AU2020256470A1

AU2020256470A1 - Coupling System

Info

Publication number: AU2020256470A1
Application number: AU2020256470A
Authority: AU
Inventors: Tewata Ratahi
Original assignee: Individual
Current assignee: Individual
Priority date: 2019-10-21
Filing date: 2020-10-19
Publication date: 2021-05-06

Abstract

Coupling System The present invention relates in general to a coupling system for use in the erection of scaffolding. The coupling system having a plurality of horizontally oriented hub assemblies affixed in coaxial alignment to a vertical post and a coupling assembly releasably attaching to a pair of apertures on each hub assembly. Each hub assembly has an annular hub body having a periphery with an outer edge and a central opening therethrough. The hub body has a plurality of first and second apertures spaced around and forming pairs of apertures radially aligned in succession and extending through the hub body. Each coupling assembly has a body with a first end and a second end, a pair of mating elements corresponding to the pair of apertures around the hub assembly, a locking member with an actuating arm is suspended from the body, and a slot is located between one of the pair of mating elements and the body. 1/24 5 6 20 21 22 23 12 24 27 225 41U------------------------------------------------------------------; 40 42 4355 51 A WO 5#53 54 12 Fig. 1

Description

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A Coupling System

FIELD OF THE INVENTION

The present invention relates generally to the field of construction scaffolding, and in particular to a coupling system for use in the erection of scaffolding and like temporary structures to support platforms. The coupling system is designed to make scaffolding systems easily assembled and disassembled and provide the scaffolding system with improved functionality.

BACKGROUND OF THE INVENTION

It should be noted that reference to the prior art herein is not to be taken as an acknowledgement that such prior art constitutes common general knowledge in the art.

Scaffolding systems for creating temporary structures to provide a means to reach elevated levels of a building, for construction, maintenance or other purposes are well known. Typically these structures are formed by connecting upright and cross members together using a coupling system to form a substantially orthorhombic scaffolding structure. Each upright member or standard comprises an elongate shaft and form the vertical members in the scaffold structure. Basically, a standard is a long pipe or tube that connects the mass of the scaffold directly to the ground, and it runs the length of the scaffolding.

The base of each standard is connected to a base plate, which helps distribute the weight each standard bears. The cross members forming the basic scaffolding elements include ledger and transom members. One of the more conventional forms of scaffolding ordinarily includes one or more upright or standard vertical posts that are interconnected by the cross members and which may be stacked on top of each other to permit workmen to work at high elevations. In order to provide workers access to the stacked multiple levels of the scaffolding, most scaffold installations incorporate ladders either integrally as part of the scaffold structure, or mounted to the scaffold structure by some form of attachment means.

Ledgers extend horizontally between two spaced apart vertical standards to further add support and weight distribution. Each ledger comprises an elongate shaft with coupling devices located on opposing ends to form the horizontal bracing members in the scaffold system. Transoms, placed on top of ledgers at a right angle to provide support for standards by holding them in position as well as supporting battens, boards or decking units. Each transom comprises an elongate shaft with coupling devices located on opposing ends to form support members in the scaffold system. Finally, the standards and cross members of the scaffolding structure also includes diagonal members utilised as angled bracing members. Each diagonal member comprises an elongate shaft with coupling devices located on opposing ends to form the bracing members in the scaffold system.

Typically the vertical standards have coupling rings or rosettes to which the horizontal or cross member components and any bracing members are coupled to the coupling rings or rosettes through coupling devices or heads. The ledgers, transoms and diagonal members are releasably attached to the rosettes by the coupling devices, the coupling devices and the rosettes forming a node in the scaffold structure. Some coupling devices allow four ledgers to be coupled in a node to the rosette, for example four ledgers extending horizontally from a standard and spaced 90 degrees apart.

A variety of releasable joints are known that permit the principal components to be joined to produce a unitary structure. One known scaffolding structure consists of a wedged clamping mortise and tenon assembly used to connect the upright and cross members together to form the scaffold structure. The lengths of the upright and cross members need not be equal but the connector assembly is limited to substantially orthogonal connections of the cross members with the upright member. Until the wedge is installed, there is significant play between the rosette on the standard and head of a horizontal member giving rise to safety concerns. Furthermore, once installed, wedges often work free when workers traverse the platform. When these wedges work free, the scaffold can become unstable and collapse. Further, even if the scaffold does not collapse, steel wedges, which are not integrated into the head or the cross member, can fall from the scaffold injuring workers below.

Also, inserting the wedge causes wear in the clamping mortise and tenon assembly, and the wedge itself. The wedge normally bears against a particular seating surface formed in the clamping mortise and tenon assembly opening. Since the wedge is driven vertically, it attacks the point of contact with considerable force, producing essentially a cutting action. The resulting wear may be gradual and tolerable in steel scaffold frames but it can quickly defeat the operation of an aluminium system.

The existing scaffolding systems suffer from a number of limitations. For example, existing scaffolding systems often include a large number of components. The components of the existing scaffolding systems are often difficult to assemble, making the assembly of the existing scaffolding systems a tedious, time-consuming endeavour.

Traditional scaffolding has proven to be useful mostly for building scaffolds disposed against a single wall or against a right-angled structure. As such, traditional scaffolding is useful for most rectangular buildings, but is less effective in conjunction with structures having unconventional shapes. For example, round storage tanks or pressure vessels present a unique and potentially dangerous problem for conventional scaffolding systems. Linear sections of conventional scaffolding must be brought together using special clamps to conform to the surface of the round tank. As such, conventional scaffolding has not been designed for curved structures. The addition of special clamps creates further expense, and in use, joints have been found to work loose and create hazardous conditions for workmen. To date, in the scaffolding industry, there has not been a satisfactory solution to the problem of scaffolding against structures having unconventional shapes such as diagonal or curved surfaces.

The known scaffold systems include numerous elements and are often cumbersome to assemble at the work site and are difficult to manipulate at the various levels. Existing designs have also been found to be insufficiently compliant with government safety regulations. Other hazards associated with scaffold systems are well known and include loss of balance, slippage, and displacement of the scaffold due to movement of workers on the scaffold, wind, or other environmental factors. Also, due to the number of components and the way in which these components connect to form the scaffold structure an installer is required to carry and use extra tools to complete the scaffold structure. This often requires the installer to wear a scaffolder's tool belt which increases the likelihood of injuries and wear and tear on the hips, lower back and knees of the installer. In particular, the installation of locking wedges increases the likelihood of injuries to the elbow, wrist and fingers of the installer.

Prior art scaffold structures typically have an average lift height of one (1) metre for each and every lift above the "first lift". The recommended, and maximum, lift height is two (2) metres. The maximum lift height is stipulated so as to guarantee that the vertical members or standards are capable of supporting the maximum safe working load of the scaffold. A lift height of one metre has a number of drawbacks for the scaffold structure. Firstly, each one metre lift is a potential working platform along which the average size person has insufficient headroom to walk without stooping. Secondly, a one metre lift height means a significant tonnage of components is required for a scaffold structure. The number of components required to provide a scaffold structure with a one metre lift means significantly more time and labour to provide the scaffold structure.

Clearly it would be advantageous if a coupling system for use in the erection of scaffolding and like temporary structures to support platforms could be devised that helped to at least ameliorate some of the shortcomings described above. In particular, it would be beneficial to provide a coupling system designed to make scaffolding systems easily assembled and disassembled and to provide the scaffolding system with improved functionality.

