Modular guardrail system

Abstract

The modular guardrail system includes a handrail with an underside T-profile track, a stanchion with dual side T-profile tracks, and a connector securing the handrail to the stanchion. The connector has a fork with tines that insert into the stanchion's side T- profile tracks, secured by set screws without external drilling. A rail -engaging clamp with fixed and movable jaws expands via a set screw to engage the handrail's underside T-profile track, allowing adjustable inclination. A kneerail is attached to the stanchion using a T-bolt fastener, enabling adjustable positioning along the stanchion. This system allows for efficient assembly, enhanced structural stability, and versatile installation while maintaining an ergonomic appearance.

Description

Modular Guardrail SystemField of the Invention

[0001] The field of the invention relates to guardrail systems, specifically modular guardrail systems designed for use in various environments, to ensure safety to workers and personnel such as access stairways and ramps, walkways and elevated platforms. The invention particularly concerns a guardrail system comprising components that are easily assembled onsite without the need for welding or drilling, or fixing by means of self-tapping screws or similar, rather utilising T-profile tracks and connectors to provide secure, adjustable, and aesthetically pleasing support structures suitable for both safety and accessibility applications.Background of the Invention

[0002] Guardrail systems are essential safety and support structures designed to assist with stability and balance to workers and personnel when navigating stairways and ramps, walkways and elevated platforms. These guardrail systems comprise various components, such as handrails and kneerails, (or stanchions and mid-rails), and connectors, baseplates and T-bolts, that are easily assembled to work together to ensure safety and structural integrity. Prior art arrangements include numerous designs intended to enhance the assembly, functionality, and aesthetic integration of guardrail systems, addressing challenges such as structural stability, ease of installation, and secure connections between components.

[0003] For example, WO 2016 / 201483 A1 (Gates Balustrade Pty Ltd) 22 December 2016 discloses a coupling device specifically designed for structural assemblies, such as barriers. This coupling device features an elongate body with an internal channel, allowing it to engage a shaft of the structural assembly. A locking mechanism secures the coupling device to the shaft, facilitating the connection of various components, including other shafts, base plates, and joint assemblies. This arrangement provides secure, orthogonal connections between components without visible fasteners.

[0004] US 2013 / 0272777 A1 (Hayter et al.) 17 October 2013 describes a frame connection system that connects frame members without visible fixings. This systememploys connection members that insert into channels of elongate frame members, secured by fasteners through corresponding holes. Side cover members are then attached to conceal the channels, providing a clean and aesthetically pleasing finish while maintaining structural integrity.

[0005] US 4102529 A (Neblung et al.) 25 July 1978 outlines a railing system featuring a mounting arrangement with brackets that fit within a longitudinal slot in rail members or uprights. The brackets and slots have complementary wedge-shaped crosssections, allowing secure placement through lateral pressure. Adjacent rail members are joined by connectors that fit into D-shaped cavities, clamped securely in place by outward flexing and clamping screws. This design allows for flexible positioning and secure connection of railing components.

[0006] US 4108422 A (Koemmerling Kunststoff) 22 August 1978 details a support arrangement for a railing system that incorporates a T -shaped clamping element with clamping members. These members engage both the hollow support and the T- shaped groove of the railing. The clamping members are movable relative to each other and are spread apart by screws to secure the railing within the support, providing a robust yet adjustable connection method.

[0007] These prior art arrangements demonstrate various approaches to coupling and securing components within guardrail and railing systems, utilising internal channels, specialised brackets, and concealed fasteners. However, challenges remain in achieving efficient assembly, robust functionality, and adaptability without requiring on-site welding or drilling, or fixing by means of self-tapping screws and similar fasteners.

[0008] The present invention addresses these challenges by offering a modular guardrail system, that simplifies assembly and enhances the structural integrity and reliability of the connections, without compromising system aesthetics or ease of installation.Summary of the Disclosure

[0009] The described guardrail system comprises a handrail defining an underside T - profile track, a stanchion with dual side T-profile tracks on opposite sides, and ahandrail connector that secures the handrail to the stanchion, using a combination of a stanchion engaging fork and a handrail engaging clamp. The stanchion engaging fork comprises a pair of tines that insert separately into respective ends of the side T-profile tracks of the stanchion, providing a secure and robust engagement between the handrail connector and the stanchion. The tines are configured to engage respective set screws that are tightened through the side T-profile tracks, enabling the tines to be secured within the side T-profile tracks without the need for external drilling or self-tapping screws. This configuration ensures a strong connection which is resistant to torsional forces while maintaining a sleek and integrated appearance. The handrail engaging clamp of the handrail connector comprises opposing jaws, with a set screw operable between them, allowing the jaws to expand and engage the underside T-profile track of the handrail. This engagement securely fixes the handrail connector to the handrail, providing a firm connection. The jaws are configured to align transversely within the handrail, facilitating a secure grip while avoiding protrusions or snag points, thus ensuring an ergonomic and aesthetically pleasing interface. The set screw is discreetly located beneath the handrail, maintaining a sleek and integrated appearance while reducing the risk of accidental contact or injury.

