A mount for a barrier system

Abstract

Disclosed herein is a mount for a barrier system. The mount comprises a base for mounting to a surface and an end cap for a stanchion. The base is configured to engage the end cap whereby the end cap is pivotable relative to the base between orientations that correspond to vertical (about 0°) and horizontal (about 90°) positions of a stanchion in use, the base comprising a first part of an interlocking assembly. A distal portion of the end cap is configured to receive a stanchion thereat and a proximal portion of the end cap comprises a second part of the interlocking assembly. The first and second parts of the interlocking assembly are configured to become interlocked only when the base and the end cap are in a joining orientation and, once interlocked, remain interlocked at orientations of the base and the end cap other than the joining orientation.

Description

A MOUNT FOR A BARRIER SYSTEMTechnical Field

[0001] The present invention relates to mounts for barrier systems and, in particular, to mounts that enable the barrier systems to be folded between flat and upright positions.Background Art

[0002] Barrier systems, such as fences and balustrades, are often used in order to prevent people, animals, etc. from entering certain areas. For example, barrier systems may be used to prevent people from falling over an edge or to keep them away from a road or train lines. Barrier systems can be relatively time consuming and labour intensive to construct, although modular barrier systems are now relatively common and can reduce some of the construction time and labour.

[0003] It would be advantageous to further reduce the time and labour associated with installing barrier systems, particularly when on site.Summary of Invention

[0004] In a first aspect, the present invention provides a mount for a barrier system. The mount comprises a base for mounting to a surface and an end cap for a stanchion. The base is configured to engage the end cap whereby the end cap is pivotable relative to the base between orientations that correspond to vertical (about 0°, i.e. upright) and horizontal (about 90°, i.e. laid flat) positions of a stanchion in use, the base comprising a first part of an interlocking assembly. A distal portion of the end cap is configured to receive a stanchion thereat and a proximal portion of the end cap comprises a second part of the interlocking assembly. The first and second parts of the interlocking assembly are configured to become interlocked only when the base and the end cap are in a joining orientation and, once interlocked, remain interlocked at orientations of the base and the end cap other than the joining orientation.

[0005] Advantageously, the present invention enables the entirety of a barrier system to be preassembled before its delivery to site, facilitating a ‘flat pack style’ transportation.Conventionally, the base mounts of a barrier system would be installed on a surface in a first installation step, with the remainder of the barrier system being installed (perhaps in a modular form such as panels etc.) onto the mounts in second and subsequent steps. As would beappreciated, however, the positioning of the base mounts in the first installation step is critical and much time and effort would need to be expended in the event of even a small misalignment. At least two operators would typically be required for the installation, further increasing operator time and costs associated with a project.

[0006] Furthermore, the present invention advantageously provides for significantly improved construction options. For example, barrier systems in accordance with the present invention can be pre-assembled on the surfaces of substructures before they are delivered to a site. Bridges, for example, are typically constructed by joining a number of substructures together in order to define the bridge’s span. Such substructures are manufactured off site, in a safer, less busy and more controlled environment, and subsequently transported to the site shortly before construction of the bridge. The height of these substructures is, however, limited, primarily due to clearance restrictions imparted by tunnels, bridges, etc. on the route between the manufacturing / assembly facility and the installation site. For this reason, conventional barriers can only be installed either on the worksite or after the bridge has been constructed, necessitating significant expenditure on safety requirements due to operators working at the edge of an elevated structure. The present invention can, however, provide the barrier systems in a flat-packed arrangement installed on the substructure without significantly increasing the height of the substructure, and which is much quicker to erect once the final structure is assembled than is the case for conventional barrier systems. The potential time and cost savings through use of the present invention are significant and sought out by many project managers.

[0007] Another advantage of the present invention is that it provides the ability for the resultant barrier system to be folded down after its installation, should this ever be necessary. For example, barrier systems at the edges of waterways prone to flooding are often damaged during flood events because of debris being carried in the flood water. The barrier system of the present invention can, however, be folded from its vertical (upright) configuration to its horizontal (laid down) position in anticipation of an upcoming flood event (i.e. after the road / path / etc. has been closed to the public). As would be appreciated, the chance of damage to the barrier system in its laid down configuration would be greatly reduced during a flood event.

[0008] In some embodiments, the joining orientation may extend for about 5° between the orientations which correspond to vertical (about 0°) and horizontal (about 90°) positions of a stanchion in use. For example, the joining orientation may be between an angle of about 25° and about 30° of the end cap with respect to the base.

[0009] In alternative embodiments, the joining orientation may be at an angle of greater than 90° of the end cap with respect to the base (e.g. at an angle of between about 115° and about 120° ofthe end cap with respect to the base). The base and end cap in such embodiments might not be able to be interlocked after the base has been mounted on a surface because the joining orientation is “below horizontal”, where the end cap is prevented from reaching the necessary orientation due to the surface (unless, of course, the base is mounted adjacent to an edge of the surface). However, such functionality provides a safety measure to ensure the two components cannot become separated during transport or whilst the stanchions / barrier system are being adjusted from their horizontal (i.e. laid flat) positions to their vertical positions.

[0010] In some embodiments, the first and second parts of the interlocking assembly may comprise one or more hinge pins and a corresponding one or more hinge barrels. The (or each) hinge pin may, for example, be located at an underside (e.g. an underside edge) of the proximal portion of the end cap and the (or each) hinge barrel be located at an upper side (e.g. an upper side edge) of the base. The (or each) hinge pin may, in some embodiments, project outwardly from a recess formed in the underside of the proximal portion of the end cap and comprise free end portions.

