A component for use in the assembly of an access structure

Abstract

A component for use in the assembly of an access structure comprises a first connector 112 for attaching to a first structural element of the access structure, a second connector 114 for attaching to

Description

Background to the Invention The present invention relates to a component for use in the assembly of an access structure and to a method of assembling an access structure and relates particularly, but not exclusively, to a component used in the installation of steel staircases, walkways or balustrades used in industrial, public or factory settings. Steel staircases, walkways and balustrades are commonly produced as kits and assembled on-site. The installation process typically involves a step-by-step construction of the stringers or aprons, treads or posts, risers and handrails. The stringers, the sides of the staircase, provide the primary support and framework, guiding the shape and inclination of the staircase. Treads are the horizontal steps where individuals place their feet. These are securely affixed to the stringers via holes, creating a stable supporting surface. Risers are the vertical components between each tread and help maintain uniformity between the steps. Typically, the handrails are used for safety and run alongside the staircase, walkway or balustrade . During the assembly process several issues might arise while installing the stringers or risers in a staircase. These include misalignment between the stringers and risers, leading to uneven steps or an unstable staircase. This misalignment can occur due to inaccurate measurements, improper cutting of materials, or human-errors in assembly. If the stringers or risers do not fit properly or are not secured in place correctly this may cause further problems. Gaps between components or poor connections can weaken the staircase and create safety hazards. Uneven staircases are unacceptable as users instinctively expect the dimensions of stairs and the spacing between them to be even and consistent. Preferred embodiments of the present invention seek to overcome or alleviate the above described disadvantages of the prior art. Summary of the Invention According to an aspect of the present invention there is provided a component for use in the assembly of an access structure, the component comprising: a first connector for attaching to a first structural element of the access structure having a first, a second and a third side wherein the third side includes at least one first opening; a second connector for attaching to a second structural element of the access structure and having at least one fourth side and a fifth side wherein the fourth side includes at least one second opening and the fifth side includes at least one third opening; and at least one securing member; wherein, when the component is assembled, the first side of the first connector extends into the second opening of the second connector such that the third opening of the second connector is aligned with the first opening of the first connector with the securing member extending therethrough and securing the first connector to the second connector. By using a first and second connector secured to the inside tread and stringer components respectively eliminates the necessity for drilling therethrough. This assembly does not require the need for nuts or bolts to be drilled through the stringer or tread, ensuring a seamless and aesthetically pleasing appearance without visible fixings on the stairs. Furthermore, this approach bypasses the need for marking, side fixing, or drilling on the stringers, alleviating concerns about alignment errors. Human error is also minimised significantly since the absence of drilling negates the need to align holes, thereby enhancing the overall precision of the staircase installation. It is also the case that the staircase can be easily initially assembled before the final tightening of the securing members (bolts). Usually, installation involves at least a two-person team, with one person manually holding each tread while the other fits the bolts. However, the connectors enables installation of the staircase to be carried out by only one person. This significantly eases the early stages of construction and allows assembly by a smaller team of builders or by a single builder. Furthermore, during a typical installation the treads remain unsteady until every bolt is fitted through the side or top of the stringers. This can lead to treads falling if a person has not secured the bolts properly or when a bolt is missing. In contrast, the connectors employ a tab and slot connection that temporarily secures both ends of the treads to the stringers, preventing them from slipping out of position until the bolts are properly in place. Further increasing safety during installation. In a preferred embodiment the second connector further comprises a sixth side. By including a sixth side the advantage is provided that the second connector is more securely fixed (welded) to the stringer . In another preferred embodiment the first opening comprises a first aperture, the second opening comprises a second aperture and the third opening comprises a third aperture. By having an elongate first aperture the tolerance when bolting the first and second connector together is increased. The added tolerance allows for a more forgiving margin of error and accommodates slight variations in alignment or measurements during installation. This increased flexibility becomes particularly beneficial in mitigating potential misalignments between the stringers and treads. Furthermore, it reduces the risk of complications or errors that could arise from demanding precision requirements during the bolting process . In a further preferred