U.S. patent application number 11/153555 was filed with the patent office on 2005-12-15 for modular railing system.
Invention is credited to Brown, Alexander.
Application Number | 20050274940 11/153555 |
Document ID | / |
Family ID | 26860783 |
Filed Date | 2005-12-15 |
United States Patent
Application |
20050274940 |
Kind Code |
A1 |
Brown, Alexander |
December 15, 2005 |
Modular railing system
Abstract
A modular railing system supports a plurality of rails in
vertically-spaced configuration. The railing system includes a
plurality of baluster units arranged between rail sets to support
the rails. The baluster units include a plurality of rail supports
grouped into double barrel support pairs or single barrel support
pairs. The baluster units may include a short section of kick rail,
and longer sections of kick rail may extend between adjacent
baluster units. Also, additional rails may be joined to the modular
railing system using baluster extensions or extender bars. A stair
rail adjuster may be used, particularly when railing staircases, to
permit adjustment of the relative vertical height of one end of a
rail. To attach rails and balusters to stair treads, a
finished-stair-tread adapter may be used. The finished-stair-tread
adapter includes a baluster mounting member, a tread plate having a
first plurality of slip nuts slidingly mounted therein, and a riser
plate having a second plurality of slip nuts slidingly mounted
therein.
Inventors: |
Brown, Alexander; (Denver,
CO) |
Correspondence
Address: |
HEIMBECHER & ASSOCIATES, LLC.
390 UNION BLVD
SUITE 650
LAKEWOOD
CO
80228-6512
US
|
Family ID: |
26860783 |
Appl. No.: |
11/153555 |
Filed: |
June 14, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11153555 |
Jun 14, 2005 |
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10299490 |
Nov 18, 2002 |
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6905110 |
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10299490 |
Nov 18, 2002 |
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09712648 |
Nov 13, 2000 |
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6481697 |
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60164702 |
Nov 10, 1999 |
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Current U.S.
Class: |
256/59 |
Current CPC
Class: |
E04F 2011/1819 20130101;
E04F 2011/1821 20130101; E04F 11/1817 20130101; Y10T 403/7117
20150115; E04F 11/1865 20130101; E04F 11/1834 20130101; E04G
21/3223 20130101; Y10S 256/06 20130101; E04F 11/1812 20130101 |
Class at
Publication: |
256/059 |
International
Class: |
E04H 017/14 |
Claims
What is claimed is:
1. A modular railing system for railing a substantially-horizontal
surface, said modular railing system comprising a plurality of
rails, said plurality of rails being grouped into a plurality of
rail sets, wherein each of said rail sets of said plurality of rail
sets comprises at least two rails of said plurality of rails, each
rail of said plurality of rails having an elongated portion
extending between and joining two connector portions; and a
plurality of baluster units for supporting said plurality of rails,
wherein a first baluster unit of said plurality of baluster units
together with a second baluster unit of said plurality of baluster
units support each rail of said at least two rails of a first rail
set of said plurality of rail sets in vertically-spaced relation to
the other rail in said first rail set when said first rail set
comprises two rails and to each of the other rails in said first
rail set when said first rail set comprises greater than two rails,
and wherein each of said baluster units of said plurality of
baluster units comprises a baluster pair comprising a first
baluster and a second baluster, said first and second balusters
being adapted to be anchored to said substantially-horizontal
surface in close proximity to each other; a first plurality of
double barrel supports spaced along and affixed to said first
baluster, each double barrel support of said first plurality of
double barrel supports having a corresponding double barrel support
of a corresponding plurality of double barrel supports each of
which is spaced along and affixed to said second baluster, wherein
each of said double barrel supports spaced along and affixed to
said first baluster together with its corresponding double barrel
support spaced along and affixed to said second baluster
collectively comprise a double barrel support pair, there thus
being a plurality of double barrel support pairs, said plurality of
double barrel support pairs being equal in number to the number of
double barrel supports in said first plurality of double barrel
supports; and a plurality of tie pipes, each tie pipe connecting
the double barrel supports comprising one double barrel support
pair of said plurality of double barrel support pairs; wherein each
of said double barrel supports comprises a first support and a
second support, and wherein each of said tie pipes comprises a
first leg and a second leg, and wherein first and second double
barrel supports of a first double barrel support pair of said
plurality of double barrel support pairs are connected by inserting
a first leg of a first tie pipe of said plurality of tie pipes into
a first support of said first double barrel support of said first
double barrel support pair of said plurality of double barrel
support pairs, and inserting a second leg of said first tie pipe
into a first support of said second double barrel support of said
first double barrel support pair of said plurality of double barrel
support pairs.
2. The modular railing system of claim 1, wherein each of said
baluster units has a lower end adapted to be adjacent to said
substantially-horizontal surface, and wherein a long section of
kick rail extends between adjacent baluster units near said lower
ends of said baluster units.
3. The modular railing system of claim 2, wherein each of said
first and second balusters has a lower portion, wherein a plurality
of retention slots are cut into said lower portion of each
baluster, wherein each of said long sections of kick rail includes
an alignment tab; and wherein each of said alignment tabs rides in
one of said retention slots.
4. The modular railing system of claim 3, wherein said plurality of
retention slots comprises four retention slots spaced at
approximately 90.degree. intervals around a circumference of said
lower portion of each baluster.
5. The modular railing system of claim 3, wherein said alignment
tab are formed by removing material from said kick rails.
6. The modular railing system of claim 3, wherein each of said kick
rails has ends, and wherein said alignment tab are formed by
crushing said ends of said kick rails.
7. The modular railing system of claim 3, wherein said kick rails
are formed from sections of C-beam having an upper flange and a
lower flange connected by a vertical member.
8. A modular railing system for railing a substantially-horizontal
surface, said modular railing system comprising a plurality of
rails, said rails being grouped into rail sets, each of said rail
sets comprising at least one rail, each rail having an elongated
portion extending between two connector portions; and a plurality
of baluster units for supporting said plurality of rails, wherein
each baluster unit of said plurality of baluster units comprises a
plurality of rail supports spaced vertically along said baluster
unit and affixed thereto, each of said rail supports having a rivet
slot punched through it, and wherein each of said connector
portions has a retention hole through it, and further wherein a
fastener removably connects each of said connector portions to one
of said rail supports using one of said rivet slots and one of said
retention holes.
9. A modular railing system for railing a substantially-horizontal
surface, said modular railing system comprising a plurality of
rails, said rails being grouped into rail sets, each of said rail
sets comprising at least two rails, each rail having an elongated
portion extending between two connector portions; and a plurality
of baluster units for supporting said plurality of rails, wherein
said plurality of baluster units support said at least two rails of
each rail set in vertically-spaced relation to each other, and
wherein each of said baluster units comprises a first vertical
baluster tube and a second vertical baluster tube, each of said
first and second balusters tubes having a lower distal end, each of
said lower distal ends having a plurality of retention slots formed
therein, and each of said lower distal ends being affixed to a
shared base plate that is adapted to be anchored to said
substantially-horizontal surface; at least one elongated web
rigidly connected between said first and second baluster tubes,
wherein each elongated web has two longitudinal edges and two
lateral edges, wherein a first of said longitudinal edges is
connected to said first baluster tube, and a second of said
longitudinal edges is connected to said second baluster tube, and
further wherein one of said lateral edges is affixed to said base
plate; and a plurality of single barrel supports spaced along and
affixed to said first baluster tube, each of said single barrel
supports that is affixed to said first baluster tube having a
corresponding single barrel support spaced along and affixed to
said second baluster tube, wherein each of said single barrel
supports on said first baluster tube together with its
corresponding single barrel support on said second baluster tube
collectively comprise a single barrel support pair.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a division of United States utility
patent application Ser. No. 10/299,490, filed 18 Nov. 2002 (the
'490 application), now U.S. Pat. No. 6,905,110, issued 14 Jun. 2005
(the '110 patent), which is a division of United States utility
patent application Ser. No. 09/712,648, filed 13 Nov. 2000 (the
'648 application), now U.S. Pat. No. 6,481,697, issued 19 Nov. 2002
(the '697 patent), which in turn claims priority to U.S.
provisional application No. 60/164,702, filed 10 Nov. 1999 (the
'702 application). The '702 application, the '648 application, the
'490 application, the '697 patent, and the '110 patent are all
hereby incorporated by reference as though fully set forth
herein.
BACKGROUND OF THE INVENTION
[0002] a. Field of the Invention
[0003] The present invention is generally directed toward safety
equipment for use at construction sites. More specifically, it
relates to a modular railing system to enhance safety at
construction sites.
[0004] b. Background Art
[0005] It is well known by those in the construction industry that,
while construction is taking place at commercial and residential
building sites, certain safety measures must be taken to protect
the workers moving around the building site. In particular, until
the structure itself is framed, when uncontained horizontal
surfaces are present, there is a need to protect those persons
working near the edges of the floors and on staircases.
[0006] Further, the regulations of the Occupational, Safety and
Health Administration (OSHA) of the United States government
require the placement of safety railings along the edges of floors
and staircases. To satisfy OSHA regulations, these safety railings
must be able to resist certain minimum lateral loads without
becoming permanently deformed or destroyed. For example, it is a
requirement under certain circumstances that the safety railing be
able to support a load of 200 lbs. in any outward or downward
direction, without component failure. Similarly, kick rails or toe
boards must, under certain circumstances, be able to support a load
of 50 lbs. in any outward or downward direction.