[0011] In some of such embodiments, the (or each) hinge barrel may comprise a knuckle, the knuckle comprising an overhanging lip configured to overlie the free end portions of the respective hinge pin and thereby retain the hinge pin within the hinge barrel. The overhanging lip comprises a notch configured for a respective free end portion to pass through when the base and the end cap are in the joining orientation, in order to locate the (or each) hinge pin within the respective hinge barrel(s). An outer surface of each knuckle may have a complimentary shape to the recess formed in the underside of the end cap, wherein an outer lip of the recess abuts the knuckles at orientations of the base and the end cap other than the joining orientation, such that disengagement of the base and the end cap is prevented. Each knuckle may comprise a lateral recess located at the upper side edge of the base, wherein an inner lip of the recess formed in the underside of the proximal portion of the end cap is configured for receipt within the lateral recess when the base and the end cap are in an orientation which corresponds to the vertical (0°) position of a stanchion in use.

[0012] In some embodiments, the upper side of the base may further comprise a tapered boss and the underside of the end cap further comprise a correspondingly tapered recess. The tapered recess may, for example, comprise an aperture that is accessible from the upper side of the end cap, the aperture being in alignment with the boss when in the orientation that corresponds to a vertical (0°) position of a stanchion in use, such that a fastener can fasten the end cap to the base. In some of such embodiments, the boss may be located at an opposite side of the base to the firstpart of the interlocking assembly (e.g. the hinge barrel) so that the parts are affixed at opposing sides for an even greater stability.

[0013] In some embodiments, the base and / or the end cap may be configured to receive an edge barrier on an inner and / or outer, in use, side. Such edge guards may be capable of preventing items from rolling off an elevated surface, or for preventing the wheels of wheelchairs, or the like from becoming caught by protruding elements of the assembled barrier system.

[0014] In a second aspect, the present invention provides a barrier system comprising the mount of the first aspect of the present invention.

[0015] In a third aspect, the present invention provides a modular barrier system comprising a plurality of the mounts of the first aspect of the present invention and a corresponding number of stanchions inserted onto the end caps. The stanchions are joined with railings and the modular barrier system is configured for joining to other modular barrier systems in order to form a complete barrier system.

[0016] In a fourth aspect, the present invention provides a method for erecting a barrier system. The method comprises:mounting a plurality of the bases of the modular barrier system of the third aspect of the present invention to a substructure and interlocking respective endcaps and stanchions with each of the bases;pivoting the stanchions into the horizontal (about 90°) configuration with respect to the substructure and transporting the substructure to a site for installation;incorporating the substructure into a final structure;pivoting each of the stanchions with respect to the substructure into the vertical (0°) configuration; andfastening the end cap to the base.

[0017] In a fifth aspect, the present invention provides a method for erecting a barrier system. The method comprises:mounting a plurality of the bases of the modular barrier system of the third aspect of the present invention to a substructure;transporting the substructure to a site for installation;incorporating the substructure into a final structure;interlocking respective endcaps and stanchions of the modular barrier system of the third aspect of the present invention with each of the bases, and pivoting each of the stanchions into their vertical (about 0°) configuration with respect to the final structure; and fastening the end cap to the base.

[0018] In a sixth aspect, the present invention provides a method for erecting a barrier system. The method comprises:assembling the modular barrier system of the third aspect of the present invention, whereby the first and second parts of the interlocking assembly are interlocked; orientating the stanchions with respect to the base into a laid down configuration at an angle of about 90°;transporting, to an installation site, a plurality of the laid down modular barrier systems; positioning each of the modular barrier systems on a surface and fastening the bases thereto;lifting the modular barrier system into a position in which the stanchions are in a substantially vertical position and fastening them in that position; andoptionally, fastening adjacent modular barrier systems together.

[0019] Other aspects, features and advantages of the present invention will be described below.Brief Description of the Drawings

[0020] Embodiments of the present invention will be described in further detail below with reference to the following drawings, in which:

[0021] Figure 1 shows a front perspective view of the base of a mount for a barrier system in accordance with an embodiment of the present invention;

[0022] Figure 2 shows a perspective view of the end cap for a stanchion of a mount for a barrier system in accordance with the embodiment of the present invention shown in Figure 1;

[0023] Figure 3 shows a perspective view of the base of Figure 1 interlocked with the end cap of Figure 2, where the endcap is in an upright (vertical) position;

[0024] Figure 4 shows a front view of the base and end cap of Figure 3;

[0025] Figure 5 shows a cross sectional view through the line A-A of the base and end cap of Figure 4;

[0026] Figure 6 shows a perspective view of the base of Figure 1 interlocked with the end cap of Figure 2, where the endcap is in a laid down (horizontal) position;

[0027] Figure 7 shows a front view of the base and end cap of Figure 6;

[0028] Figure 8 shows a cross sectional view through the line D-D of the base and end cap of Figure 7;

[0029] Figures 9A, 9B and 9C illustrate the interlocking of the base and the end cap of a mount for a barrier system in accordance with the embodiment of the present invention shown in Figures 1 to 8, where the stanchion finishes in an upright (vertical) position;

[0030] Figures 10A and 10B show perspective views of the base of a mount for a barrier system in accordance with another embodiment of the present invention;

[0031] Figures 11 A and 1 IB show perspective views of the end cap for a stanchion of a mount for a barrier system in accordance with the embodiment of the present invention shown in Figure 10;

[0032] Figure 12 shows an enlarged view of a portion of the interlocking assembly of the base of Figure 10;

[0033] Figure 13 shows an enlarged view of a portion of the interlocking assembly of the endcap of Figure 11;

[0034] Figures 14A and 14B show perspective views of the base of Figure 10 interlocked with the end cap of Figure 11, where the endcap is in a laid down (horizontal) position and an upright (vertical) position, respectively;

[0035] Figures 15A to 15D show perspective views of stepwise positions of the base of Figure 10 and the end cap of Figure 11 during the interlocking process;

[0036] Figures 16A to 16C show side views of stepwise positions of the base of Figure 10 and the end cap of Figure 11 during the final part of the interlocking process;

[0037] Figures 17A to 17C show a modular barrier in accordance with an embodiment of the present invention being moved between a laid down (transport) position and an upright (installed) position;

[0038] Figures 18A and 18B show perspective views of the base of a mount for a barrier system in accordance with yet another embodiment of the present invention;

[0039] Figures 19A and 19B show perspective views of the end cap for a stanchion of a mount for a barrier system in accordance with the embodiment of the present invention shown in Figure 10; and