embodiment, the first opening comprises a first slot, the third opening comprises a second slot and the first slot has a first height greater than a second height of the second slot. Having a height difference between Hl and H2 increases the tolerance during the bolting of the first and second connectors. This added tolerance provides a more lenient margin for error, allowing for minor variations in alignment or measurements during installation. Such flexibility proves especially advantageous in addressing potential misalignments between the stringers and treads. Additionally, it minimises the likelihood of issues or mistakes that might result from strict precision requirements in the bolting process. In another preferred embodiment the securing member comprises a nut and bolt and the nut is welded to the second connector adjacent the third opening. In an additional preferred embodiment, the securing member comprises a bolt and the third opening comprises a threaded aperture . In a further embodiment the second connector comprises a fourth opening and the fourth opening comprises a fourth aperture, and when in use the first side of the first connector extends into the fourth opening. By including a fourth elongate aperture, in particular one that matches the third aperture, the advantage is provided that the second connector is not handed and therefore can be used in either the left or right hand side of the staircase. According to another aspect of the present invention there is provided a kit of parts for assembling an access structure comprising: a plurality of components as set out above; a plurality of first structural elements; and a plurality of second structural elements. In a preferred embodiment of the present invention the first connectors are welded to the second structural elements and the second connectors are welded to the first structural elements . In another preferred embodiment of the present invention the first structural element comprises a tread and the second structural element comprises a stringer. In a further preferred embodiment of the present invention the first structural element comprises a post and the second structural element comprises an apron. According to a further aspect of the present invention there is provided a method of assembling an access structure using a kit of parts as set out above, the method comprising: fixing a plurality of first connectors to a plurality of first structural elements; fixing a plurality of second connectors to a plurality of second structural elements; inserting the first side of the first connector into the second opening of the second connector; and inserting the securing members into the openings and thereby securing the first and second connectors. In a preferred embodiment the first structural element comprises a tread and said second structural element comprises a stringer. In another preferred embodiment said first structural element comprises a post and said second structural element comprises an apron. In a preferred embodiment of the present invention the fixing is secured by a nut, by a weld or by a welded nut. Brief Description of the Drawings Preferred embodiments of the present invention will now be described, by way of example only, and not in any limitative sense with reference to the accompanying drawings in which:- Figure 1 is a perspective view of a component of the present invention; Figure 2 is a front view of the component of figure 1; Figure 3 is a perspective view of the first connector of the component of figure 1; Figure 4 is another perspective view of the first connector of figure 1; Figure 5 is a perspective view of the second connector of the component of figure 1; Figure 6 is another perspective view of the second connector of figure 1; Figure 7 is a side view of the component of figure 1 in use; Figure 8 is a top-down view of the component of figure 1 in use; Figure 9 is a perspective view of the component of figure 1 in use ; Figure 10 is a perspective view of a second embodiment of the component of the present invention; Figure 11 is a front view of the second embodiment of the component of figure 10; Figure 12 is a perspective view of the second embodiment of the component of figure 10; Figure 13 is a perspective view of a third embodiment of the component of the present invention; and Figure 14 is a front view of the third embodiment of the component of figure 13. Detailed Description of the Invention Referring initially to figures 1 and 2, there is provided a component 10 having a first and a second connector, 12 and 14, which are used to secure together components of an access structure such as steel staircase 16. The components of the staircase 16 include a second structural element in the form of a stringer 18, a first structural element in the form of a tread 20 and risers 22. The stringers 18 and treads 20 are secured together by the component 10 with the riser 22 extending vertically from the tread. When the staircase 16 and component 10 are fully constructed the first connector 12 is welded to the tread 20 and the second connector 14 is welded to the stringer 18. Securing the first and second connectors, 12 and 14, together is a fixing member in the form of a nut and bolt, 24a and 24b. Additionally referring to figures 3 and 4, the first connector 12, formed from steel, includes a first side 26 (also known as a flange), a second side 28 and a third side 30. Each of the three sides 26, 28 and 30 are aligned substantially perpendicular to each other and are connected by a first and a second rounded edge, 32 and 34. The second side 28 is located in between the first and second rounded edges 32 and 34, and the first and third sides 26 and 28 are located opposing each other. The third side 30 extends from the first rounded edge and