[0007] Although other safety railing systems have been constructed
and used in the past, there remains a need for a modular railing
system that provides adequate safety to construction workers,
including construction workers using stilts.
BRIEF SUMMARY OF THE INVENTION
[0008] It is desirable to be able to construct a railing system
that is modular and relatively easily tailored to meet a variety of
physical circumstances present at job sites.
[0009] Accordingly, it is an object of the disclosed invention to
provide an improved modular railing system for construction
sites.
[0010] In a first preferred form, the modular railing system is
used for railing a substantially-horizontal surface. In this form,
the invention comprises a plurality of rails, the rails being
grouped into rail sets, each of the rail sets comprising at least
one rail, and each rail having an elongated portion extending
between two connector portions. A plurality of baluster units
support the plurality of rails, and each baluster unit comprises a
plurality of rail supports spaced vertically along the baluster
unit and affixed thereto. The baluster units according to the first
preferred form comprise a baluster pair including a first baluster
and a second baluster, the first and second balusters being
anchored to the substantially-horizontal surface in close proximity
to each other; a plurality of double barrel supports spaced along
and affixed to the first baluster, each of the double barrel
supports that is affixed to the first baluster having a
corresponding double barrel support spaced along and affixed to the
second baluster, wherein each of the double barrel supports on the
first baluster together with its corresponding double barrel
support on the second baluster collectively comprise a double
barrel support pair; and a plurality of tie pipes, each tie pipe
connecting the double barrel supports of one double barrel support
pair.
[0011] Each baluster unit according to a first alternative form
comprises an inverted-U-shaped main baluster tube having first and
second legs, each leg having a lower distal end that has a
plurality of retention slots formed therein, the distal ends of the
legs being affixed to an elongated base plate that includes an
integrated short kick rail having lateral ends that are
accommodated by two of the plurality of retention slots, wherein
the base plate is anchored to the substantially-horizontal surface;
and a plurality of single barrel supports spaced along and affixed
to the first leg, each of the single barrel supports that is
affixed to the first leg having a corresponding single barrel
supports spaced along and affixed to the second leg, wherein each
of the single barrel supports on the first leg together with its
corresponding single barrel support on the second leg collectively
comprise a single barrel support pair.
[0012] Each baluster unit according to a second alternative form
comprises a first vertical baluster tube and a second vertical
baluster tube, each of the first and second balusters tubes having
a lower distal end, each of the lower distal ends having a
plurality of retention slots formed therein, and each of the lower
distal ends being affixed to a shared base plate that is anchored
to the substantially-horizontal surface; at least one elongated web
rigidly connected between the first and second baluster tubes,
wherein each elongated web has two longitudinal edges and two
lateral edges, wherein a first of the longitudinal edges is
connected to the first baluster tube, and a second of the
longitudinal edges is connected to the second baluster, and further
wherein one of the lateral edges is affixed to the base plate; and
a plurality of single barrel supports spaced along and affixed to
the first baluster tube, each of the single barrel supports that is
affixed to the first baluster tube having a corresponding single
barrel support spaced along and affixed to the second baluster
tube, wherein each of the single barrel supports on the first
baluster tube together with its corresponding single barrel support
on the second baluster tube collectively comprise a single barrel
support pair.
[0013] Each baluster unit according to another alternative form
comprises an elongated web having first and second longitudinal
edges and two lateral edges, wherein one of the lateral edges is
affixed to a base plate that is anchored to the
substantially-horizontal surface, and wherein at least one
retention slot exists through the elongated web adjacent to the
lateral edge that is affixed to the base plate; and a plurality of
single barrel supports spaced along and affixed to the first
longitudinal edge, each of the single barrel supports that is
affixed to the first longitudinal edge having a corresponding
single barrel support spaced along and affixed to the second
longitudinal edge, wherein each of the single barrel supports on
the first longitudinal edge together with its corresponding single
barrel support on the second longitudinal edge collectively
comprise a single barrel support pair.
[0014] Each baluster unit according to yet another alternative form
comprises at least two elongated webs, each having first and second
longitudinal edges and two lateral edges, wherein one of the
lateral edges of each elongated web is affixed to a base plate that
is anchored to the substantially-horizontal surface, and wherein at
least one retention slot exists through the elongated webs adjacent
to the lateral edges affixed to the base plate; first and second
narrow web strips, wherein the first narrow web strip is
perpendicularly affixed to the first longitudinal edges of the
elongated webs, and the second narrow web strip is perpendicularly
affixed to the second longitudinal edges of the elongated webs; and
a plurality of single barrel supports spaced along and affixed to
the first narrow web strip, each of the single barrel supports that
is affixed to the first narrow web strip having a corresponding
single barrel support spaced along and affixed to the second narrow
web strip, wherein each of the single barrel supports on the first
narrow web strip together with its corresponding single barrel
support on the second narrow web strip collectively comprise a
single barrel support pair.
[0015] Each baluster unit according to another alternative form
comprises a first vertical baluster tube and a second vertical
baluster tube, each of the first and second balusters tubes having
an upper distal end and a lower distal end, each of the lower
distal ends having a plurality of retention slots formed therein,
and each of the lower distal ends being affixed to a shared base
plate that is anchored to the substantially-horizontal surface;
first and second web sections, the first web section being rigidly
connected between the first and second baluster tubes adjacent to
the lower distal ends of the baluster tubes, and the second web
section being rigidly connected between the first and second
baluster tubes adjacent to the upper distal ends of the baluster
tubes, wherein each of the first and second web sections has first
and second lateral edges and two longitudinal edges, wherein the
first lateral edges are connected to the first baluster tube, and
the second lateral edges are connected to the second baluster tube,
and further wherein one of the longitudinal edges of the first web
section is affixed to the base plate; and a plurality of single
barrel supports spaced along and affixed to the first baluster
tube, each of the single barrel supports that is affixed to the
first baluster tube having a corresponding single barrel support
spaced along and affixed to the second baluster tube, wherein each
of the single barrel supports on the first baluster tube together
with its corresponding single barrel support on the second baluster
tube collectively comprise a single barrel support pair.
[0016] Each baluster unit according to still another alternative
form comprises a first vertical baluster tube and a second vertical
baluster tube, each of the first and second balusters tubes having
an upper distal end and a lower distal end, each of the lower
distal ends having a plurality of retention slots formed therein,
and each of the lower distal ends being affixed to a shared base
plate that is anchored to the substantially-horizontal surface; a
first web section rigidly connected between the first and second
baluster tubes adjacent to the lower distal ends of the baluster
tubes, wherein the first web section has first and second lateral
edges and two longitudinal edges, wherein the first lateral edge is
connected to the first baluster tube, and the second lateral edge
is connected to the second baluster tube, and further wherein one
of the longitudinal edges of the first web section is affixed to
the base plate; an X-shaped structural support member rigidly
connected between the first and second baluster tubes adjacent to
both the lower and upper distal ends of the baluster tubes; and a
plurality of single barrel supports spaced along and affixed to the
first baluster tube, each of the single barrel supports that is
affixed to the first baluster tube having a corresponding single
barrel support spaced along and affixed to the second baluster
tube, wherein each of the single barrel supports on the first
baluster tube together with its corresponding single barrel support
on the second baluster tube collectively comprise a single barrel
support pair.
[0017] In another preferred form, the present invention comprises a
device for adding an additional rail to a top of an existing
modular railing system. In this preferred form, the device
comprises a plurality of baluster extensions, each of the
extensions having an upper end and a lower end, wherein each of the
lower ends is tapered to fit into an upper end of a corresponding
baluster, and further wherein a substantially horizontal hole
extends through the tapered lower ends of the extension, and
corresponding holes extend through upper ends of the balusters,
wherein the holes align to receive a fastener when the baluster
extensions are in place in the upper ends of the balusters.
[0018] In an alternative form of the device for adding an
additional rail to the top of an existing modular railing system,
the device comprises an extender bar. The extender bar comprises a
main bar that is bent into a configuration having two
downwardly-extending legs, each of the legs having an upper end and
a lower end, wherein a single barrel support is affixed to each leg
adjacent to its upper end, and wherein each of the lower ends of
the legs is tapered to fit into an upper end of a corresponding
baluster, and further wherein a substantially horizontal hole
extends through the tapered lower ends of the extender bar legs,
and corresponding holes extend through upper ends of the balusters,
wherein the holes align to receive a fastener when the extender bar
is in place in the upper ends of the balusters.
[0019] In another preferred form, the invention comprises a modular
railing system for railing a staircase. In this form, the invention
includes a plurality of staircase rails, the staircase rails being
grouped into rail sets, each of the rail sets comprising at least
one rail, each staircase rail having an elongated portion extending
between a first connector portion and a second connector portion,
wherein the first connector portion forms a first relative angle
with the elongated portion, and wherein the second connector
portion forms a second relative angle with the elongated portion,
the second relative angle being different from the first relative
angle; and a plurality of baluster units for supporting the
plurality of staircase rails. The railing system for railing a
staircase may also include a stair rail adjuster, the stair rail
adjuster comprising a rail support having an internal
cross-sectional configuration; and a longer cylindrical piece
affixed to the rail support and having an external cross-sectional
configuration designed to be slippingly accommodated by the
internal cross-sectional configuration of the rail support.
