shown in FIG. 9, the horizontal guardrails 5 may be connected to the stanchion extension 25 by conventional nailing 27 or other techniques for fastening wood components.
The operation of the preferred embodiment of the invention is as follows. Referring to FIG. 3, the stanchion 1 is attached only to the rafter, roof truss, or roof member 11 and is attached up to two inches from horizontal roof edge 18. The attachment bracket 2 is comprised of the upper rear flange 2A, the upper front flange 2B, the securing plate 2C, and the lower flange 2D. Working in concert with its comprised parts, the attachment bracket 2, envelopes the girth of rafter, roof truss, or roof member 11, and once stanchion 1 is attached at securing plate 2C, by means of nailing, and or screwing, welding, strapping, gluing, bolting, or any known equivalent, no additional points of attachment are necessary. Since this is the only necessary connection to the rafter, roof truss, or roof member 11, it becomes evident that the ideal location for this connection is on the ground before the rafter, roof truss, or roof member 11 is hoisted onto the wall 14. Ground level installation has many advantages. The installation can be more precise, is easy to install, and due to the firm footing of ground level installation, the occurrences of injury from heights (ladders, scaffolding, lift equipment, etc.) is eliminated. Lock bracket 21 may be installed while still on the ground or after the trusses are hoisted and seated on the wall 14.
The lock bracket 21 may be tethered to the attachment bracket 2 by a chain or other member to minimize the possibility of it being lost and inadvertently not used. Furthermore, to assure that the lock bracket 21 may not slide off, a headed stop pin 24 may be inserted into a hole in the lower plate 2D to block the lock bracket 21 from being removed. The stop pin 24 may likewise be tethered to the attachment bracket 2 to prevent inadvertent loss or nonuse.
Ground level installation of the fall protection device stanchion 1 greatly reduces the work time involved in assembly, and allows the system to be substantially assembled prior to the workman being in peril Immediately after the rafter, roof truss, or roof member 11 is hoisted onto structure 15, the horizontal slide arrest guardrail 5 can be hoisted up and secured. Therefore, fall protection can be in position prior to the installation of the first sheathing/roof decking and if used until all roof operations are complete, it will provide the absolute time maximum uninterrupted fall guard protection possible.
The process of ground level installation, although preferred, does not limit the attachment of the fall protection stanchion 1 in other situations, such as existing structures, or in conventional framing, i.e., framing in which the construction of the structure must be built in the field, on the job site, such as hips, dormers, or any other roof or balcony configuration as is known to one of ordinary skill in the art. Such alternative attachments may require the use of additional equipment (ladders, scaffolding, lift equipment, etc.).
Optional dimensions of attachment bracket 2 are available to accommodate other nominal sizes of rafters, roof trusses, roof members 11, or for any architecturally specified size rafter, roof truss, or roof member 11.
Once stanchion 1 is properly attached to the rafter, roof truss, or roof member 11, and the rafter, roof truss, or roof member 11 is properly affixed to building 15 and the slide arrest guardrails 5 are installed, a continuous barrier around the perimeter of the roof is formed. Such guardrails 5 may be composed of a nominal 2.times.4 or greater wood plank, a metal member, a crossbar, a rope, a strap, mesh netting or any known equivalent. The slide arrest guardrail 5 may be strung or inserted through the slide arrest guard bracket 3 and may be optionally fixed in place by means of nailing, screwing, welding, strapping, gluing, or bolting the strap to the bracket 3, such nails, screws, bolts and equivalents, passing through the orifices 4 in the bracket 3.
The stanchions 1 are secured to adjacent manufactured rafter, roof trusses or roof member 11 at horizontal roof edge 18, they extend down below the fascia 6 location and up above the horizontal roof edge 18 where the 2.times.4 wood plank, metal member, crossbar, mesh netting or any known equivalent, horizontal slide arrest guardrail 5 is attached to the guard rail bracket 3 by means of nailing, screwing, welding, strapping, gluing, bolting, or any known equivalent and thus becomes the barrier which a sliding workman would contact thus preventing the workman from sliding off of the roof.
