Fall protection system

Abstract

A fall protection system is used in constructing a vertical wall comprising multiple stacked courses. The fall protection system includes a plurality of anchors adapted for engaging the wall and forming respective fixed points of support. A plurality of posts are secured by respective anchors, and are designed to extend above a leading edge of the wall during construction. A fence extends between adjacent posts to provide a protective barrier between a working level adjacent the wall and the leading edge.

Description

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

This invention relates generally to fall protection in the construction industry, and more specifically to a system especially designed for use during installation of dry-stacked block retaining walls. In many commercial applications, these walls may reach 15 or more feet in height. The unguarded leading edge of the wall is a safety hazard. The present invention effectively addresses this hazard in a manner which is both time and cost efficient, and which protects the safety of workers constructing the wall consistent with federal guidelines established by OSHA.

Each year, falls consistently account for the greatest number of fatalities in the construction industry. Events surrounding these types of accidents often involve a number of factors, including unstable working surfaces, misuse of fall protection equipment, and human error. Studies have shown that the use of guardrails and other fencing at unprotected leading edges can prevent many deaths and injuries from falls. Despite the promulgation of the OSHA Construction Standards in 1971, fall accidents resulting in injuries and fatalities continue to occur at construction sites.

In constructing commercial retaining walls, OSHA guidelines for fall protection are often disregarded. Given the typical nature of the surroundings and the changing elevation of the wall, common safety measures practiced in other construction fields require more time and effort to implement, and are generally too costly and impractical. Fixed railing and other safety supports do not conveniently adjust with the rising elevation of the wall. Other measures, such as tethering, are also cumbersome and inconvenient, and may themselves present further safety hazards.

SUMMARY OF INVENTION

Therefore, it is an object of the invention to provide a fall protection system which is especially useful in the installation of dry-stacked block retaining walls.

It is another object of the invention to provide a fall protection system which meets federal guidelines established by OSHA.

It is another object of the invention to provide a fall protection system which is quickly assembled and raised during construction of the wall.

It is another object of the invention to provide a fall protection system which is entirely removable from the wall once construction is completed.

It is another object of the invention to provide a fall protection system which does not damage the wall.

It is another object of the invention to provide a fall protection system which anchors directly and entirely to the wall.

It is another object of the invention to provide a safety method for fall protection used during construction of a vertical wall.

These and other objects of the present invention are achieved in the preferred embodiments disclosed below by providing a fall protection system for use in constructing a vertical wall comprising multiple stacked courses. The fall protection system includes a plurality of anchors adapted for engaging the wall and forming respective fixed points of support. A plurality of posts are secured by respective anchors, and are designed to extend above a leading edge of the wall during construction. Means extending between adjacent posts are provided to create a protective barrier between a working level adjacent the wall and the leading edge.

According to another preferred embodiment, each of the plurality of anchors comprises a rigid anchor plate. The anchor plate has a proximal end adapted for being sandwiched between adjacent wall courses, and a distal end adapted for projecting from the face of the wall.

According to another preferred embodiment, the proximal end of the anchor plate defines a catch adapted for engaging a course connector located between the adjacent wall courses.

According to another preferred embodiment, the catch defines a pin slot adapted for receiving a vertical pin located between the adjacent wall courses.

According to another preferred embodiment, the distal end of the anchor plate defines a post hole designed to receive the post.

According to another preferred embodiment, the distal end of the anchor plate further defines a tool hole designed to receive a plate removal tool.

According to another preferred embodiment, an anchor basket depends from the post hole, and receives a bottom end of the post to hold the post at a fixed height relative to the wall.

According to another preferred embodiment, the anchor basket is removably received within the post hole.

According to another preferred embodiment, the means for creating a protective barrier comprises at least one horizontal cable line.

According to another preferred embodiment, the means for creating a protective barrier comprises a flexible grid wall.

According to another preferred embodiment, at least one of the plurality of posts is marked with gradations.