[0010] Furthermore, the guardrail system includes a kneerail that is attached against the outside of the stanchion by a kneerail connector engaging a respective side T- profile track using a set screw, such as in the form of a T-bolt fastener. The dualpurpose side T-profile tracks not only secure the handrail connector but also facilitate attachment of the kneerail, enhancing the versatility of the guardrail system and simplifying its overall modular design. The set screw such as a T-bolt fastener, engages the T-profile track to secure the kneerail to the stanchion without the need to disassemble the handrail connector, thus facilitating the kneerail to be positioned at adjustable heights along the stanchion. This arrangement offers significant flexibility in site installation over prior systems, enabling easy adjustments and modifications to be made both during and after site assembly. The open-ended extremities of the kneerails, may be provided with press-fit end caps.

[0011] Unlike prior systems that often require on-site drilling or the use of self-tapping screws, the present guardrail system allows for assembly using set screws and T-bolt fasteners, that can be tightened by means of a hex drive or Allen key. This greatly simplifies the installation process and reduces assembly time, by eliminating the need for specialised tools or invasive fixing methods, thus making it ideal for on-site assembly.

[0012] The stanchion of the guardrail system features a relatively simple and robust hollow structure with side T-profile tracks integrated into the opposite sidewalls. This design permits multi-purpose usage of the T-profile tracks, enabling the same channels that engage the tines of the stanchion engaging fork to also secure the kneerail to outside of the stanchion. This common use of the stanchion channels simplifies the guardrail system design, reduces manufacturing complexity, and enhances structural integrity without the need for additional attachment points.

[0013] The stanchion engaging fork of the handrail connector comprises a pair of tines that insert separately into the opposite channels of the T-profile tracks, thus providing a secure engagement resistant to torsional or twisting forces commonly encountered in prior systems. This enhances the overall rigidity and durability of the connection between the handrail and the stanchion.

[0014] The side T-profile track channels offer significant versatility in the positioning of the kneerail, facilitating it to be attached at adjustable heights using the kneerail connector. This arrangement facilitates the attachment or detachment of the kneerail without needing to disconnect the handrail connector, thus enabling easy adjustments during site assembly and convenient modifications after installation. The design of the guardrail system facilitates a highly adaptable and user-friendly approach to configuring the handrail and kneerail arrangement.

[0015] Additionally, the stanchion engaging fork is concealed within the upper end of the stanchion, and the handrail engaging clamp, with its opposing jaws aligned with in the handrail, provides an ergonomic interface free of protrusions or snag points. The set screw operative on the jaws is discreetly located beneath the handrail, maintaining a sleek appearance while reducing the risk of accidental contact or injury.

[0016] The handrail engaging clamp preferably comprises a fixed jaw and a movable jaw, allowing the clamp to securely engage the underside internal profile of the handrail, while facilitating adjustments for alignment and engagement. This configuration provides enhanced stability and flexibility during assembly, thus contributing to the overall ease of site installation and secure attachment of the handrail to the stanchion.

[0017] Preferably, the movable jaw is articularly retained within a socket adjacent to the fixed jaw, with the distal end of the set screw engaging an indentation of the movable jaw to prevent dislocation.

[0018] In an embodiment, the set screw between the jaws is recessed within the fixed jaw when tightened, thus contributing to a streamlined and snag-free profile that enhances the ergonomic interface of the guardrail system, and reduces potential hazards and maintaining a sleek appearance.

[0019] Preferably, the distal ends of the jaws include claws that align transversely to the handrail, facilitating variable inclination of the handrail with respect to the stanchion. This feature allows the handrail to adapt to different angles such as on stairways and ramps, thus enhancing the versatility and adaptability of the guardrail system. Each claw may define a circular cross-section, which facilitates pivoting movement, allowing the handrail to be inclined or adjusted easily while maintaining a secure engagement. The handrail engaging clamp may further define side triangular profiles, that provide clearance for the variable inclination of the handrail relative to the stanchion. This design ensures that the handrail can be inclined without obstruction or snagging. The triangular profiles may define angled faces at 90° with respect to each other, providing up to 45° of inclination for the handrail, thus enhancing the versatility of the guardrail system for various architectural needs and user preferences.