[0040] Figure 20 shows the joining orientation of the base of Figure 18 and the end cap of Figure 19.Detailed Description of the Invention

[0041] The overarching purpose of the present invention is to further simplify the task of installing a barrier system. The present invention thus provides a mount for a barrier system, the mount comprising a base for mounting to a surface and an end cap for a stanchion. The base is configured to engage the end cap such that the end cap is pivotable relative to the base between orientations that correspond to vertical (about 0°, i.e. upright) and horizontal (about 90°, i.e. laid flat on the surface) positions of a stanchion in use. The base also comprises a first part of an interlocking assembly. A distal portion of the end cap is configured to receive a stanchion thereat and a proximal portion of the end cap comprises a second part of the interlocking assembly. The first and second parts of the interlocking assembly are configured to engage and become interlocked only when the base and the end cap are in a joining orientation and, once interlocked, remain interlocked at orientations of the base and the end cap other than the joining orientation. Also provided are barrier systems and modular barrier systems comprising the mounts of the present invention, as well as installation methods for barrier systems including these mounts.

[0042] As described above, the present invention advantageously enables the entirety of a barrier system to be preassembled before its delivery on site. The pivotability of the interlocked base with respect to the end cap and associated stanchion of the barrier system’s body enables a preassembled barrier system to be transported and positioned for installation with the mount preattached and laid down flat against other parts of the barrier system. Such a “flat-packed” structure increases the height of a substructure only by a very small amount, greatly simplifying transport options between construction and installations sites. Whilst references to “horizontal” and “about 90°” and “laid flat on the surface” are used herein, it will be appreciated that small variances from this exact value will not affect the utility of the present invention. For example, shipping / transport may occur between 80° and 100°, depending on factors such as the topography of the substrate, use of shims / packers under the base, and varying restraint methods(e.g. dunnage) used for transport. As used herein, the term “about” is intended to mean up to ±10% of the recited value.

[0043] The base mounts can then be mounted to the surface in exactly the required configuration for the stanchions of the barrier system, after which a single operator can simply pivot the barrier system into its upright configuration. The safety requirements associated with such a straightforward operation (i.e. compared with multiple operators having to drill holes and install barriers at the edge of an elevated structure such as a bridge, for example) would be significantly reduced. Other advantageous assembly methods made possible by the present invention will be described below.

[0044] The present invention relates to a mount for a barrier system. Barrier systems which the inventors see an immediate application for the invention include handrails, barriers, commercial balustrades and guardrail systems. However, it will be appreciated that any barrier system that would benefit from the advantageous functionality enabled by the invention could benefit from the teachings contained herein.

[0045] The present invention provides a mount that includes a base for mounting to a surface and an end cap for a stanchion. Each of these components of the invention will be described below, firstly in general terms and then in the context of specific embodiments.

[0046] The base is configured to receive the end cap such that the end cap is moveable by pivoting relative to the base between orientations that correspond to horizontal and vertical positions of a stanchion in use (i.e. as a barrier system). The base also includes a first part of an interlocking assembly, which will be described in further detail below.

[0047] The base may have any configuration that enables it to be attached to a surface in a conventional manner, such as via apertures provided in a flange extending outwardly from the base. Appropriate fasteners, such as expansion bolts or ground anchors, may thus be used to securely affix the base (and hence the barrier system) to the surface.

[0048] The base may have any configuration that enables it to receive the end cap in the recited manner. In some embodiments, for example, the base may include a laterally or longitudinally aligned cylindrical groove for receipt of a corresponding portion of the end cap thereat. Relative rotation of the end cap with respect to the base results in the cylindrical portions of the end cap and base sliding against one another, providing for a smooth and unhindered movement between the laid down and upright positions described herein.

[0049] In alternative embodiments, the first and second parts of the interlocking assembly may include a hinge pin (or multiple hinge pins) and a corresponding hinge barrel. The hinge pinmay be located at an underside edge of the end cap and the hinge barrel located at an upper side edge of the base. The hinge pin may project outwardly from a recess formed in the underside edge of the end cap and comprise free end portions.

[0050] In some of such embodiments, the hinge barrel may include knuckles at opposing ends, each knuckle including an overhanging lip configured to overlie the free end portions of the hinge pin and thereby retain the hinge pin within the hinge barrel. The overhanging lips may include a notch configured for a respective free end portion to pass through when the base and the end cap are in the joining orientation, in order to locate the hinge pin within the hinge barrel.

[0051] An outer surface of each knuckle may have a complimentary shape to the recess formed in the underside edge of the end cap, where an outer lip of the recess abuts the knuckles at orientations of the base and the end cap other than the joining orientation, such that disengagement of the base and the end cap is prevented. Each knuckle may also include a lateral recess positioned at the upper side edge of the base, with an inner lip of the recess being configured for receipt within the lateral recess when the base and the end cap are in an orientation which corresponds to the horizontal (90°) position of a stanchion in use.

[0052] Typically, the base (and the end cap) would also include means for securely fastening the end cap / stanchion in at least its upright position. For example, apertures that are adapted to receive a fastener and which are in alignment when in the orientation that corresponds to a vertical position of a stanchion in use may be provided in the base and / or the end cap.

[0053] In some embodiments, for example, the upper side of the base may also include a tapered boss and the underside of the end cap include a correspondingly tapered recess. The tapered recess may include an aperture that is accessible from the upper side of the end cap, the aperture being in alignment with the boss when in the orientation that corresponds to a vertical position of a stanchion in use, such that a fastener can be used to fasten the end cap to the base (i.e. at a location separate from the hinge). In some of such embodiments, the boss may be located at an opposite side of the base to the hinge barrel.

[0054] The base may include other components that are compatible with its functionality. For example, the base my also include U-shaped side walls configured to snugly receive a stanchion, particularly in its upright position. Such side walls would further stabilise the stanchion (and hence barrier system more generally) in its upright configuration.