SUMMARY OF THE INVENTION

In accordance with a first aspect, the present invention provides a coupling system for a scaffold structure, the coupling system comprising: a plurality of horizontally oriented hub assemblies affixed in coaxial alignment to a vertical post, each hub assembly is spaced along the length of the post at intervals corresponding to a grid pattern to be formed for the scaffold structure, each hub assembly comprising: an annular hub body having a periphery with an outer edge and a central opening therethrough for receiving the vertical post; a plurality of first apertures spaced around and extending through the hub body, each first aperture located adjacent the periphery of the hub body; a plurality of second apertures spaced around and extending through the hub body, each second aperture located adjacent the central opening of the hub body; and wherein the first and second apertures form pairs of apertures, each pair is radially aligned in succession around the hub body; a coupling assembly releasably attaching to the pair of apertures on the hub assembly, the coupling assembly comprising: a body have a first end and a second end, the first end having a part-cylindrical, radially inward bearing surface of a radius equal to an outer peripheral radius of the vertical post, and the second end having an attachment member for receiving an elongate scaffold member; a pair of mating elements corresponding to the pair of apertures radially aligned in succession around the hub assembly; a locking member suspended from the body, the locking member having an actuating arm; and a slot located between one of the pair of mating elements and the body; and wherein in use, as the pair of mating elements are located within the pair of apertures of the hub assembly, the actuating arm contacts the outer edge of the annular hub body and the actuating arm is automatically moved in a first direction to allow the outer edge of the hub body to be received within the slot of the coupling assembly, as the actuating arm moves past the hub body the actuating arm automatically moves in a second direction to secure the coupling assembly to the at least one hub assembly.

Preferably, the scaffold structure may be formed from: a plurality of vertical posts with one end of each vertical post connected to a base plate which helps distribute the weight each vertical post bears in the scaffold structure, another end of each vertical post has a socket which is adapted to receive the one end of a further vertical post to allow a height of the scaffold structure to be extended vertically; a plurality of horizontal and/or diagonal elongate scaffold members which are fastened to respective horizontally oriented hub assemblies on the vertical posts, each elongate scaffold member having the coupling assembly attached at opposite ends thereof to connect the respective elongate scaffold member to the annular hub body; and wherein the horizontal and/or diagonal elongate scaffold members and the vertical posts are connected to form the grid pattern for the scaffold structure.

Preferably, the hub assembly may have a planar top surface spaced apart from a planar bottom surface, each aperture and the central opening extending through the hub body between the top surface and the bottom surface. Each first aperture may be formed as a cylindrical aperture extending through the hub body. Each second aperture may be formed as a slotted aperture extending through the hub body, each slotted aperture having a pair of curved sides extending between semicircular ends.

Preferably, the pairs of apertures radially aligned in succession around the hub body may be spaced radially apart from adjacent pairs of apertures by an angle of between 30 to 60 degrees. Alternatively, the pairs of apertures radially aligned in succession around the hub body may be spaced radially apart from adjacent pairs of apertures by an angle of approximately 45 degrees.

Preferably, the first and second ends of the coupling assembly may be aligned on a central axis passing longitudinally through the body of the coupling assembly. The second end may have a cylindrical body with an opening for receiving therein an end of the elongate scaffold member. The pair of mating elements may be located adjacent the first end of the body. The pair of mating elements may extend downwardly from the first end of the body. The coupling assembly may be adapted to attach to horizontal elongate scaffold members.

Preferably, the second end of the coupling assembly may extend at an angle with respect to a central axis passing longitudinally through the body of the coupling assembly. Preferably, the angle which the second end may extend with respect to the central axis is between 20 and 60 degrees. Alternatively, the angle which the second end may extend with respect to the central axis is approximately 45 degrees. The second end of the coupling may be adapted to form a mounting pad for an elongate scaffold member. The mounting pad may be formed at the angle with respect to the central axis passing longitudinally through the body of the coupling assembly.

Preferably, the mounting pad may have an aperture passing through the body of the coupling assembly and the mounting pad, the aperture may be adapted to receive therein a fastener for attachment to an end of the elongate scaffold member. The coupling assembly may be adapted to attach to diagonal elongate scaffold members.

Preferably, each end of the diagonal elongate scaffold member may be provided with a flat tang having a cylindrical bore through which the fastener passes.

Preferably, the coupling assembly may further comprise a pair of lateral curved surfaces extending from opposite sides of the part-cylindrical, radially inward bearing surface located at the first end of the body, in use when coupling assemblies are placed in adjacent pairs of apertures radially aligned in succession around the hub body the adjacent lateral curved surfaces on each coupling assembly allow the adjacent coupling assemblies to be located in close relation to or abutting against each other.

Preferably, the locking member may further comprise a spring to allow the actuating arm to be biased to move automatically in the first and second directions. In use, when the pair of mating elements may be located within the pair of apertures of the hub assembly, the actuating arm contacts the annular hub body and the movement of the actuating arm in the first direction compresses the spring to allow the outer edge of the hub body to be received within the slot of the coupling assembly, as the actuating arm moves past the outer edge of the hub body the spring moves the actuating arm in the second direction to secure the coupling assembly to the at least one hub assembly.

Preferably, when the actuating arm may be moved in the second direction the actuating arm is positioned adjacent the planar bottom surface of the hub assembly, the actuating arm securing the outer edge of the hub assembly within the slot of the coupling assembly to secure the coupling assembly to the hub assembly.

Preferably, the actuating arm may be a longitudinally extending member which has a first end and a second end, the first end is positioned abutting the spring and the second end extends across the slot to substantially close the slot. The second end of the actuating arm may be tapered to aid in the movement of the actuating arm in the first direction as it contacts the outer edge of the hub assembly.

Preferably, the locking member may further comprise a handle attached to the actuating arm, the handle allowing the actuating arm to be moved manually to compress the spring and move the actuating arm in the first direction to allow the coupling assembly to be released from the hub assembly. The handle may allow the actuating arm to move laterally to release the outer edge of the hub assembly from within the slot of the coupling assembly. The handle may be attached to the actuating arm at an angle perpendicular to a central axis extending longitudinally through the actuating arm.

Preferably, one of the pair of mating elements corresponding to the pair of apertures radially aligned in succession around the hub assembly may be a removable pin. The removable pin may be received within a threaded opening extending through the body of the coupling assembly.

Preferably, the spacing of the adjacent pairs of apertures around the hub body in combination with the aligned coupling assemblies allows horizontal elongate scaffold members to be positioned around any shaped structure.

Preferably, the combination may further comprise the coupling assemblies with the first end extending at an angle allows the connection of diagonal scaffold members to further reinforce the scaffold structure.

Preferably, in use, the coupling assembly may be placed onto, and thereby mounted on, the hub assembly in such a manner that the pair of mating elements enter the corresponding pair of apertures in the top planar surface of the hub body and extend therethrough to be positioned below the planar bottom surface of the hub assembly, as the pair of mating elements pass through the corresponding pair of apertures the actuating arm of the locking member passes over and around the outer edge of the hub body and is positioned adjacent the planar bottom surface of the hub assembly, the actuating arm securing the outer edge of the hub assembly within the slot of the coupling assembly to secure the coupling assembly to the hub assembly, wherein the coupling assembly and the hub assembly form a rigid structural assembly.

Preferably, in use, when the coupling assembly may be mounted onto the hub assembly of the vertical post the part-cylindrical, radially inward bearing surface of the first end of the coupling assembly is positioned to bear radially inward against the vertical post in surface-to-surface contact therewith.

