Quick Deploy Scaffolding

Abstract

The QDS scaffolding system can be delivered to the job-site in a pre-assembled but stowed configuration and can then be rapidly assembled on the job-site. Assembly may be accomplished using an external power source such as a crane, an internal power source such as a hydraulic actuator or an electrical motor, or any other suitable power source. In certain circumstances, manual erection could even be used. It is a modular system consisting of structural frameworks, quick deploy mechanisms, locking frameworks and working platforms. The quick deploy mechanisms are integrated within the structural frameworks and allow each structural framework to be erected from its stowed position to full working height by an auxiliary power source, such as a crane. In some instances the structural frameworks can be erected using an internal power source or even manually. Multiple base assemblies can be connected together to form a scaffolding system of various heights with one or more working platforms

Description

RELATED APPLICATIONS

This application claims the benefit of commonly owned U.S. Provisional application 62/780,188, filed om 14 Dec. 2018. This application incorporates by reference the disclosure of 62/780,188.

GOVERNMENT SUPPORT

Not Applicable

FIELD OF THE INVENTION

The present invention relates generally to the field of scaffolding and, in particular, to a novel type of scaffolding which can be deployed/erected very rapidly. The present invention also relates to a method for rapidly deploying scaffolding on an existing structure.

BACKGROUND

Scaffolding is a critical and costly component to many types of construction, repair, maintenance and/or modernization jobs. While there are a number of different varieties of scaffolds—traditional frame, tube and clamp, ringlock, cuplock, suspension, to name a few—the market is essentially commoditized where scaffolding contractors compete on assembly and disassembly labor costs which can account for 80% of the total service cost¹. It has been estimated that well over half the labor time on many scaffolding jobs is dedicated to transportation of scaffolding parts during assembly and disassembly. This is clearly inefficient and can pose safety hazards.² When working with ships, maintenance schedules are often tight which can make it even more expensive due to overtime labor costs or schedule slip. In addition, when dealing with ships, severe weather may cause threats to the shipyard/facility where the work is being performed and may require rapid disassembly and removal of any deployed scaffolding to protect ships and personnel. It is well-known that the usual response to a severe weather threat is to get the ships out to sea where they can ride out the severe weather in safety. ¹Private communication with Austal, Inc.² “KEWAZO Assembling the Future,” KEWAZO www.kewazzo.com/Accessed 4 Dec. 2018

A navy report³ written in 1992 states that “scaffolding methods used by most shipyards are costly, and in general, inefficient” and identified a need for “innovative scaffolding methods and . . . state-of-the-art scaffolding systems and equipment”. In spite of this clear call for improvement and innovation, the 26 year old report describes the drawbacks of the same scaffold systems which remain in use today. Despite the obvious desirability and long felt need for cost reductions and safety improvements in virtually all types of scaffolding jobs for construction, repair, maintenance and/or modernization—there has not been any widely accepted innovation in scaffolding for many years. This lack has been particularly felt in the area of marine scaffolding. [1] ³ Santoyo, J. F. (1992) Final Report: Staging Systems for Ships During New Construction and Repair. National Steel and Shipbuilding Company submitted to US Dept. of the Navy.

An example of an “inefficient” scaffolding system used by a naval shipyard to work on the superstructure of an aircraft carrier. This type of scaffolding system tends to be very complex. To cover the superstructure of an aircraft carrier you need approximately 80 bays of scaffolding with each bay having vertical supports, planking, bracing, handrails, toe kicks and attachment means to attach the scaffolding to the ship. This scaffolding system would comprise approximately 200 vertical supports, 80 units of planking, 80 handrails, and 160 cross braces plus about 160 tie-in units to secure the scaffolding to the structure. Erecting this massive system by hand [as is customary] is clearly extremely labor intensive, costly and inefficient.

SUMMARY OF THE INVENTION

The invention aims to solve this long-felt need by providing a novel scaffolding system which can be delivered to the job-site in a pre-assembled but stowed configuration and which can be rapidly deployed on the job-site. Assembly may be accomplished through use of an external power source such as a crane, an internal power source such as a hydraulic actuator or an electrical motor, or any other suitable power source. In certain circumstances, manual erection could even be used.

