GUARD RAIL SUPPORT ASSEMBLY
This specification is to a guard support assembly used to support guard rails. Greater strength for the guard support assembly is obtained by attaching a C channeled framing member, like a stud, to a groove in a base plate. Handle like guard supports are used to support the actual guard rails.
This application is a continuation-in-part application of U.S. patent application Ser. No. 19/299,423 filed Aug. 14, 2025 and claims priority from U.S. Provisional Application No. 63/682,949 filed Aug. 14, 2024, and U.S. patent application Ser. No. 19/299,423 filed Aug. 14, 2025 the teachings of which both are incorporated in their entirety herein.
BACKGROUNDKnee Walls, Pony Walls, Half Walls, and Hip Walls all refer to a wall that does not stretch from the floor to the ceiling.
These walls are typically used as room dividers within spaces of a larger open room. These walls are often framed and sheathed the same as full-height walls.
A knee wall is usually less than 3 feet high (falling below the knee), and is typically used to support something, such as a countertop or attic rafters.
Pony walls are more of an interior design choice to separate a room.
Knee walls need additional structural support to prevent the unsupported top of the smaller wall from flexing and failing. These are typically called knee wall assemblies.
The additional support is typically in the form of a support bracket consisting of a base plate that is bolted to the floor and a framing member that is a heavier gauge than the rest of the knee wall framing members.
There is always the need for a stronger support made with less material, whether it is used to support a knee wall assembly or a guard support assembly or guard rail support assembly.
SUMMARYThis specification discloses a knee wall support assembly having a framing member which has a framing member first end with a framing member first end profile, a framing member second end with said framing member comprising a web, a first flange extending from a web first edge, and a second flange extending from a web second edge (1350). The knee wall support will also have a base plate having a base plate width, a base plate length, a base plate height, a base plate top parallel to a plane defined by the base plate width and the base plate length, a base plate bottom opposite the base plate top, a plurality of base plate mounting holes, and a base plate groove having a base plate groove wall. It is further disclosed that 1 the framing member first end is disposed within the base plate groove and there is a weld that joins the framing member and the base plate.
It is also disclosed that there may be a first lip extending from the first flange and a second lip extending from the second flange.
The specification also discloses that the framing member may be a unitary piece of cold rolled steel and that the thickness of the steel maybe 14 gauge steel.
It is further disclosed that the framing member may be in frictional contact with one of the group consisting of the first flange, the second flange and the web or the framing member may be in frictional contact with all three of the first flange, the second flange and the web.
It is further disclosed that there may be gap between the groove wall and the framing member with a distance between the groove wall and the framing member and that distance may be less than or equal to 1 inch, less than or equal to 0.5 inch, less than or equal to 0.25 inch, less than or equal to 0.125 inch, less than or equal to 0.0625 inch.
The specification also discloses a framing assembly comprising the knee wall support assembly wherein the framing assembly has a wall face, and the knee wall support assembly is oriented so that the web is perpendicular to the wall face.
It is further disclosed the knee wall support assembly may have features that allow it to become a guard support assembly by adding at least a first support clip having a first support clip lateral support leg, a first support clip base support leg extending from a first support clip lateral support leg first edge, a first support clip lower attachment leg extending from a first clip base support leg first edge, with the first support clip lower attachment leg attached to the web so that a first support clip lateral leg second edge opposite the first support clip lateral support leg first edge is oriented towards the framing member second end and a first support clip lower attachment leg first edge is oriented towards the framing member first end.
It is further disclosed that the guard support assembly may further comprises a second support clip and that the distance from the first support clip base support leg to the framing member first end is approximately equal to a distance from the second support clip base support leg to the framing member first end.
It is also disclosed that the guard support assembly may further have at least one visibility device and/or visibility mark.
It is further disclosed that the support clips may be in a shape of a handle further comprising a support clip top leg and a support clip top attachment leg attached to the framing member.
It is also disclosed that the guard support assembly may further include a toe guard assembly having at least a toe guard support and a toe guard support attachment assembly.
