AU2019203879A1 - Support brace - Google Patents

Abstract

SUPPORT BRACE Abstract A support brace (10) comprising: a bracket (20), the bracket (20) having at least two planar mounting surfaces (22) configured to connect to a vertical surface of a wall having a thickness, the mounting surfaces (22) being generally co-planar; a main plate (30) connected to said bracket (20), the main plate (30) being generally perpendicular to the mounting surfaces (22) and having a first end (31a), the first end (31a) being configured to penetrate the vertical surface in a direction normal to the mounting surfaces (22) for a length (95) that is less than the thickness of the wall, until the main plate (30 is in an installed position; a holder (40) connected to the bracket (20) and/or the main plate (30), the holder (30) being configured to receive an end portion of a prop (80). 59b Fig. 13

Description

SUPPORT BRACE

Field [0001] This invention relates to a support brace. More specifically, but not exclusively, the invention relates to a support brace used to support masonry during construction work, and more particularly remedial construction work.

Background [0002] During construction of, or renovation work performed on, masonry surfaces, there is frequently a need to provide support to the existing construction while elements, such as window assemblies, doorjambs, or bricks requiring replacement, are removed. Currently, this support is often provided by masonry support devices that are attached at an upper free end of a prop. Examples of such masonry support devices are masonry needles and proppa wall supports. These devices may be attached to acrow props, post shores, BS props, jackscrews, telescoping props, adjustable steel columns, adjustable steel props, adjustable metal props, shore posts, and the like to offset the direct load in an eccentric way onto the prop. For brevity, the term “prop” will be used throughout the specification to refer to these devices of similar purpose and design. The prop is normally anchored against the ground, or floor, present at a worksite. This approach can be time consuming and dangerous when the worksite is located a significant distance, both vertically and along the ground, from usable ground that a prop may be installed on.

[0003] Further, if work is performed on a large masonry wall, scaffolding is often used to provide safe access to the higher areas of the large masonry wall. It is often a time consuming and dangerous task to install the required masonry support braces, impeded by the surrounding scaffolding, before commencing work. This type of temporary scaffolding is also prone to movement, which can result in the prop not sufficiently supporting the masonry wall as desired, and/or the prop imparting undesirable loads into the wall and/or onto the temporary scaffolding.

[0004] Yet further, even the construction of the scaffolding can be impeded, especially on worksites where access is required to areas that are low enough to be considered unsuitable for a scaffolding, but high enough to cause serious injury in the case of an accident. Scaffolding also tends to be avoided in areas where there is insufficient ground access, or space on the ground, to

2019203879 03 Jun 2019 position the required props to support the scaffolding. Scaffolding also tends to be difficult to construct on sites with significantly sloping ground, as the adjustment of the scaffolding to provide an adequately level access platform to then support masonry therefrom is an extremely time-consuming task. These disincentives to construct a safe scaffolding structure are impediments to a safe working environment around masonry structures.

[0005] Yet even further, construction material is often delivered to construction sites and left on the ground. This can impede easy access to the site, causing trip hazards and wasted time when moving materials to access a location. Additionally, materials can be damaged by humidity causing rot and deformation in the material when stored on the ground.

[0006] Finally, on some worksites materials require additional processing, for example by dropsaw, requiring a safe, level work surface. Due to this, sometimes, unforeseen requirement, this work is often performed unsafely on inadequate temporary surfaces. Alternatively, when this requirement is accounted for, the transport of dedicated work surfaces can be costly.

Summary of Invention [0007] It is an object of the present invention to at least substantially ameliorate one or more of the above disadvantages, or at least provide a useful alternative to the above described devices.

[0008] In a first aspect, the present invention provides a support brace comprising:

a bracket, the bracket having at least two planar mounting surfaces configured to connect to a vertical surface of a wall having a thickness, the mounting surfaces being generally coplanar;

a main plate connected to said bracket, the main plate being generally perpendicular to the mounting surfaces and having a first end, the first end being configured to penetrate the vertical surface in a direction normal to the mounting surfaces for a length that is less than the thickness of the wall, until the main plate is in an installed position;

a holder connected to the bracket and/or the main plate, the holder being configured to receive an end portion of a prop.