[0020] In still another preferred form, the modular railing system
of the present invention comprises a plurality of staircase rails;
a plurality of balusters for supporting the plurality of staircase
rails; and a finished-stair-tread adapter. The finished-stair-tread
adapter comprises a baluster mounting member; a tread plate having
a first plurality of slip nuts slidingly mounted therein, each slip
nut of the first plurality of slip nuts having a fastener hole
through it; and a riser plate having a second plurality of slip
nuts slidingly mounted therein, each slip nut of the second
plurality of slip nuts having a fastener hole through it.
[0021] In another preferred form, the present invention comprises a
clamp-on railing system for railing a staircase having stringers or
a pan staircase. This clamp-on railing system comprises a plurality
of staircase rails, the staircase rails being grouped into rail
sets, each of the rail sets comprising at least one rail, each
staircase rail having an elongated portion extending between a
first connector portion and a second connector portion, wherein the
first connector portion forms a first relative angle with the
elongated portion, and wherein the second connector portion forms a
second relative angle with the elongated portion, the second
relative angle being different from the first relative angle; and a
plurality of baluster and mounting bracket combinations for
supporting the plurality of staircase rails. Each of the mounting
brackets comprises a C-shaped channel in which a plurality of large
slip nuts are slippingly mounted, and each of the balusters has at
least one mounting holes drilled though its lower end. At least one
fastener is inserted through one of the mounting holes and fastened
in a fastener hole through a center of a first one of the plurality
of large slip nuts. The preferred form of the clamp-on system
further comprises two L bolts, each L bolt being threaded into a
large slip nut from the plurality of large slip nuts and threaded
against an inner surface of the C-shaped mounting brackets to seat
the corresponding slip nut firmly against inwardly-turned
longitudinal edges of the C-shaped mounting bracket.
[0022] Other aspects, features, and details of the present
invention will be apparent from reading the following description
and claims, and from reviewing the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is an isometric fragmentary view depicting different
sections of the modular railing system of the present invention in
place at a multi-leveled construction site where a lower
substantially horizontal surface and an upper substantially
horizontal surface are connected by a staircase.
[0024] FIG. 2 is an enlarged isometric view of a portion of the
section of the modular railing system depicted in FIG. 1 that is
mounted on the lower substantially horizontal surface.
[0025] FIG. 3 is an enlarged fragmentary view of a portion of the
section of the modular railing system depicted in FIG. 1 that is
mounted on the staircase.
[0026] FIG. 4 is an enlarged, fragmentary, partially-exploded
isometric view of a portion of the modular railing system depicted
in FIGS. 1-3.
[0027] FIG. 5 is an enlarged, fragmentary, exploded isometric view
of the lower end of a baluster and one end of a first embodiment of
a kick rail.
[0028] FIG. 6 is a top plan view of a portion of the section of the
modular railing system depicted in FIG. 2.
[0029] FIG. 7 is an elevation of the portion of the modular railing
system depicted in FIG. 6.
[0030] FIG. 8 is a fragmentary sectional view taken along line 8-8
of FIG. 7, including kick rail portions according to the first
embodiment of the kick rails.
[0031] FIG. 9 is a fragmentary cross-sectional view of the lower
portion of a baluster and two kick rails, taken along 9-9 of FIG.
8.
[0032] FIG. 10 is a partial cross-sectional view of a baluster and
a double barrel support taken along line 10-10 of FIG. 7.
[0033] FIG. 11 depicts a single baluster standing alone from a
first perspective.
[0034] FIG. 12 depicts the baluster of FIG. 11 from a view that is
offset 90.degree. about the longitudinal axis of the baluster as
shown in FIG. 11.
[0035] FIG. 13 is a fragmentary cross-sectional view along line
13-13 of FIG. 11, depicting the removable end cap in an upper
portion of a baluster.
[0036] FIG. 14 is a cross-sectional view along line 14-14 of FIG.
11, depicting attachment of the double barrel support to a baluster
and showing the rivet slots comprising part of each support.
[0037] FIG. 15 is a cross-sectional view along line 15-15 of FIG.
11, clearly depicting the relative position of the four retention
slots of the preferred embodiment.
[0038] FIG. 16 is similar to FIG. 12, but depicts an alternative
embodiment of a baluster designed to support only two rails.
[0039] FIG. 17 is similar to FIG. 2, but depicts extensions that
may be used in the modular railing system of the present invention
to add an additional rail.
[0040] FIG. 17A depicts an enlarged view of an extender bar, which
provides an alternative way to that shown in FIG. 17 for adding an
additional rail.
[0041] FIG. 18 is an enlarged fragmentary cross-sectional view
along line 18-18 of FIG. 17.
[0042] FIG. 19 is a view similar to FIG. 5 but depicts the lower
end of a baluster and one end of a second embodiment of a kick
rail.
[0043] FIG. 20 is a fragmentary elevation of the second embodiment
of the kick rail.
[0044] FIG. 21 is a fragmentary end view of the kick rail of FIG.
20 taken along line 21-21 of that figure.
[0045] FIG. 22 is a fragmentary cross-sectional view of the kick
rail of FIG. 20 taken along line 22-22 of that figure.
[0046] FIG. 23 is an exploded isometric view of a first alternative
baluster unit according to the present invention.
[0047] FIG. 24 is an assembled isometric view of one side of the
first alternative baluster unit depicted in FIG. 23.
[0048] FIG. 25 is similar to FIG. 24, but depicts the first
alternative baluster unit from the opposite side.
[0049] FIG. 26 is similar to the baluster unit depicted in FIGS.
23-25, but depicts a baluster unit having four support pairs rather
than tree.
[0050] FIG. 27 is an isometric view of a second alternative
baluster unit according to the present invention.
[0051] FIG. 28 is an isometric view of a third alternative baluster
unit according to the present invention.
[0052] FIG. 29 is an isometric view of a fourth alternative
baluster unit according to the present invention.
[0053] FIG. 30 is an isometric view of a fifth alternative baluster
unit according to the present invention.
[0054] FIG. 31 is an isometric view of a sixth alternative baluster
unit according to the present invention.
[0055] FIG. 32 is an isometric view of a seventh alternative
baluster unit according to the present invention.
[0056] FIG. 33 is an isometric view of an eighth alternative
baluster unit according to the present invention.
[0057] FIG. 34 is an isometric view of a ninth alternative baluster
unit according to the present invention
[0058] FIG. 35 is an isometric view of a stair rail adjuster and
depicts the use of rivet holes rather than the single rivet slot
shown in, for example, FIG. 4.
[0059] FIG. 36 is an isometric, fragmentary view depicting a
section of rail mounted on a straight staircase using balusters
mounted to finished-stair-tread adapters.
[0060] FIG. 37 is an enlarged and partially-exploded isometric view
of a portion of a baluster mounted on a finished-stair-tread
adapter shown in position above a portion of a staircase to which
it will be attached.
[0061] FIG. 38 is a further enlarged, exploded isometric view of a
portion of a baluster and the components comprising the
finished-stair-tread adapter shown assembled in FIG. 37.
[0062] FIG. 39 is similar to FIG. 37, but depicts the baluster and
finished-stair-tread adapter combination affixed to a staircase
with a portion of the upper stair tread broken away for
clarity.
[0063] FIG. 40 is a fragmentary, cross-sectional view taken along
line 40-40 of FIG. 39, but depicting stair treads having rounded
leading edges.
[0064] FIG. 41 is a fragmentary, cross-sectional view along line
41-41 of FIG. 40.
[0065] FIG. 42 is similar to FIG. 36, but depicts the railing
system mounted on a curved staircase.
[0066] FIG. 43 is a fragmentary, cross-sectional view taken along
line 43-43 of FIG. 42
[0067] FIG. 44 depicts a clamp-on staircase railing system for use
on pan staircases or staircases having stringers
[0068] FIG. 45 is an enlarged, isometric view of one baluster or
stanchion and its mounting bracket as used in the clamp-on
staircase railing system depicted in FIG. 44.
[0069] FIG. 46 is an enlarged, isometric view similar to FIG. 45,
but depicting the stanchion and its mounting bracket from a
different direction.
[0070] FIG. 47 is an enlarged, fragmentary cross-sectional view
taken along line 47-47 of FIG. 44.
[0071] FIG. 48 is a cross-sectional view taken along line 48-48 of
FIG. 45.
[0072] FIG. 49 is a cross-sectional view taken along line 49-49 of
FIG. 45.
[0073] FIGS. 50-52 depict the process of attaching the baluster and
mounting bracket combination shown in FIGS. 44-49 to a
staircase.