This fall protection device stanchion 1 attaches directly to the truss tail, and does not touch the fascia 6; therefore there is no interference with the process of snapping a line from the first rafter, roof truss, or roof member 11, to the last rafter, roof truss, or roof member 11, for the purpose of determining which horizontal roof edges 18, do not line up. At this point the roof edge 18 can be saw cut straight for a square cut 6, or plumb cut 6, fascia without interference from the fall protection device stanchion 1, thus allowing the attachment of the fascia 6. Due to the encompassing features of the attachment bracket 2, fascia optional architecture (open design with no fascia) still allows continuous fall protection for workman.
The continuous row of the J shaped stanchions 1 mounted along the horizontal roof edge 18, allows a useful area in their inner radii for the temporary support of long stock materials, (i.e., fascia stock material or sub fascia stock material) thus providing a safer environment for the installation of the fascia 6. Once the fascia 6 is attached and horizontal slide arrest guardrail 5 is properly fastened by nailing, screwing, welding, strapping, gluing, bolting, or any known equivalent; the sheathing process may begin. Therefore the safety of workers is enhanced even before stanchion 1 begins providing fall protection.
Depending on the pitch and or overall size of a roof, OSHA requires additional slide guards at specific intervals going up the roof. As the sheathing or roofing progresses the stanchion 1 can be used as a brace against which a grid of additional 2.times.4 supports and slide guards can be constructed with minimal or no penetration of the roofing surface.
The fall protection device stanchion 1 remains attached to the rafter, roof truss, or roof member 11 thus allowing all trades which may have to work on the roof surface, such as framers, roofers, plumbers, HVAC, electricians, window installers, siding installers, soffit installers, etc. to complete all work necessary while assuring continuous fall protection for all workman.
The attachment bracket 2 encompasses the rafter, roof truss, or roof member overhang 11, in such a manner as to allow the girth of the rafter, roof truss, or roof member 11 to support the fall protection device stanchion 1. This strong connection is suitable for attachment of additional devices such as stanchion extensions with additional guard rails, proprietary or others, and may be fastened by means of nailing, screwing, welding, strapping, gluing, bolting, or any known equivalent.
The fall protection device stanchion 1 attaches only to the rafter, roof truss, or roof member 11 and therefore does not interfere with the exterior finishes such as siding, lath, stucco, paint, trim, or other exterior claddings.
The fall protection stanchion 1 becomes suitable for additional devices such as bracket arm extensions 21 with additional nets, rope, cables, straps or any known equivalents. Additional ropes, cables, straps, harnesses or any known equivalent may be attached tied, strapped, clamped or any known equivalent to the fall protection stanchion 1 or harness ropes may be placed over the crown of the roof to a stanchion on the opposing side for support of the workers on the roof.
The fall protection stanchion 1 can be used to support any number of other devices such as Jacob's ladders, swings, swinging scaffolds, roof jacks, safety harnesses (for workman and materials) ropes, pulleys, beams, and cables upon which to hang lights, drapes or any known equivalent.
The attachment bracket 2 is preferably double-sided and can be used on either side of any given roof truss, rafter, or roof member 11. Furthermore, the fall protection system is economical, has little or no moving parts, is sturdy, requires nominal if any maintenance, and provides value far beyond the cost to build install and maintain. Lastly, the device easily and safely removed and is fully reusable.