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- 1000 depicts a framing member.
- 1100 depicts a framing member length.
- 1110 depicts a framing member width.
- 1120 depicts a framing member height.
- 1130 depicts a framing member channel.
- 1150 depicts a framing member channel width.
- 1160 depicts a framing member channel height.
- 1170 depicts a framing member first end.
- 1180 depicts a framing member second end.
- 1200 depicts a framing member profile.
- 1210 depicts a framing member outer perimeter.
- 1220 depicts a framing member inner perimeter.
- 1300 depicts a framing member web.
- 1310 depicts a framing member web length.
- 1320 depicts a framing member web width.
- 1330 depicts a framing member web height.
- 1340 depicts a framing member web first edge.
- 1350 depicts a framing member web second edge.
- 1400 depicts a framing member first flange.
- 1410 depicts a framing member first flange first edge.
- 1420 depicts a framing member first flange second edge.
- 1430 depicts a framing member first flange length.
- 1440 depicts a framing member first flange width.
- 1450 depicts a framing member first flange outer height.
- 1460 depicts a framing member first flange inner height.
- 1500 depicts a framing member second flange.
- 1510 depicts a framing member second flange first edge.
- 1520 depicts a framing member second flange second edge.
- 1530 depicts a framing member second flange length.
- 1540 depicts a framing member second flange width.
- 1550 depicts a framing member second flange outer height.
- 1560 depicts a framing member second flange inner height.
- 1600 depicts a framing member first lip.
- 1700 depicts a framing member second lip.
- 2000 depicts a base plate.
- 12010 depicts a base plate length.
- 2020 depicts a base plate width.
- 2030 depicts a base plate height.
- 2040 depicts base plate mounting holes.
- 2050 depicts a base plate top end.
- 2060 depicts a base plate bottom end.
- 2070 depicts a base plate groove.
- 2080 depicts a base plate groove wall.
- 3000 depicts a weld.
- 4000 depicts a knee wall support assembly.
- 5000 depicts a support clip.
- 5100 depicts a support clip lateral support leg.
- 5110 depicts a support clip lateral support leg first edge.
- 5115 depicts a support clip lateral support leg second edge.
- 5200 depicts a support clip base support leg.
- 5210 depicts a clip base support leg first edge.
- 5300 depicts a support clip lower attachment leg.
- 5310 depicts a support clip lower attachment leg first edge.
- 5315 depicts a support clip lower attachment leg second edge.
- 5400 depicts a support clip top leg.
- 5500 depicts a support clip top attachment leg.
- 5700 depicts a visibility device.
- 5800 depicts a weld used to attach the support clip to framing member.
- 6000 depicts a guard assembly.
- 10000 depicts a support clip in the form of a handle.
- 10900 depicts through holes in the support clip lateral support leg.
- 11000 depicts a toe guard support.
- 11130 depicts a toe guard support web.
- 11140 depicts a toe guard support first flange.
- 11150 depicts a toe guard support second flange.
- 11500 depicts holes through the toe guard first flange and/or second flange
- 12000 depicts a toe guard support attachment assembly.
- 12100 depicts a toe guard support attachment plate through hole.
- 12200 depicts a toe guard mounting plate of the toe guard support attachment assembly.
- 12300 depicts a toe guard support attachment plate.
- 15000 depicts a guard rail, also known as a horizontal cross member, inserted into the support clip.
As shown in
As shown in
Also shown is the framing member first end (1170) and the framing member second end (1180).
While the flanges could be welded to the web, it is more preferable that the framing member be formed from a coil or sheet of steel. In this manner the framing member could be a unitary piece of cold rolled steel.
As shown in
This framing member can be made cold roll steel where steel coil or steel sheet is fed into rollers that form the shape. As shown in
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The base plate groove may be dimensioned so that it is in frictional contact with at least one of the first flange, second flange, and web. The base plate groove may be dimensioned so that it is in frictional contact with the first flange, the second flange, and the web.