[0009] Preferably, the mounting surfaces are each connected to the vertical surface with at least one fastener.

2019203879 03 Jun 2019 [0010] Preferably, the main plate comprises a projection movable between a secured and an unsecured position, wherein the projection, when in the secured position, prevents substantial movement of the main plate from the installed position.

[0011] Preferably, any one of the bracket, the main plate, and the holder have at least one first opening that is aligned with at least one second opening in any one or more other of the bracket, the main plate, and the holder, so that the first and second openings are connectable by a fastener.

[0012] Preferably, each of the bracket, the main plate, and the holder have at least one opening, each opening being aligned so that the bracket, the main plate, and the holder are connectable with a fastener through the openings.

[0013] Preferably, the holder has a cut-out ending in a semi-circular profile for engagement with the end portion of the prop.

[0014] Preferably, the holder is mounted on the main plate such that a gap for receiving a flange of the end portion of the prop is created.

[0015] Preferably, the holder has a locking pin, the locking pin having a locked and an unlocked position, wherein in the unlocked position the locking pin allows engagement or disengagement of the prop with the holder, and wherein in the locked position the locking pin prevents engagement or disengagement of the prop from the holder.

[0016] Preferably, the locking pin is a removable pin supported by at least one projection of the holder.

[0017] Preferably, the main plate has, at a second end, a cut-out adapted to be gripped by a user of the support brace.

2019203879 03 Jun 2019 [0018] Preferably, the support brace further comprises:

an extension plate supported by the bracket, the extension plate being suitable for supporting a load.

[0019] Preferably, the load is one or more walk boards.

[0020] Preferably, the load is construction material.

[0021] Preferably, the load is a flat surface adapted to be used as a workbench.

[0022] Preferably, the extension plate is received in a gap between the holder and the bracket.

[0023] Preferably, the extension plate comprises a second projection movable between a secured and an unsecured position, wherein the second projection, when in the secured position, prevents substantial movement of the extension plate relative to the holder.

[0024] Preferably, the extension plate has a mounting bracket at an end facing away from the vertical surface, the mounting bracket being adapted to support a post of a guardrail.

[0025] Preferably, the extension plate has a second holder, wherein the second holder is configured to receive an end portion of a second prop, and wherein the second holder faces a direction opposite the holder.

[0026] Preferably, the second holder has a second locking pin, the second locking pin having a locked and an unlocked position, wherein in the unlocked position the second locking pin allows engagement or disengagement of the second prop with the second holder, and wherein in the locked position the second locking pin prevents engagement or disengagement of the second prop from the second holder.

[0027] Preferably, the support brace has at least two second holders, and the extension plate supports at least four walk boards.

2019203879 03 Jun 2019 [0028] In a second aspect the present invention provides a support brace comprising:

a bracket, the bracket having at least two planar mounting surfaces configured to connect to a vertical surface of a wall having a thickness, the mounting surfaces being generally coplanar;

a main plate connected to said bracket, the main plate having:

a first portion that is generally co-planar with the mounting surfaces; and a second portion that is generally perpendicular to the mounting surfaces;

a holder connected to the bracket and/or the main plate, the holder having a cut-out for receiving an end portion of a prop, and two projections adjacent the cut-out configured to receive a locking pin to prevent substantial movement of the end portion of the prop from the cut-out.

Brief Description of Drawings [0029] Preferred embodiments of the present invention will now be described, by way of examples only, with reference to the accompanying drawings:

[0030] Fig. 1 is an isometric top view of a support brace according to the present invention.

[0031] Fig. 2 is an isometric bottom view of the support brace of Fig. 1.

[0032] Fig. 3 is an isometric disassembled view of the bracket of the support brace of Fig. 1.

[0033] Fig. 4 is an isometric top view of the main plate of the support brace of Fig. 1.

[0034] Fig. 5 is an isometric top view of the holder of the support brace of Fig. 1.

[0035] Fig. 6 is an isometric bottom view of the extension plate of the support brace of Fig. 1.

[0036] Fig. 7 is an isometric bottom view of a second embodiment of the extension plate of the support brace of Fig. 1.