In accordance with a second aspect, the present invention provides a scaffold system comprising: a plurality of first vertical posts, each first vertical post having a lengthwise axis extending between a first end and a second end, each first vertical post comprising: a base plate connected to each first end, the base plate helps distribute the weight each vertical post bears in the scaffold system; and a plurality of horizontally oriented hub assemblies affixed in coaxial alignment to the vertical post, each hub assembly is spaced along the length of the post at intervals corresponding to a grid pattern to be formed for the scaffold system; a plurality of horizontal elongate scaffold members, each horizontal scaffold member having a pair of opposite end coupling assemblies for fastening to respective horizontally oriented hub assemblies on the vertical posts; wherein each one of the horizontally oriented hub assemblies comprises: an annular hub body having a periphery with an outer edge and a central opening therethrough for receiving the vertical post; a plurality of first apertures spaced around and extending through the hub body, each first aperture is located adjacent the periphery of the hub body; a plurality of second apertures are spaced around and extending through the hub body, each second aperture is located adjacent the central opening of the hub body; and adjacent first and second apertures form pairs of apertures radially aligned in succession around the hub body; wherein each end coupling assembly comprises: a body have a first end and a second end, the first end having a part-cylindrical, radially inward bearing surface of a radius equal to an outer peripheral radius of the vertical post, and the second end having an attachment member for receiving an elongate scaffold member; a pair of mating elements corresponding to the pair of apertures radially aligned in succession around the hub assembly; a locking member suspended from the body, the locking member having an actuating arm; and a slot located between one of the pair of mating elements and the body; wherein the horizontal elongate scaffold members and the first vertical posts are connected to form the grid pattern for the scaffold system by: positioning each pair of mating elements on each end coupling assembly of a horizontal scaffold member within the pair of apertures of each aligned hub assembly on adjacent vertical posts; and pressing downwardly on each horizontal scaffold member so that the actuating arm within each end coupling assembly contacts the annular hub body and the actuating arm is automatically moved in a first direction to allow the outer edge of the hub body to be received within the slot of the coupling assembly, as the actuating arm moves past the hub body the actuating arm automatically moves in a second direction to secure the coupling assembly to the hub assembly.

Preferably, the scaffold system may further comprise a plurality of diagonal elongate scaffold members, each diagonal scaffold member having a pair of opposite end coupling assemblies for fastening to respective horizontally oriented hub assemblies located at different vertical positions on adjacent vertical posts.

Preferably, a socket may be located in the second end of each vertical post, the socket is adapted to connect the first end of another vertical post to allow a height of the scaffold system to be extended vertically.

Preferably, each hub assembly may have a planar top surface spaced apart from a planar bottom surface, each first and second aperture and the central opening extending through the hub body between the top surface and the bottom surface. Each first aperture may be formed as a cylindrical aperture extending through the hub body. Each second aperture may be formed as a slotted aperture extending through the hub body, each slotted aperture having a pair of curved sides extending between semicircular ends.

Preferably, the pairs of apertures radially aligned in succession around each hub body may be spaced radially apart from adjacent pairs of apertures by an angle of between 30 to 60 degrees. Alternatively, the pairs of apertures radially aligned in succession around each hub body may be spaced radially apart from adjacent pairs of apertures by an angle of approximately 45 degrees.

Preferably, the first and second ends of the coupling assembly on each horizontal scaffold member may be aligned on a central axis passing longitudinally through the body of the coupling assembly. The second end may have a cylindrical body with an opening for receiving therein an end of the horizontal elongate scaffold member. The pair of mating elements on the coupling assembly may be located adjacent the first end of the body and extend downwardly from the body.

Alternatively, the second end of the coupling assemblies of each diagonal elongate scaffold member may extend at an angle with respect to a central axis passing longitudinally through the body of the coupling assembly. The angle which the second end may extend with respect to the central axis is between 20 and 60 degrees. Alternatively, the angle which the second end may extend with respect to the central axis is approximately 45 degrees.

Preferably, the second end of the coupling assembly may have a mounting pad with an aperture passing through the body of the coupling assembly and the mounting pad, the aperture is adapted to receive therein a fastener for attachment to an end of the diagonal elongate scaffold member. Each end of the diagonal elongate scaffold member may be provided with a flat tang having a cylindrical bore through which the fastener passes.

Preferably, each coupling assembly may further comprise a pair of lateral curved surfaces extending from opposite sides of the part-cylindrical, radially inward bearing surface located at the first end of the body, in use when coupling assemblies are placed in adjacent pairs of apertures radially aligned in succession around the hub body the adjacent lateral curved surfaces on each coupling assembly allow the adjacent coupling assemblies to be located in close relation to or abutting against each other.

Preferably, the locking member of each end coupling assembly may further comprise a spring to allow the actuating arm to be biased to move automatically in the first and second directions. In use, when the pair of mating elements may be located within the pair of apertures of the hub assembly, the actuating arm contacts the annular hub body and the movement of the actuating arm in the first direction compresses the spring to allow the outer edge of the hub body to be received within the slot of the coupling assembly, as the actuating arm moves past the outer edge of the hub body the spring moves the actuating arm in the second direction to secure the coupling assembly to the at least one hub assembly.

In accordance with a still further aspect, the present invention provides a method of coupling a vertical post to an elongate scaffold member to form a scaffold structure, the method comprising the steps of: a) providing a plurality of horizontally oriented hub assemblies affixed in coaxial alignment to the vertical post, each hub assembly having a plurality of first apertures spaced around and extending through the hub body, each first aperture located adjacent the periphery of the hub body, and a plurality of second apertures spaced around and extending through the hub body, each second aperture located adjacent the central opening of the hub body, and the first and second apertures form pairs of apertures, each pair is radially aligned in succession around the hub body; b) providing the elongate scaffold member with at least one coupling assembly, the coupling assembly having a body with a first end and a second end, the first end having a part-cylindrical, radially inward bearing surface of a radius equal to an outer peripheral radius of the vertical post, and the second end having an attachment member for receiving an elongate scaffold member, a pair of mating elements corresponding to the pair of apertures radially aligned in succession around the hub assembly, a locking member suspended from the body, the locking member having an actuating arm, and a slot located between one of the pair of mating elements and the body; and c) connecting the elongate scaffold member to the vertical post by: i) positioning the pair of mating elements of the coupling assembly within the pair of apertures of the hub assembly; ii) contacting the annular hub body with the actuating arm to automatically move the actuating arm in a first direction; iii) allowing the outer edge of the hub body to be received within the slot of the coupling assembly; and iv) moving the actuating arm past the hub body to allow the actuating arm to automatically move in a second direction to secure the coupling assembly to the hub assembly.

Preferably, the method may further comprise any one of the features of the coupling system of the first aspect.

In accordance with a still further aspect, the present invention provides a method of erecting a scaffold system comprising the steps of: a) providing a plurality of first vertical posts, each first vertical post having a lengthwise axis extending between a first end and a second end, and a plurality of horizontally oriented hub assemblies affixed in coaxial alignment to each first vertical post, each hub assembly is spaced along the length of the post at intervals corresponding to a grid pattern to be formed for the scaffold system; b) connecting a base plate to each first end of each first vertical post, the base plate helps distribute the weight each first vertical post bears in the scaffold system; c) providing within each one of the plurality of horizontally oriented hub assemblies: i) a central opening therethrough for receiving the vertical post; ii) a plurality of first apertures spaced around and extending through a hub body, each first aperture is located adjacent the periphery of the hub body, iii) a plurality of second apertures spaced around and extending through the hub body, each second aperture is located adjacent the central opening of the hub body; and iv) adjacent first and second apertures form pairs of apertures, each pair is radially aligned in succession around the hub body; d) providing a plurality of horizontal elongate scaffold members for fastening to respective horizontally oriented hub assemblies on the vertical posts; e) providing each end of each horizontal scaffold member with an end coupling assembly, each end coupling assembly comprising: i) a body have a first end and a second end, the first end having a part-cylindrical, radially inward bearing surface of a radius equal to an outer peripheral radius of the vertical post, and the second end having an attachment member for receiving an elongate scaffold member; ii) a pair of mating elements corresponding to the pair of apertures radially aligned in succession around the hub assembly; iii) a locking member suspended from the body, the locking member having an actuating arm; and iv) a slot located between one of the pair of mating elements and the body; f) positioning each end of the horizontal scaffold member on a hub assembly on adjacent first vertical posts so that the pair of mating elements are aligned with the pairs of apertures in the hub assembly; g) securing each end of the horizontal scaffold member to the hub assemblies by automatically activating the locking member as the actuating arm contacts the annular hub body the actuating arm is automatically moved in a first direction to allow the outer edge of the hub body to be received within the slot of the coupling assembly, as the actuating arm moves past the hub body the actuating arm automatically moves in a second direction to secure the coupling assembly to the hub assembly; and h) repeating steps f) and g) to form the grid pattern for the scaffold system.