In another embodiment, the invention is a safety method for fall protection used during construction of a vertical wall comprising multiple stacked courses. The safety method includes the steps of locating a plurality of anchors between two adjacent wall courses. The anchors are spaced apart along the wall at a base elevation, and form respective fixed points of support. A plurality of posts are then secured to respective anchors. The posts extend vertically from the base elevation above a leading edge of the wall during construction. A protective barrier is then located between adjacent posts, and between a working level adjacent the wall and the leading edge.

According to another preferred embodiment, the safety method includes locating a second plurality of anchors at a raised elevation above the base elevation. The first and second plurality of anchors reside in substantial vertical alignment and cooperate to secure respective posts.

According to another preferred embodiment, the second plurality of anchors is located at least two courses above the first plurality of anchors at the base elevation.

According to another preferred embodiment, the safety method includes removing and replacing the anchors to raise the base elevation during construction.

According to another preferred embodiment, the safety method includes releasably securing each anchor to a course connector located between adjacent courses of the wall.

According to another preferred embodiment, the safety method includes removing the anchors, posts, and protective barrier after construction of the wall.

According to another preferred embodiment, the safety method includes locating the anchors no more than 8 feet apart along the wall at the base elevation.

According to another preferred embodiment, the safety method includes extending the posts at least 3 feet above the leading edge of the wall.

BRIEF DESCRIPTION OF THE DRAWINGS

Some of the objects of the invention have been set forth above. Other objects and advantages of the invention will appear as the description proceeds when taken in conjunction with the following drawings, in which:

FIG. 1 is an environmental perspective view of a fall protection system according to one preferred embodiment of the present invention;

FIG. 2 is a perspective view of the anchor plate positioned on a lower course wall block;

FIG. 3 is a top view of the anchor plate;

FIG. 4 is a view demonstrating insertion of the post basket into the post hole of the anchor plate;

FIG. 5 shows the post basket inserted in the post hole and depending from the anchor plate;

FIG. 6 is a fragmentary perspective view of a vertical wall with the base elevation anchor plate and post basket installed;

FIG. 7 is a fragmentary perspective view of the wall showing the second anchor plate installed in vertical registration with the first;

FIG. 8 is a fragmentary perspective view of the wall showing the first and second anchor plates installed, and additional block courses laid above the second plate;

FIG. 9 is a fragmentary perspective view the wall with the safety post fed through the post opening of the second anchor plate and into the post basket of the first anchor plate;

FIG. 10 is a view showing the face of the wall, and demonstrating movement of the safety post from a first elevation to a raised elevation as the wall is constructed; and

FIG. 11 is an environmental perspective view of a fall protection system according to a second preferred embodiment of the present invention;

DESCRIPTION OF THE PREFERRED EMBODIMENT AND BEST MODE

Referring now specifically to the drawings, a fall protection system according to the present invention is illustrated in FIG. 1, and shown generally at reference numeral 10. The fall protection system 10 is especially applicable for use during construction of a vertical retaining wall 11 comprising courses of dry-stacked concrete block 12. The system 10 is quickly and conveniently raised during construction as the wall height increases. When the wall 11 is completed, the system is readily removed without damage to the wall or various components of the system 10.

Referring to FIGS. 1, 2, and 3, the system 10 utilizes rigid steel anchor plates 14 which project from a face of the wall 11 and secure respective safety posts 15. The posts 15 extend vertically above a leading edge 16 of the wall 11, and cooperate to carry a flexible grid fence 18 or other protective barrier. The fence 18 extends between a working level adjacent the wall 11 and the leading edge 16 to protect the safety of workers as the wall blocks 12 are stacked and set during construction. Typical wall blocks 12, such as those described in prior U.S. Pat. No. 6,615,561 to Keystone Retaining Wall Systems, weigh as much as 80 pounds and can be relatively difficult to handle. The complete disclosure of this patent is incorporated herein by this reference.