Referring now to FIG. 10, as noted above, the attachment bracket 2 may be affixed to the end of the truss 11 by any suitable means. As shown in FIG. 10, one method may comprise forming a multiplicity of barbs 30 in the center web 2C, preferably extending on both surfaces thereof to engage into the surface of the truss 11 during assembly. Due to the engagement of the barbs 30 into the wood of the truss 11, the attachment bracket 2 is firmly secured to the truss 11.
It is noted that in some applications, it may be desirable to have the J-shaped stanchion removably connected to the attachment bracket 2. For example, as shown in FIG. 12, the attachment bracket 12 may comprise a boss 34 formed on the underside of the lower flange 2D which comprises a configuration and is properly dimensioned to fit into the tubular stanchion 1. Aligned holes 36 and 38 formed in the stanchion 1 and the boss 34 allows a fastener 40 to be inserted therethrough to removably interconnect the bracket 2 to the stanchion 1. During installation, the attachment bracket 2 may be installed to the end of the truss 11 whereupon the truss may then be hoisted onto the wall and, once secured; the stanchion 1 may then be connected to the bracket 2 by means of the boss 34 and fastener 40. The removability of the stanchion 1 from the bracket 2 allows more convenient installation and erection of the fall protection system of the invention.
FIG. 13 illustrates still another method for attaching the attachment bracket 2 to the end of a truss 11. More specifically, a plurality of barbs 30 are punched into the center web 2C so as to engage into the wood of the truss 11 as described previously in connection with FIG. 10. The embodiment of FIG. 13, however, comprises a one-sided bracket, as opposed to the double-sided brackets described above. This one-sided bracket 2 is particularly adaptable to be installed at a truss factory during the fabrication of the truss itself. Indeed, it is contemplated that brackets 2 would be customarily installed at the fabrication plant during fabrication of the trusses whereupon, on the job site, the trusses would be erected onto the walls and the stanchions 11 then connected to the brackets by means of the removable connection composed of the boss 34 and fastener 40 that engages through hole 38.
FIG. 14 illustrates still another embodiment of a one-sided bracket 2 intended to be factory-installed during fabrication of the trusses. More particularly, in this embodiment, in lieu of the center web 2C, the bracket 2 includes two upstanding webs 2W, each having inwardly facing barbs 30. During assembly, the truss 11 is placed within the U-shaped channel formed by the lower flange 2D and the upstanding flanges 2W whereupon the barbs 30 of the upstanding flanges 2W are then pressed into the wood of the truss 11 for assuring a secure connection.
As noted above, the attachment bracket 2 may be factory-installed or installed on the job site. In either case, the attachment bracket 2 with a removable connection may be used as a way of removably connecting modified stanchion members 42 to the attachment bracket 2 via the boss 34 and fastener 40 that engages into corresponding holes 36 and 38. More particularly, as shown in FIG. 15, the stanchion member 42 may comprise a support for a satellite dish 44. In FIG. 16, it is seen that the stanchion member 42 may be provided with an ornament hook 46 for connecting Christmas ornaments, plants, or any other object along the roof line of the structure. Indeed, the hook 46 with its bracket 46B may be directly connected to the boss 34. In FIG. 17, it is seen that the stanchion member 42 may be fitted with a flag pole 48 for supporting a flag, pennant or other object 50. Finally, FIG. 18 illustrates a stanchion member 42 having an elongated length to which is mounted a conventional basketball assembly 52 having a backboard 52 rigidly connected to the stanchion member 42 by brackets 54.
Without departing from the spirit and scope of the invention it should be appreciated that FIGS. 15 through 18 are exemplary and that stanchion member 42 may be used to support many other objects along the roof line of a structure.
It is noted that in re-roofing applications, the roofing plywood is already nailed to the trusses 11 and therefore, it would be difficult to force the upper rear and front flanges 2A and 2B therebetween. Accordingly, in order to facilitate forcing the flanges 2A and 2B between the roofing plywood and the truss 11, as shown in FIG. 11, the ends of the upper rear and front flanges 2A and 2B may comprise points 32 and be beveled. In this manner, the points 32 along with their bevels form a web shape that can be more easily driven between the roofing plywood and the truss 11.