DETAILED DESCRIPTION OF THE INVENTION
[0074] The present invention comprises a modular railing system 10
that may be custom tailored to a variety of construction sites with
a minimum of alteration. The modular railing system 10 depicted in,
for example, FIG. 1 may be rapidly assembled at the construction
site and rapidly disassembled when it is no longer needed. The
resulting temporary railing system is smooth, with nothing that can
readily catch on a worker's equipment or clothing
[0075] Referring first to FIG. 1, a schematic representation of a
construction site is shown with a first preferred embodiment of the
modular railing system 10 of the present invention in position. As
depicted, the construction site comprises a lower substantially
horizontal surface 12 (or lower walking working surface) and an
upper substantially horizontal surface 14 (or upper walking working
surface) connected by a vertical wall 16, with a staircase 18
providing access between the lower surface 12 and the upper surface
14. As shown to best advantage in FIG. 1, the first preferred
embodiment of the modular railing system 10 comprises two major
types of sections. The first type of section is connected together
on a horizontal surface like the depicted lower horizontal surface
12. The second type of section is used on sloping surfaces like the
staircase 18 depicted in FIG. 1.
[0076] Referring more particularly to FIG. 2, which depicts a
section of modular railing used on horizontal surfaces, various
details of a first preferred embodiment of the present invention
are described. The section depicted in FIG. 2 is three rails high,
the three rails 17 being supported in vertically-spaced relation to
one another, and each modular rail 17 has a
substantially-horizontal elongated portion 19 between two
substantially-vertical connector portions 21. In the first
preferred embodiment for supporting the rails 17, two standards or
balusters 20, 20', which are identical in the preferred embodiment,
are attached to a substantially horizontal surface (e.g., the lower
horizontal surface 12 depicted in FIG. 1) in close proximity to
each other, thereby forming a baluster pair 22. In the first
preferred embodiment of the three-rail system depicted in, for
example, FIGS. 1 and 2, the balusters 20, 20' of a baluster pair 22
are substantially parallel and spaced apart approximately six to
nine inches.
[0077] As will be described in more detail below, in the first
preferred embodiment, each baluster 20, 20' includes a plurality of
double barrel supports 24, 24'. In particular, as depicted in the
section of modular railing shown in FIG. 2, three double barrel
supports 24, 24' are welded to each baluster 20, 20'. If necessary,
however, (e.g., if workers are using thirty-two or forty-two inch
stilts) a fourth rail 26 (FIG. 17) may be added to the modular
railing system 10 depicted in FIG. 2 using, for example, the
baluster extensions 28, 28' depicted in FIGS. 17 and 18, or the
extender bar 30 depicted in FIG. 17A, both of which are described
further below. As shown in FIG. 2, a plurality of tie pipes 32 are
used to connect the balusters 20, 20' of a baluster pair 22. With
the balusters 20, 20' of a baluster pair 22 placed six inches
apart, the tie pipes 32 have the inverted U-shaped appearance
depicted. If, however, it were desirable to space the balusters 20,
20' of a baluster pair 22 a different distance apart, obviously the
shape of the tie pipe 32 would vary accordingly. Each tie pipe 32
has two legs. One leg 34 (see FIG. 17) of a tie pipe 32 is inserted
into one support 36 of a double barrel support 24 on one baluster
20 of a baluster pair 22. The opposite leg 38 (FIG. 17) of that
same tie pipe 32 is inserted into one support 36' of a
corresponding double barrel support 24' on the adjacent baluster
20' of the baluster pair 22. The two double barrel supports 24, 24'
that are thus connected by a single tie pipe 32 comprise a double
barrel support pair 40. The three-rail arrangement depicted in FIG.
2, wherein the balusters 20, 20' of each baluster pair 22 are
placed approximately six inches apart, has been found to produce a
modular railing system that is able to support the lateral load
limits required by OSHA regulations.
[0078] As also shown in FIG. 2 and as explained further below in
connection with FIG. 5, a base plate 42, 42' is fixed (e.g., by
welding) to the lower end of each baluster 20, 20'. A short section
of kick rail (or toe board) 44 is placed between the lower ends of
the balusters 20, 20' of the baluster pair 22 just above the base
plates 42, 42'. The two vertical balusters 20, 20' of a baluster
pair 22, each with its own base plate 42, 42', a plurality of
double barrel support pairs 40 (e.g., three in FIG. 2), a
corresponding plurality of tie pipes 32, and a short section of
kick rail 44, together comprise a "baluster unit" 46 according to a
first preferred embodiment. Thus, the assembly between rail sets or
at the end of a rail set is referred to herein as a "baluster unit"
46. FIGS. 23-34, which are described more fully below, depict
alternative embodiments of baluster units. The baluster units 46
according to the first preferred embodiment just described in
connection with primarily FIG. 2 use double barrel support pairs
40, while the alternative baluster unit embodiments described below
in connection with FIGS. 23-34 use single barrel support pairs 48
(FIG. 24) for reasons discussed more fully below.
[0079] In the preferred embodiments, a plurality of support pairs
(double barrel support pairs 40 or single barrel support pairs 48)
are suspended one above another in spaced configuration. For
example, FIGS. 1-3, 6, 7, and 17 depict the use of double barrel
support pairs 40. Looking in particular at FIG. 2, three double
barrel supports 24 are welded to a first baluster 20 and three
corresponding double barrel supports 2' are welded to a
corresponding second baluster 20' of a baluster pair 22 at a
preselected vertical spacing to achieve a desired vertical rail
separation. Each double barrel support 24 in combination with its
corresponding double barrel support 24' together comprise a double
barrel support pair 40. As shown in FIG. 2, a first double barrel
support 24 of a first double barrel support pair 40 is welded to
the first baluster 20 of a baluster pair 22, and a corresponding
first double barrel support 24' of the first double barrel support
pair 22 is welded to the second baluster 20' of the baluster pair
22. These two double barrel supports 24, 24' are welded to their
respective balusters 20, 20' at the same longitudinal position
along the balusters 20, 20'. In FIG. 2, the balusters 20, 20' of a
baluster pair 22 are "tied" together by multiple tie pipes 32 and a
short section of kick rail 44. In this embodiment, each tie pipe 32
has one leg 34 inserted into one support 36 of a first double
barrel support 24, and the other leg 38 inserted into one support
36' of a corresponding double barrel support 24'. As shown in FIGS.
6 and 7, for example, when double barrel supports 24, 24' are used,
one support 36, 36' of each double barrel support 24, 24'
accommodates one leg 34 of a tie pipe 32, and the other support 50,
50' can accommodate the connector portion 21 (FIGS. 2, 4, and 17)
of a rail 17. As described further below, FIGS. 23-34 depict
alternative baluster unit configurations where single barrel
support pairs 48 are used. In each of these alternative baluster
unit configurations, tie pipes 32 are not required. Thus, double
barrel supports 24, 24' are unnecessary.
[0080] A long section of kick rail 52 (FIG. 2) is placed between
one baluster 20, 20' from each of two adjacent baluster units 46.
These long sections of kick rail 52 and the short sections of kick
rail 44 mentioned above provide containment. Thus, if a worker on
the lower horizontal surface 12 depicted in FIG. 1 were to drop a
tool, it would be contained from rolling or being kicked off of the
lower horizontal surface 12 by the short and long sections of kick
rail 44, 52, respectively, connecting the lower ends of the
balusters 20, 20'. In an alternative configuration, a single
section of kick rail (not shown) that is longer than the long
section 52 depicted in, for example, FIG. 2, extends between
adjacent baluster units 46 in a manner that satisfies the
containment function of the kick rails 44, 52. For example, the
single, longer section of kick rail (not shown) could extend from
the leftmost baluster 20 depicted in FIG. 2 to the baluster 20 that
is second from the right in that figure, replacing one short
section 44 and one long section 52, while continuing to provide the
desired containment.
[0081] Referring next to FIG. 3, some details concerning the
section of the modular railing system used on sloping surfaces like
the depicted staircase 18 are described next. In FIG. 3, a portion
of a staircase 18 is shown. As shown in FIG. 1, a stringer 54 is
attached along each longitudinal edge of the treads 56 and risers
58 comprising the depicted staircase 18. In FIG. 3, only one
stringer 54 is shown and is attached to the rear edges of the stair
treads 56 and risers 58. The front stringer has been removed in
this figure for clarity. Since the stringers 54 provide the
containment that is provided by the kick rails 44, 52 on the
substantially horizontal surfaces 12, 14 it is not necessary to use
kick rails on each sloped staircase 18. Further, since workers are
not permitted to walk on the steps of the staircase 18 with stilts,
it is typically only necessary to provide two staircase rails 17'
on the portions of the modular railing system 10 that are attached
to staircases 18.
[0082] Another difference between the sections of the modular
railing system used on substantially horizontal surfaces 12, 14 and
the sections of the modular railing system used on sloped surfaces
like staircases 18 comprises the relative angles 60, 62 (FIG. 3)
between the elongated portion 19' of a staircase rail 17' and the
connector portions 21' of the same rail 17'. Although the same
balusters 20, 20' are used to support both horizontal rails 17
(e.g., FIG. 2) and inclined staircase rails 17' (e.g., FIG. 3), the
rails themselves are different. For each horizontal rail 17, the
end or connector portions 21 are bent 90.degree. downwardly from
the elongated horizontal portion 19 to form the vertical connector
portions 21. For inclined applications (e.g., staircases 18),
however, one vertical connector portion 21' of the staircase rail
17' forms an angle of approximately 130.degree. with the inclined
elongated portion 19' of the rail 17', and the other vertical
portion 21' of the same staircase rail 17' forms an angle of
approximately 60.degree. with the inclined elongated portion 19'.