As shown in FIGS. 2 and 3, each plate 14 has a flat proximal end 14A designed to sandwich between upper and lower blocks 12 in adjacent stacked courses, and a generally flat distal end 14B defining a post opening 21 for receiving and securing the safety post 15. The anchor plates 14 are first installed at a base elevation approximately 3-4 courses above the ground. The proximal end 14A of each plate 14 defines a pin slot 22 or other catch formed to receive a course connecting pin 24 projecting vertically from a top of the lower course block 12. As the lower course of block 12 is laid, the anchor plates 14 are installed approximately 8 feet apart from each other along the course at the base elevation. The upper course of block 12 is then stacked on the lower course over respective proximal ends 14A of the anchors plates 14. Each upper course block 12 has complementary pin openings arranged to receive the course connecting pins 24 projecting from the lower course blocks 12, as described in the '561 Patent. The course connecting pin 24 located in the pin slot 22 prevents the anchor plate 14 from pulling outward away from the face of the wall 11. The pin slot 22 is formed in the side of the anchor plate 14 adjacent the rear edge, as best shown in FIG. 3. The weight of the stacked block 12 above the anchor plate 14 further secures the plate between the courses, and prevents inadvertent shifting and rotation. In an alternative embodiment (not shown), the proximal end of the anchor plate has no pin slot, and simply engages an integrally-formed knuckle or other block structure sufficient to secure the plate between the courses. In yet another embodiment, for retaining walls without existing mechanical course connectors, separate anchor pins may be installed between the courses in order to secure respective anchor plates.

Referring to FIGS. 4, 5, and 6, once the anchor plate 14 is installed at the base elevation, a supporting post basket 25 is inserted into the post opening 21 formed with the distal end 14B. The post basket 25 has a generally U-shaped body 26 which depends from the anchor plate 14, and opposing outward flanges 27 and 28 which support the basket 25 in the post opening 21.

After inserting post baskets 25 in each of the base elevation anchor plates 14, an additional 3-5 courses of block are stacked as the wall 11 is raised. A second row of spaced anchor plates 14′ are then placed in substantial vertical registration above the first anchor plates 14 (See FIG. 7). The second anchor plate 14′ is installed in a manner identical to that previously described, except that no post basket 25 is inserted in the post opening 21. An additional 2-3 courses of block 12 are then stacked above the second row of anchor plates 14′, as shown in FIG. 8. Once the working level elevation exceeds 6 feet, the safety posts 15 are fed through the post openings 21′ in the second row of anchor plates 14′ and into the post baskets 25 of the base elevation anchor plates 14, as shown in FIG. 9. Preferably, the safety posts 15 are marked with gradations 31 to readily determine the length of post extending above the leading edge 16 of the wall 11 and working level. The posts 15 may also include hooks 32, shown in FIG. 1, or other clamping means for attaching the flexible grid fence 18. According to OSHA guidelines, the posts 15 must support at least 42-inches of protective fencing above the working level. The first and second rows of anchor plates 14 and 14′ cooperate to secure the posts 15 to the face of the wall 11.

As the height of the wall 11 increases, the fall protection system 10 must be raised as prescribed by OSHA guidelines. The system 10 is raised by separately lifting and removing each safety post 15 from its first and second anchor plates 14 and 14′. The post basket 25 of the first anchor plate 14 is removed and inserted into the post hole 21′ of the second anchor plate 14′. The first anchor plate 14 is then removed using a hammer or other suitable tool. By striking the anchor plate 14 at or near point 35 shown in FIG. 2, the plate 14 shifts and rotates away from the course connecting pin 24. A second tool, such as a screw driver, may then be inserted into a tool hole 36 and employed to help pull the plate 14 away from the wall 11. Once removed, the first anchor plate 14 is replaced in the wall 11 above the second anchor plate 14′ and in substantial vertical alignment for receiving the safety post 15. The safety posts 15 scale the face of the wall 11, as indicated in FIG. 10, as the wall height increases—the goal being to maintain at least 42-inches of protective fence 18 above the working level at all times.