It is recognized that there could be a gap between the framing member and the groove walls. One of ordinary skill would recognize that it is preferable that the base plate groove be dimensioned so that there is no gap between the groove walls and the framing member inside the groove. However, small gaps are permissible.
It is preferred that the largest distance of any gap between the framing member and groove wall be less than or equal to 1 inch. One of ordinary skill will recognize that the maximum gap occurs when one side of the framing member touches a groove wall, and the gap exists from the opposite side of the framing member. Were the framing member equidistant from the groove wall at all points, the largest gap would be ½ inch.
Using the same methodology, a maximum gap of less than or equal to 0.75 inches is more preferred, with a maximum gap of less than or equal to 0.5 inches or less than or equal to 0.25 inches, being even more preferred. Most preferred is a maximum gap of less than or equal to 0.125 inches which would result in the gap being 0.0625 inches ( 1/16 inch) when the groove wall is equidistant from the framing member. The grove in the working example was laser cut to 0.074 inch +/−0.004 inch.
In some embodiments, the groove will pass through the base plate and the framing member first end will be flush with the base plate bottom.
The knee wall support assembly also has a weld (
The welded base plate to stud assembly will be referred to as a knee wall support assembly.
The knee wall support assembly can be made of steel, with the framing member being made of 12, 14, or 16 gauge steel with a preferred thickness of 14 gauge. The base plate can be made of steel with a preferred thickness between ⅜″ to ½″.
The knee wall support assembly is also installed in a unique way. Currently these types of pony walls or knee walls are installed as part of a framing assembly. The framing assembly has studs running vertical from the floor to the top track of the knee wall. The base of the studs may be located in an upward facing channel. The studs form a horizontal wall line where the wall is attached to the studs. The wall face is the plane defined by the horizontal wall line and the vertical wall line which is parallel with the studs as they extend from the floor to the ceiling. Prior art has the knee wall support assembly oriented with the web parallel to the wall face. This places the load from the wall at the web. It has been surprisingly discovered and confirmed through testing of physical parts that the invented knee wall support assembly can be installed with the web perpendicular to the wall face. This places the load on both at one of the flanges with one flange in compression and the opposite flange in tension.
This orientation is shown in
The knee wall support assembly was evaluated against a prior art knee wall. The prior art framing member was 350S162-97, 12 gauge steel. The prior art base plate was 8 inches by 3.375 inches and 0.5 inches thick without a groove. Typically, these are installed with two pony or knee wall studs per prior art framing member, thus the reason it is oriented with the web parallel to the wall face. That is the wall force load is on the web.
The working example of the knee wall support assembly had a framing member of 300S162-68 14 gauge steel. The working example base plate was 8 inches by 3.375 inches and 0.375″ inches thick with a groove with the framing member inserted into the groove. While the prior art requires two pony or knee wall studs per prior per framing member, this knee wall support assembly is strong enough require only one knee wall stud per knee wall support assembly thus the reason it is oriented with the web parallel to the wall face. As shown in
Both the prior art example and the working example were evaluated by placing a load at the wall face. In the prior art example, the load was placed on the web of the knee wall support assembly. In the working example, the load was placed on of the flanges. Up to 58% more force was required to deform the working example, proving that the new design and orientation allowed for a stronger wall with less material in the base plate and knee wall support assembly stud, and less installation labor for 1 versus 2 mating studs.
The knee wall assembly can be modified into a support guard assembly (6000) as shown
The support guard assembly will have a framing member (1000) having a framing member first end (1170) with a framing member first end profile (1200), a framing member second end (1180) with said framing member comprising a web (1300), a first flange (1400) extending from a web first edge (1340), and a second flange (1500) extending from a web second edge (1350) a base plate (2000) having a base plate width (2020), a base plate length (2010), a base plate height (2030), a base plate top (2050) parallel to a plane defined by the base plate width and the base plate length, a base plate bottom (2060) opposite the base plate top, a plurality of base plate mounting holes (2040), and a base plate groove (2070) having a base plate groove wall (2080); and wherein the framing member first end is disposed within the base plate groove. a weld (3000) joins the framing member and the base plate. These features have been fully explained early in the specification.