[0020] In accordance with an embodiment, the guardrail system may further comprise a handrail splice joint connector configured to connect adjacently aligned handrail portions. The handrail joiner assembly includes a splice that fits within the internal channels of the handrail portions, and a collar that engages between the ends of thehandrail portions. This joiner assembly provides a seamless connection between handrail portions, maintaining structural integrity while allowing for modular assembly. The splice may define angled side flanges that expand when the set screw is tightened, causing the flanges to splay apart and engage the inner surfaces of the handrail channels. This mechanism enhances the stability and security of the connection, ensuring a tight fit between co-joined handrail portions. The collar may define locating tabs that key into the ends of the handrail portions, ensuring correct alignment and orientation during site assembly.

[0021] Preferably, the guardrail system includes a handrail knuckle joint connector configured to connect adjacent non-aligned handrail portions, with joint knuckle members that rotatably engage respective tongue members inserted into the T -profile tracks of the handrail portions. This configuration allows for flexible articulation between the handrail portions, accommodating changes in direction and alignment with ease. The tongue members may define hubs rotatably engaged by surrounding collars, allowing the knuckle joint members to pivot smoothly. This rotational capability enhances the adaptability of the guardrail system, enabling it to conform to complex architectural configurations. The set screws securing the tongue members may be engaged non-perpendicularly, allowing them to draw the tongue members into the T-profile tracks securely. This angled engagement provides a more robust connection, resisting displacement and ensuring consistent performance under varying load conditions.

[0022] In an embodiment, the kneerail defines a T-profile track, and the kneerail connector is configured to engage this T-profile track. The kneerail may define a flat surface that interfaces flush against the stanchion, enhancing the stability of the attachment and ensuring a sleek, integrated appearance. This design provides a solid connection point, minimising movement and increasing the rigidity of the guardrail system. The flat surface of the kneerail may be offset from the T-profile track of the stanchion at a non-orthogonal angle, facilitating secure engagement and resisting torsional forces. This feature furthermore enhances the durability and longevity of the guardrail system under regular use by workers and personnel. The kneerail connectordefines a curved portion that wraps around the kneerail, providing a secure and supportive interface that reduces the risk of movement or displacement. The curved portion of the kneerail connector may define a protrusion that inserts into the T-profile track of the kneerail, further securing the connection and preventing lateral movement. This design feature provides an additional level of rigidity, ensuring that the kneerail is securely locked into position.

[0023] In an exemplary method of assembling the guardrail system, the tines of the stanchion engaging fork are inserted into the end of the side T-profile tracks of the stanchion and secured with set screws, ensuring a firm and stable connection without the need for drilling or external fasteners. The handrail engaging clamp is then tightened to secure the handrail to the handrail connector, providing a robust and adjustable attachment. Finally, the kneerail is attached using the kneerail connector inserted into the T-profile tracks, lower down from the stanchion engaging fork, and securely engaged by means of the set screw, such as in the form of a T-bolt fastener. This assembly method allows for versatile positioning and easy adjustments during and after site installation highlighting the efficiency, ease of use, and adaptability of the guardrail system in various applications.

[0024] Overall, the described guardrail system as described, integrates the handrail, stanchion, and kneerail through a coordinated arrangement of T-profile tracks and connectors, clamps and set screws, providing a robust, adjustable, and aesthetically refined solution that addresses many of the limitations inherent to prior art arrangements, particularly in terms of ease of site assembly and installation, stability and adaptability. The use of set screws tightened by means of standard tools such as a hex drive or Allen key, simplifies the assembly process, reduces installation time, and enhances the overall structural integrity of the guardrail system, resulting in a significant advancement in guardrail design and application.

[0025] Other aspects of the invention are also disclosed.Brief Description of the Drawings

[0026] Notwithstanding any other forms which may fall within the scope of the present invention, preferred embodiments of the disclosure will now be described, by way of example only, with reference to the accompanying drawings in which:

[0027] Figure 1 shows a general arrangement perspective view of a typical guardrail system installation.