Preferably, the method may further comprise any one of the features of the scaffold system of the second aspect.

Any one or more of the above embodiments or preferred features can be combined with any one or more of the above aspects.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be understood more fully from the detailed description given hereinafter and from the accompanying drawings of the preferred embodiment of the present invention, which, however, should not be taken to be limitative to the invention, but are for explanation and understanding only.

Fig. 1 shows an exploded perspective view of the coupling system components for a scaffold structure of the present invention; Figs 2 and 3 show top and perspective views of the hub assembly of the present invention; Fig. 4 shows a perspective view of the coupling assembly for connecting horizontal members to the hub assembly; Fig. 5 shows an exploded perspective view of the coupling assembly of Fig. 4; Figs. 6 to 9 illustrate side, end, top and bottom views of the coupling assembly of Fig. 4; Fig. 10 shows a sectional view of the coupling assembly taken along line AA of Fig. 8; Figs. 11 to 13 show side, top and bottom views of the coupling system of Fig 1 in use with the horizontal members attached to the hub assembly of a scaffold structure of the present invention; Fig. 14 shows a perspective view of the coupling assembly for connecting diagonal members to the hub assembly; Fig. 15 shows an exploded perspective view of the coupling assembly of Fig. 14; Figs. 16 to 18 illustrate side, top and bottom views of the coupling assembly of Fig. 14; Fig. 19 shows a sectional view of the coupling assembly taken along line BB of Fig. 17; Fig. 20 shows an exploded view of the connection between the diagonal member and the coupling assembly of Fig. 14; Figs. 21 and 22 show side views of the diagonal member connected to the coupling assembly of Fig. 14; Fig. 23 illustrates a perspective view of the combination of horizontal and diagonal members when connected to the hub assembly on the vertical member in a scaffold structure; Fig. 24 shows a top view of Fig. 23; Fig. 25 illustrates an exploded view of the components of Fig. 23; Fig. 26 shows a perspective view of a scaffold structure incorporating the coupling systems of the present invention;

Fig. 27 shows a perspective partial view of the base assembly of the scaffold structure of Fig. 26 of the present invention; Fig. 28 shows an enlarged section of one corner of the base assembly of Fig. 27 showing the connection to the ground plane; and Figs. 29 to 31 illustrate side perspective views of the horizontal and diagonal members of the scaffold structure of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description, given by way of example only, is described in order to provide a more precise understanding of the subject matter of a preferred embodiment or embodiments.

The present invention was designed to make scaffolding systems easily assembled and disassembled and provide the scaffolding system with improved functionality that overcomes the safety, rigidity, and labour issues inherent in conventional scaffold systems.

Scaffolding systems of the present invention are formed from a number of interconnecting components which connect to form the scaffolding structure. The system is utilised to create a temporary structure to provide a means to reach elevated levels of a building, for construction, maintenance or other purposes. The components consist of upright and cross members connected together using the coupling system of the present invention.

The present invention in its broadest form provides a coupling system 20, 50 for a scaffold structure as illustrated in Figs. 1 to 13. The coupling system is largely used to connect vertical and horizontal scaffold components to form a grid pattern. The vertical member 5 or vertical standard consists of a vertical post 12 and horizontally oriented hub assemblies 50 affixed in coaxial alignment to the vertical post 12. The vertical post 12 is typically cylindrical tubes comprised of hot-dip galvanized steel, aluminium or aluminium alloys. In a typical vertical standard 5, hub assemblies 50 are equally spaced along the length of the post 12 at intervals corresponding to the grid pattern to be formed for the scaffold structure. Each hub assembly 50 is horizontally orientated with respect to the vertical post 12. By way of example only, a six metre long vertical member 5 may have twelve hub assemblies 50 equally spaced along the post 12. Alternatively, the vertical member 5 may be of any length and have any number of hub assemblies 50 equally spaced along the post 12. A collar with an expanded or reduced diameter or a spigot at either or both ends of the vertical member 5 facilitates the joining of vertical members 5 from end to end. Typically, a six (6) metre long vertical member 5 the twelve hub assemblies 50 are spaced apart a distance of approximately 0.5 metres apart. The first hub assembly 50 is spaced approximately 0.2 metres from the bottom of the vertical post 12 and the twelfth hub assembly is spaced approximately 0.3 metres from the top of the vertical post 12.

The hub assembly 50 has an annular hub body having a periphery with an outer edge 54 and a central opening 56 extending therethrough for receiving the vertical post 12. Each hub assembly 50 is positioned and then welded or otherwise attached along the vertical post 12. The hub assembly 50 allows the horizontal member 6 and associated connector 20 to be coupled to the vertical member 5. Each hub assembly 50 has a plurality of first and second apertures 51, 52 spaced around and extending through the hub body between the top and bottom planar surfaces 53, 60. Each first aperture 51 is located adjacent the periphery or outer edge 54 of the hub body. Each second aperture 52 is located adjacent the central opening 56 or inner edge 55 of the hub body. The first and second apertures 51, 52 form pairs of apertures with each pair radially aligned in succession around the hub body.

In order to releasably attach the horizontal member 6 to the hub assembly 50, a coupling assembly 20 is attached to an end of the horizontal member 6. Each coupling assembly 20 has a body 21 with a first end 23 and a second end 28, the first end 23 having a part-cylindrical, radially inward bearing surface of a radius equal to an outer peripheral radius of the vertical post 12. The second end 28 has an attachment member for receiving an elongate scaffold member 11. Each coupling assembly 20 has a pair of mating elements 25, 26 corresponding to the pair of apertures 51, 52 radially aligned in succession around the hub assembly 50. The mating elements or locking pins 25, 26 locate within the corresponding pair of apertures 51, 52 to secure the coupling assembly 20 to the hub assembly 50.

A locking member 40 is suspended from the body 21 of the coupling assembly 20 for locking the horizontal member 6 to the hub assembly 50. The locking member 40 has an actuating arm 43 which in an extended position closes the slot 27 located between the mating element 26 and the body 21 of the coupling assembly 20.

In use, as the pair of mating elements 25, 26 are located within the pair of apertures 51, 52 of the hub assembly 50, the actuating arm 43 contacts the annular hub body and the actuating arm 43 is automatically moved in a first direction to allow the outer edge 54 of the hub body to be received within the slot 27 of the coupling assembly 20. As the actuating arm 43 moves past the outer edge 54 of the hub body the actuating arm 43 automatically moves in a second direction to secure and lock the coupling assembly 20 to the hub assembly 50.

Each horizontal member 6 has a coupling assembly 20 located at opposing ends thereof. Each coupling assembly 20 is designed to be located within and around a hub assembly 50 on the vertical member 5. As horizontal members 6 are attached to each hub assembly 50 this forms a grid pattern for the required scaffold structure. As will be discussed below in relation to Figs.14 to 22 diagonal members 7 are also attached to the hub assembly 50 to allow the scaffold structure to be braced diagonally.

Fig. 1 shows an exploded view showing one end of a horizontal member 6 aligned for connection to the hub assembly 50 on the post 12 of a vertical member 5. Each horizontal member 6 has a pair of coupling assemblies 20 located and spaced apart at opposite ends of a tubular member 11. The dotted lines indicate the position and alignment of the pair of mating elements 25, 26 with the corresponding apertures 51, 52 on the hub assembly 50. The shape of the first mating element 25 corresponds to the shape of the aperture 52. Each first mating element 25 has two long curved sides which are joined at opposite ends by two short curved or semicircular ends. When positioned within the aperture 52 the element 25 is a snug fit therein and the free end of the element 25 extends through the hub body to be positioned just below or adjacent to the bottom planar surface 60 of the hub assembly 50. By way of example only, the free end of the element 25 extends approximately 5 mm from the bottom planar surface 60 of the hub assembly 50. Likewise, the second mating element 26 corresponds to the shape of the aperture 51. The mating element 26 is formed as the end section of the removable pin 22. The pin 22, the mating element 26 and the aperture 51 are all round or circular shaped. When positioned within the aperture 51, the second mating element 26 is a snug fit therein and the free end of the element 26 extends through the hub body to be positioned just below or adjacent to the planar bottom surface 60 of the hub assembly 50. Like the free end of the element 25 the free end of the element 26 extends approximately 5 mm from the bottom planar surface 60 of the hub assembly 50.