In the embodiment of FIG. 11, the fall protection system 50 utilizes a number of vertically-spaced horizontal steel cables 52 extending between the posts 54 to create a safety barrier between the working level and leading edge of the wall 55. All other elements, features, and installation of the fall protection system 50 are as previously described with regard to the system 10.

A fall protection system is described above. Various details of the invention may be changed without departing from its scope. Furthermore, the foregoing description of the preferred embodiment of the invention and best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation—the invention being defined by the claims.

Claims

1. A fall protection system for use in constructing a vertical wall comprising multiple stacked courses, said fall protection system comprising:

a plurality of anchors adapted for engaging the wall and forming respective fixed points of support;

a plurality of posts secured by respective anchors, and designed to extend above a leading edge of the wall during construction; and

means extending between adjacent posts to create a protective barrier between a working level adjacent the wall and the leading edge.

2. A fall protection system according to claim 1, wherein each of said plurality of anchors comprises a rigid anchor plate, said anchor plate having a proximal end adapted for being sandwiched between adjacent wall courses, and a distal end adapted for projecting from the face of the wall.

3. A fall protection system according to claim 2, wherein the proximal end of said anchor plate defines a catch adapted for engaging a course connector located between the adjacent wall courses.

4. A fall protection system according to claim 3, wherein said catch comprises a pin slot adapted for receiving a vertical pin located between the adjacent wall courses.

5. A fall protection system according to claim 2, wherein the distal end of said anchor plate defines a post hole designed to receive said post.

6. A fall protection system according to claim 5, wherein the distal end of said anchor plate further defines a tool hole designed to receive a plate removal tool.

7. A fall protection system according to claim 5, and comprising an anchor basket depending from said post hole, and receiving a bottom end of said post to hold said post at a fixed height relative to the wall.

8. A fall protection system according to claim 7, wherein said anchor basket is removably received within said post hole.

9. A fall protection system according to claim 1, wherein said means for creating a protective barrier comprises at least one horizontal cable line.

10. A fall protection system according to claim 1, wherein said means for creating a protective barrier comprises a flexible grid wall.

11. A fall protection system according to claim 1, wherein at least one of said plurality of posts is marked with gradations.

12. In a vertical wall comprising multiple stacked courses, the invention comprising a fall protection system used during construction of the wall, the fall protection system comprising:

a plurality of spaced anchors engaging the wall and forming respective fixed points of support;

a plurality of posts secured by respective anchors, and extending above a leading edge of the wall during construction; and

means extending between adjacent posts to create a protective barrier between a working level adjacent the wall and the leading edge.

13. A safety method for fall protection used during construction of a vertical wall comprising multiple stacked courses, said safety method comprising the steps of:

locating a plurality of anchors between two adjacent wall courses, the anchors being spaced apart along the wall at a base elevation and forming respective fixed points of support;

securing a plurality of posts to respective anchors, the posts extending vertically from the base elevation above a leading edge of the wall during construction; and

locating a protective barrier between adjacent posts, and between a working level adjacent the wall and the leading edge.

14. A safety method according to claim 13, and comprising locating a second plurality of anchors at a raised elevation above the base elevation, the first and second plurality of anchors residing in substantial vertical alignment and cooperating to secure respective posts.

15. A safety method according to claim 14, wherein the second plurality of anchors is located at least two courses above the first plurality of anchors at the base elevation.

16. A safety method according to claim 13, and comprising removing and replacing the anchors to raise the base elevation during construction.

17. A safety method according to claim 13, and comprising releasably securing each anchor to a course connector located between adjacent courses of the wall.

18. A safety method according to claim 13, and comprising removing the anchors, posts, and protective barrier after construction of the wall.

19. A safety method according to claim 13, and comprising locating the anchors no more than 8 feet apart along the wall at the base elevation.

20. A safety method according to claim 13, and comprising extending the posts at least 3 feet above the leading edge of the wall.