[0028] Figure 2 shows an assembled perspective view of a guardrail system in accordance with an embodiment;

[0029] Figure 3 shows an exploded perspective view of the guardrail system;

[0030] Figure 4 shows a perspective view detailing a handrail to stanchion connector in an embodiment;

[0031] Figure 5 shows a side view illustrating the handrail to stanchion connector facilitating pivoting of the handrail embodiments;

[0032] Figure 6 shows a cross-sectional view of the handrail to stanchion connector interfacing a handrail and a stanchion;

[0033] Figure 7 shows a cross sectional view of the stanchion engaging the handrail to stanchion connector;

[0034] Figure 8 shows the handrail to stanchion connector with jaws thereof closed together to facilitate insertion into the handrail;

[0035] Figure 9 shows the handrail to stanchion connector with the jaws thereof expanded to engage the handrail;

[0036] Figure 10 shows an exploded perspective view of a handrail knuckle joint connector in accordance with an embodiment;

[0037] Figure 1 1 shows a cross-sectional view of the handrail knuckle joint connector;

[0038] Figure 12 shows an exploded perspective view of a handrail splice joint connector in accordance an embodiment;

[0039] Figure 13 shows a cross-sectional view of the handrail splice joint connector at a midpoint thereof;

[0040] Figure 14 shows an off-centre cross-sectional view of the handrail splice joint connector;

[0041] Figure 15 shows a side view of a kneerail to stanchion connector engaging a kneerail against the side of the stanchion;

[0042] Figure 16 shows a cross-sectional view of the kneerail to stanchion connector assembly shown in Figure 14;

[0043] Figure 17 shows a cross-sectional view of a kneerail splice joint connector at a midpoint thereof in accordance with an embodiment; and

[0044] Figure 18 shows an off-centre cross-sectional view of the new kneerail joint connector.Description of Embodiments

[0045] Figure 2 shows a guardrail system 100 comprising a handrail 101 A and a stanchion 102, each having a uniform longitudinal cross-section, such as extruded from high strength aluminium. With reference to Figure 4, the handrail 101 A defines an underside T-profile track 103A, and the stanchion 102 defines dual side T-profile tracks 103B on opposite sides. These stanchion T-profile tracks 103B are generally defined by side rails 136, creating a relatively narrow opening leading into a larger interior channel. During assembly, various T-fasteners, comprising T-nuts and T-bolts can be inserted into the larger channel to engage the stanchion side rails 136.

[0046] Figure 1 shows a possible installation of the guardrail system 100 on an elevated platform 150 with double stringer stairway 152, whereby stanchion base plates 148 attach to side rails 151 of the platform 150 and stringers 149 of the stairway 152 with appropriate fasteners. In embodiments, the stanchion base plates 148 to an inside T-profile track 103B of the stanchion 102 by means of a T-bolt fastener 144 and defines side fastener apertures.

[0047] With reference to Figure 7, the side T-profile tracks 103B are located within the side walls 137A of the stanchion 102, facing the respective inner and outer sides of the guardrail system 100, as shown in Figure 2, contrasted with the end walls 137B of the stanchion 102, facing along the lengthwise axis of handrail 101 A. The stanchion 102 may define a rectangular profile having a width less than an exterior diameter of the handrail 101 A.

[0048] Figure 4 illustrates a handrail to stanchion connector 104 configured to attach the handrail 101 A to the stanchion 102. Referring to Figure 6, the handrail connector104 includes a stanchion engaging fork assembly 138 and a handrail engaging clamp assembly139. The stanchion engaging fork 138 comprises a pair of tines 106 that insert separately into the respective ends of the stanchion side T-profile tracks 103B, securing the handrail connector 104 to the upper end of the stanchion 102. The pair of tines 106 are preferably fixed in relation to each other, such as when the stanchion engaging fork assembly 138 is monolithically may be of cast aluminium.

[0049] The pair of tines 106 engage respective set screws 105, which can be tightened through the stanchion side T-profile tracks 103B. Tightening the set screws105 forces both tines 106 against the stanchion side rails 136. As shown in Figure 7, the tines 106 and the set screws 105 are designed to be recessed within the side walls 137A of the stanchion 102, to avoid snag points that could interfere with the ergonomic use of the guardrail system 100. The set screws 105 may be headless, entirely threaded and tightened by means of an internal drive or Allen key. As evident from Figure 7, the internal hexagon drive operates through the stanchion side T- profile tracks 103B to compress the tines 106 against the side rails 136, thereby securing the tines 106 within the stanchion 102 as well as the handrail connector 104 within the handrail 101 A. With reference to Figure 4, each tine 106 may comprise an inner wide portion 140A that inserts into the width of the interior channel of the stanchion side T-profile track 103B, and an outer narrow portion 1406 that inserts between the stanchion side rails 136, providing a flush or sleek interface.