[0055] The base (or, indeed, the end cap) may include features that enable other components of a barrier system to be fastened to it. For example, on construction sites it is a requirement that any edges from which items might fall be protected with an edge barrier about 10cm high. Thus, insome embodiments, the base may be configured to receive an edge barrier on an outermost, in use, side. The base may, for example, include apertures or ridges / grooves. etc. to facilitate this attachment.

[0056] As described above, the base includes a first part of an interlocking assembly and the proximal portion of the end cap includes a second part of the interlocking assembly. The first and second parts of the interlocking assembly are configured to join when the base and the end cap are in a joining orientation. In some embodiments, the joining orientation may be between the orientations that correspond to horizontal and vertical positions of a stanchion in use. In alternative embodiments, the joining orientation may be outside of these orientations, for example, past the horizontal (90°) configuration described above. In all other orientations of the base and the end cap, the two components are interlocked.

[0057] The joining orientation may occur at a specific orientation / angle of the base and end cap or at a more general range of orientations / angles of the base and end cap. The joining orientation may, for example be at about halfway between the orientations which correspond to vertical (0°) and horizontal (90°) positions of a stanchion in use, such a relative orientation being one that is readily easy to achieve and likely to be memorable to people assembling the barriers. The joining orientation may, for example be between an angle of about 30° and about 60° of the end cap with respect to the base. Such a broadjoining orientation would provide a degree of leeway for the people assembling the barrier, although as joining orientations become wider there is an increased risk of the base and end cap inadvertently decoupling during transition from horizontal to vertical positions, and vice versa.

[0058] In alternative embodiments, the joining orientation may thus extend for only about 5° between the orientations which correspond to vertical (0°) and horizontal (90°) positions of a stanchion in use. For example, the joining orientation may be between an angle of about 20°, 25° or 30° of the end cap with respect to the base.

[0059] In alternative embodiments, the joining orientation may be at an angle of greater than 90° of the end cap with respect to the base (e.g. at an angle of between about 115° and about 120° of the end cap with respect to the base). As noted above, in such “below horizontal” relative orientations, the base and end cap in such embodiments might not be able to be interlocked after the base has been mounted on a surface, but such functionality provides a safety measure to ensure the two components cannot become separated during transport or whilst the stanchions / barrier system are being adjusted from their horizontal (i.e. laid flat) positions to their vertical positions.

[0060] If, however, the base is mounted close to an edge of the surface, such as pre-mounted to a concrete U-trough beam, the top surface of which is quite narrow, the end cap might be capable of hinging into such a below horizontal position before it contacts the inside edge of the U-trough. Thus, the two components, in some embodiments, would still be separable even given a below horizontal joining orientation.

[0061] The interlocking assembly may have any configuration that provides the functionality described herein. Specific embodiments of the interlocking assembly are described below and the following comments relate to more general features of interlocking assemblies falling with the scope of the present invention.

[0062] In some embodiments, the first and second parts of the interlocking assembly may include a featured shaft and a correspondingly featured recess. The shaft may, for example, include one or more outwardly projecting members configured to overhang edges of the recess when in orientations other than the joining orientation.

[0063] A proximal end of the shaft may, for example, be T shaped. One arm of the T-shaped protrusion may, for example, overhang a return on a rear wall of the base as the end cap is moved relative to the base towards the orientation that corresponds to the horizontal position of a stanchion in use. The other arm of the T-shaped protrusion may overhang an edge of an aperture in base as the end cap is moved relative to the base towards the orientation that corresponds to the vertical position of a stanchion in use. Physical interactions between the arms of the T-shaped protrusion and features present in the end cap combine in order to prevent the T-shaped protrusion being moved away from the base in orientations other than the joining orientation.

[0064] Given its intended use, the components of the present invention may be formed from any durable material. Modular barriers are conventionally formed from materials such a galvanised or cast iron, which would also be suitable in the present invention. Aluminium or stainless steel components might also be used.

[0065] As noted above, the present invention also provides methods for erecting a barrier system. In one general form, the method comprises:assembling the modular barrier system disclosed herein whereby the first and second parts of the interlocking assembly are interlocked;orientating the stanchions with respect to the base into a laid down configuration at an angle of about 90°;transporting, to an installation site, a plurality of the laid down modular barrier systems;positioning each of the modular barrier systems on a surface and fastening the bases thereto;lifting the modular barrier system into a position in which the stanchions are in a substantially vertical position and fastening them in that position; andoptionally, fastening adjacent modular barrier systems together.

[0066] In another general form, the method comprises:mounting a plurality of the bases of the modular barrier system disclosed herein to a substructure and interlocking respective endcaps and stanchions with each of the bases; pivoting the stanchions into the horizontal (about 90°) configuration with respect to the substructure and transporting the substructure to a site for installation; incorporating the substructure into a final structure;pivoting each of the stanchions with respect to the substructure into the vertical (0°) configuration; andfastening the end cap to the base.

[0067] In another general form, the method comprises:mounting a plurality of the bases of the modular barrier system disclosed herein to a substructure;transporting the substructure to a site for installation;incorporating the substructure into a final structure;interlocking respective endcaps and stanchions of the modular barrier system with each of the bases, and pivoting each of the stanchions into their vertical (about 0°) configuration with respect to the final structure; andfastening the end cap to the base.

[0068] Specific embodiments of these installation methods will be described in further detail below.

[0069] Specific embodiments of the mount, barrier system and methods of the present invention will now be described below. Figures 1 to 9 depict a first embodiment of the present invention, Figures 10 to 16 a second embodiment and Figures 18 to 20 a third embodiment. Each embodiment will be described in turn below.

[0070] Referring generally to Figures 1 to 8, shown is a mount 10 for a barrier system (not shown), the mount including a base 12 and an end cap 14 in accordance with an embodiment of the present invention. Figure 1 shows the base 12 in isolation, Figure 2 shows the end cap in isolation and Figures 3 to 8 show the base 12 and end cap 14 of the mount 10 in their upright configuration (Figures 3 to 5) and in their laid down configuration (Figures 6 to 8).