Referring now to FIGS. 19-22, another embodiment of the fall protection system 100 of the invention is designed for reroofing applications. More particularly, in typical reroofing applications the existing shingles (e.g., asphalt or concrete shingles) are removed. Likewise, the underlayment (e.g., felt underlayment) is removed; thereby leaving exposed the plywood roof. Any damaged plywood may be replaced with new sheets of plywood. Flashing/drip edges along the roof's edges are commonly left in place and reused (although any damaged flashing or drip edges may likewise be removed and replaced). New shingles are then installed.
It should be appreciated that fall hazards exist during reroofing applications. In order to minimize such hazards, the fall protection system 100 of the invention may be installed before the reroofing process begins.
More specifically, the fall protection system 100 comprises a roof truss plate 110 preferably having a generally elongated rectangular plate 112 (e.g., steel) and having opposing transverse members 114 welded to the end of the elongated rectangular plate 110. A bottom plate 116 interconnects the opposing transverse members 114 to form an opened box construction.
The open box construction forms a rectangular socket for removably receiving a corresponding T-bar 120 welded to a J-shaped bracket 122 formed at the lower end of a stanchion 124.
During installation, the existing roof shingles along the edge 128 of the roof 130 are peeled back (or removed altogether) allowing elongated rectangular plates 112 to be installed along the roof edge 128 in a generally spaced-apart configuration. More specifically, each of the elongated rectangular plates 112 is aligned down the roof line with the opposing transverse members 114 extending over the edge 128 of the roof 130 (and over the roof's drip edge 131). Each of the elongated rectangular plates 112 includes a plurality of holes 132 allowing the roof truss plate 110 to then be nailed to and therefore permanently affixed to the plywood of the roof 130.
After the plurality of the roof truss plates 110 are affixed along the edge 128 of the roof 130, the T-bar 120 of the J-shaped bracket 122 may be slipped sideways into the end of the box enclosure formed by the end of the elongated rectangular plate 112, opposing transverse members 114 and bottom plate 116, whereupon the stanchion 124 is prevented from tilting in any direction and is thereby held rigidly but removably in an upright position.
In accordance with one aspect of the invention, because roof gutters 134 are typically mounted to the fascia 136 of the roof 130 underneath the drip edge 131, the J-shaped brackets 122 are preferably configured and dimensioned to fit within configuration of the gutter 134. When configured and dimensioned in this manner, the roof truss plates 110 may be nailed to the roof 130 and the T-bar 120 slipped into the box structure as described above without having to remove the gutters 134 (see cross-sectional view of FIG. 22).
Once all the stanchions 124 are installed, guard rails 138 (shown in phantom) may be installed in the stanchions' guard brackets 140 to interconnect the stanchions 124 and thereby provide fall protection. Workers on the roof may then safely begin removing the balance of the shingles (and the underlayment) and installing the new roof. It is noted that since the new shingles are installed from roof's edge upwardly and thereby cover the elongated rectangular plate 112 of the roof truss plate 110, the plate 112 is preferably provided with nail access cut-outs 142 to provide less obstructions while nailing shingles. The roof truss plates 110 are intended to be permanently left in place once the roof 130 is completed. Nevertheless, when fall protection is no longer needed, the stanchions 124 may be readily removed by simply taking down the guard rails 138 and then for each stanchion 124, sliding its T-bar 120 out from the box enclosure formed by the end of the elongated rectangular plate 112, opposing transverse members 114 and bottom plate 116.
Referring now to FIGS. 23-29, another embodiment of the invention comprises a combination fall protection/catwalk bracket 150 that is intended to be nailed to the wall 152 of an above-ground floor 154 (e.g., a deck) to provide fall protection around the perimeter of the above-ground floor 154 while at the same time providing a catwalk allowing workers to work around the floor 154 without walking on it (e.g., to allow painting of the floor 152 out to the edge).