The locking member 40 consists of a body 41 which is attached or fixed to the bottom side of the body 21 of the coupling assembly 20. Each locking member 40 has an actuating member 43 which is attached to a handle 42, with the actuating member 43 biased in the extended position as shown. The handle 42 extends perpendicular to the body 41 and is attached to the actuating member 43. The handle 42 allows the actuating member 43 to be moved from the extended position in which the actuating arm 43 closes the slot 27 to a retracted position in which the slot 27 is open.

The coupling assembly 20 has a substantially cylindrical body 21 with a first end 23 and a second end 28. The first end 23 has a part-cylindrical, radially inward bearing surface of a radius equal to an outer peripheral radius of the vertical post 12. The second end 28 has an opening 34 for receiving an end of the horizontal tube member 11 therein. When the coupling assembly 20 is positioned on the hub assembly 50 the part-cylindrical, radially inward bearing surface of the first end 23 allows the coupling assembly 20 to sit adjacent the vertical post 12. A pair of lateral curved flanges 24 extends rearwardly from opposing sides of the part-cylindrical, radially inward bearing surface of the first end 23. When the coupling assembly 20 is positioned upon the hub assembly 50, the lateral curved flanges 24 allow adjacent coupling assemblies 20 to abut or fit snuggly side-by-side upon the hub assembly 50.

Figs. 2 and 3 show the hub assembly 50 which in a scaffold structure is attached to the post 12 of the vertical member 5. Each hub assembly 50 has an annular body with a central aperture 56 through which the vertical post 12 is received. The hub assembly 50 has an outer peripheral edge 54 which is spaced apart from an inner ring 55. The inner ring 55 sits adjacent the outer edge of the post 12. Each hub assembly 50 has spaced apart top and bottom planar surfaces 53, 60 which are separated by the outer edge 54 and the inner ring 55.

The hub assembly 50 illustrated has eight pairs of apertures 51, 52 evenly spaced around hub body 53. A centreline 57 passes through the hub assembly 50 and through the centre of the first and fifth pairs of apertures 51, 52. A further line 58 passes from the centre of the hub assembly 50 and through the centre of the second pair of apertures 51, 52. Each pair of apertures 51, 52 extending around the hub assembly 50 is spaced apart by the angle a as indicated by reference 59. In an eight pair hub assembly 50 each pair of apertures 51, 52 is spaced approximately 45 degrees apart around the hub assembly 50. In other embodiments (not shown) the hub assembly 50 may have any number of pairs of apertures 51, 52 spaced around the hub assembly 50 at angles between 0 to 90 degrees apart. Preferably, the pairs of apertures may be spaced apart around the hub assembly at angles between 30 to 60 degrees apart. More preferably and as illustrated the pairs of apertures 51, 52 are spaced apart by the angle a and approximately 45 degrees apart around the hub assembly 50.

Each hub assembly 50 is typically constructed from steel or similar material and when the post 12 is inserted through the central aperture 56 the hub assembly is fixed to the post 12. Preferably, the hub assembly 50 is welded in place at intervals along the post 12 of the vertical member 5.

Figs. 4 to 10 illustrate a number of views of the coupling assembly 20 in accordance with the present invention. The coupling assembly 20 has a substantially cylindrical body 21 extending between the first and second ends 23, 28. Fig. 4 shows a perspective view from below and best illustrates the positioning of the first and second mating elements 25, 26 and the locking assembly 40. Both mating elements 25, 26 extend perpendicularly down from a planar bottom surface 29 of the cylindrical body 21. The planar bottom surface 29 extends from the first end 23 to an interconnecting edge with the approximately perpendicular flange 30. In use, the planar bottom surface 29 sits upon the top planar surface 53 of the hub assembly 50. The perpendicular face of the flange 30 aligns with the front end 46 of the mounting body 41 of the locking assembly 40. In use, the perpendicular face of the flange 30 abuts against the outer edge 54 of the hub assembly 50. The area adjacent the outer edge 54 of the hub assembly 50 sits within the slot 27 formed between the planar bottom surface 29, the flange 30 and the mating element 26.

As described above the mating elements 25, 26 are shaped to correspond to the shape of the apertures 51, 52 in the hub assembly 50. The element 26 is formed as an end of the pin 22 which extends through the body 21 of the coupling assembly 20. The element 25 is shaped to correspond to the aperture 52. The longer curved sides of the element 25 are shaped to correspond largely with the part-cylindrical, radially inward bearing surface of the first end 23 of the coupling assembly 20. The length which both elements 25, 26 extend below the planar bottom surface 29 is approximately 5 mm greater than the depth of the hub assembly 50. That is, the distance that the planar top and bottom surfaces 53, 60 of the hub assembly 50 are spaced apart plus 5mm. This ensures that when the elements 25, 26 are inserted into the apertures 51, 52 the bottom ends of each element 25, 26 is positioned to lie just below the planar bottom surface 60 of the hub assembly 50.

The locking assembly 40 extends from below the bottom cylindrical surface of the body 21 of the coupling assembly 20. A top surface 38 of the mounting body 41 is shaped to correspond to the outer cylindrical surface of the body 21. The mounting body 41 has spaced apart front and rear ends 46, 47.

The bottom surface of the mounting body 41 has a slotted aperture 45 for receiving an end of the handle 42 therein and is adapted to allow the handle 42 to move the locking pin 43 laterally between the extended and retracted positions. In the extended position the locking pin 43 is biased to extend across the slot 27 formed between the mating element 26, planar bottom surface 29 and the perpendicular flange 30. The locking pin 43 also has a tapered end 44.

Fig. 5 shows an exploded perspective view of the components which form each coupling assembly 20. The cylindrical body 21 has an opening 33 extending through the body 21 and spaced from the first end 23. The opening 33 has an internal thread 32 for receiving therein the corresponding external thread 31 of the pin 22. This allows the pin 22 to be removable from within the body 21 of the coupling assembly 20. This is particularly advantageous when the scaffold structure is erected in harsh conditions as the pin 22 can be easily replaced if the pin 22 becomes worn or corroded.

The locking assembly 40 and the mounting body 41 has a top surface 38 which is curved to correspond to the outer surface of the cylindrical body 21 of the coupling assembly 20. The front end 46 of the mounting body 40 has an opening 48 therein for receiving the biasing spring 49 and an end 36 of the locking pin 43. During assembly, the spring 49 is first inserted into the opening 48 and positioned towards the rear end 47 of the mounting body 41. The locking pin 43 is pushed against an end of the spring 49 and compresses the spring 49, the handle 42 is inserted through the slotted aperture 45 in the bottom side of the body 41. The thread 39 on the handle 42 is received within the corresponding threaded socket 65 in the locking pin 43 to lock the pin 43 within the opening 48. The seating of the spring 49 against the rear surface 47 of the body 41 biases the locking pin 43 in the extended position as shown in Fig. 6.

Figs. 6 and 7 show side and end views of the coupling assembly 20. The opening 34 in the end 28 of the coupling member 20 is sized to receive therein an end of the horizontal pipe or tube 11. The end of the horizontal pipe or tube 11 is positioned and then welded or otherwise attached within the opening 34 of the coupling assembly 20. Different sized pipe or tube 11 can be secured within the opening 34 and is typically sized dependent upon the use requirements for the scaffold structure.