[0037] Fig. 8 is an isometric top view of the extension plate of Fig. 7.

[0038] Fig. 9 is an isometric bottom view of a third embodiment of the extension plate of the support brace of Fig. 1.

2019203879 03 Jun 2019 [0039] Fig. 10 is an isometric top view of a second embodiment of a support brace according to the present invention.

[0040] Fig. 11 is an isometric view of the support brace of Fig. 1 used as a load support structure.

[0041] Fig. 12 is a schematic perspective view of the support brace of Fig. 1 used as a workbench.

[0042] Fig. 13 is a schematic isometric view of the support brace of Fig. 1 used as a low height access platform.

[0043] Fig. 14 is an isometric top view of a support brace according to a further embodiment of the invention.

Description of Embodiments [0044] Figs. 1 and 2 show a support brace 10 having a bracket 20, a main plate 30, and a holder 40. The bracket 20 has two mounting surfaces 22, and three openings 21 located in each mounting surface 22. The mounting surfaces 22 are generally co-planar. The openings 21 are configured to receive fasteners (not shown). The bracket 20 further has two triangular surfaces 23 extending perpendicularly from the mounting surfaces 22, and three openings 24 located in each triangular surface 23. The openings 24 are also configured to receive fasteners (not shown). Finally, the bracket 20 has a support surface 25 joining the triangular surfaces 23 and being generally perpendicular to the triangular surfaces 23 and the mounting surfaces 22 so that the support surface 25, at least one of the triangular surfaces 23, and at least one of the mounting surfaces 22 are generally orthogonal to each other. Preferably, the bracket 20 is constructed from two bracket portions 26a, 26b, each bracket portion 26a, 26b having a mounting surface 22, a triangular surface 23, and a support surface 25.

[0045] As shown in Fig. 2, the support surfaces 25 support the main plate 30. As best seen in Fig. 4, the main plate 30 has a first end 31a and a second end 3 lb. The first end 31a has a tapered shape, the second end 31b has a rounded shape and a cut-out 32, the cut-out 32 also having a rounded shape. The main plate 30 has two mounting flanges 33, each mounting flange

2019203879 03 Jun 2019 having three openings 34. The openings 34 are aligned with the openings 24 and configured to receive fasteners (not shown). The main plate 30 further has an opening 35 located near the first end 31a, the opening 35 being configured to receive a projection, in a preferred embodiment the projection is a fastener (not shown), more preferably a nut and bolt.

[0046] As best seen in Fig. 5, the holder 40 has two mounting flanges 41, each mounting flange 41 having three openings 42. The openings 42 are aligned with the openings 24, 34 and configured to receive fasteners (not shown). The holder 40 also has a retaining surface 43 connecting the mounting flanges 41. The retaining surface 43 has a cut-out 44, the cut-out 44 being a substantially straight slot with a semi-circular termination. The holder 40 is positioned, by virtue of alignment of the openings 42 with the openings 24, 34, such that a gap 45 exists between the holder 40 and the main plate 30 as shown in Fig. 1.

[0047] The holder 40 also comprises a locking pin 46, held by two triangular projections 47 that are formed on the retaining surface 43 as shown in Fig. 1.

[0048] The support brace 10 further comprises an extension plate 50. As best seen in Fig. 6, the extension plate 50 has a first end 51a and a second end 51b. The first end 5la is received in the gap 45 between the holder 40 and the main plate 30. The extension plate has a mounting bracket 52 located at the second end 5 lb. As shown ion Fig. 7, the mounting bracket 52 has a plurality of openings 53, the openings 53 configured to each receive a fastener (not shown).

[0049] The extension plate 50 further has an opening 54, the opening 54 being configured to receive a projection, in a preferred embodiment the projection is the fastener (not shown). The extension plate 50 yet further has two stiffening flanges 58, and a support surface 55 connecting the two stiffening flanges 58. The stiffening flanges 58 each have a locating notch 56. As shown in Fig. 7, a second holder 60 is mounted using the locating notches 56.