The fall protection/catwalk bracket 150 comprises a generally L-shaped backplate 156 whose longer leg portion 156L comprises a plurality of holes 156LH formed therethrough for rigidly connecting it to the wall 152 of the floor 154 by fasteners 158 (e.g., screws or nails). The shorter leg portion 156S extends outwardly from the floor 154 to form a lip (as described in more detail below the lip extends over a plank 160 forming the catwalk). The shorter leg portion 156S may also comprise plurality of holes 156SH formed therethrough for rigidly connecting it to the plank 160 by fasteners 158 (e.g., screws or nails).
The fall protection/catwalk bracket 150 further comprises a T-shaped web member 162 composed of a center web 162C extending downwardly from a transverse top web 162T. The T-shaped web member 162 is welded at its ends to the longer leg portion 156L of the L-shaped backplate 156 to extend outwardly therefrom.
The upper surface of the top web 162T of the T-shaped web member 162 functions as a platform on which the plank 160 may rest to form the catwalk. The center web 162C of the T-shaped web member 162 functions as a mounting plate to which a generally J-shaped bracket 164 of stanchion 166 may be removably connected (see FIG. 26).
In one embodiment, J-shaped bracket 164 comprises a generally U-shaped configuration composed of generally parallel side members 1645 extending upwardly from opposing sides of a bottom member 164B. A pair of blind slots 164BS are formed inwardly from the ends of the bottom member 164B.
The center web 162C of the T-shaped web member 162 comprises downwardly extending tabs 162CT that are dimensioned to fit into the respective blind slots 164BS of the bottom web 164B when the opposing parallel side members 162S straddle the center web 162C. Once extended into the slots 164BS, the tabs 162CT may be locked into position by fasteners 158 (e.g., nails or screws) inserted into holes 162H.
It is noted that segments of angle iron 168 may be welded to the opposing sides of the center web 162C to take up the play between the opposing parallel side members 162S and the center web 162C, thereby minimizing the wobbling of stanchion 166. It is also noted that for roofing fall-protection applications, a plurality of holes 164H are formed through the side members 1465 allowing the J-shaped bracket 164 to be connected directly to the roof truss or to a factory-installed bracket such as those described above.
During installation, as best shown in FIG. 5, a plurality of combination fall protection/catwalk brackets 150 are affixed spaced-apart about the peripheral wall 152 of the above-ground deck or floor 154 by the fasteners 158. For added securement, a slot 174 may be formed in the longer leg portion 156L close to the bend in the L-shaped backplate 156 so as to be in approximate alignment with the surface of the floor 154. A nail strap 170 may then be folded over a conventional nail 172 and then inserted into the slot 174 and nailed to the upper surface of the floor 154.
Once all the stanchions 166 are connected to their respective combination fall protection/catwalk brackets 150, the planks 160 may be slid into position onto top web 162T and under the lip of the shorter leg portion 1565 of the backplate 156, and fasteners 158 installed. Guard rails 176 may be installed in the stanchions' guard brackets 178 to interconnect the stanchions 166. As the work on the floor 154 is underway, full fall protection is provided along with a catwalk allowing the workers to work around the floor 154 without stepping on it.
After the work is completed, the guard rails 176, stanchions 166 and combination fall protection/catwalk brackets 150 may be easily removed. However, it should be appreciated that the nail strap 170, if concealed or covered over by carpeting, tile or other floor coverings, may be simply left in place permanently by pulling the nail 172 out from in between the folded-over nail strip 170 allowing the bracket 150 to be removed.
The present disclosure includes that contained in the appended claims, as well as that of the foregoing description. Although this invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention.
Now that the invention has been described,