This knee wall assembly becomes a guard support assembly when support clips are added to the at least one of the web, the first flange or the second flange of the framing member as shown in
The first support clip (5000) should have at least a first support clip lateral support leg (5100), a first support clip base support leg (5200). The first support clip base support leg extends from a first support clip lateral support leg first edge (5110). As shown in the
The first clip base support leg forms a right angle (90 Degrees) with the first support clip lower attachment leg (5300) extending from a first clip base support leg first edge (5210).
The first support clip is attached to one of the web, the first flange or the second flange. This could be done by welding, gluing, nut/bolt arrangement. The first support clip lower attachment leg attached so that the first support clip lateral leg second edge (5115) opposite the first support clip lateral support leg first edge (5110) is oriented towards the framing member second edge and the first support clip lower attachment leg first edge (5310) is oriented towards the framing member first end.
When two support guard assemblies are installed, the clips form a place to lodge a guard rail, or cross member, in the space between the web and the first support clip lateral support leg. Alternatively, the space could be between the first flange or the second flange and the first support clip lateral support leg.
The guard rails, also known as cross members, or horizontal cross members or slanted cross members could be wood, steel, metal framing, or even strong plastic. The clip design could be chosen to accommodate a multitude of cross member materials, designs and geometries.
The support guard assembly shown in
This particular embodiment in
In the embodiment in
An alternative embodiment is to stagger the support clip attached to the web from the support clip attached to the flange. In this embodiment the distance from the first support clip base support leg to the framing member first end is not equal to a distance from the second support clip base support leg to the framing member first end. In the fact the differences in the distances is at least the length of the support clip lateral support leg and more preferably at least 1.5 times the length of the support clip lateral support leg, with at least 2 times the length being most preferable. This is done so that the guard rail/cross member can easily slip into the space between the support clip lateral support leg.
Also shown in
The visibility device is to highlight the safety guards. Reflective tape is well known visibility device. It comes in many patterns and colors. As a tape, it is just adhered to the guard assembly.
In some instances, the visibility device can be a visibility marking, like a reflective paint.
Lights are also a visibility device often used on the posts of guard rail systems.
To keep the steel from rusting, some or all of the components can be coated such as with a Zinc-rich cold galvanizing coating.
Another embodiment of a different support clip is shown in
As shown in
An additional embodiment is shown in
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The following test were run Two 16 ga. 1.5″×1.5″×0.5″ support clips were welded (5500) to at 42″ & 21″ of a Knee Wall with ½″ base plate.
The knee walls were spaced 6 feet apart and 1.5″×1.5″ steel tubing was used to mimic a wood 2×4.
Clips were changed to 1.5″ clip support attachment leg, 1.75″ support clip base, and a 3.5″ support clip lateral support leg to facilitate wood 2×4's.
The support guard was mounted to a concrete floor at the base plate with 2 one inch long bolts in each base plate of the two guard assemblies. Outward Load was applied at the 3′ midpoint of the horizontal beam.
The guard assembly was also mounted to metal framing floor joists: 800S300-97, covered with 0.044″ thickness sheet stock.
Loads were applied to mid-rail at the mid-point in outward direction and downward directions at 42″ and 21″.
All outward loads were greater than greater than 800 lbs. of force thus exceeding the OSHA minimum load of 200 lbs.
All downward loads exceeded 896 lbs. force.