[0071] Referring now to Figure 1, shown is the base 12 of the mount for a barrier system. Base 12 includes a seat 16 upon which the end cap 14 can be received in the manner described below. Seat 16 includes a longitudinally arranged (with respect to the base 12) cylindrical groove having an aperture 17 at a centre thereof. The cylindrical groove facilitates rotation of the end cap 14 in the base 12 and the aperture 17 forms part of an interlocking assembly with the end cap 14, both of which will be described in further detail below. Base 12 also has generally U-shaped side walls 18, which are dimensioned such that a stanchion (not shown) can be snugly received therein. Providing such a snug fit extending up the lower portion of a stanchion will contribute to the ultimate stability of the barrier system. Side wall 18 may also include an aperture or other feature through which a fastener may pass in order to securely affix the stanchion to the base 12.

[0072] Base 12 also includes side flanges 20, both of which have apertures 22, 22 for receiving surface fasteners. These apertures are configured to receive fasteners such as ground anchors, and the like, in order to fasten the base 12 to a surface such as the ground or a concrete substructure in a conventional manner.

[0073] Turning now to Figure 2, shown is the end cap 14 of the mount for a barrier system. End cap 14 has a distal portion 24 that is configured to receive a stanchion (not shown) thereat, and a proximal portion 26. In use, an end of a stanchion can be slid over the distal portion 24 until it abuts ridge 25. The fit may be sufficiently tight for the end cap 14 to be securely retained on the end of the stanchion, or a fastener (e.g. that described in the preceding paragraph) may be used to secure the end cap to the stanchion.

[0074] The proximal portion 26 of end cap 14 includes a number of features that interrelate with corresponding features in the seat 16 of the base 12. Proximal portion 26 has a cylindrical member 28 which is configured to be located on seat 16, whereupon the end cap 14 can smoothly rotate with respect to the base 12 over a range of about 90°, as will be described below. Proximal portion 26 also has a T-shaped interlocking member 30 at an end thereof. Member 30 has in use upper 32 and lower 34 arms and is shaped such that arms 32, 34 fit through aperture 17 in seat 16 when the end cap 14 in an appropriate orientation (i.e. the joining orientation) with respect to the base 12. Once member 30 has been inserted through aperture 17 (i.e. whenmember 28 is against seat 16), the interactions described below prevent end cap 14 from being lifted off base 12.

[0075] The interlocking functionality of the end cap 14 and base 12 will now be described with reference to Figures 3 to 8. Figures 3 to 5 illustrate the mount 10 in its “upright” configuration, where a stanchion (not shown) would be in an upright position with respect to the base 12.Figures 6 to 8 illustrate the mount 10 in its “laid down” configuration, where the stanchion would be laying on the ground, either for transport of the barrier system (etc.) to site, or during its preliminary installation.

[0076] Figures 5 and 8 are cross sectional views of the mount 10 in these positions and which illustrate the features of the base 12 and end cap 14 which result in the two components being interlocked at relative orientations other than the joining orientation. Comparing Figures 5 and 8, it can be seen that end cap 14 has been rotated anticlockwise by 90°. At all times during this rotation, cylindrical member 28 of the end cap 14 sits within and slides over seat 16 of the base 12, with their complementary circular surfaces facilitating a smooth rotational movement. The T-shaped interlocking member 30 has passed through aperture 17 and causes the end cap 14 to be retained by the base 12 due to the interactions between arms 32, 34 and the components of the base 12 described below.

[0077] In Figure 5, it can be seen that arm 34 is located underneath an edge 36 of aperture 17. This interaction prevents end cap 14 from being lifted out of base 12 but does not prevent the end cap from being rotated with respect to the base towards the orientation shown in Figure 8. Once in the orientation shown in Figure 8, it can be seen that the other arm 32 has been positioned underneath a return 38 on the side wall 18. This interaction prevents end cap 14 from being pulled away from base 12 but again does not prevent the end cap from being rotated with respect to the base towards the orientation shown in Figure 5. At some relative orientations of the end cap 14 with respect to the base 12 between those shown in Figures 5 and 8, however, the arm 34 is clear of the edge 36 and the arm 32 is clear of the return 38. In such orientations, it is possible to lift the end cap 14 away from the base 12, through the aperture 17 defined between edges 36 and 38, in order to decouple them (and, conversely, recouple them).

[0078] Referring finally to Figure 9, an in use application of the mount 10 will be described. In Figure 9A, a stanchion 38 having an end cap 14 fitted to one end thereof is shown in an angled orientation with respect to a base 12 positioned on a surface. The orientation of stanchion 38 presents end cap 14 to base 12 in a joining orientation, as described above, where the arms 32, 34 of the interlocking member 30 are able to pass through aperture 17.

[0079] In Figure 9B, the interlocking member 30 has passed through aperture 17 and the cylindrical member 28 of the end cap 14 has been positioned against seat 16 of the base 12, the complementary surfaces thereof enabling the stanchion 38 to be pivoted up or down, depending on the next action. In the present case, the stanchion 38 may be pivoted upwardly into its vertical position, as shown in Figure 9C. In this orientation, the interactions between the first and second parts of the interlocking assembly described above with reference to Figures 5 and 8 lock the stanchion 38 to the base 12. Appropriate fasteners (not shown) could then be used to secure the stanchion (and its associated barrier system, also not shown) permanently in the upright position.

[0080] The second embodiment will now be described referring generally to Figures 10 to 16, which depict a mount 100 for a barrier system (see Figure 14, described below) in accordance with another embodiment of the present invention. The mount 100 includes a base 112 and an end cap 114, with Figures 10A and 10B showing the base 112 in isolation and Figures 11 A and 1 IB showing the end cap 114 in isolation.

[0081] Referring to Figures 10A and 10B, base 112 is a generally planar sheet of suitable material, in this case, galvanised iron, having a thickness commensurate with its purpose as a mount for a barrier system. Base 112 includes the first part of an interlocking assembly 116, to be described in further detail below, at an upper edge thereof, as well as spaced apart mounting apertures 120, 120, through which a fastening means such as a concrete anchor can be passed in order to securely mount the base 112 to a surface (e.g. a concrete surface). Base 112 also includes a tapered boss 122 opposite the interlocking assembly 116, as will also be described below in further detail.