[0050] With reference to Figure 6, the handrail engaging clamp assembly 139 comprises a pair of opposing jaws 107 with a set screw 105 operable between them , to expand the jaws 107 and engage the underside T -profile track 103A, of the handrail 101 A as shown in Figure 9. Specifically, Figure 8 shows the set screw 105 in an untightened state with the jaws 107 retracted, whereas Figure 9 shows the jaws 107 expanding into a tightened state when the set screw 105 is tightened. When tightened, the set screw 105 may be recessed within the handrail engaging clamp assembly139 to avoid snag points, providing a sleek interface.

[0051] The jaws 107 preferably comprise a fixed jaw 107A and a movable jaw 107B. The fixed jaw 107A engages the set screw 105 through a threaded screw hole 108, while the movable jaw 107B may have a side indentation 109 that captures the distal end of the set screw 105. The rail engaging clamp assembly 139 may define a socket 1 10 into which the movable jaw 107B is inserted, and this socket may have a rounded profile to facilitate the rotation of the movable jaw 107B. When the set screw 105 is partially tightened, it may engage the side indentation 109 of the movable jaw 107B, as shown in Figure 6, preventing dislocation of the movable jaw 107B from the socket 1 10. The stanchion engaging fork assembly 138 and the fixed jaw 107A may be of monolithically cast aluminium, whereas the movable jaw 107B may be separately cast and inserted into the socket 1 10 during assembly.

[0052] The distal ends of the jaws 107 may comprise claws 1 1 1 that engage behind the side rails 122 of the underside T-profile track 103A of the handrail 101 A. As shown in Figures 4 and 5, these claws 1 1 1 may be aligned transversely to the handrail 101 A to facilitate variable inclination of the handrail 101 A relative to the stanchion 102, which is particularly useful in applications like stairways. The claws 1 1 1 may define a circular cross-section to facilitate pivoting motion. The rail engaging clamp assembly 139 may define side triangular profiles 1 12 for clearance during variable inclination of the handrail 101 A, as Illustrated in Figure 4. These triangular profiles 1 12 may define angled faces 141 that abut flush against the underside T-profile track surfaces of the handrail 101 A, at extreme ranges of pivoting motion. These angled faces 141 may be set at 90° with respect to each other to facilitate up or down inclinations of up to 45° on either side.

[0053] The handrail 101 A may further define an internal channel 1 15 above or adjacent to the underside T-profile track 103A. The guardrail system 100 may also comprise a handrail splice joint connector 1 13A, as shown in Figure 12, configured to connect aligned handrail portions 101 A. The handrail splice joint connector 1 13A comprises a splice 1 14A configured to insert through the ends of the internal channels 1 15 of the aligned handrail portions 101 A, and through a collar 1 16A separable from the splice 1 14A between the ends of the handrail portions 101 A. As evident fromFigure 2, the collar 1 16A spaces the ends of the handrail portions 101 A apart, and defines an exterior ergonomic profile conforming to the surface curvature of the handrail 101 A. The collar 1 16A may be generally circular, as shown in Figure 12.

[0054] The collar 1 16A engages an underside set screw 105, which serves to expand the edges 121 of the splice 1 14A against the inner surfaces 142A of the handrail internal channels 1 15A. The splice 1 14A may define angled side flanges 1 18A that splay apart when tightening of the underside set screw 105, causing the edges 121 to press against the inner surfaces 142A. The edges 121 may have a boot-shaped profile to increase the contact surface area for frictional engagement with the inner surfaces 142A. The splice 1 14A can be made of resilient polymers such as nylon, or metals such as aluminium. Figures 13 and 14 show mid-part and off-centre crosssections of the handrail splice joint connector 1 13A. The splice 1 14A may define a threaded screw hole 1 17 for the set screw 105 to secure the angled side flanges 1 18A, that compress against the angled surfaces 1 19 of an interior wall 120 dividing the underside T-profile track 103A and the closed handrail channel 1 15A of the handrail 101 A. These angled surfaces 1 19 cause the side flanges 1 18A to splay apart, wedging the edges 121 against the internal surfaces of the handrail portions 101 A. Figure 14 also shows that the collar 1 16A may comprise locating tabs 123 that key against the internal surfaces of the handrail portions 101 A, ensuring correct orientation of the collar 1 16A with respect to the handrail portions 101 A.