[0050] The second holder 60 has a cut-out 61, the cut-out 61 being a substantially straight slot with a semi-circular termination. The second holder 60 also comprises a locking pin 62, held by two triangular projections 63 that are formed on the second holder 60. The second holder 60 is mounted using the locating notches 56 such that a gap 65 exists between the second holder 60 and the extension plate 50.

2019203879 03 Jun 2019 [0051] Fig. 14 shows a yet further embodiment of the support brace 100 that is similar to the support brace 10 in all aspects except those discussed here. Like reference numbers refer to like features, while features that have been modified, but are substantially similar, are referred to in increments of 100. In this embodiment, the main plate 130 includes a first main plate portion 130a and a second main plate portion 30b, the first main plate portion 130a being generally perpendicular to the second main plate portion 130b and generally co-planar with the mounting surfaces 22. The first main plate portion 130a has an opening 137 adapted to receive a fastener (not shown) to fasten the first main plate portion 130a to the vertical wall. The opening 137 is vertically elongate.

[0052] Use of the support brace 10 will now be discussed.

[0053] The support brace 10 is assembled on site or off site by fasteners (not shown) which are used to connect the bracket 20, the main plate 30 and the holder 40 through the openings 24, 34, 42.

[0054] The support brace 20 is then positioned adjacent a vertical surface (not shown) of a wall having a thickness. The first end 31a of the main plate 30 is advanced, preferably manually, but if necessary also by means of a hammer or similar, into the vertical surface (not shown) of the wall for a length 95. Advantageously, the support brace 10 is positioned such that the main plate 30 penetrates the vertical surface at an interstitial site between masonry elements, and below an intended worksite on the vertical surface. The main plate 30 is inserted for the length 95 until it reaches an installed position, that is until the mounting surfaces 22 of the bracket 20 are flush with the vertical surface. The bracket 20 is now secured against the walls using fasteners (not shown) tightened through openings 21.

[0055] As best seen in Fig. 13, a lower free end of a prop 85 may now be inserted into the gap 45 via the cut-out 44. Following insertion of the prop 85, the locking pin 46 is inserted into a locked position in the triangular protrusions 63 to prevent movement of the prop relative to the holder 40. The upper free end of the prop 85 may now be used, in combination with known masonry supporting equipment 86, to support the vertical surface above the intended worksite. Following proper installation of such supporting equipment 86, masonry elements may be removed between the site on the vertical surface where the support brace 10 is installed, and the site on the vertical surface where supporting equipment 86 is installed.

2019203879 03 Jun 2019 [0056] Alternatively, or additionally, the extension plate 50 may be inserted into the gap 45 prior to insertion of the prop. The extension plate 50 may be inserted prior to installation of the support brace 10, or after installation of the support brace 10 on the vertical surface. Preferably, the extension plate 50 is installed after installation of the support brace 10. The extension plate 50 is inserted until it reaches an installed position, that is until the opening 54 aligns with the opening 35. The fastener is now inserted through the opening 54 and through opening 35 to prevent the main plate 30 and the extension plate 50 from moving relative to each other. The gap 45 can now receive the prop as discussed above. Similarly, an upper free end of a second prop 80 may be inserted into the gap 65 via the cut-out 61. A lower end of the second prop 80 is now able to be positioned on a ground surface (not shown) to provide additional support to the extension plate 50. The upper free end of the second prop 80 may be secured to the extension plate 50 by means of the locking pin 62.

[0057] The extension plate 50 is adapted to carry at least one walk board 70 on the support surface 55, in the preferred embodiment shown in Figs. 1 and 2, the extension plate is adapted to carry two walk boards 70. A post 59 of a guardrail 59b may be mounted on the mounting bracket 51 via fasteners (not shown) mounted through the openings 53. In another embodiment, as best seen in Fig. 11, the extension plate 50 is adapted to carry a load 90, for example construction material such as timber, steel, gyprock board or the like. In this embodiment, the post 59 is adapted to act as a retainer to securely retain the load 90 on the extension plate 50.

[0058] In a yet further embodiment, as best seen in Fig. 12, the load 90 is a workbench for using common equipment found on construction sites, such as the circular saw shown in Fig. 12.