These relative angles 60, 62 may vary somewhat, but the relative
angle 60 between the elongated portion 19' and the connector
portion 21' at an upper end of a rail 17' will be less than
90.degree., and the relative angle 62 at a lower end of the same
rail 17' will be greater than 90.degree.. Once one knows the aspect
ratio of the staircase 18 (i.e., the length of the treads 56
vis-a-vis the height of the risers 58), the relative angles 60, 62
are easily calculated.
[0083] Referring next to FIG. 4, details concerning one preferred
form for the interconnection of a rail 17 and a baluster 20 or of a
tie pipe 32 and a baluster 20 are described next. FIG. 4 is a
fragmentary, partially-exploded isometric view of the top end of
one baluster 20. As shown in less detail in FIGS. 1-3, each
baluster has a plurality of double barrel supports 24 attached
thereto. In the preferred embodiment, each support 36, 50 of a
double barrel support 24 is made from a section of circular pipe
having an inside diameter sufficiently large to accommodate the
outside diameter of a rail 17, 17'or tie pipe 32. In the preferred
embodiment, the outside diameter of the rails 17, 17'is the same as
the outside diameter of the tie pipes 32 so that a single inside
diameter pipe may be used for each support 36, 50 of a double
barrel support 24 attached to a baluster 20.
[0084] FIG. 4 depicts a first preferred technique for holding a
rail 17, 17' or tie pipe 32 in a support 36, 50. As shown in FIG.
4, and as described further below, the rails 17, 17' and tie pipes
32 are held in position in a support 36, 50 using a combination of
a retention hole 64, a rivet slot 66, and a rivet 68. For example,
the retention hole 64 in the connector portion 21 of the rail 17
depicted in FIG. 4 is clearly visible. A similar retention hole
(not shown) may be drilled on each leg 34, 38 of a tie pipe 32.
During assembly, the rails 17 and tie pipes 32 are placed in the
appropriate supports 36, 50 on the balusters 20. Once the modular
railing system 10 is desirably positioned, rivets 68 are inserted
through the rivet slots 66 in the supports 36, 50 and into the
retention hole 64 in either a tie pipe 32 or connector portion 21
of a rail 17. The rivet slots 66 permit access to the retention
holes 64 independent of the angular position of either the rail 17
or tie pipe 32 in the support 36, 50. The rivet 68 thus securely,
but removably, secures the rail 17 or tie pipe 32 to a baluster 20.
If desired, bolts, screws, or other similar connectors (not shown)
could be used in place of the rivet 68 depicted in FIG. 4. Also
depicted to clear advantage in FIG. 4 is a removable end cap 70.
These removable end caps 70 are inserted into the top of each
baluster 20, 20' to keep contaminates like water and construction
debris from getting packed in the balusters 20, 20'. As will be
discussed further below with reference to FIGS. 17 and 18, if
baluster extensions 28, 28' are used, the end caps 70 are removed
from the balusters 20, 20' and placed in the ends of the extensions
28, 28'.
[0085] FIG. 5 is a view similar to FIG. 4, but depicts the lower
portion of a baluster 20. As shown in FIG. 5, a base plate 42 is
affixed to the bottom of each baluster 20. In the preferred
embodiment, the baluster 20 is centered on the base plate 42, but
that is not required. For example, as shown in FIG. 3, the
balusters 20, 20' may be offset slightly from the center of their
respective base plates 42, 42'. When a baluster is offset slightly
from the centers of its base plate, it may be possible to place
that baluster closer to the edge of an attachment surface, whether
that be a horizontal surface or a stair tread. As clearly shown in
FIG. 5, each base plate 42 has a plurality of attachment holes 72.
Nails or preferably bolts passing through the attachment holes are
used to attach each base plate 42 to an attachment surface.
[0086] As shown in FIG. 5, a plurality of retention slots 74 are
cut or stamped into the lower portion of each baluster 20. In the
preferred embodiment, these retention slots 74 are spaced at
approximately 90.degree. intervals around the circumference of each
baluster 20 as shown to good advantage in FIG. 15. Each kick rail
44, 52 in the preferred embodiments includes an alignment tab 76
that is inserted into one of the retention slots 74 during
assembly. In the first preferred embodiment of the kick rails 44,
52, which is shown to best advantage in FIGS. 5, 8, and 9, these
alignment tabs 76 on the ends of the various sections of kick rail
are formed by cutting or punching during formation of the kick
rails 44, 52. Alternatively, and most preferably, in a second
preferred embodiment of the kick rails, the alignment tabs 76' are
formed by crushing the ends of the kick rail as described more
fully below in connection with FIGS. 19-22. As described further
below in connection with FIGS. 8 and 9, the kick rails may be
quickly assembled to the balusters by inserting the alignment tabs
76, 76' into appropriate retention slots 74. Each kick rail in the
preferred embodiment is in the form of a C-beam having an upper
flange 78 (FIG. 9) and a lower flange 80 (FIGS. 8 and 9) connected
by a vertical member 82. A variety of cross-sectional
configurations could, however, be used for the kick rails.
[0087] Referring next to FIGS. 6 and 7, further assembly details
may be seen. FIG. 6 is a top plan view of the section of the
modular railing system depicted in FIG. 2. Thus, FIG. 6 clearly
shows many of the angular relationships between various components.
For example, in the preferred embodiment, the long sections of kick
rail 52 extend between one baluster 20 of two adjacent baluster
units 46. In the preferred arrangement, the balusters 20, 21' of a
baluster unit 46, two of such baluster units 46 being depicted in
FIGS. 6 and 7, are positioned such that the double barrel supports
24, 24' on each baluster 20, 20' are facing one another, with the
"outside supports" 36, 36' of each double barrel support pair 40
being directly across from each other. The "outside supports" 36,
36' are the ones that accommodate tie pipes 32. This permits the
remaining support 50, 50' of each double barrel support 24, 24' to
accommodate the connector portion 21 of a rail 17. The balusters
20, 20' of a baluster unit 46 are thus preferably positioned in a
slightly offset configuration rather than directly across from each
other. For example, in FIG. 7, which is an elevation taken
substantially perpendicular to the plane of the depicted section of
the modular railing system, the two balusters 20, 20' of each
baluster unit 46 appear side-by-side rather than one behind the
other. When connected properly, the tie pipes 32 help maintain the
desired relative position of the balusters 20, 20' of a baluster
unit 46 as does the short piece of kick rail 44 between the lower
ends of the balusters 20, 20' of a baluster unit 46. As shown in
FIG. 6, the long section of kick rail 52 forms a shallow X with the
rails 17 mounted above that particular long section of kick rail
52. Also, as shown in FIG. 7, in the preferred embodiment, the
elongated portion of each top rail extends above the top of the
balusters to which it is connected.
[0088] Referring next to FIGS. 8 and 9, details concerning the
connection of the short and long kick rail sections 44, 52 to
balusters 20, 20' is described next. The alignment tabs 76 are
designed to fit within the retention slots 74 in the lower ends of
each baluster 20, 20'. It is desirable to have the retention slots
74 in close proximity to the lowest end of the balusters 20, 20' so
that the kick rails 44, 52 are as close as possible to the
horizontal surface (e.g., the lower horizontal surface 12 depicted
in FIG. 1) when the modular railing system 10 is fully assembled.
This prevents objects from inadvertently slipping or rolling under
the kick rails 44, 52 and defeating their safety (i.e.,
containment) purpose. As shown in FIG. 9, the kick rails may be
notched on their ends, adjacent the alignment tabs 76. This
notching not only clearly defines the alignment tabs 76, but also
makes room for weld beads 84 that may be present at the union
between the baluster 20 and its base plate 42.
[0089] Referring next to FIG. 10, attachment of the supports 50, 36
of a double barrel support 24 to a baluster 20, and subsequent
attachment of either a leg 34, 38 of a tie pipe 32 or a connector
portion 21 of a rail 17 to its respective support 36, 50 is
described next. In the first preferred embodiment, the supports 36,
50 of a double barrel support 24 are welded to a baluster 20 and to
each other as shown by the three weld beads 86 in FIG. 10. Other
known methods of attaching components could be used in place of the
welding technique of the preferred embodiment without deviating
from the present invention. For example, the supports could be
attached to the baluster by a wire or band of metal (not shown)
wrapped around the baluster 20 and the supports 36, 50. If the
rivets 68 are tightly fastened, the rails 17 or tie pipes 32 may be
substantially fixed in position after assembly is complete. If
desired, however, the rivets 68 may be left slightly loose since
the primary purpose of the rivets 68 is to keep the rails 17 and
tie pipes 32 from inadvertently coming out of the supports 36, 50
rather than to rigidly fix the rails 17 and tie pipes 32 in a
specific angular position within the supports 36, 50. When it is
time to remove the modular railing system 10 of the present
invention from a construction site, the rivets 68 may be cut or
drilled out to permit removal of the rails 17 and tie pipes 32 from
the supports 36, 50 and subsequent disassembly of the entire
modular railing system. Clearly, bolts, screws, or other similar
connectors could be used in place of the rivets 68.
[0090] Referring next to FIGS. 11-15, additional features of the
balusters 20, 20' and supports 36, 50 in the present invention are
described. As shown in FIGS. 11 and 13, the removable end cap 70
previously discussed is slipped into the top of each baluster 20.