The Quick Deploy Scaffolding [QDS] is a modular system consisting of structural frameworks, quick deploy mechanisms, locking frameworks and working platforms. The quick deploy mechanisms are integrated within the structural frameworks and allow each structural framework to be erected from its stowed position to full working height by an auxiliary power source, such as a crane. In some instances the structural frameworks can be erected using an internal power source or even manually. Multiple base assemblies can be connected together to form a scaffolding system of various heights with one or more working platforms.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a deployed base assembly of the invention.

FIG. 2 illustrates the deployed base assembly of FIG. 1 with handrails and horizontal supports installed

FIG. 3 shows a stowed base assembly.

FIG. 4 shows a partially deployed base assembly.

FIG. 5 shows the locking mechanism for the base assembly in the open position.

FIG. 6 shows the locking mechanism for the base assembly in the closed and locked position.

FIG. 7 illustrates a preconfigured 4-high Quick Deploy Scaffolding ready for delivery to the job-site.

FIG. 8 illustrates the preconfigured scaffolding of FIG. 7 with railing and toe kicks installed on the top platform.

FIG. 9 illustrates a deployed section of a 4-high Quick Deploy Scaffolding.

FIG. 10 illustrates one form for a locking mechanism for the structural framework.

FIG. 11 illustrates the locking mechanism of FIG. 10 in place to lock the structural framework in the closed position.

FIG. 12 shows the locking mechanism being carried on the structural framework when the structural framework is open.

FIG. 13 illustrates an maternal means to activate the quick deploy mechanism which is carried on the base assembly.

DETAILED DESCRIPTION OF THE INVENTION

The Quick Deploy Scaffolding (QDS) has been designed to be a modular system. That is, multiple base assemblies can be connected together to form a scaffolding system of various heights with one or more working platforms. FIG. 1 shows a base assembly 10 in the deployed position. Each base assembly 10 includes a locking framework 12, working platforms 14, 14′. and structural framework 16, 16′. Locking framework 12 is shown as a scissors frame comprising lift arms 18, 18′, 18″ and 19, 19′ and 19″. The lift arms 18 and 19 are pivoted at 20. In like manner, lift arms 18′ and 19′ are pivoted at 20′ and lift arms 18″ and 19″ are pivoted at 20″. Lower lift arm 18″ and upper lift arm 19 are pivoted on their left ends at 21 and 21′. The right end of arm 19″ slides within open topped receptacle 22′. The right end of arm 19″ is locked by pivoting, slotted latch 24′ [See FIGS. 5 and 6 below]. In like manner, the right end of arm 18 slides within open bottomed receptacle 22 and is locked by pivoting, slotted latch 24. The operation of the pivoting, slotted latches 24 and 24′ is further shown in FIGS. 5 and 6 and will be explained below. In addition, 6 known adjustable height leveling assemblies are removably attached to the bottom of working platform 14′ to permit leveling of the scaffolding. Only three of the six adjustable height leveling assemblies are shown in the drawings [25, 26 and 27].

FIG. 2 shows the deployed base assembly of FIG. 1 with handrails 30 and horizontal supports 32 removably installed.

FIG. 3 illustrates the deployed base assembly shown in FIG. 1 in a stowed position. Locking framework 12 is stowed within the hollow areas of open bottomed receptacle 22 and 22′. Structural framework 16, 16′ is folded into slotted areas 40 and 40′ as shown in FIG. 4.

FIG. 4 shows base assembly 10 of FIG. 1 approximately half-way between the open configuration shown in FIG. 1 and the stowed configuration shown in FIG. 3. It should be noted that structural framework 16, 16′ folds into open topped receptacles 40, 40′ which are in different locations than open bottomed receptacle 22 and open topped receptacle 22′ which receive locking framework 12 as it is folded to the stowed configuration.