[0055] Figure 10 illustrates the handrail knuckle joint connector 124A, which is configured to connect the adjacent non-aligned handrail portions 101 A. The handrail knuckle joint connector 124A comprises mating joint members 127 that rotatably engage respective tongue members 143. The tongue members 143 define integral tongues 125, that insert into the ends of the underside T-profile tracks 103A of the non-aligned handrail portions 101 A, and engage respective set screws 105 that insert into threaded holes in the tongues and through the underside T-profile tracks 103A. Tightening the set screw 105 forces the tongue 125 against the inner rails 122 of the underside T-profile track 103A, securing the tongue 125 within the underside T-profile track 103A. The tongue members 143 may define integral hubs 129, which may becircular in cross-section, and which are rotatably engaged by integral surrounding collars 128 defined by the mating joint members 127. As shown in Figure 1 1 , the set screws 105 may engage non-perpendicularly to draw the tongues 125 into the underside T-profile tracks 103A.

[0056] The guardrail system 100 further comprises a kneerail 101 B (sometimes referred to as a mid-rail) located beneath the handrail 101 A. The kneerail 101 B may be somewhat smaller in cross-sectional dimension compared to the handrail 101 A, and is configured to attach against the side of the stanchion 102, as shown in Figure 2, using the same dual side T-profile tracks 103B, further detailed in Figures 1 5 and 16. The kneerail 101 B attaches to the stanchion 102 using a kneerail to stanchion connection bracket 130, and engages the respective stanchion dual side T-profile track 103B by means of a set screw 105 inserted through a threaded hole 135. In the embodiment shown in Figures 15 and 16, the set screw 105 is in the form of a T- fastener designed to non-releasably engage the dual side T-profile track 103B. The T-fastener may comprise a T-bolt 145 screwing into a T-nut 146 engaged within the dual side T-profile track 103B. The T-nut 146 may be a twist lock nut, elongate and able to fit through the stanchion side rails 136 into the T-profile track 103B, then rotated by a quarter turn to engage the T-profile track 103B.

[0057] This configuration allows the kneerail 101 B to be easily attached at any height along the stanchion 102, without needing to disassemble the handrail to stanchion connector 104 to access the stanchion side T-profile track 103B.

[0058] The kneerail may define a flat surface 131 A that presses flush against the side wall 137A of the stanchion 102 for compactness and reduced movement. The kneerail 101 B may also define an underside T-profile track 103C, and the kneerail to stanchion connector 130 may engage this T-profile track 103C, as shown in Figure 16. The kneerail to stanchion connector 130 may define a curved portion 133 conforming to the surface curvature of the kneerail 101 B, and a protrusion 134 that engages within the T-profile track 103C. The flat surface 131 A may be offset from the kneerail T- profile track 103C at a non-orthogonal angle, allowing the protrusion 134 to insert intothe T-profile track 103C, securing the kneerail 101 B between the stanchion 102 and the protrusion 134.

[0059] Figures 17 and 18 detail a kneerail splice joint connector 1 13B, similar to the previously described handrail splice joint connector 1 13A. It comprises a similar splice 1 14B configured to insert into the closed channels 1 15B of aligned kneerail portions 101 B and into a splice joint collar 1 16B. The splice 1 14B may define a threaded screw hole 1 17B for the set screw 105, to secure the angled side flanges 1 18B that splay apart when forced by the set screw 105, to wedge against the internal surfaces 142B of the closed kneerail channel 1 15B. The collar 1 16B may also have a flat surface 131 to interface flush against the stanchion inside walls 137A. Figure 3 illustrates that the guardrail system 100 may also include a smaller kneerail knuckle joint connector 124B suitable for the kneerail 101 B, similar to the handrail knuckle joint connector 124A suitable for the handrail 101 A.

[0060] In embodiments, press fit end caps 147A and 147B as shown in Figure 3 may be used to close ends of the handrail 101 A and the kneerail 101 B respectively. These end caps 147A and 147B may comprise tongues similar to those of the aforedescribed tongue members 143 which frictionally insert into the corresponding T-profile tracks 103A and 103C respectively.

[0061] An exemplary method of assembly and installation of the handrail system 100 is now described with reference to the accompanying figures. The assembly and installation process begins by positioning the stanchion 102 in the desired location and attaching the stanchion baseplate 148 by means of a T-bolt fastener. The baseplate 148 is then securely fixed to a structural member by means of appropriate fasteners, specific to the site environment. Once the stanchion 102 is secured, the assembly of the handrail to stanchion connector 104 can proceed.