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Claims
1. A guard support assembly (6000) comprising:
- a framing member (1000) having a framing member first end (1170) with a framing member first end profile (1200), a framing member second end (1180) with said framing member comprising a web (1300), a first flange (1400) extending from a web first edge (1340), and a second flange (1500) extending from a web second edge (1350);
- at least a first support clip (5000) having a first support clip lateral support leg (5100), a first support clip base support leg (5200) extending from a first support clip lateral support leg first edge (5110), a first support clip lower attachment leg (5300) extending from a first clip base support leg first edge (5210), with the first support clip lower attachment leg attached to the web so that a first support clip lateral leg second edge (5115) opposite the first support clip lateral support leg first edge (5110) is oriented towards the framing member second end and a first support clip lower attachment leg first edge (5310) is oriented towards the framing member first end;
- a base plate (2000) having a base plate width (2020), a base plate length (2010), a base plate height (2030), a base plate top (2050) parallel to a plane defined by the base plate width and the base plate length, a base plate bottom (2060) opposite the base plate top, a plurality of base plate mounting holes (2040), and a base plate groove (2070) having a base plate groove wall (2080); and
- wherein the framing member first end is disposed within the base plate groove, and a weld (3000) joins the framing member and the base plate.
2. The guard support assembly of claim 1, further comprising a second support clip (5000) having a second support clip lateral support leg (5100), a second support clip base support leg (5200) extending from a second support clip lateral support leg first edge (5110), a second support clip lower attachment leg (5300) extending from a second clip base support leg first edge (5210), with the second support clip lower attachment leg attached to the first flange or the second flange so that a second support clip lateral leg second end opposite of a second support clip lateral support leg first edge is oriented towards the framing member second end and a second support clip lower attachment leg first end is oriented towards the framing member first end.
3. The guard support assembly of claim 2, wherein a distance from the first support clip base support leg to the framing member first end is approximately equal to a distance from the second support clip base support leg to the framing member first end.
4. The guard support assembly of claim 1, further comprising at least one visibility device and/or visibility mark (5700).
5. The guard support assembly of claim 2, further comprising at least one visibility device and/or visibility mark.
6. The guard support assembly of claim 3, further comprising at least one visibility device and/or visibility mark.
7. The guard support assembly of claim 1, wherein the first support clip is in a shape of a handle further comprising a support clip top leg (5400) and a support clip top attachment leg (5500) attached to the framing member.
8. The guard support assembly of claim 2, wherein the second support clip is in a shape of a handle further comprising a support clip top leg (5400) and a support clip top attachment leg (5500) attached to the framing member.
9. The guard support assembly of claim 3, wherein the first support clip and the second support clip are in a shape of a handle each further comprising a support clip top leg (5400) and a support clip top attachment leg attached (5500) to the framing member.
10. The guard support assembly of claim 7, further comprising a plurality of visibility devices attached to at least one member of the group consisting of the web, the first flange and the second flange.
11. The guard support assembly of claim 8, further comprising a plurality of visibility devices attached to at least one member of the group consisting of the web, the first flange and the second flange.
12. The guard support assembly of claim 9, further comprising a plurality of visibility devices attached to at least one member of the group consisting of the web, the first flange and the second flange.
13. The guard support assembly of claim 1, further comprising a toe guard assembly having at least a toe guard support and a toe guard support attachment assembly.
14. The guard support assembly of claim 2, further comprising a toe guard assembly having at least a toe guard support and a toe guard support attachment assembly.
15. The guard support assembly of claim 3, further comprising a toe guard assembly having at least a toe guard support and a toe guard support attachment assembly.
16. The guard support assembly of claim 7, further comprising a toe guard assembly having at least a toe guard support and a toe guard support attachment assembly.
17. The guard support assembly of claim 8, further comprising a toe guard assembly having at least a toe guard support and a toe guard support attachment assembly.
18. The guard support assembly of claim 9, further comprising a toe guard assembly having at least a toe guard support and a toe guard support attachment assembly.
Type: Application
Filed: Apr 7, 2026
Publication Date: Aug 13, 2026
Applicant: Telling Industries, LLC (Willoughby, OH)
Inventors: Charles Andrew HABA (Kirtland, OH), Thomas D. OGLE (York, SC), Rahim A. ZADEH (Sandy Springs, GA), Shawn Patrick LEECH (Delaware, OH)
Application Number: 19/640,544