includes two elongate first openings 36 that are located adjacent distal ends of the third side. In the embodiment shown in the figures the first openings are in the form of two first elongate apertures 36. However, third or fourth or even more elongate apertures could be included. The height (H) of the first elongate apertures 36 are such that only the tail of the bolt 24b can be inserted therethrough and secured with the nut 24a. Moreover, the length of the first elongate aperture 36 is long enough for the tail of the bolt 24b (when inserted) to move side-to-side. The length of the second and third sides, 28 and 30 and the first rounded edge 32 are equal whereas the lengths of the first side 26 and second rounded edge 34 are shorter. Extending from the second rounded edge 34, the first side 26 is symmetrically located between the distal ends of the second side 28 . Turning now to figures 4 and 5, the second connector, also formed from steel, includes fourth, fifth and sixth sides 35, 38 and 40 respectively. Similar to the first connector 12 the fourth, fifth and sixth sides 35, 38 and 40 are connected by third and fourth rounded edges 42 and 44. Aligned substantially perpendicular to each other the third rounded edge 42 connects the fourth and fifth side, 35 and 38, whist the fourth rounded edge 44 connects the fifth and sixth sides, 38 and 40, together. Located adjacent and in between a first and second distal end 46 and 48 of the fourth side 35 is a second elongate opening 50. As seen in figures 5 and 6, this elongate opening 50 is an elongate recess cut into a long edge of the fourth side 35 that is the edge opposing the third rounded edge 42. As will be seen later, this elongate recess becomes a second elongate aperture 50 when the second connector is in use and is connected to the stringer 18. This second aperture 50 is wide and long enough for the first side 26 of the first connector 12 to extend therethrough. Situated equidistant apart from each other on the fifth side 38 is a series of three third openings in the form of third apertures 52. The diameter of each of these third apertures 52 is large enough for the tail of the bolt 24b to be insert therethrough and secured with the nut 24a. From figure 4 and 5 it can be seen that these third apertures are circular, leaving very little room for the bolt to move side-to-side. Situated in between a third and fourth distal end, 54 and 56, of the sixth face is a fourth elongate opening 58. In common with the first opening 50, the fourth opening 58 is formed as a recess and becomes an enclosed elongate aperture in use. This fourth aperture 58 is equally sized and positioned directly opposite to the second aperture 50 making the second connector symmetrical along a line through the centre of the third apertures 52. As a result, the second connector can be used on either side of the staircase by being inverted meaning that the fourth aperture 58 also allows the first side 26 of the first connector 12 to extend therethrough. Both the first and second connectors 12 and 14 are formed from sheet steel which is cut to the required shape and bent to form the first to sixth sides described above. In order to facilitate easy assembly of the component 10, the hex nut 24a is tac welded to the inside surface of the fourth side 38. The nuts 24a are positioned such that the hole of the nut 24a aligns with the third apertures 52 of the fourth side 38. Depending on the number of first elongate apertures 36 the first connector 12 has, either two or three hex nuts 24a are tac welded to the second connector 14. Referring now to additional figures 7, 8 and 9 the method of assembling the component 10 and construction of the access structure in the form of a staircase 16 will now be described. Once the design of the staircase 16 has been finalised, the stringer pair 18, desired number of treads 20 and a walkway 60 are cut and shaped. The under-surface of the treads 20 are cleaned and prepped to guarantee a strong weld bond. One of each first connector 12 is aligned along the shorter edge of the tread 20, perpendicular to the length. Next the second side 28 of the first connectors 12 are then welded to each side of the treads 20. Finally, depending on the length of the walkway, a number of first connectors are also welded along the shorter edges. Figure 9 shows an example of a walkway 60 including three first connectors 12 welded to the underside. For each tread 20 that is required for the stair case 16, a pair of second connectors 14 are positioned along each stringer 18 to line up with the location of the first connectors 12. Due to its symmetrical shape lengthways, the second connector 14 is bi-directional and when welded to the stringer 18 along either way. The second connectors 14 are then welded to the stringers 18 along the first and second distal ends, 46 and 48, of the fourth side 35 and along the fifth and sixth distal ends, 54 and 56 of the sixth side 40. As a result, the surface of the stringer 18 and recesses in the fourth and sixth side 35 and 40 form the second elongate aperture 50 and the fourth elongate aperture 58. Each of the treads 20, stringer pair 18 and walkway 60 are then transported to the location for which the staircase 16 is to be installed. To connect and secure each of the treads 20 to the stringer pair 18 the first connectors 12 are aligned with each of the second connectors 14. The first connectors 12 of the treads 20 are then lowered into the second connectors 14 of the stringers 18, such that the first side 26 of the first connector extends into the second elongate aperture 50 of the second connector. This loose connection of the stringers and treads together is simple and does not require the use of any tools during this initial construction. Once all the treads 20 and