These removable end caps 70 could be made from, for example, a
flexible plastic or rubber material so that, once in position, they
resist easy removal to prevent them from inadvertently falling out
of the balusters 20. As shown to best advantage in FIG. 14 and as
previously discussed in connection with FIG. 10, in the preferred
embodiment the supports are attached to a baluster by welding. As
shown in FIG. 15, the preferred embodiment uses four attachment
holes 72 through which base plate bolts (see e.g., FIG. 38) attach
the base plates 42 to either a horizontal working surface 12, 14 or
the top of the treads 56 in the case of rails 17' used on
staircases 18. Although the base plate 42 design depicted in FIG.
15 has worked well in this preferred embodiment, myriad different
configurations for the base plate 42 and the attachment holes 72
could be used without deviating from the scope of the present
invention.
[0091] FIG. 16 depicts another embodiment of a baluster 20
according to the present invention. This baluster could be used on
a staircase 18 where three rails are not required. It could also be
used in construction situations where the extra height provided by
the three-rail system shown in, for example, FIGS. 1, 2, and 7 is
not mandated by the OSHA regulations.
[0092] Referring next to FIGS. 17 and 18, baluster extensions 28,
28', which permit the ready attachment of an additional rail, are
described next. If, for example, a fourth rail 26 were desired or
required to be added to the modular railing system 10 depicted in
FIG. 2, a plurality of extensions 28, 28' could be inserted into
the balusters 20, 20' depicted in FIG. 2 to facilitate the addition
of a fourth double barrel support pair 40 to accommodate additional
tie pipes 32 and fourth rails 26. It should be noted that the
extensions 28, 28' depicted in FIGS. 17 and 18 could also be used
with the shorter baluster depicted in FIG. 16 to add a third
rail.
[0093] As shown to best advantage in FIG. 18, the lower end 88 of
an extension 28 is wedged or otherwise reduced to fit into the
upper end of a corresponding baluster 20. For example, the
removable end cap 70 (see FIGS. 4 and 12) could be removed from the
upper end of a baluster 20 and placed into the upper end of an
extension 28. Then, the tapered lower end 88 of the extension 28
could be placed into the now open upper end of the baluster 20. In
the preferred embodiment for the extensions 28 depicted in FIGS. 17
and 18, a substantially horizontal hole 90 passing through the
tapered lower end 88 of the extension 28 aligns with a
corresponding hole 92 in the upper end of the baluster 20. Thus,
when the extensions 28, 28' are inserted into the upper ends of the
balusters 20, 20', a retention bolt 94 and nut 96 combination may
be used to removably retain the extensions 28, 28' in the balusters
20, 20'. Alternatively, rivets, screws, or other similar connectors
could be used in place of the depicted retention bolt 94 and nut 96
combination, particularly since the selected connector will not be
required to bear any substantial shear stress. Preferably, if the
extensions 28, 28' are used to create the four-rail modular railing
system depicted in FIG. 17, the center of the top rail 26 is
approximately eighty-four inches above the surface to which the
balusters are attached. The balusters 20, 20' of a baluster unit 46
are preferably placed twelve inches apart in such a four-rail
modular railing system.
[0094] FIG. 17A depicts an extender bar 30, which provides an
alternative technique to that shown in FIGS. 17 and 18 for adding
an additional rail. The extender bar 30 comprises a main bar 98
that is bent into a configuration that resembles a lower case
letter "N" having legs with tapered lower ends 100. Each leg of the
main bar 98 is depicted as also having a shoulder or slight inward
jog 102 formed therein between the respective single barrel rail
support 47, which is preferably welded to the main bar 98, and
tapered lower end 100. These jogs 102 can provide additional
rigidity to the extender bar 30 or help position the single barrel
supports 47 to receive the connector portions 21 of an added top
rail. The extender bar 30 is designed primarily for embodiments
having vertical baluster tubes 20, 20' (e.g., the embodiments
depicted in FIGS. 2, 7, 17, 27, 28, 33, and 34) that permit
insertion of the tapered lower ends 100 of the extender bar 30 into
the upper ends of the vertical balusters 20, 20' to add a fourth
rail 26. Alternatively, if the first alternative baluster unit 46'
depicted in FIGS. 23-26, which does not have a vertical baluster
tube 20, were modified to use a double barrel support pair 40 at
least in place of the top single barrel support pair 48, then the
extender bar 30 depicted in FIG. 17A could also be used with this
type of baluster unit. The extender bar 30 depicted in FIG. 17A
would work as well, or better in certain applications, without the
jog 102. For example, this "jogless" extender bar (not shown) would
work well with embodiments that have vertical baluster tubes 20,
20'.
[0095] FIGS. 19-22 depict an alternative kick rail alignment tab
76'. FIG. 19 is most similar to FIG. 5. When the alignment tabs 76'
according to the second preferred embodiment for them are used, the
retention slots 74' may need to be slightly larger. This up-sizing
of the retention slots 74' may be seen from a close comparison of
FIGS. 5 and 19. The retention slots 74' must be made slightly
larger since the alignment tabs 76' according to the second
preferred embodiment for them are formed by crushing the ends of
the kick rails 52. In particular, as shown to good advantage in
FIG. 20, a portion of the upper flange 78 and a portion of the
lower flange 80 are crushed against the vertical member 82 of the
kick rail 52 to form the alternative embodiment for the alignment
tabs 76'. FIG. 21 is a fragmentary end view along line 21-21 of
FIG. 20 and clearly depicts the crushed portions of the upper and
lower flanges 78, 80 being pressed against the vertical member 82
of the kick rail 52. FIG. 22 is a fragmentary cross-sectional view
along line 22-22 of FIG. 20 of an uncrushed portion of kick rail.
The embodiment of the alignment tabs 76' depicted in FIGS. 19-22
are preferred over the embodiment of the alignment tabs 76 depicted
most clearly in FIGS. 5, 8, and 9. The alignment tabs 76' depicted
in FIGS. 19-22 are simpler to manufacture.
[0096] FIGS. 23-34 depict alternative ways to make baluster units.
In FIGS. 23-26, a first alternative baluster unit 461 according to
the present invention is depicted. As shown, each such baluster
unit 461 comprises a U-shaped main baluster tube 104, which is
inverted and then welded to an elongated base plate 106. In this
particular embodiment, the base plate 106 includes an integrated
short kick rail 108, the lateral ends of which are accommodated by
retention slots 74" on the distal ends of the main baluster tube
104. Alternatively, the short kick rail could be welded to the base
plate rather than comprising an integral part thereof.
[0097] FIG. 27 depicts a second alternative baluster unit 46II
according to the present invention, and FIG. 28 depicts a third
alternative baluster unit 46III according to the present invention.
In these figures, the "baluster unit" comprises two vertical
baluster tubes 20" sharing a single, common base plate 106'; a
plurality of single barrel support pairs 48; and a single elongated
web 110 (FIG. 27) or a pair of elongated webs 112 (FIG. 28).
Retention slots 74" are formed at 90.degree. intervals around the
lower ends of the two vertical balusters 20".
[0098] FIGS. 29-32 depict, respectively, fourth, fifth, sixth, and
seventh alternative baluster units 46IV, 46V, 46VI, 46VII according
to the present invention. These baluster units do not use vertical
baluster tubes. The "baluster units" depicted in FIGS. 29 and 30
are similar to those depicted in FIGS. 27 and 28, respectively. In
the embodiments of FIGS. 29 and 30, however, the three single
barrel support pairs 48 are directly welded to edges 114 of an
elongated web 110 (FIG. 29) or to narrow web strips 116 that
perpendicularly join first and second elongated webs of an
elongated web pair 112, thereby forming a narrow "box beam"
configuration (FIG. 30). The retention slots 74" for the kick rails
are formed in the elongated web or webs. Additionally, in FIG. 30,
an additional retention slot 74" may be formed in the narrow web
strips 116.
[0099] The "baluster units" depicted in FIGS. 31 and 32 are most
similar to the "baluster unit" depicted in FIG. 29. In FIG. 31,
however, which depicts the sixth alternative baluster unit 46VI
according to the present invention, the plain elongated web 110
(FIG. 29) has been replaced by an elongated mesh web 118 having
retention slots 74" formed near a lower end thereof. In FIG. 32,
the plain elongated web 110 depicted in FIG. 29 has been replaced
by an elongated decorative metal web 120 (e.g., "diamond plate").
The mesh web 118 or the decorative web 120 could also be formed
into a narrow box beam configuration like that shown in FIG.
30.
[0100] In FIG. 33 is shown an eighth alternative baluster unit
46VIII according to the present invention. This baluster unit is
most similar to the baluster unit 4611 shown in FIG. 27. In the
embodiment of the baluster unit 46VIII depicted in FIG. 33,
however, the single elongated web 110 has been replaced by two
smaller web sections 108, 122. The lower of these web sections 108
serves as a kick rail and could be integrally formed with the
common base plate 106. The upper of these smaller web sections 122
ties the two vertical baluster tubes 20" together. The baluster
unit 46IX shown in FIG. 34 is similar to the baluster unit 46VIII
embodiment shown in FIG. 33, but the upper web section 122 has been
replaced with a horizontal support piece 124 welded between the two
vertical baluster tubes 20". In this ninth alternative embodiment,
an X-shaped structural support member 126 also has been welded
between the two vertical baluster tubes 20". In view of the
X-shaped structural support member 126, the horizontal support
piece 124 is not required, but provides additional structural
integrity.