[0059] The cut-out 32 may be used during dismounting of the support brace 10, to remove the support brace 10 from its installed position in the vertical surface. Naturally, the fasteners inserted in openings 21 must be removed first.

[0060] The support brace 100 shown in Fig. 14 is used substantially similarly. However, instead of inserting the main plate 30 until the mounting surfaces 22 of the bracket 20 are flush with the vertical surface, the support brace 100 is placed against the vertical surface such that the first main plate portion 130a and the mounting surface 22 are flush with the vertical surface. The bracket 20 is then secured against the walls using fasteners (not shown) tightened through openings 21 and 137.

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2019203879 03 Jun 2019 [0061] Advantages of the support brace 10 will now be discussed.

[0062] As the support brace 10 uses the vertical surface at a lower site to provide support to the vertical surface at a higher site, it removes the need for time intensive, costly, and dangerous installation of ground props, this is particularly advantageous where the site is on sloping ground. The support brace 10 is also substantially smaller, and lighter than the ground prop system currently in use, making the support brace 10 easier and cheaper to transport to a worksite.

[0063] Further, the support brace 10 enables the installation of walk boards 70 and guardrails (not shown) without the necessity of a complete scaffolding prop system. This is particularly useful for worksites with narrow access to the vertical surface, or worksites with extremely uneven ground surfaces. The support brace 10 also does not require the complete penetration of the wall, as no fastener on an opposite side of the wall (not shown) from the vertical surface is required, which minimizes damage to interiors of a structure.

[0064] Yet further, the ability to insert the prop 85 into the holder 40 after installation of the support brace 10, allows the construction of a low height access platform, as shown in Fig. 13, and the subsequent installation of a masonry support device 86 above the platform, without timeconsuming construction of a level scaffolding.

[0065] The components of the support brace 10 are also interchangeable, that is, the same bracket 20, main plate 30, and holder 40 can be used to either support masonry above the installation site of the support brace 10, or, in combination with the extension plate 50, support walk boards 70 and a guardrail. It is also possible to both support masonry above the installation site, and support walk boards 70 and a guardrail.

[0066] The safety features, that is locking pins 46, 62 enable quick and easy inspection of the installed support brace 10 to ensure that it is safe to use.

[0067] The storage of construction material 90 above ground, often conveniently sheltered by scaffolding constructed above the support brace 10 or eaves of a building of which the vertical wall forms a part, keeps the construction materials 90 dry. Additionally, the storage of the construction material 90 at a distance from the ground reduces the bending and lifting required

2019203879 03 Jun 2019 by a worker to access the material, removes trip hazards around the work site, and reduced congestion by opening up space.

[0068] Similarly, the use of support brace 10 as a workbench as shown in Fig. 12 allows the quick assembly and disassembly of an area for performing work using power equipment such as circular or drop saws, without necessitating the transport of heavy conventional workbenches. The use of the support brace 10 as a worksite also advantageously provides the opportunity to assemble a temporary workbench when the use thereof has not been anticipated, decreasing the use of unsafe work surfaces to perform unforeseen tasks.

[0069] In this embodiment of Fig. 14, the support brace 100 is able to transfer load from the prop 85 connected to the cut-out 44 to the vertical wall by fasteners (not shown) connecting the mounting surfaces 22 and the first main plate portion 130a to the vertical wall. Thus, the need to remove mortar between bricks making up the vertical wall may be avoided, if desired. The vertically elongate opening 137 allows precise positioning of the support brace 100 while supporting the weight of the support brace 100, avoiding fall risks of the support brace 100.

[0070] Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

[0071] For example, as seen in Figs. 7 and 8, the extension plate 50 may omit the opening 54.

[0072] Further, as seen in Fig. 9, the extension plate 150 may be longer and include a plurality of second holders 160 for a plurality of second props (not shown) to support the walk boards 70. The longer extension plate 150 enables the support of more than two walk boards 70, providing a wider access platform to the site, as seen in Fig. 13.

[0073] Yet further, as seen in Fig. 10, the threaded opening 35 may be located near the second end 31b and the locking pin 46 may be omitted. The fastener now secures the lower free end of the prop, while the main plate 30 is held in place by the fasteners through openings 24, 34, 42.