walkway 60 have been connected to the stringer pair 18 each component 10 is secured with either a pair or trio of bolts 24b. The tail of the bolt is inserted into the first apertures 36 of the first connector and further threaded into the tac welded nut 24a located on the inside of the second connector 14. As a result of the first aperture 36 being elongate and enabling the bolt 24b to move sideways, if the second connector has been welded in a slightly wrong position there is an inbuilt tolerance for the bolt to be moved. Once all of the bolts 24b have been tightened onto the nuts 24a, the staircase construction has been completed. Referring now to figure 10 in which components equivalent to those in figures 1 to 9 have been identified with like reference numerals increased by 100, the component 110 includes a first connector 112 and a second connector 114. The connectors 112 and 114 are used to join together components of an access structure in the form of a steel staircase 116. The staircase 116 includes second structural elements in the form of stringers 118, first structural elements in the form of treads 120, and risers 122, with the risers extending vertically from the treads. When the staircase 116 and component 110 are fully assembled, the first connector 112 is welded to the tread 120 and the second connector 114 is welded to the stringer 118. The first and second connectors, 112 and 114, are secured together by a fastening member, consisting of a nut, bolt and washer 124a, 124b and 124c. The first connector 112 includes a first, second and third side 126, 128 and 130 each aligned substantially perpendicular to each other. The first and third sides 126 and 130 are opposing each other whilst the second side 128 is positioned therebetween. The third side 130 has two first openings 136 located near the distal ends of the third side. In this embodiment shown in the figures, the first openings are depicted as two first slots 136. The height (Hl) of these slots 136 is designed such that only the tail of the bolt 124b can pass through and be secured with the nut 124a. The second connector 114 includes a fourth side 135, a fifth side 138, and a sixth side 140. Similar to the first connector 112, these sides are arranged substantially perpendicular to each other, with the fifth side 138 positioned in between the fourth and sixth sides 135 and 140. Near the centre of the fourth side 135, between the first and second distal ends 146 and 148, is a second elongate opening 150. As seen in figures 10, 11 and 12 this opening is a recess cut into a long edge of the fourth side 135. This recess becomes a second elongated aperture 150 when the second connector is in use and attached to the stringer 118. This aperture is large enough to allow the first side 126 of the first connector 112 to extend through it. Located on the fifth side 138 are two third openings in the form of second slots 152. Each slot 152 is sufficiently large, with a height H2 for the tail of the bolt 124b to pass through and be secured with the nut 124a and such that the height (H2) of the second slot 152 is less than the height (Hl) of the first slot 136. Referring now to figures 11 and 12, the bolt 124b is used to secure the first and second connectors 112 and 114. Located adjacent to the head of the bolt 124b is a square-shaped protrusion 124d. This bolt 124b engages with the nut 124a to secure the first and second connectors 112 and 114. Additionally, the bolt 124b is equipped with a washer 124c that provides a secure interface between the nut 124a and the connectors . During the assembly process, the bolt 124b, along with the washer 124c and nut 124a, is pre-assembled loosely before engaging with the connectors 112 and 114. When the connectors 112 and 114 are aligned, the tail of the bolt 124b slides into the open ends of the slots 136 and 152 to its designated position. As the bolt 124b moves along the slots, the squareshaped protrusion 124d remains oriented in a manner that allows it to slide freely. Upon reaching the desired position, the nut 124a is threaded onto the tail of the bolt 124b. As the nut 124a is tightened, the bolt 124b begins to rotate due to the threading action. However, the protrusion 124d is specifically shaped and positioned to engage with the underside surface of the second connector 114 during this rotation. The square geometry of the protrusion 124d is designed to engage the edges of the slot 152. The distance between opposing edges of the square-shaped protrusion 124d match the height H2 of the slot 152, preventing rotation of the bolt 124b. This interaction effectively locks the head of the bolt 124b in place, allowing the nut 124a to be securely fastened without causing the bolt 124b to turn. Referring now to figures 13 and 14, in which components equivalent to those in figures 1 to 9 have been identified with like reference numerals increased by 200, the component 210 includes a first connector 212 and a second connector 214. The components are used to join elements of an access structure 216, such as a walkway or a balustrade that incorporates a post 262. The access structure 216 includes first structural elements in the form of posts 262 (or balusters) and second structural elements in the form of aprons 218 (or horizontal board, horizontal support or base rail). When the balustrade 216 and component 210 are fully assembled, the first connector 212 is attached to the post 262 by welding, while the second connector 214 is welded to the apron 218. Two fastening members, comprising a nut, bolt, and washers 224a, 224b, and 224c, are used to secure the first and second connectors, 212 and 214, together . The first connector 212 includes a first side, a second side 228, and a third side 230, each aligned substantially perpendicular to one another. The