FIG. 5 illustrates the interaction of locking framework 12 and pivoting, slotted latch 24′. As noted above, the right end of lift arm 19″ slides within open topped receptacle 22′. The outermost portion of the right end of lift arm 19″ caries pin 42 which slides within slot 44 which slot closely constrains pin 42. Slot 44 is cut into the outer wall 41 of open topped receptacle 22. Pin 42 is shown extending through slot 44 in FIG. 5. Pivoting, slotted latch 24′ is pivoted to the outer wall 41 of open topped receptacle 22 by pivot pin 46. As shown in FIG. 5, pivoting, slotted latch 24′ carries three spaced slots 48, 50 and 52. It is noted that pin 42 slides from the right hand portion of slot 44 towards the left hand portion of slot 44 during the deployment of base member 10 from its stowed position shown in FIG. 3 to the deployed position shown in FIG. 1. As shown in FIG. 5, as pin 42 slides to the left within slot 44, pin 42 will cam the pivoted, slotted latch 24′ upwards because of the slope of the slots 48, 50 and 52 as clearly shone in FIGS. 5 and 6. In this manner, pin 42 can continue its motion towards the left end of slot 44. As the pin 42 continues to travel towards the left end of slot 44, it will enter the next slot [50] in pivoted, slotted latch 24′ and allow the latch to fall downwards with pin 42 being somewhat restrained by slot 50. If, at this time, pin 42 attempts to move back towards the right end of slot 44, this motion will be blocked by the interaction of pin 42 and slot 50—again because of the slope of slot 50—and the motion to the right of pin 42 [and thus lift arm 19′] will be firmly stopped. This would leave base member 10 partially deployed in a manner very similar to that shown in FIG. 4. Thus, the interaction of pin 42 and pivoted, slotted latch 24′ functions as a safety interlock to prevent unwanted motion of pin 42 and thus, of arm 19″.

FIG. 6 shows pin 42 firmly enclosed within and restrained by slot 48 in pivoted, slotted latch 24′. This position of pin 42 and thus, of lift arm 19″, corresponds to the fully deployed configuration of base member 10 shown in FIG. 1. It should be noted that the forces exerted on pin 42 by the slot 44 are also important here because the slot keeps pin 42 from moving downward so that it is not necessary to further constrain pivoted, slotted latch 24′ against clockwise rotation since pin 42 has very limited freedom to move up or down within slot 44.

The end user of the Quick Deploy Scaffolding can order scaffolding specific to their height, width and working platform requirements from the supplier. Multiple base assemblies can be configured to fit the end-user's specific requirements and assembled offsite. The pre-assembled base assemblies can then be shipped to the job-site. Of course, it is also possible to ship multiple, individual base assemblies to the job-site where they can be configured as desired by the end user. FIG. 7 shows such a preconfigured set of base assemblies 50, 52, 54 and 56 attached together and ready to be shipped to a job-site. Once the preconfigured assemblies arrive at the job-site, the scaffolding will be assembled from the top down. Assuming the job calls for scaffolding about four times the height of the deployed base assembly 10 shown in FIG. 1, four base assemblies would be pre-configured offsite and shipped to the job site. Once the preconfigured assemblies are positioned where desired at the job-site, the desired railing for the topmost working platform would be installed on the topmost working platform. Next the locking mechanisms would be opened to deploy top base assembly 50. The top base assembly might be deployed using a crane. Once top base assembly 50 was fully deployed, handrails, horizontal support members and ladders would be added between the top two working platforms [note FIG. 2]. It is noted that the addition of the handrails and horizontal support members to the structural framework creates a positive connection which keeps the vertical members upright and helps to maintain the base assembly in the deployed configuration.

The process described above would be repeated for the base assembly just below the one just deployed [base assembly 52 as shown in FIG. 7] and the process would be repeated for the remaining base assemblies [54 and 56] until the entire scaffold was deployed. The process would be done in reverse to stow the scaffold.

FIG. 8 shows the preconfigured set of base assemblies shown in FIG. 7 with handrails 58, 58′ installed on the top base assembly. Toe kicks 60, and 60′ are also shown installed on the top base assembly. After these items have been installed, the top base assembly will be deployed as the next step in the erection of the scaffolding.