Claims (21)

1. A support brace comprising:

a bracket, the bracket having at least two planar mounting surfaces configured to connect to a vertical surface of a wall having a thickness, the mounting surfaces being generally coplanar;

a main plate connected to said bracket, the main plate being generally perpendicular to the mounting surfaces and having a first end, the first end being configured to penetrate the vertical surface in a direction normal to the mounting surfaces for a length that is less than the thickness of the wall, until the main plate is in an installed position;

a holder connected to the bracket and/or the main plate, the holder being configured to receive an end portion of a prop.

2. The support brace according to claim 1, wherein the mounting surfaces are each connected to the vertical surface with at least one fastener.

3. The support brace according to claim 1, wherein said main plate comprises a projection movable between a secured and an unsecured position, wherein the projection, when in the secured position, prevents substantial movement of the main plate from the installed position.

4. The support brace according to claim 1, wherein any one of the bracket, the main plate, and the holder have at least one first opening that is aligned with at least one second opening in any one or more other of the bracket, the main plate, and the holder, so that the first and second openings are connectable by a fastener.

5. The support brace according to claim 1, wherein each of the bracket, the main plate, and the holder have at least one opening, each opening being aligned so that the bracket, the main plate, and the holder are connectable with a fastener through the openings.

6. The support brace according to claim 1, wherein the holder has a cut-out ending in a semi-circular profile for engagement with the end portion of the prop.

7. The support brace according to claim 1, wherein the holder is mounted on the main plate such that a gap for receiving a flange of the end portion of the prop is created.

2019203879 03 Jun 2019

8. The support brace according to claim 1, wherein the holder has a locking pin, the locking pin having a locked and an unlocked position, wherein in the unlocked position the locking pin allows engagement or disengagement of the prop with the holder, and wherein in the locked position the locking pin prevents engagement or disengagement of the prop from the holder.

9. The support brace according to claim 8, wherein the locking pin is a removable pin supported by at least one projection of the holder.

10. The support brace according to claim 1, wherein the main plate has, at a second end, a cut-out adapted to be gripped by a user of the support brace.

11. The support brace according to claim 1, wherein the support brace further comprises:

an extension plate supported by the bracket, the extension plate being suitable for supporting a load.

12. The support brace according to claim 11, wherein the load is one or more walk boards.

13. The support brace according to claim 11, wherein the load is construction material.

14. The support brace according to claim 11, wherein the load is a flat surface adapted to be used as a workbench.

15. The support brace according to claim 11, wherein the extension plate is received in a gap between the holder and the bracket.

16. The support brace according to claim 11, wherein the extension plate comprises a second projection movable between a secured and an unsecured position, wherein the second projection, when in the secured position, prevents substantial movement of the extension plate relative to the holder.

2019203879 03 Jun 2019

17. The brace according to claim 11, wherein the extension plate has a mounting bracket at an end facing away from the vertical surface, the mounting bracket being adapted to support a post of a guardrail.

18. The support brace according to claim 11, wherein the extension plate has a second holder, wherein the second holder is configured to receive an end portion of a second prop, and wherein the second holder faces a direction opposite the holder.

19. The support brace according to claim 11, wherein the second holder has a second locking pin, the second locking pin having a locked and an unlocked position, wherein in the unlocked position the second locking pin allows engagement or disengagement of the second prop with the second holder, and wherein in the locked position the second locking pin prevents engagement or disengagement of the second prop from the second holder.

20. The support brace according to claim 15, wherein the support brace has at least two second holders, and the extension plate supports at least four walk boards.

21. A support brace comprising:

a bracket, the bracket having at least two planar mounting surfaces configured to connect to a vertical surface of a wall having a thickness, the mounting surfaces being generally coplanar;

a main plate connected to said bracket, the main plate having:

a first portion that is generally co-planar with the mounting surfaces; and a second portion that is generally perpendicular to the mounting surfaces;

a holder connected to the bracket and/or the main plate, the holder having a cut-out for receiving an end portion of a prop, and two projections adjacent the cut-out configured to receive a locking pin to prevent substantial movement of the end portion of the prop from the cut-out.