[0101] FIGS. 35-43 depict components used to attach a railing
system to straight and curved staircases, particularly those having
finished treads. The "stair rail adjuster" 128 depicted in FIG. 35
is required to adjust the height of the upper end of inclined rails
17' when the balusters 20 are used on staircases 18 as shown in,
for example, FIG. 36. Typically, in a two-rail system, the rails
must be twenty-one inches apart. Thus, in the embodiment shown in
FIG. 36, the top rail would be forty-two inches above the stair
treads 56. OSHA regulations, however, provide that, when stairs are
railed and the top horizontal rail acts as the handrail, that
handrail must be .+-.one inch from thirty-six inches above the nose
or leading edge 130 of the stair tread 56. The leading edge 130
typically sticks out 11/2 inches from the riser 58 of the next
lower step. To make it possible to use a standard baluster 20 on
staircases 18, a stair rail adjuster 128 must be used to bring the
top rail height down from forty-two inches to thirty-seven inches
above the leading edge 130 of the stair tread 56 to comply with
OSHA requirements. Since the risers 58 are typically five inches
high, this results in the upper rail being thirty-seven inches from
the nose 130 of the stair treads 56 along the entire length of the
top rail.
[0102] Although the stair rail adjuster 128 is designed to decrease
the vertical distance between the upper end of an inclined rail 17'
and the nose 130 of the tread 56 by approximately five inches,
additional vertical adjustability is available since the longer
cylindrical piece 132 of the stair tread 128 adapter rides in one
side of the double barrel support 24. Also, the stair rail adapter
128 may be pivoted within the one side of the double barrel support
24 to account for varying distances between one baluster and the
next. In particular, stair treads must be at least nine inches
deep, but are typically ten inches or ten and one-half inches deep.
Since the stair rail adjuster may be pivoted in the double barrel
support 24 in which it is mounted, it is unnecessary to have as
many different lengths of rail 17' to select from to accommodate a
wide variety of staircases 18. Whereas the horizontal rails 17 are
preferably made in six inch increments to accommodate as many
installation scenarios as reasonably possible, the staircase rails
17' used for incline applications are manufactured in ten inch
increments based upon the fact that most stair treads 56 are ten
inches deep. The ability to pivot the stair rail adapter 128 in one
support of the double barrel support 24 allows the system to
accommodate different stair tread depths and irregularities, even
though there is preferably a limited number of rail lengths from
which to choose.
[0103] Referring most particularly to FIGS. 36-41, a
finished-stair-tread adapter 134, which is used to rail both
straight and curved staircases, is shown. The finished-stair-tread
adapter 134 may be used on any staircase built to the requirements
of the universal building code, including straight staircases (FIG.
36), curved staircases (FIG. 42), circular staircases, switchback
staircases, and even irregular staircases, but it is particularly
useful for finished stairs (e.g., oak hardwood), which have
previously been difficult to rail. It may also be used whether the
leading edge of the stair tread is squared (e.g., FIGS. 36, 37, and
39) or rounded (e.g., FIG. 40). If a standard railing system
attachment is used, it causes unsightly blemishes to the
to-be-finished stair treads. In particular, most railing systems
require large lag screws or bolts that unacceptably mar finished
treads 56. As discussed further below, a standard single baluster
20 mounts on the finished-stair-tread adapter 134, which is then
mounted on a stair tread 56 using one screw 136 into the riser 58.
This permits the attachment of any standard baluster 20 on any
staircase 18, including high-end staircases that are themselves
finished rather than being carpeted over.
[0104] Referring to FIGS. 36-43, details concerning the
finished-stair-tread adapter 134 are described next. As shown to
best advantage in FIG. 38, the essential components of the
finished-stair-tread adapter 134 include a baluster mounting member
138, a riser plate 140, a tread plate 142, a plurality of slip nuts
174, and assorted screws and bolts. As shown in the upper portion
of FIG. 38, the baluster mounting member 138 comprises a baluster
support plate 146 having positioning slots 148 therethrough, a
vertical back plate 150 having attachment holes 151 therethrough,
and a leveling or positioning member 152. As shown to good
advantage in FIGS. 38 and 40, the baluster support plate 146 may
include a rear edge 154 that is joined to a lower edge 156 of the
vertical back plate 150. Alternatively, the baluster support plate
146 and the vertical back plate 150 may be formed from a single
piece of material that is bent at approximately 90.degree. to form
the baluster support plate 146 and vertical back plate 150. The
leveling or positioning member 152 is then attached to a lower
surface of the baluster support plate 146 adjacent to the rear edge
154 of the baluster support plate 146 as shown in FIG. 40.
[0105] The tread plate 142 includes a horizontal mounting surface
158, a vertical leading edge surface 160, and an inwardly-turned
ledge 162 extending from the lower edge of the leading edge surface
160. This inwardly-turned ledge 162, in combination with the
leading edge surface 160 and a portion of the horizontal mounting
surface 158 together form a leading edge clip, which holds the
tread plate 142 in position over the leading edge 130 of a stair
tread 56 (see, e.g., FIG. 40) whether that leading edge 130 is
rounded (FIG. 40) or squared (FIG. 39). Two, elongated, C-shaped
slip nut channels 164 are mounted (e.g., by welding) to the
horizontal mounting surface 158 in spaced parallel configuration.
Each of these slip nut channels 164 comprises a bottom wall 166,
two side walls 168, two top walls 170, and two overhung free
longitudinal edges 172. In the preferred embodiment, two slip nuts
174 are mounted in each of the horizontal slip nut channels 164.
Each slip nut 174 has a threaded hole 175 through it. The cross
section of each slip nut in a plane that is perpendicular to the
axis of the threaded hole 175 is substantially square. As shown to
best advantage in FIG. 41, which is a cross-sectional view taken
along line 41-41 of FIG. 40 through two of the slip nuts 174, each
slip nut includes a raised central portion 176 straddled on each
side by an edge seat 178 that slippingly rides along one of the
overhung free longitudinal edges 172 of a slip nut channel 164. As
seen in FIG. 41, the raised central portion 176 is slightly
narrower than the gap between the overhung free longitudinal edges
172 of the slip nut channels 164. This provides some play in the
system to accommodate staircase irregularities.
[0106] The riser plate 140 comprises a vertical mounting surface
180 having a plurality of attachment holes 182 therethrough. In the
preferred embodiment, two elongated, C-shaped slip nut channels
164' are affixed (e.g., by welding) to the vertical mounting
surface 180 in spaced parallel configuration. A slip nut 174 is
slippingly mounted in each of these vertical slip nut channels 164'
mounted to the vertical mounting surface 180 of the riser plate
140. The slip nuts 174 mounted in the vertical slip nut channels
164' mounted to the vertical mounting surface 180 of the riser
plate 140 are interchangeable with the slip nuts 174 mounted in the
horizontal slip nut channels 164 mounted to the horizontal mounting
surface 158 of the tread plate 142.
[0107] When a finished-stair-tread adapter 134 is mounted to a
straight staircase, four baluster mounting bolt 184 and washer 186
combinations are passed through the attachment holes 72 in the base
plate 42 of the baluster 20. These baluster mounting bolts 184 are
then routed through one of the positioning slots 148 in the
baluster support plate 146. Finally, the baluster mounting bolts
184 are threaded into one of the slip nuts 174 that are positioned
in the horizontal slip nut channels 164. Similarly, additional
mounting bolt 184 and washer 186 combinations are passed through
attachment holes 151 in the vertical back plate 150 of the baluster
mounting member 138 and threaded into corresponding slip nuts 174
mounted in the vertical slip nut channels 164' affixed to the
vertical mounting surface 180 of the riser plate 140. A riser plate
mounting screw 136 is then passed through one of the plurality of
attachment holes 182 through the vertical mounting surface 180 of
the riser plate 140 and threaded into a staircase riser 58. If the
baluster 20 would interfere with placement of the riser plate
attachment screw 136 through the vertical mounting surface 180 of
the riser plate 140, the riser plate 140 may be attached to the
riser 58 using the riser plate attachment screw 136 before the
mounting bolts 184 that attach the baluster mounting member 138 to
the riser plate 140 are threaded into position.
[0108] To prevent damage to the finished stair treads 56, an
anti-mar mat 188 is placed between the bottom of the horizontal
mounting surface 158 of the tread plate 142 and the top of the
finished stair tread 56. This anti-mar mat 188 can comprise any
material that would protect the finished stair tread 56 (e.g.,
rubber, a piece of cardboard, a piece of carpet, or Masonite). The
tread plate 142 is positioned on the stair tread 56 by hooking the
tread clip at the leading edge of the tread plate 142 over the
leading edge 130 of a stair tread 56 as shown in FIGS. 36, 39, and
40. Once the baluster unit 20 and finished tread adapter 134 are in
position on a stair tread 56 as shown in FIG. 39, all of the
mounting bolts 184 can be tightened to position the railing system
on the staircase 18. When the mounting bolts 184 are tightened into
their corresponding slip nuts 174, this drives the overhung free
longitudinal edges 172 of the C-shaped channels 164, 164' firmly
against the edge seats 178 straddling the threaded holes 175
through each slip nut 174, thereby firmly positioning the railing
system on the staircase 18.