FIG. 9 shows the Quick Deploy Scaffolding preconfigured set of base assemblies of FIG. 8 completely deployed with handrails, horizontal supports and ladders installed in each deployed base assembly section. It is to be noted that the QDS scaffolding is designed to be attached end to end to connect many different sections such as shown in FIG. 9 together to provide scaffolding for long structures.

FIG. 10 illustrates one method of locking the folding structural framework in the open or deployed configuration. Vertical sections 102, 104 of the structural framework 100 are shown in the erect or deployed position. These sections are pivoted by pivot pin 106. Section 104 carries a transverse support shelf 108. Collar 110 is also shown dismounted from the structural framework. FIG. 11 shows structural framework 100 locked by having collar 110 deployed over the pivot joint between vertical sections 102 and 104. Collar 110 rests upon transverse shelf 108 and covers the pivot joint and locks it in the erect or deployed position. When it is desired to stow the structural framework 100, collar 110 is slid upwards on section 102 and the structural framework is allowed to fold as shown in FIG. 12. This is one means to lock the structural framework in the erect or deployed position, but any available and suitable locking means could also be used. Other means could be used to lock the folding structural framework in the open or deployed configuration. One such other means would be to incorporate the locking means into the horizontal supports 32 shown in FIG. 2. The horizontal supports could have threaded means installed to shorten or lengthen them, thus locking the vertical arms 16, 16′ of the structural framework in the deployed position.

FIG. 13 illustrates one manner in which a base assembly could be deployed with on-board power or manually. Working platform 114 is shown in cross section with open topped receptacle 122′ attached to the left side of working platform 114. The outer end of lift leg 119″ is contained within open topped receptacle 122′. Pin 142 is carried by the outer end of lift leg 119″ and cooperates with pivoted, slotted latch plate 124′ in the same manner that pin 42 carried by the outer end of left leg 19″ cooperates with pivoted, slotted latch plate 24′, as shown in FIGS. 5 and 6, to control movement of the locking framework of the scaffolding. However, pin 142 is extended from the other side of lift leg 119″ into the interior of working platform 114 as shown in FIG. 13. Interior bulkheads 150 mounted within working platform 114 support pin 142 and have slots [not shown in the figures] therein similar to slot 44 of FIG. 5. Pin [′42] can thus slide within the not illustrated slots of bulkheads 150. Screw nut 160 is mounted on pin 142 and has a threaded screw 116 mounted therein. Turning screw 116 causes screw nut 160 to move within working platform 114 and it carries pin 142 and lift leg 119″ with it. Obviously, the motion will be into or out of the plane of the FIG. 13 drawing. This will cause the locking framework to erect or deploy the base assembly or to stow the base assembly depending upon the direction threaded screw 116 is turned. Threaded screw 116 can be powered by an electric motor or a hydraulic motor or any other suitable motive device [none of which are illustrated in the drawings]. It would even be possible to arrange for threaded screw 116 to be turned by hand to manually erect/deploy or stow the base assembly.

It is possible to provide a visual reference as to whether or not the base assembly is locked or unlocked in several different ways. For example, a red outline of pivoted, slotted latch plate 24′ could be painted on side wall 41 of open topped receptacle 22′ directly underneath of the closed [down] position for latch plate 24′. Thus, when latch plate 24′ was in the closed position shown in FIG. 6 [down], for example, none of the red paint would be visible—thus indicating that the locking framework would be locked when the lifting forces were removed from the base assembly. If any of the red paint were visible, this would be an indication that the locking framework was in the unlocked condition. It is also possible to attach some of the items which now have to be installed on the QDS after deployment in such a manner that they are automatically deployed when the base assembly is deployed. For example, the horizontal supports and the railings could be pivoted to and carried by the structural framework—even in the stowed configuration of the base assembly so that when the base assembly was deployed these items would automatically move to their desired locations and already be fixed on the structural framework. Of course, these items might have to be locked in position after deployment and this locking procedure might well take time but it would be a huge savings of time if the horizontal supports and the railings were attached to the structural framework.