Claims

1. A fall protection system comprising: a stanchion comprising a J-shaped configuration; an attachment bracket connected to said stanchion, said attachment bracket comprising a center web to which is connected an upper rear flange, an upper front flange and a lower flange; and a guardrail mounted to said stanchion.

2. The fall protection system as set forth in claim 1, wherein said stanchion comprises a guardrail bracket to which said guardrail is mounted.

3. The fall protection system as set forth in claim 1, wherein said attachment bracket is double-sided.

4. The fall protection system as set forth in claim 1, wherein said attachment bracket is single-sided.

5. The fall protection system as set forth in claim 1, wherein said center web includes an orifice through which a fastener may be inserted for connecting said center web to a roof member.

6. The fall protection system as set forth in claim 1, wherein said attachment bracket is removably connected to said stanchion.

7. The fall protection system as set forth in claim 6, further including a boss that removably connects with said stanchion.

8. The fall protection system as set forth in claim 1, wherein said guardrail comprises a plank.

9. The fall protection system as set forth in claim 8, further including stacked attachment brackets for securing overlapping planks.

10. The fall protection system as set forth in claim 1, wherein said J-shaped stanchion is configured to extend substantially perpendicularly relative to a roof to which the attachment bracket is connected.

11. The fall protection system as set forth in claim 2, wherein a plurality of said stanchions are connected to trusses of a building whereupon guardrails are then mounted to the stanchions along the roof line of the building.

12. The fall protection system as set forth in claim 2, wherein said stanchion further comprises an extended stanchion with at least one guardrail bracket allowing installation of additional rows of guardrails.

13. The fall protection system as set forth in claim 12, wherein said extended stanchion is removably connected to said stanchion.

14. The fall protection system as set forth in claim 1, further including a lock bracket for securely attaching the attachment bracket to a roof.

15. The fall protection system as set forth in claim 14, wherein said lock bracket comprises a generally L-shaped configuration having an inturned end which engages said lower flange of said attachment bracket.

16. The fall protection system as set forth in claim 1, further comprising an extended stanchion composed of a plank to which said guardrails may be mounted thereto, said plank being connected to said stanchion by a connector.

17. The fall protection system as set forth in claim 1, wherein one or both of said upper flanges comprise a pointed configuration.

18. The fall protection system as set forth in claim 1, wherein said center web comprises a plurality of barbs.

19. The fall protection system as set forth in claim 18, wherein said barbs extend on both sides of said center web.

20. The fall protection system as set forth in claim 1, wherein said J-shaped stanchion may be replaced by a modified stanchion for supporting an object such as a satellite dish, a hook, a flag pole, or a basketball backboard.

21. A fall protection system for mounting to a roof truss of a building, comprising:

an attachment bracket comprising two upstanding members forming a U-shaped channel for receiving the roof truss therebetween, said upstanding members being dimensioned to be contiguous with the roof truss and mechanically attached thereto during the manufacture of the roof truss; and

after the roof truss is transported to a job site and erected onto the building, a stanchion comprising a J-shaped configuration is connected to said attachment bracket and a guardrail is mounted to said stanchion.

22. The fall protection system as set forth in claim 21, wherein one or both of said upstanding members comprises at least one barb that engages into the roof member.

23. The fall protection system as set forth in claim 22, wherein said attachment bracket is removably connected to said stanchion.

24. The fall protection system as set forth in claim 23, further including a boss that removably connects with said stanchion.

25. The fall protection system as set forth in claim 21, wherein said guardrail comprises a plank.

26. The fall protection system as set forth in claim 25, further including stacked attachment brackets for securing overlapping planks.

27. The fall protection system as set forth in claim 21, wherein said J-shaped stanchion is configured to extend substantially perpendicularly relative to the member to which the attachment bracket is connected.

28. The fall protection system as set forth in claim 21, wherein a plurality of said stanchions are connected to the trusses of a building whereupon one or more guardrails are then mounted to the stanchions along the roof line of the building.

29. The fall protection system as set forth in claim 21, wherein said stanchion further comprises an extended stanchion to which is mounted said guardrails allowing installation of additional rows of guardrails.

30. The fall protection system as set forth in claim 29, wherein said extended stanchion is removably connected to said stanchion.

31. The fall protection system as set forth in claim 21, further comprising an extended stanchion composed of a plank to which said guardrail may be mounted thereto, said plank being connected to said stanchion by a connector.

32. The fall protection system as set forth in claim 21, wherein said J-shaped stanchion may be replaced by a modified stanchion for supporting an object such as a satellite dish, a hook, a flag pole, or a basketball backboard.

33. A fall protection system for reroofing a roof, comprising in combination:

a roof truss bracket to be nailed on the roof to be reroofed; and

a J-shaped stanchion having a J-shaped truss attachment bracket with a T-bar that removably engages into the roof truss bracket.

34. A combination fall protection/catwalk system for an above-ground floor, comprising in combination:

a combination fall protection/catwalk bracket to be affixed to the wall of the above-ground floor to which a catwalk plank may then be mounted thereon; and

a J-shaped stanchion removably connected to said combination fall protection/catwalk bracket.

35. The combination fall protection/catwalk system as set forth in claim 34, further including a tie strap for interconnecting said combination fall protection/catwalk bracket to the floor.