[0082] Referring now to Figures 11 A and 1 IB, end cap 114 includes the second part of an interlocking assembly 118, to be described in further detail below, at a lower edge thereof. The upwardly facing (in use) portion of the end cap 114 includes a cup 128 configured to snugly receive a stanchion (not shown) therein. Once a stanchion is received into cup 128, fasteners can be passed through apertures 130 in order to securely fix the stanchion to the end cap 114 in a conventional manner. End cap 114 also includes a tapered recess 124 on its underside at the opposite side of the interlocking assembly 118, the purpose of which will also be described below in further detail.

[0083] As will be described in further detail below, the first 116 and second 118 parts of the interlocking assembly are configured to engage when the base 112 and the end cap 114 are in a joining orientation which is between the orientations that correspond to horizontal (90°) and vertical (0°) positions of a stanchion in use, the first and second parts of the interlockingassembly being interlocked at orientations of the base and the end cap other than the joining orientation.

[0084] Figures 12 and 13 show enlarged views of the first part of the interlocking assembly 116 (Figure 12) and the second part of the interlocking assembly 118 (Figure 13). Referring firstly to Figure 12, the interlocking assembly 116 of the base 112 includes a hinge barrel 132 having knuckles 136 at opposing ends thereof (only one knuckle is shown in Figure 12). An inner edge of knuckle 136 includes an overhanging lip 139, which extends in an arcuate manner over a portion of an edge of the barrel 132. The overhanging lip 139 does not extend over the entirety of the barrel, with a notch 140 being provided at an inwardly facing portion of the knuckle 136. The outer surface of the knuckle 136 includes a groove 142, an abutting surface 144 and a lateral recess 148, the purpose of which will be described below.

[0085] Referring now to Figure 13, the interlocking assembly 118 of the end cap 114 includes a hinge pin 134 that projects outwardly from a recess 137 in a lowermost edge of the end cap 114. Hinge pin 134 includes free end portions 138, 138 at opposing sides thereof, which overhang the member that joins the hinge pin to the end cap 114. The recess 137 includes an outer lip 146 and an inner lip 150.

[0086] Before moving onto a description of how the base 112 and the end cap 114 become interlocked, Figures 14A and 14B depict the base and the end cap in the orientations that correspond to horizontal (90°) and vertical (0°) positions of a stanchion (not shown) in use. In Figure 14A, a stanchion received in end cap 114 would be in a substantially horizontal position which, as described above, would enable a barrier system to be pre-assembled and transported to site more efficiently than is currently possible. The base 112 can be affixed to the upper surface of a substructure (e.g. a portion of a bridge span) in a conventional manner, and the end cap 114 pivoted about the interlocking assembly 116, 118 into the orientation shown in Figure 14B, where the stanchion (and any associated railings, etc.) would be in a vertical, installed position (i.e. after the bridge has been constructed). A fastener, shown in the form of a bolt 126 can then be used to fasten the opposite side of the end cap 114 to the base 112, and hence lock the stanchion in the vertical orientation.

[0087] Referring now to Figures 15 and 16, the manner in which the end cap 114 and the base 112 become interlocked will be described. In Figure 15 A, the end cap 114 is shown being brought towards the base 112 at a relative angle of about 25°, where the recess 137and hinge pin 134 present to the hinge barrel 132 and knuckles 136, 136 in a joining orientation. In this orientation, the free end portions 138, 138 are in alignment with the notches 140, 140 and, at the same time, outer lip 146 is in alignment with grooves 142, 142. Moving the hinge pin 134 intothe hinge barrel 132 whilst in the joining orientation causes the outer lip 146 to pass over the grooves 142, 142 and abut the outer surfaces 144, 144 of the knuckles 136, 136. However, once the end cap 114 is pivoted about the hinge such that it is no longer in the joining orientation, engagement of the outer lip 146 and surfaces 144, 144 and prevents the hinge pin 134 from escaping the hinge barrel 132. The inner lip 150 of recess 137 also engages with the outer surface of the knuckles 136, 136, and particularly so when the relative angle of the end cap 114 with respect to the base 112 approaches 0° (i.e. vertical).

[0088] In this regard, and now referring to Figures 16A to 16C, the relative movement of the end cap 114 on the base 112 as their relative angles approach 0° (i.e. vertical) will now be described. The hinge pin 134 is securely retained within the barrel 132 at all relative orientations of the end cap 114 and base 112 due to the engagement between the outer lip 146 and outer surfaces 144, 144 of the knuckles 136, 136. As the relative angles approach 0°, however, an additional interaction takes place that even further enhances the strength of the connection between the end cap 114 and base 112. In this regard, inner lip 150 enters into lateral recess 148 as the relative angles approach 0° and, at the same time, the tapered boss 122 enters the tapered recess 124. As can be seen in Figures 16B and 16C, this has the effect of pushing the end cap 114 towards the left in the Figures, whereupon the inner lip 150 is pushed further into the lateral recesses 148, 148 such that any possibility of relative movement between the end cap 114 and base 112 on that side is effectively prevented. Once in the position shown in Figure 16C (and as described above in relation to Figure 14B), a fastener through the tapered recess 124 and tapered boss 122 securely fastens the opposite side of the mount 100 together, whereupon relative movement is effectively precluded.