[0062] With reference to Figure 4, the handrail to stanchion connector 104 is assembled by inserting the tines 106 of the stanchion engaging fork assembly 138 separately into the respective ends of the dual side T-profile tracks 103B of the stanchion 102. The pair of tines 106 are then secured within the dual side T-profile tracks 103B by tightening the set screws 105 through the dual side T-profile tracks103B, as depicted in Figure 7. The set screws 105 force the tines 106 against the stanchion side rails 136, providing a robust and secure engagement of the handrail to stanchion connector 104 to the stanchion 102.

[0063] Following the assembly of the stanchion engaging fork 138, the handrail engaging clamp assembly 139 is prepared for securing the handrail 101 A. As shown in Figure 6, the handrail 101 A is aligned with the handrail engaging clamp assembly 139, such that the pair of jaws 107A and 107B of the clamp assembly align with the underside T-profile track 103A of the handrail 101 A. The set screw 105 between the opposing jaws 107A and 107B is then tightened, causing the jaws to expand and engage securely within the underside T -profile track 103A, as shown in Figure 9. The engagement between the opposing jaws 107A and 107B and the underside T-profile track 103A serves to fix the handrail 101 A to the handrail to stanchion connector 104, completing the assembly of the handrail 101 A to the stanchion 102.

[0064] To install the kneerail 101 B, the kneerail to stanchion connector 130 is positioned against the dual side T-profile track 103B of the stanchion 102, as detailed in Figures 15 and 16. The set screw 105, such as in the form of a T-fastener, is inserted into the dual side T-profile track 103B and engaged. The T-fastener is then tightened to secure the kneerail to stanchion connector 130 to the stanchion 102. The kneerail 101 B is aligned with the kneerail connector 130, and the curved portion 133 engages the underside T-profile track 103C of the kneerail 101 B. The internal protrusion 134 of the curved portion 133 is then inserted into the underside T-profile track 103C, securing the kneerail 101 B to the stanchion 102.

[0065] If connection of adjacent handrail portions 101 A in alignment is required, the handrail splice joint connector 113A is utilised, as shown in Figure 12. The splice 114A of the handrail splice joint connector 1 13A is inserted into the internal closed channels 1 15A of the adjacent handrail portions 101A and the collar 116A is positioned between the ends of the handrail portions 101A. The underside collar set screw 105 is then tightened to expand the splice side flange edges 121 of the splice 114A against the inner surfaces 142A of the internal handrail channels 1 15A, thereby securing the connection between the handrail portions 101 A.

[0066] In installations where non-aligned handrail portions 101 A need to be connected, the handrail knuckle joint connector assembly 124A, as depicted in Figure 10, is utilised. The tongue members 143 of the handrail knuckle joint connector 124A are inserted into the underside T-profile tracks 103A of the non-aligned handrail portions 101A, and the set screws 105 tightened to secure the internal tongues 125 within the underside T-profile tracks 103A. The hubs 129 of the tongue members 143 engage with the integral collars 128 surrounding the handrail knuckle joint mating members 127, facilitating for rotational movement and accommodating the non- alignment between the connected handrail portions 101A.

[0067] Throughout the assembly and installation of the guardrail system 100, adjustments can be made to the positioning of the kneerail 101 B along the stanchion 102, by loosening and re-tightening the set screws 105, allowing the kneerail 101 B to be re-positioned without disassembling the handrail to stanchion connector 104.

[0068] The overall assembly process as described, is designed to facilitate straightforward site installation utilising standard tools such as a hex drive or Allen key, without the need for welding or drilling, or using self-tapping screws, thereby streamlining the site setting up of the guardrail system 100 and ensuring secure and stable connections between its components.

[0069] The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that specific details are not required in order to practise the invention. Thus, the foregoing descriptions of specific embodiments of the invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed , as obviously many modifications and variations are possible in view of the above teachings. The embodiments were selected and described in order to best explain the principles of the invention and its practical applications, thereby enabling others skilled in the art to best utilise the invention and various embodiments with various modifications, as are suited to the particular application contemplated. It is intended that the following claims and their equivalents define the scope of the invention.

Claims

Claims1 . A guardrail system comprising: a handrail defining an underside T-profile track; a stanchion defining dual side T-profile tracks on opposite sides thereof; and a handrail to stanchion connector defining: a stanchion engaging fork comprising a pair of tines which insert separately into respective ends of the side T-profile tracks, to fix the handrail to stanchion connector to an end of the stanchion, the tines engaging respective set screws operable through the side T-profile tracks; a handrail engaging clamp comprising opposing jaws with a set screw operative between the jaws to expand the jaws to engage within the underside T - profile track to fix the handrail to stanchion connector to the handrail; and a kneerail attached against one side of the stanchion by a kneerail to stanchion connector, engaging a respective side T-profile track with a T-bolt fastener.