first side and third side 230, are positioned opposite each other, while the second side 228 is located between them. On the third side 230, there are two first openings 236 positioned near its distal ends. In the figures, these first openings are illustrated as two first slots 236. The height of the slots 236 is configured to ensure that only the tail of the bolt 224b can pass through and be secured with the nut 224a. To maximise the welding surface area of the first connector 212 for the post 262, the first side of the first connector 212 is significantly taller compared to previous embodiments. This increased surface area accommodates the loadbearing requirements of the posts 262, which must support forces applied at the top. These forces typically come from a handrail attached to the top of the posts 262 for individuals to grip. The torque generated by these forces results in much greater stresses at the base of the post 262. Therefore, a larger welding surface area between the post 262 and the first connector 212 is preferable to ensure stability of the posts. The second connector 214 includes a fourth side 235, a fifth side, and a sixth side 240. Similar to the first connector 212, these sides are arranged substantially perpendicular to each other, with the fifth side positioned between the fourth and sixth sides 235 and 240. Near the centre of the fourth side 235, between the first and second distal ends, is a second elongate opening. This aperture is large enough to allow the first side of the first connector 212 to extend through it. Located on the fifth side are two third openings in the form of second slots. Each slot is sufficiently large, with a height for the tail of the bolt 224b to pass through and be secured with the nut 224a, and such that the height of the second slot is less than the height of the first slot 236. During the installation of the balustrade 216 (or walkway), the first connector 212 is welded to the post 262 (or baluster), and the second connector 214 is welded to the apron 218. Once these components are secured, the assembly process begins by aligning the first connector 212 with the second connector 214. The first side of the first connector 212, is positioned to extend through the second elongate opening on the fourth side 235 of the second connector 214. This alignment ensures that the first connector 212 fits securely within the second connector 214. To secure the connection, the bolts 224b are inserted through the first slots 236 on the first connector 212 and the second slots on the fifth side of the second connector 214. The washers 224c and nuts 224a are then used to tighten the bolts, locking the first and second connectors 212 and 214 together. This fastening mechanism ensures a stable connection between the post 262 and the apron 218, allowing the balustrade 216 to withstand the applied forces during regular use. Once all connections are tightened, additional welding may be performed along critical joints to enhance the overall strength and durability of the balustrade 216. It should be clear from the description that this third embodiment works essentially in the same way as the second embodiment, some features of the first and second connectors are not visible. The preceding examples are a non-exhaustive list of suitable techniques and others are available which may be selected at the discretion of the person skilled in the art. It will be appreciated by persons skilled in the art that the above embodiments have been described by way of example only and not in any limitative sense, and that various alterations and modifications are possible without departure from the scope of the protection which is defined by the appended claims. In particular, where various embodiments and aspects of the invention have been described above, features and steps of the apparatus and method are interchangeable between the embodiments and aspects of the invention. For example, where dimensions are indicated in the examples set out above these are examples of ideal measurements but should not be taken as being indicative of being essential to the performance of the invention. For example, the above includes a bolt and tac welded nut however the nut could be replaced with a thread extending along the edges of the third aperture of the second connector. Another example of securing the first and second connectors is to weld the bolt once in place. The above embodiment has been described as being made from steel and this is most typically galvanised steel. However, other materials could be used including any suitable metal in which components can be welded together. A further example includes the shape of the protrusion 124d as described as square shaped. However, the protrusion can be any shape that would suitably prevent the head of the bolt from rotating when tightening the nut 124a. Furthermore, in the above embodiment the protrusion is sized to fit inside the slot. However, the protrusion could also be sized such that it was larger than the head of the bolt. In this case the tail of the bolt would insert into the slot and the protrusion would prevent the head of the bolt from turning by abutting the inside of the connector . Another example is the number of bolts used to secure the connecting members. While the figures illustrate two bolts, the number can be adjusted as needed to ensure a strong connection. For instance, four bolts could be used, with two positioned on each side of the connectors. Although the above embodiments describe a sixth side on the second connector, it is not essential for the functionality of the connector. The second connector would function in the same manner with only a fourth and fifth side, as it requires only two sides rather than three to achieve the intended operation.