Claims

1. A modular quickly deployable scaffolding system comprising:

at least one base assembly comprising an upper and lower working platform, a structural framework and a locking framework;

with said upper and lower working platforms being so arranged and interconnected by said structural framework that they may be moved from a stowed position where said upper and lower working platforms are aligned and separated by a first predetermined distance to a deployed position where said upper and lower working platforms remain aligned but are separated by a second predetermined distance to form a scaffold;

each of said upper and lower working platforms further comprise an elongated, rectangular box-like structure comprising top and bottom surfaces, front, back and side surfaces and wherein said top and bottom surfaces are generally rectangular with four corners;

said upper working platform further comprising two downwardly open recesses defined in the bottom surface of said upper working platform, with one of said recesses running along and inward from one of said side surfaces and with the other recess running along and inward from the second of said side surfaces;

wherein said upper working platform further comprises four upper support rods each having a pivoted end and a free end with each said pivoted end being pivoted to the bottom surface of said upper working platform at each said corner thereof and with each said upper support rod being pivotally movable from a generally horizontal stowed position within one of said recesses to a generally vertical position wherein said free ends of each of said upper support rods extend vertically downwards below the bottom surface of said upper working platform,

wherein said lower working platform further comprises two upwardly open recesses defined in the upper surface of said lower working platform, with one of said recesses running along and inward from one of said side surfaces and with the other recess running along and inward from the second of said side surfaces,

wherein said lower working platform further comprises four lower support rods having a pivoted end and a free end with each said pivoted end being pivoted to the top surface of said lower working platform at each said corner thereof and with each said lower support rod being pivotally movable from a generally horizontal stowed position within one of said recesses to a generally vertical position wherein said free ends of each of said lower support rods extend vertically upward above the top surface of said lower working platform,

with the free ends of said upper four support rods being connected to the corresponding free ends of said lower four support rods so as to form four elongated, folding support rods which run from the bottom of said upper working platform to the top of the lower working platform at each corner of said upper and lower working platforms, such that when said four elongated, folding support rods are in their generally vertical positions said upper and lower working platforms are aligned but separated by said second predetermined distance to form a deployed scaffold and when said four elongated support rods are folded into their generally horizontal positions and contained within said downwardly open recesses and said upwardly open recesses said upper and lower working platforms are separated by said first predetermined minimum distance to form a stowed base assembly;

a locking framework connected connecting said upper working platform and said lower working platform in order to move said upper working platform from the stowed position where said platforms are separated by said first predetermined distance to a deployed position where said platforms are separated by said second predetermined distance to form a scaffold.

2. The modular quickly deployable scaffolding system of claim 1 wherein said locking framework can also move said upper working platform from said deployed position to said stowed position.

3. The modular quickly deployable scaffolding system of claim 1 wherein said locking framework further comprises locking means to lock said upper and lower working platforms at said second predetermined distance when said base assembly is deployed.

4. The modular quickly deployable scaffolding system of claim 3 wherein said locking means locks said upper and lower working platforms at said first predetermined distance when said base assembly is stowed.

5. The modular quickly deployable scaffolding system of claim 1 wherein said locking framework further comprises a scissors arrangement means of pivoted rods which can be extended and collapsed to move said upper working platform away from or towards said lower working platform.

6. The modular quickly deployable scaffolding system of claim 5 wherein said locking framework further comprises locking means to lock said upper and lower working platforms at said second predetermined distance when said base assembly is deployed.

7. The modular quickly deployable scaffolding system of claim 6 wherein said locking means further comprises a pin carried by the lowermost rod of said scissors arrangement means and a pivotable, slotted latch plate means with multiple slots therein, said pin being received in one of said multiple slots to lock said upper and lower working platforms at said second predetermined distance when said base assembly is deployed.

8. The modular quickly deployable scaffolding system of claim 7 wherein said locking means locks said upper and lower working platforms at said first predetermined distance when said base assembly is stowed by having said pin being received in an other of said multiple slots.

9. The modular quickly deployable scaffolding system of claim 1 wherein horizontal supports are removably attached between pairs of said elongated folding support rods in order to provide additional stability.