Figs. 8 and 9 show top and bottom views of the coupling assembly 20. The first and second ends 23, 28 of the coupling assembly 20 are aligned on a central axis 35 passing longitudinally through the body 21 of the coupling assembly 20. Also aligned along or passing through the central axis 35 are the locating elements 25, 26, the locking pin 43 and the handle 42.

Fig. 10 shows a sectional view taken along line AA of Fig. 8. One end of the spring 49 is seated within the socket 37 located towards the rear end 47 of the mounting body 41 of the locking assembly 40. The other end of the spring 49 abuts against the end 36 of the locking pin 43. To secure the handle 42 in place the thread 39 on the end of the handle 42 is placed within the slotted aperture 45 and screwed into the threaded socket 65 located in the locking pin 43. The spring 49 biases the handle 42 towards the front end of the slotted aperture 45 and positions the locking pin 43 to substantially close across the slot 27 in the coupling assembly 20. The handle 42 is able to move laterally within the slotted aperture 45 but due to the spring 49 will always be biased towards the front end 46 of the body 41 or in the extended position as shown.

Figs. 11 to 13 illustrate side, top and bottom views of two horizontal members 6 connected to a vertical member 5. As illustrated by the vertical and horizontal axes 15, 16, the vertical axis 15 extends longitudinally through the centre of the post 12 of the vertical member 5 and the horizontal axis 16 runs perpendicular to the vertical axis 15 and through the middle of the hub assembly 50. Each hub assembly 50 is affixed in coaxial alignment to the post 12 and spaced along the length of the post 12 at intervals corresponding to the grid pattern required for the respective scaffold structure. Each horizontal member 6 is connected to the hub assembly 50 by the coupling assemblies 20, with each horizontal member 6 forming a right angle with respect to the post 12 and on opposing sides of the post 12. Each horizontal member 6 has a longitudinally extending horizontal pipe 11 extending from the coupling assembly 20.

The locking assembly 40 on each coupling assembly 20 secures the horizontal member 6 to opposing sides of the hub assembly 50. In use, as each coupling assembly 20 is located on the hub assembly 50 the locating elements 25, 26 are positioned within the corresponding aperture pairs 51, 52 and the tapered end 44 of the locking pin 43 comes into contact with the outer edge 54 of the hub assembly 50. As the locking pin 43 contacts the outer edge 54 of the hub assembly 50, the spring 49 is compressed to automatically laterally move the locking pin 43 in a first direction to allow the outer edge 54 of the hub assembly 50 to be received within the slot 27 of the coupling assembly 20. That is, the locking pin 43 moves into the opening 48 or rearward against the tension of the spring 49. As the locking pin 43 moves past the outer edge 54 and the locating elements 25, 26 are contained within the apertures 51, 52 the locking pin 43 moves in a second direction to a position beneath the hub assembly 50 and adjacent and/or abutting against the planar bottom surface 60 of the hub assembly 50. That is, the spring 49 returns the locking pin 43 to the starting position. In this position the planar bottom surface 29 of the coupling assembly 20 sits upon the top planar surface 53 of the hub assembly 50 and the perpendicular face of the flange 30 abuts against the outer edge 54 of the hub assembly 50. Also, both locating elements 25, 26 extend through the apertures 51, 52 in the hub assembly 50 such that the free end of each element 25, 26 is positioned approximately 5 mm below the planar bottom surface 60 of the hub assembly 50. In this position, and as best illustrated in Figs. 12 and 13 the coupling assemblies 20 are locked into position on the hub assembly 50. In other embodiments (not shown) the free end of each element 25, 26 may be positioned adjacent to the planar bottom surface 60 of the hub assembly 50.

In Fig. 12, the top view best illustrates the position of each first end 23 of the coupling assembly 20 on the vertical post 12. The part-cylindrical, radially inward bearing surface of the first end 23 of the connector assembly 20 has a radius equal to the outer peripheral radius of the post 12. This ensures that when the coupling assembly 20 is positioned on the hub assembly 50 the first end 23 abuts against the vertical post 12. This provides a rigid connection between the vertical and horizontal members 5, 6. While only two horizontal members 6 have been illustrated connected to the vertical member 5, the design of each coupling assembly 20 and how they connect to the hub assembly 50 allows up to eight horizontal members 6 to be connected to each hub assembly 50. While it is not expected that each hub assembly 50 will have all of the spaces around the hub assembly 50 connected at one time it does illustrate the ability to position a horizontal member 6 at any position or angle around the hub assembly 50. This provides a user with the ability to construct a scaffolding structure that is useful for surrounding unconventional shapes. For example, round storage tanks, pressure vessels or any structure with a diagonal or curved surface.

In Fig. 13, the bottom view best illustrates the position of each locking pin 43 and the locating elements 25, 26 contained within the apertures 51, 52 of the hub assembly 50. The central two pair of apertures 51, 52 located on opposing sides of the pipe 12 contains the elements 25, 26 from respective coupling assemblies 20 of the horizontal members 6. The elements 25, 26 are shaped to correspond to and fit snugly within each aperture 51, 52. With each horizontal member 6 positioned on the hub assembly 50 the locking pin 43 is biased by spring 39 to the extended position shown. This locks each horizontal member 6 to the hub assembly 50.

In order to release the horizontal member 6 from the hub assembly 50 the handle 42 is moved laterally towards the horizontal pipe 11 or towards the end 28 of each coupling assembly 20. This allows the coupling assembly 20 to be lifted vertically and the elements 25, 26 to be removed from within the apertures 51, 52. At the same time, the outer edge 54 of the hub assembly 50 is released from the slot 27 in the coupling assembly 20 and the handle 42 is released and biased by the spring 39 to return to close the slot 27.

Figs. 14 to 19 illustrate a number of views of the coupling assembly 70 in accordance with the present invention. Each diagonal member 7 has a pair of coupling assemblies 70 located and spaced apart at opposite ends of a tubular member 13. The coupling assembly 70 attach the diagonal members 7 to the hub assembly 50 on the post 12 of a vertical member 5. The coupling assembly 70 is substantially the same as the coupling assembly 20 with the exception of the angled mounting pad 85 and mounting bolt 100 which are positioned towards the rear end 78 of the coupling assembly 70. The angled mounting pad 85 and mounting bolt 100 are provided to allow for the attachment of the diagonal tube 13 at any angle required.

The diagonal members 7 are utilised as a brace connecting the lower and upper frames of a scaffold structure to improve the stability of the structure and provide sideways and lengthways bracing. The diagonal member 7 can also be utilised as a spur member which is an inclined load-bearing member that transmits a load to the supporting structure. This extends the scaffold structure of the present invention to be utilised to support special duty scaffolds such as a cantilever scaffolds or spur scaffolds. Another exemplary use of the diagonal member 7 includes as a shore or raking shore member. The diagonal member 7 can be used to prop or brace a structure that is leaning at an angle (on the rake) to support the side of a building or other structure. The shore takes any thrust from the walls to the ground. Alternatively the diagonal member 7 can be utilised as a raker tie. For example, a diagonal member 7 attached to the scaffold structure at one end and to a building or structure at the other at obtuse angles.

The coupling assembly 70 has a substantially cylindrical body 71 extending between the first and second ends 73, 78. Fig. 14 shows a perspective view from below and best illustrates the positioning of the first and second mating elements 75, 76 and the locking assembly 90. Both mating elements 75, 76 extend perpendicular to the planar bottom surface 79 of the cylindrical body 71. The planar bottom surface 79 extends from the first end 73 to an interconnecting edge with the approximately perpendicular flange 80. The perpendicular face of the flange 80 aligns with the front end 96 of the mounting body 91 of the locking assembly 90. In use, the planar bottom surface 79 sits upon the planar top surface 53 of the hub assembly 50 and the perpendicular face of the flange 80 abuts against the outer edge 54 of the hub assembly 50.