Claims

1. A component for use in the assembly of an access structure, the component comprising:a first connector for attaching to a first structural element of the access structure having a first, a second and a third side wherein said third side includes at least one first opening;a second connector for attaching to a second structural element of the access structure and having at least one fourth side and a fifth side wherein said fourth side includes at least one second opening and said fifth side includes at least one third opening; andat least one securing member;wherein, when said component is assembled, said first side of said first connector extends into said second opening of said second connector such that said third opening of said second connector is aligned with said first opening of said first connector with said securing member extending therethrough and securing said first connector to said second connector.

2. A component according to claim 1, wherein said second connector further comprises a sixth side.

3. A component according to any preceding claim wherein said first opening comprises a first aperture.

4. A component according to any preceding claim wherein said second opening comprises a second aperture.

5. A component according to any preceding claim wherein said third opening comprises a third aperture.

6. A component according to any of claims 1 to 2 wherein said first opening comprises a first slot.

7. A component according to any preceding claim wherein said third opening comprises a second slot.

8. A component according to claims 6 and 7 wherein said first slot has a first height greater than a second height of said second slot.

9. A component according to any preceding claim wherein said securing member comprises a nut and bolt.

10. A component according to claim 9, wherein said nut is welded to said second connector adjacent said third opening.

11. A component according to claims 1 to 8, wherein said securing member comprises a bolt and said third opening comprises a threaded aperture.

12. A component according to any preceding claim wherein said second connector comprises a fourth opening.

13. A component according to claim 12 wherein said fourth opening comprises a fourth aperture.

14. A component according to claim 12 to 13 wherein when in use said first side of said first connector extends into said fourth opening.

15. A kit of parts for assembling an access structure comprising:a plurality of components as according to any preceding claim;a plurality of first structural elements; anda plurality of second structural elements.

16. A kit of parts according to claim 15 wherein said first connectors are welded to said second structural elements and said second connectors are welded to said first structural elements .

17. A component according to claim 15 or 16, wherein said first structural element comprises a tread and said second structural element comprises a stringer.

18. A component according to claim 15 or 16, wherein said first structural element comprises a post and said second structural element comprises an apron.

19. A method of assembling an access structure using a kit of parts according to claims 15 to 18 comprising:fixing a plurality of first connectors to a plurality of first structural elements;fixing a plurality of second connectors to a plurality of second structural elements;inserting said first side of said first connector into said second opening of said second connector; andinserting said securing members into said openings and thereby securing said first and second connectors.

20. A method according to claim 19 wherein said first structural element comprises a tread and said second structural element comprises a stringer.

21. A method according to claim 19 wherein said first structural element comprises a post and said second structural element comprises an apron.

22. A method according to claims 19 to 21 wherein said fixing is secured by a nut.

23. A method according to claim 19 to 21 wherein said fixing is secured by a weld.

24. A method according to claim 19 to 21 wherein said fixing is secured by a welded nut.

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