[0109] FIGS. 42 and 43 depict the railing of a curved staircase 18'
using the finished-stair-tread adapter 134 discussed above. As
shown to best advantage in FIG. 43, which is a fragmentary,
cross-sectional view taken along line 43-43 of FIG. 42, depending
upon the extent of curvature in the staircase 18', it may be
necessary to use only two slip nuts 174 in the horizontal slip nut
channels 164 comprising part of the tread plate 142.
[0110] FIGS. 44-52 depict a clamp-on railing system 190 for
staircases having stringers 54 or for pan staircases. This system
190 is particularly useful on most temporary staircases, which
typically are narrower than final staircases. Thus, as clearly
shown in FIGS. 44 and 52, the clamp-on system 190 hooks on the
outside of the staircase 18 rather than being affixed to the stair
treads 56, which desirably saves tread width. In other words, since
temporary staircases are typically narrow, contractors do not want
to further narrow the useful path by putting the railing system on
the stair treads 56. The clamp-on system 190 of the present
invention maximizes the path width on staircases, particularly
temporary staircases, while still providing protection.
[0111] Referring most particularly to FIGS. 44-49, various details
of the clamp-on railing system 190 are described next. In the
clamp-on railing system 190, a plurality of alternative staircase
balusters or stanchions are bolted to a corresponding plurality of
C-shaped mounting brackets 194. The stanchion 192 and mounting
bracket 194 combinations are then attached to the staircase
stringers 54 and connected by the desired number of staircase rails
17'. As shown in FIG. 44, you again need to use the stair rail
adjusters 128 to ensure that the top rail is within the
thirty-seven inch max OSHA requirement.
[0112] FIGS. 44 and 45 also show a most preferred means to
facilitate temporary attachment of rails 17, 17' to balusters or
stanchions (see also FIGS. 35 and 36). In particular, rather than
using rivet slots 66 in each rail support (e.g., FIGS. 4 and 7),
two round punch holes 196 are used. The two round holes 196 are
less costly to punch than are the rivet slots 66. Once a rail 17,
17' is properly positioned in a support, a fastener is placed in a
punch hole 196 to attach the connector portion 21 of the rail to
the support. A preferred fastener is a self-tapping #10 screw
having a #12 head, which may be inserted into a punch hole 196 and
screwed into the connector portion 21 of the rail without first
drilling a new hole in the rail's connector portion. Other
fasteners (e.g., a rivet 68 (FIG. 4), a regular screw, or a bolt)
could be used. Alternatively, once a rail 17, 17' is properly
positioned in a rail support 47, a hole may be drilled into the
connector portion 21 of the rail 17, 17' using a punch hole 196 as
a guide. A fastener may then be inserted through the punch hole 196
and the just-drilled hole through the connector portion 21 to
temporarily connect the rail 17, 17' to the support 47. Also, if a
retention hole 64 (FIG. 4) already exists in the connector portion
of the rail, and if that retention hole lines up with a punch hole
196, a fastener could use that existing retention hole to
temporarily connect the rail to the support.
[0113] FIG. 47 is an enlarged, fragmentary cross-sectional view
taken along line 47-47 of FIG. 44. A fragmentary portion of a rail
support 47 is shown in the upper left portion of FIG. 47 attached
to a fragmentary portion of a stanchion 192. Two mounting holes 198
are drilled through the lower end of the stanchion 192. Each
attachment bolt 200 is subsequently threaded into a large slip nut
202 that is slippingly mounted in the C-shaped mounting bracket
194.
[0114] FIG. 48 is an enlarged cross-sectional view taken along line
48-48 of FIG. 45, and FIG. 49 is an enlarged cross-sectional view
taken along line 49-49 of FIG. 45. As clearly shown in each of
FIGS. 48 and 49, the large slip nuts 202 are similar to the slip
nuts 174 described above in connection with FIGS. 38 and 41. Each
large slip nut 202 again includes a raised central portion 204
straddled by two edge seats 206. The edge seats 206 slippingly
accommodate inwardly-turned longitudinal edges 208 of the C-shaped
mounting bracket 194. The raised central portion 204 is
approximately the same width as the gap between these
inwardly-turned longitudinal edges 208. Thus, the raised central
portion 204 essentially fills the gap between the inwardly-turned
longitudinal edges 208. The large slip nuts 202 again include a
threaded hole 210 through their centers.
[0115] As clearly shown in FIGS. 45, 47, and 48, the attachment
bolts 200 are each threaded into a large slip nut 202 to rigidly
connect a stanchion 192 to its C-shaped mounting bracket 194. As
clearly shown in FIGS. 45, 47, and 49, "L" bolts 214 are threaded
into corresponding large slip nuts 202 and arranged to point
inwardly towards each other. The vertical distance 212 (FIG. 47)
between the "L" bolts 214 is adjustable by loosening the "L" bolts
214 in their slip nuts 202, and moving the slip nuts 202 to a
desired position along the C-shaped mounting bracket 194 and then
tightening the "L" bolt 214. Thus, the clamp-on system 190 easily
accommodates stringers 54 having different widths. In the depicted
embodiment, the "L" bolts 214 must bottom out and be tightened
firmly against an inner surface 216 of the C-shaped mounting
bracket 194. Thus, the "L" bolts 214 are selected based upon the
thickness of the stringer 54 or other member to which the stanchion
192 and C-shaped mounting bracket 194 combination are being
attached. Lower end caps 218, intermediate end caps 220, and upper
end caps 222 are provided to give a finished look while helping to
keep dust and other contaminants from getting into the stanchions
192 and mounting brackets 194.
[0116] FIGS. 50-52 depict the steps followed to attach a stanchion
192 and its mounting bracket 194 to a stringer 54 or pan staircase.
As shown in FIG. 50, the stanchion 192 and mounting bracket 194
combination is angled relative to the staircase to permit the
stringer 54 to pass between the upper and lower "L" bolts 214.
Generally this means that the longitudinal axis 224 of the
stanchion 192 and mounting bracket 194 combination is arranged to
be perpendicular to the longitudinal axis 226 of the stringer 54.
Once in position over the stringer 54 as shown in FIG. 50, the
stanchion 192 and mounting bracket 194 combination is rotated in
the direction of arrow 228 in FIG. 51 and into the final position
shown in FIG. 52. After two adjacent stanchions 192 are in the
position along one side of a staircase, rails 17' may be placed
between the stanchion 192 and mounting bracket 194 combinations as
shown in FIG. 44.
[0117] Although various embodiments of this invention have been
described above, those skilled in the art could make numerous
alterations to the disclosed embodiments without departing from the
spirit or scope of this invention. For example, although many of
the drawings show the rails 17, 17' as being of substantially the
same length no matter where used, it is an important aspect of the
present invention that the rails 17, 17' may be made to any length
to accommodate particular construction sites. For example, the user
could be supplied with numerous different rail lengths from which
they could choose during a particular installation of the modular
railing system 10. Current OSHA regulations permit use of
horizontal rails up to eight feet long. In the most preferred
embodiment, however, it is desirable to produce rails 17 that vary
from six inches long to six feet and six inches long in six inch
increments. It is also desirable to produce staircase rails 17' of
sufficient length to extend at an angle along a section of
staircase comprising up to eighty inches of horizontal stair treads
56 (i.e., staircase rails that can be used to rail eighty inch runs
of stairs). Also, the diameter of the rails 17, 17' and tie pipes
32, when made from round stock, may vary depending on the type of
material used and the strength or support required. The most
preferred embodiment of the present invention uses 11/4 inch
diameter round steel stock for the rails 17, 17' and the tie pipes
32. It is possible, however, to make the rails 17, 17', tie pipes
32, and balusters 20 from stock having a noncircular cross-section.
The distance between vertically adjacent rails 17, 17' or tie pipes
32 can also vary widely without deviating from the spirit or scope
of the present invention, but in the preferred embodiment, the
rails 17, 17' in sections like those depicted in FIGS. 2, 3, 7, 17,
36, 42, and 44 are approximately twenty-one inches apart.
[0118] Thus, in the three-rail system depicted in, for example,
FIGS. 2 and 7, the center of the top rail is approximately
sixty-three inches above the surface to which the balusters units
46 are attached. Preferably, the balusters 20, 21 are constructed
from 13/4 inch diameter, 16 gauge (U.S. standard) steel stock. By
way of example, the balusters for a two-rail system (see FIG. 16)
are forty inches long, and the balusters for a three-rail system
(see FIG. 12) are sixty inches long. The supports 47 are preferably
made from six inch lengths of 11/2 inch diameter, 13 gauge (U.S.
standard) steel stock. All directional references (e.g., upper,
lower, upward, downward, left, right, leftward, rightward, top,
bottom, above, below, vertical, horizontal) are only used for
identification purposes to aid the reader's understanding of the
present invention, and do not create limitations, particularly as
to the position, orientation or use of the disclosed invention. It
is intended that all matter contained in the above description or
shown in the accompanying drawings will be interpreted as
illustrative only and not limiting.
* * * * *