[0089] Referring now to Figures 17A to 17C, depicted is the assembly of a modular barrier system 200 that includes a plurality (four, in the Figures) of the mounts 100. In Figure 17 A, the pre-assembled modular barrier is affixed to the upper surface of a substructure 202 for transporting to a worksite site in order to assemble a structure (e.g. a bridge). Advantageously, no measurements need to be made in order to drill holes in the surface 202 that are in alignment with the apertures 120, 120 in the base 112 (see Figure 10) because the bases are already in situ. Furthermore, the barrier can be positioned at an edge of substructure 202 without any need for the safety equipment that would be required, for example, if the barrier was being assembled on the side of an already assembled bridge. Instead, the work required to affix the bases 112 to the surface (e.g. holes drilled and concrete anchors passed through apertures 120, 120 into the concrete substructure 202) can be carried out in a controlled environment, away from the busy worksite. The barrier system 200 can then be folded into the laid-flat, horizontal position shownin Figure 17A and the entire substructure 202 and barrier system 200 loaded onto a vehicle for transporting to site. Advantageously, the height of the substructure 202 and barrier system 100 is only very slightly greater than the substructure itself, and is certainly much lower than would be the case if the barrier system 100 was in a vertical (installed position, e.g. as shown in Figure 17C), as per conventional barrier systems. Once on-site, the substructure 202 can be assembled with other substructures (not shown) in order to form the final structure (e.g. a bridge or overpass, etc.).

[0090] After this time, it is a simple matter to pivot the barrier 100 about the base into the upright position, as shown in Figures 17B and 17C, after which fasteners can be used, as described above, to affix the barrier in its upright orientation. Additional modular barrier systems may be assembled adjacent to each other and joined using conventional means, in order to produce the entirety of the barrier system. This operation is far simpler than that required in order to install an entirely new barrier system at the edge of an elevated surface.

[0091] The third embodiment will now be described referring generally to Figures 18 to 20, which depict a mount 300 for a barrier system (see Figure 20, described below) in accordance with another embodiment of the present invention. The mount 300 includes a base 312 and an end cap 314, with Figures 18A and 18B showing the base 312 in isolation and Figures 19A and 19B showing the end cap 314 in isolation. Features of base 312 and an end cap 314 that are similar to those described above in the context of the first and second embodiments will not be described again.

[0092] Referring to Figures 18A and 18B, base 312 is shown in the form of a generally planar sheet of suitable material. Base 312 includes the first part of an interlocking assembly 316, a tapered boss 322 opposite the interlocking assembly 316 and a recess 346 positioned in an aperture at the centre of the base 312. Base 312 also includes two, spaced apart mounting apertures 320, through which a fastening means such as a concrete anchor can be passed in order to securely mount the base 312 to a surface (e.g. a concrete surface).

[0093] Referring now to Figures 19A and 19B, end cap 314 includes the second part of an interlocking assembly 318, to be described in further detail below, at a lower portion thereof. End cap 314 also includes a tapered recess 324 on its underside at the opposite side of the interlocking assembly 318 and a protrusion 348 located therebetween. Additional apertures 360, 360 may be provided in a rearwardly facing portion of the end cap 314 and used for attaching toe guards / edge guards and the like (not shown) to the resultant barrier system. Toe / edge guards suitable for use with the present invention include those described in the applicant’s earlier patent application, international (PCT) patent application no. PCT / AU2014 / 000227.

[0094] As can be seen in Figure 20, the first 316 and second 318 parts of the interlocking assembly are configured to engage when the base 312 and the end cap 314 are in a joining orientation of about 118°, which is about 28° below the horizontal orientation of a stanchion in its laid flat position. Thus, the upper (left hand side in Figure 20) portion of the end cap 314 needs to be lower than the underside of the base 312 in order to join the components, providing a safety function where, once interlocked and the base 312 mounted on a surface, it is not possible to separate the components (unless the base is mounted directly adjacent to an edge of the surface).

[0095] The interlocking assembly 316 of the base 312 includes a hinge barrel 332 extending between knuckles 336, 336. An inner edge of each knuckle 336 includes an overhanging lip 339, which extends in an arcuate manner over a portion of an inside edge of the knuckle 336. The overhanging lip 339 does not extend over the entirety of the knuckle, with a notch 340 being provided at an outwardly facing portion of the knuckle 336. The outer surface of each knuckle 336 includes an abutting surface 344, the purpose of which will be described below.

[0096] Referring now to Figure 19, the interlocking assembly 318 is provided in the form of two hinge pins 334, 334 that project outwardly from recesses 337, 337 in a lowermost portion of the end cap 314. Each recess 337 includes an outer lip 346 and an inner lip 350. End cap 314 also has a raked edge portion 352, providing clearance for the assembly procedure described below.

[0097] Referring now to Figure 20, the manner in which the end cap 314 and the base 312 become interlocked will be described. The end cap 314 is shown being brought towards the base 312 at a relative angle of about 118° (-28° below horizontal), where each recess 337 and hinge pin 334 present to the respective knuckle 336 in a joining orientation. In this orientation, the hinge pins 334, 334 are in alignment with the notches 340, 340 and, at the same time, recesses 337, 337 are in an orientation that enables knuckles 336, 336 to enter the recesses. The knuckles’ abutting surfaces 344, 344 abut inner lips 350, 350. Once hinge pins 334, 334 are located within knuckles 336, 336 and an imaginary axis between hinge pins 334, 334 within hinge barrel 332 (facilitated by raked edge portion 352), the end cap 314 can be rotated about the hinge towards 90°, whereupon the inner lips 350, 350 engage abutting surfaces 344, 344 and prevent the end cap 314 from being separated from the base 312.

[0098] In this position, a stanchion (not shown) can lay flat on the surface (i.e. in its 90° orientation), ready for rotation into its upright position (i.e. in its 0° orientation), with there being no orientation in between these positions where the parts can decouple. Once in the vertical position, protrusion 348 is received into recess 346, further strengthening the join between the end cap 314 and base 312, with a fastener being passed through the tapered boss 322 and the tapered recess 324, as described above, in order to complete the assembly.

[0099] The inventors envisage that the mount systems disclosed herein will allow for the preassembly of mounting components in a controlled off-site environment, which can then be attached to substrates or substructures. This approach significantly reduces installation time and minimizes personnel exposure to hazardous conditions, such as leading edges and live construction environments, on-site.