10. The modular quickly deployable scaffolding system of claim 1 wherein hand railings are removably attached to the top surface of each of said upper and lower working platforms to provide additional safety.

11. The modular quickly deployable scaffolding system of claim 1 wherein two of said base assemblies are connected together by connecting the lower working platform of one of said base assemblies to the upper working platform of the other of said two base assemblies.

12. The modular quickly deployable scaffolding system of claim 1 wherein four of said base assemblies are connected together.

13. A modular quickly deployable scaffolding system comprising:

at least one base assembly comprising an upper and lower working platform, a structural framework and a locking framework;

said upper working platform being movably connected to said lower working platform by said structural framework such that the upper working platform may be moved from a stowed position where said upper and lower working platforms are aligned and close together to a deployed position where said upper and lower working platforms remain aligned but are separated by a predetermined distance;

said locking framework being connected to said upper and lower working platforms such that said locking framework can move said upper working platform away from said lower working platform such that said platforms are deployed and separated by said predetermined distance to form a scaffold.

14. The modular quickly deployable scaffolding system of claim 11 wherein said locking framework is connected to a power source internal to said lower working platform and also connected to said locking framework in order to cause said locking framework to move said upper working platform away from said lower working platform such that said platforms are separated by said predetermined distance to form a scaffold.

15. The modular quickly deployable scaffolding system of claim 12 wherein said locking framework can also be moved by said power source to move said upper working platform towards said lower working platform such that said platforms are stowed and separated by said first predetermined distance.

16. A method of quickly deploying a scaffolding system comprising:

providing at least one base assembly further comprising; an upper and lower working platform, a structural framework and a locking framework, with said upper working platform being movably connected to said lower working platform by said structural framework such that the upper working platform may be moved from a stowed position where said upper and lower working platforms are aligned and close together to a deployed position where said upper and lower working platforms remain aligned but are separated by a predetermined distance; said locking framework being connected to said upper and lower working platforms such that said locking framework can move said upper working platform away from said lower working platform such that said platforms are deployed and separated by said predetermined distance;

positioning a first base assembly in stowed configuration on top of a second base assembly also in a stowed configuration and causing said first and second base assemblies to be aligned with each other;

assembling said first and said second base assemblies together in an aligned configuration by removably fastening the lower working platform of the first base assembly to the upper working platform of said second base assembly;

moving said assembled first and second base assemblies to a remote job-site;

positioning said assembled first and second base assemblies where desired on said remote job-site;

deploying said first base assembly using an external power source to its deployed position with the upper and lower working platforms of said first base assembly being separated by said predetermined distance;

deploying said second base assembly using said external power source to its deployed position with the upper and lower working platforms of said second base assembly being separated by said predetermined distance to form a scaffold.

17. A method of quickly deploying a scaffolding system comprising:

providing at least two base assemblies further comprising; an upper and lower working platform, a structural framework and a locking framework, with said upper working platform being movably connected to said lower working platform by said structural framework such that the upper working platform may be moved from a stowed position where said upper and lower working platforms are aligned and close together to a deployed position where said upper and lower working platforms remain aligned but are separated by a predetermined distance; said locking framework being connected to said upper and lower working platforms such that said locking framework can move said upper working platform away from said lower working platform such that said platforms are deployed and separated by said predetermined distance;

positioning said at least two base assemblies in a stowed configuration;

moving said at least two stowed base assemblies to a remote job site;

positioning a first of said at least two stowed base assemblies at a desired location on said job-site;

positioning a second stowed base assembly on top of said first base assembly and causing said first and second base assemblies to be aligned with each other;

assembling said first and said second base assemblies together in an aligned configuration by removably fastening the lower working platform of the first base assembly to the upper working platform of said second base assembly;

deploying said first base assembly using an external power source to its deployed position with the upper and lower working platforms of said first base assembly being separated by said predetermined distance;

deploying said second base assembly using said external power source to its deployed position with the upper and lower working platforms of said second base assembly being separated by said predetermined distance to form a scaffold.