2. The guardrail system according to claim 1 , wherein the opposing jaws comprise a fixed jaw and a movable jaw.

3. The guardrail system according to claim 2, wherein the movable jaw is articu larly retained within a socket adjacent to the fixed jaw, and wherein a distal end of the set screw between the opposing jaws engages an indentation of the movable jaw to prevent dislocation of the movable jaw.

4. The guardrail system according to claim 2, wherein the set screw between the opposing jaws is recessed within the fixed jaw when tightened.

5. The guardrail system according to claim 2, wherein distal ends of the opposing jaws comprise claws which align transversely to the handrail, to facilitate variable inclination of the handrail with respect to the stanchion.

6. The guardrail system according to claim 5, wherein each claw defines a circular cross-section.

7. The guardrail system according to claim 1 , wherein the handrail engaging clamp defines side triangular profiles providing clearance for the variable inclination of the handrail with respect to the stanchion.

8. The guardrail system according to claim 7, wherein the triangular profiles each define angled faces at 90° with respect to each other.

9. The guardrail system according to claim 1 , wherein the handrail further defines an internal channel adjacent to the underside T-profile track and wherein the guardrail system further comprises: a handrail splice joint connector configured to connect adjacently aligned handrail portions, the handrail splice joint connector comprising: a splice configured to fit through the ends of the internal channels of the handrail portions; and a collar separately engaging the splice with the collar being engaged between the ends of the handrail portions, spacing the ends of the handrail portions apart and defining an exterior ergonomic profile conforming to the surface curvature of the handrail, and wherein the collar engages an underside set screw operable to expand the edges of the splice against the inner surfaces of the handrail internal channels.

10. The guardrail system according to claim 9, wherein the splice defines angled side flanges defining the edges, and wherein tightening of the set screw causes the side flanges to splay apart, against the inner surfaces of the handrail internal channels.1 1 . The guardrail system according to claim 9, wherein the collar defines locating tabs which key within respective ends of the handrail portions.

12. The guardrail system according to claim 1 , further comprising a handrail knuckle joint connector configured to connect adjacent nonaligned handrail portions, the handrail knuckle joint connector comprising: knuckle joint members coupled to form a composite joint; and the knuckle joint members rotatably engaging respective tongue members, the tongue members defining tongues which insert into respective ends of the underside T-profile tracks of the non-aligned handrail portions, and engage set screws operable through the underside T-profile tracks.

13. The guardrail system according to claim 12, wherein the respective tongue members define circular hubs rotatably engaged by surrounding hub collars defined by the joint members.

14. The guardrail system according to claim 12, wherein the set screws are engaged non-perpendicularly to draw the tongues into the underside T-profile tracks.

15. The guardrail system according to claim 1 , wherein the kneerail defines a T- profile track and wherein the kneerail to stanchion connector is configured to engage the T-profile track of the kneerail.

16. The guardrail system according to claim 15, wherein the kneerail defines a flat surface which lies flush against a side of the stanchion.

17. The guardrail system according to claim 16, wherein the flat surface is offset from the T-profile track of the kneerail at a non-orthogonal angle.

18. The guardrail system according to claim 15, wherein the kneerail to stanchion connector defines a curved portion which interfaces around the kneerail.

19. The guardrail system according to claim 18, wherein the curved portion of the kneerail to stanchion connector defines an internal protrusion which inserts into the T-profile track of the kneerail.

20. The guardrail system according to claim 1 , wherein the kneerail defines an underside T-profile track configured for engagement by the kneerail to stanchion connector.21 . The guardrail system according to claim 1 , further comprising press-fit end caps for the handrail and the kneerail.

22. The guardrail systems according to claim 1 , further comprising a base plate configured to attach to a T-profile track of the stanchion by means of a T-bolt fastener and which defines side fastener apertures.

23. A method of assembling a guardrail system according to claim 1 , the method comprising: inserting the tines of the stanchion engaging fork into respective ends of the side T-profile tracks of the stanchion; tightening the set screws through the side T-profile tracks of the stanchion to secure the tines within the T-tracks; expanding the movable jaw of the handrail engaging clamp by means of the set screw, to engage within the underside T-profile track of the handrail; and attaching the kneerail to one side of the stanchion using the kneerail to stanchion connector or, engaging the respective side T-profile track with a T-bolt fastener.

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