[0100] As would be appreciated, the present invention provides a number of significant and commercially important advantages over existing mounts for barrier systems. Advantages include:• faster, easier and cheaper installation of barrier systems can be achieved due to the interlocked nature of the base and end cap / stanchion / b airier;• the installation process is less dependent on precise measurements on site and can be carried out with fewer personnel;• the installation process subject to less time constraints under live site conditions due to the ability to work in more controlled off-site settings for the majority of the install works;• the barrier systems can be pre-attached to substrates / substructures in one location, strapped to horizontal enabling transit to alternate locations without significant increases in structure height, thus allowing for more direct routes to be taken (e.g. through tunnels and under bridges);• alternative methods of installation can be enabled with partial mounts connected prior, or whole systems to transit to site; and• the base components can be provided ahead of system assembly to enable affixing to substrates, and coordination of pre-set anchoring methods.

[0101] It will be understood to persons skilled in the art of the invention that many modifications may be made without departing from the spirit and scope of the invention. All such modifications are intended to fall within the scope of the following claims.

[0102] It is to be understood that any prior art publication referred to herein does not constitute an admission that the publication forms part of the common general knowledge in the art.

[0103] In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

Claims

CLAIMS:

1. A mount for a barrier system, the mount comprising:a base for mounting to a surface; andan end cap for a stanchion,wherein the base is configured to engage the end cap whereby the end cap is pivotable relative to the base between orientations that correspond to vertical (about 0°) and horizontal (about 90°) positions of a stanchion in use, the base comprising a first part of an interlocking assembly,wherein a distal portion of the end cap is configured to receive a stanchion thereat and a proximal portion of the end cap comprises a second part of the interlocking assembly, wherein the first and second parts of the interlocking assembly are configured to become interlocked only when the base and the end cap are in a joining orientation and, once interlocked, remain interlocked at orientations of the base and the end cap other than the joining orientation.

2. The mount of claim 1, wherein the joining orientation extends for about 5° between the orientations which correspond to vertical (about 0°) and horizontal (about 90°) positions of a stanchion in use.

3. The mount of claim 1 or claim 2, wherein the joining orientation is at an angle of between about 25° and about 30° of the end cap with respect to the base.

4. The mount of claim 1, wherein the joining orientation is at an angle of greater than 90° of the end cap with respect to the base.

5. The mount of claim 1 or claim 4, wherein the joining orientation is at an angle of between about 115° and about 120° of the end cap with respect to the base.

6. The mount of any one of claims 1 to 5, wherein the first and second parts of the interlocking assembly comprise one or more hinge pins and a corresponding one or more hinge barrels.

7. The mount of claim 6, wherein the or each hinge pin is located at an underside of the proximal portion of the end cap and the or each hinge barrel is located at an upper side of the base.

8. The mount of claim 6 or claim 7, wherein the or each hinge pin projects outwardly from a recess formed in the underside of the proximal portion of the end cap, the or each hinge pin comprising free end portions.

9. The mount of claim 8, wherein the or each hinge barrel comprises a knuckle, the knuckle comprising an overhanging lip configured to overlie the free end portion of the respective hinge pin and thereby retain the hinge pin within the hinge barrel, wherein the overhanging lip comprises a notch configured for a respective free end portion to pass through when the base and the end cap are in the joining orientation in order to locate the or each hinge pin within the respective hinge barrel(s).

10. The mount of claim 9, wherein an outer surface of each knuckle has a complimentary shape to the recess formed in the underside of the end cap, and wherein an outer lip of the recess abuts the knuckles at orientations of the base and the end cap other than the joining orientation, whereby disengagement of the base and the end cap is prevented.

11. The mount of claim 9 or claim 10, wherein each knuckle comprises a lateral recess located at the upper side edge of the base, and wherein an inner lip of the recess formed in the underside of the proximal portion of the end cap is configured for receipt within the lateral recess when the base and the end cap are in an orientation which corresponds to the vertical (0°) position of a stanchion in use.

12. The mount of any one of claims 1 to 11, wherein the upper side of the base further comprises a tapered boss and the underside of the end cap further comprises a correspondingly tapered recess.

13. The mount of claim 12, wherein the tapered recess comprises an aperture that is accessible from the upper side of the end cap, the aperture being in alignment with the boss when in the orientation that corresponds to a vertical (0°) position of a stanchion in use, whereby a fastener can fasten the end cap to the base.

14. The mount of claim 12 or claim 13, wherein the boss is located at an opposite side of the base to the first part of the interlocking assembly.

15. A barrier system comprising the mount of any one of the preceding claims.

16. A modular barrier system comprising a plurality of the mounts of any one of claims 1 to 14 and a corresponding number of stanchions inserted onto the end caps, the stanchions being joined with railings, and wherein the modular barrier system is configured for joining to other modular barrier systems in order to form a complete barrier system.

17. A method for erecting a barrier system, the method comprising:mounting a plurality of the bases of the modular barrier system of claim 16 to a substructure and interlocking respective endcaps and stanchions with each of the bases;pivoting the stanchions into the horizontal (90°) configuration with respect to the substructure and transporting the substructure to a site for installation; incorporating the substructure into a final structure;pivoting each of the stanchions with respect to the substructure into the vertical (0°) configuration; andfastening the end cap to the base.

18. A method for erecting a barrier system, the method comprising:mounting a plurality of the bases of the modular barrier system of claim 16 to a substructure;transporting the substructure to a site for installation;incorporating the substructure into a final structure;interlocking respective endcaps and stanchions of the modular barrier system of claim 16 with each of the bases, and pivoting each of the stanchions into their vertical (0°) configuration with respect to the final structure; andfastening the end cap to the base.

19. A method for erecting a barrier system, the method comprising:assembling the modular barrier system of claim 16 whereby the first and second parts of the interlocking assembly are interlocked;orientating the stanchions with respect to the base into a laid down configuration at an angle of 90°;transporting, to an installation site, a plurality of the laid down modular barrier systems; positioning each of the modular barrier systems on a surface and fastening the bases thereto;lifting the modular barrier system into a position in which the stanchions are in a substantially vertical position and fastening them in that position; andoptionally, fastening adjacent modular barrier systems together.

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