The mating elements 75, 76 and the locking assembly 90 are identical to those components described in relation to coupling assembly 20. The mating elements 75, 76 are shaped to correspond to the shape of the apertures 51, 52 in the hub assembly 50. The element 76 is formed as an end of the pin 72 which extends through the body 71 of the coupling assembly 70. The element 75 is shaped to correspond to the aperture 52. The longer curved sides of the element 75 are shaped to correspond largely with the part-cylindrical, radially inward bearing surface of the first end 73 of the coupling assembly 70. Both elements 75, 76 extend approximately 5 mm below the planar bottom surface 79 which equates approximately to the depth of the hub assembly 50. That is, the distance that the planar top and bottom surfaces 53, 60 of the hub assembly 50 are spaced apart plus approximately 5 mm. This ensures that when the elements 75, 76 are inserted into the apertures 51, 52 the bottom or free ends of each element 75, 76 is positioned to lie just below the planar bottom surface 60 of the hub assembly 50. Alternatively, the free ends of each element 75, 76 is positioned to adjacent to the planar bottom surface 60 of the hub assembly 50.

When the coupling assembly 70 is positioned on the hub assembly 50 the part-cylindrical, radially inward bearing surface of the first end 73 allows the coupling assembly 70 to sit adjacent the post 12. A pair of lateral curved flanges 74 extends rearwardly from opposing sides of the part-cylindrical, radially inward bearing surface of the first end 73. When the coupling assembly 70 is positioned upon the hub assembly 50, the lateral curved flanges 74 allow adjacent coupling assemblies 20, 70 to abut or fit snuggly upon the hub assembly 50.

The locking assembly 90 extends from below the bottom cylindrical surface of the body 71 of the coupling assembly 70. A top surface 88 of the mounting body 91 is shaped to correspond to the outer cylindrical surface of the body 71. The mounting body 91 has spaced apart front and rear ends 96, 97. The bottom surface of the mounting body 91 has a slotted aperture 95 for receiving an end of the handle 92 therein and is adapted to allow the handle 92 to move the locking pin 93 laterally between the extended and retracted positions. In the extended position the locking pin 93 is biased to extend across the slot 77 formed between the mating element 76, planar bottom surface 79 and the perpendicular flange 80. The locking pin 93 also has a tapered end 94.

In order to allow the connection of the diagonal member 7 to the coupling assembly 70 at any angle, the rear end 78 has an angled mounting pad 85 with the mounting bolt 100 extending through the mounting pad 85 and the body 71. The first end 73 of the coupling assembly 70 is aligned on a central axis passing longitudinally through the body 71 of the coupling assembly 70. Also aligned along the central axis are the locating elements 75, 76, the locking pin 93 and the handle 92. The angle the mounting pad 85 forms with respect to the central axis passing through the body 71 allows the connection of the diagonal pipe 13 to the mounting bolt 100 at any angle. The mounting bolt 100 is inserted through the body 71, such that the bolt 100 extends perpendicular to the mounting pad 85.

Fig. 15 shows an exploded perspective view of the components which form each coupling assembly 70. The cylindrical body 71 has an opening 83 extending through the body 71 and spaced from the first end 73. The opening 73 has an internal thread 82 for receiving therein the corresponding external thread 81 of the pin 72. This allows the pin 72 to be removable within the body 71 of the coupling assembly 70. As previously noted this is particularly advantageous when the scaffold structure is erected in harsh conditions as the pin 72 can be easily replaced if the pin 72 becomes worn or corroded. The mounting bolt 100 has a thread 101 for receiving the fastener 102 which as is illustrated in Figs. 20 to 22 secures the diagonal member 7 to the coupling assembly 70.

The locking assembly 90 and the mounting body 91 has a top surface 88 which is curved to correspond to the outer surface of the cylindrical body 71 of the coupling assembly 70. The front end 96 of the mounting body 91 has an opening 98 therein for receiving the biasing spring 99 and an end 86 of the locking pin 93. During assembly, the spring 99 is first inserted into the opening 98 and positioned towards the rear end 97 of the mounting body 91. The locking pin 93 is pushed against an end of the spring 99 and compresses the spring 99, the handle 92 is inserted through the slotted aperture 95 in the bottom side of the body 91. The thread 89 on the handle 92 is received within the corresponding threaded socket 105 in the locking pin 93 to lock the pin 93 within the opening 98. The seating of the spring 99 against the rear surface 97 of the body 91 biases the locking pin 93 in the extended position.

Figs. 16 to 18 show side, top and bottom views of the coupling assembly 70. The thread 101 of the mounting bolt 100 of the coupling member 70 is positioned to receive an end of the diagonal pipe or tube 13. Figs. 17 and 18 show top and bottom views of the coupling assembly 70. The first end 73 is aligned on a central axis passing longitudinally through the body 71 and also aligned with the locating elements 75, 76, the locking pin 93 and the handle 92.

Fig. 19 shows a sectional view taken along line BB of Fig. 17. One end of the spring 99 is seated within the socket 87 located towards the rear end 97 of the mounting body 91 of the locking assembly 90. The other end of the spring 99 abuts against the end 86 of the locking pin 93. To secure the handle 92 in place the thread 89 on the end of the handle 92 is placed within the slotted aperture 95 and screwed into the threaded socket 105 located in the locking pin 93. The spring 99 biases the handle 92 towards the front end of the slotted aperture 95 and positions the locking pin 93 to close across the slot 77 in the coupling assembly 70. The handle 92 is able to move laterally within the slotted aperture 95 but due to the spring 99 will always be biased towards the front end 96 of the body 91.

Figs. 20 to 22 show the connection of the diagonal member 7 to the coupling assembly 70. Each diagonal member 7 has a pair of coupling assemblies 70 located and spaced apart at opposite ends of a tubular member 13. The tubular member 13 has a tang-link head 18 that can be produced from steel pipe stock. In particular, the tang-link head 18 is produced by deformation of thin-walled sheet-steel pipe. The tang-link head 18 at its rear includes a male or insert portion having a cylindrical external surface 17 onto which a light metal pipe 13 can be pushed into mounted position. By way of example only, the walls of the male or insert portion of head 18 are provided with apertures (not shown). When light-metal tubular pipe member 13 is pushed into mounted position on the male portion of head 17, hemispherical indentations provided on pipe member 13 engage the apertures, thereby securing the pipe member 13 in mounted position on the male portion of head 18. Alternatively, the head 18 can be welded or otherwise fastened to the pipe 13.

The forward, free, coupling portion of the tang-type coupling head 18 is worked to form a generally flat-rectangle tang, which then is compressed at its transversely intermediate interval to form the shown intermediate recess 14. Recess 14 accommodates mounting bore 19 which allows the diagonal member 7 to be mounted to the coupling assembly 70. The mounting bore 19 receives therein the end of the mounting bolt 100, the thread 101 extends through the bore 19 and the fastener 102 secures the tang-type coupling head 18 to the coupling assembly 70. This connection allows the diagonal member 7 to be varied to an angle which suits the required scaffold structure.

Figs. 21 and 22 illustrate the diagonal member 7 attached to the coupling assembly 70. In use the diagonal member 7 and the coupling assembly 70 are utilised to form bracing or reinforcing elements for the scaffold structure. Each diagonal member 7 is connected to the hub assembly 50 by the coupling assemblies 70, with each diagonal member 7 forming and extending away at an angle with respect to the vertical post 12. Each diagonal member 7 has a longitudinally extending diagonal pipe 13 extending from the coupling assembly 70. The angled mounting plate 85 and the mounting bolt 100 allows the angle of the diagonal member 7 attached thereto to be easily adjusted to suit the required bracing for the scaffold structure.

The locking assembly 90 on each coupling assembly 70 secures the diagonal member 7 to the hub assembly 50. As the coupling assembly 70 is located on the hub assembly 50 the locating elements 75, 76 are positioned within the corresponding aperture pairs 51, 52 and the tapered end 94 of the locking pin 93 comes into contact with the outer edge 54 of the hub assembly 50. As the locking pin 93 contacts the outer edge 54 of the hub assembly 50, the spring 99 is compressed to automatically laterally move the locking pin 93 in a first direction or rearward to allow the outer edge 54 of the hub assembly 50 to be received within the slot 77 of the coupling assembly 70. As the locking pin 93 moves past the outer edge 54 and the locating elements 75, 76 are contained within the apertures 51, 52 the locking pin 93 moves in a second direction to a position beneath the hub assembly 50 and adjacent and/or abutting against the planar bottom surface 60 of the hub assembly 50. Also, in this position the planar bottom surface 79 sits upon the planar top surface 53 of the hub assembly 50 and the perpendicular face of the flange 80 abuts against the outer edge 54 of the hub assembly 50. Also, both locating elements 75, 76 extend through the hub assembly such that the end of each element 75, 76 is positioned to sit just below the planar bottom surface 60 of the hub assembly 50. In this position, the coupling assembly 70 is locked onto the hub assembly 50.

Figs. 23 to 25 illustrate a node within a scaffold structure in which two horizontal members 6 and a diagonal member 7 are illustrated attached to the hub assembly 50 on a vertical member 5. By way of example only, each horizontal member 6 could be formed as a ledger or transom in the scaffold structure and the diagonal member 7 could be used to brace the node in the structure.

Fig. 24 shows a top view of the node of Fig. 23 and best illustrates the connection of each member 6, 7 to the hub assembly 50. In particular, how the coupling assemblies 20, 70 fit adjacent to one another. Each coupling assembly 20 for the horizontal members 6 are connected to the hub assembly 50 and form a right angle between each horizontal member 6. The coupling assembly 70 sits adjacent one of the coupling assemblies 20 with a diagonal member 7 extending from the coupling assembly 70. The part-cylindrical, radially inward bearing surface of the first ends 23, 73 of each coupling assembly 20, 70 are positioned abutting against the outer cylindrical surface of the post 12. To ensure a snug fit, the part-cylindrical, radially inward bearing surface of the first ends 23, 73 is of a radius equal to an outer peripheral radius of the post 12 of the vertical member 5. Likewise, the coupling assemblies 20,

70 when positioned upon the hub assembly 50, the lateral curved flanges 24, 74 allow the adjacent coupling assemblies 20, 70 to abut or fit snuggly side-by side upon the hub assembly 50.

As illustrated in Fig. 25 the dotted lines indicate the position and alignment of the pair of mating elements 25, 26 and 75, 76 with the corresponding apertures 51, 52 on the hub assembly 50. The shape of the first mating elements 25, 75 corresponds to the shape of the aperture 52. Each first mating element 25, 75 has two long curved sides which are joined at opposite ends by two short curved or semicircular ends. When positioned within the aperture 52 the elements 25, 75 form a snug fit therein and the free end of the elements 25, 75 extends through the hub body and is positioned to lie just below or adjacent to the bottom planar surface 60 of the hub assembly 50. Likewise, the second mating elements 26, 76 correspond to the shape of the aperture 51. The mating elements 26, 76 are formed as the end section of the removable pins 22, 72. The pins 22, 72, the elements 26, 76 and the aperture 51 are all circular or round in shape. When positioned within the aperture 51, the second mating element 26, 76 form a snug fit therein and the free end of the element 26, 76 extends through the hub body and is positioned to lie just below or adjacent to the planar bottom surface 60 of the hub assembly 50.

Figs. 26 to 28 illustrate a section of a scaffold structure constructed using the components of the present invention. As illustrated the structure consists of eight vertical members 5 which when the scaffold structure is complete connects the mass of the scaffold directly to the ground. Each vertical member 5 provides vertical support and is supplied with a base 130. The base 130 may be a stable platform that is an interface between the vertical member 5 and the ground. The base 130 may have, for example, a screw-type leveling mechanism that allows the scaffolding system to be erected on uneven terrain. Alternatively, the leveling mechanism may also be, for example, hydraulic or have a telescoping section that may be secured by a pin, for example.

In order to form the grid structure each vertical member 5 has a plurality of hub assemblies 50 placed along the vertical post 12 using a predetermined spacing between hub assemblies 50. As illustrated each vertical member 5 has a total length of six (6) metres from top to bottom. Each vertical member 5 has twelve (12) hub assemblies 50 spaced evenly at 0.5 metre intervals along the length of the vertical member 5. The scaffold structure is formed as three lifts, with each lift above the first lift formed at the maximum lift height of two (2) metres. The design and interlocking relationship of the coupling members 20, 70 to the hub assemblies 50 allow the operator to provide the maximum lift height of two (2) metres.

In the grid structure hub assemblies 50 are connected to horizontal and diagonal members 6, 6a, 7. The structure illustrated has three levels formed by the horizontal and diagonal members 6, 6a, 7 which are connected to the vertical members 5 at the hub assemblies 50. Each level is formed from six longer horizontal members or ledgers 6 extending horizontally between the spaced apart vertical members or standards 5. Each level also consists of four shorter horizontal members or transoms 6a placed at right angles to the ledgers 6 on the hub assemblies 50. The transoms 6a placed at right angles provide support for standards 5 by holding them in position as well as supporting battens, boards or decking units 120. The diagonal members 7 are utilised as angled bracing members to increase the stiffness and rigidity of the scaffold structure.

Each end of the horizontal members 6, 6a has a coupling assembly 20 which connects the horizontal members 6, 6a to the hub assemblies 50 on the vertical standards 5. As each end of the horizontal members 6, 6a is located upon the hub assembly 50 the locating elements 25, 26 are positioned in the apertures 51, 52 of the hub assembly 50. Under the combined weight of the coupling assembly 20 and the horizontal tube 11, the locking pin 43 of the locking assembly 40 on each end of the horizontal members 6, 6a moves laterally as the locking pin 43 engages with the outer edge 54 of the hub assembly 50. As the locking pin 43 contacts the outer edge 54 of the hub assembly 50, the spring 49 is compressed to automatically laterally move the locking pin 43 in a first direction to allow the outer edge 54 of the hub assembly 50 to be received within the slot 27 of the coupling assembly 20. As the locking pin 43 moves past the outer edge 54 and the locating elements 25, 26 are contained within the apertures 51, 52 the locking pin 43 moves in a second direction to a position beneath the hub assembly 50 and adjacent and/or abutting against the planar bottom surface 60 of the hub assembly 50. Also, both locating elements 25, 26 extend through the hub assembly such that the end of each element 25, 26 is positioned to sit just below or adjacent to the planar bottom surface 60 of the hub assembly 50. In this position, the coupling assembly 20 on each end of the horizontal members 6, 6a is locked onto the hub assembly 50. Likewise, the diagonal members 7 are also positioned and locked onto the hub assemblies 50 by coupling assemblies 70 in same manner described above.

The above process can be performed by a single operator as the connection of the members 6, 6a, 7 automatically connect to the hub assemblies 50 due to the biased locking members 40, 90, no tools are required to construct the scaffold structure.

In order to provide workers access to the stacked multiple levels of the scaffolding structure ladders 110 are incorporated either integrally as part of the scaffold structure, or mounted to the scaffold structure by some form of attachment means. As illustrated, one end of the ladder 110 is mounted on a transom 6a and the opposite end is supported on the decking boards 120 of the level below. In between levels of the scaffold structure ledgers transoms or horizontal members 6, 6a can be utilised as hand-rails or guard-rails. Once each level is constructed by connecting ledgers 6, transoms 6a, and diagonal braces 7 to the respective hub assemblies 50 on the vertical standards 5, decks or platforms 120 made of, e.g., hot-dip galvanized steel, aluminium, wood or an aluminium frame with plywood board are installed to allow workers to traverse the scaffold structure and install the guardrails 6, 6a.

In order to deconstruct the scaffold structure, an operator is required to access the handles 42, 92 on the locking assembly 40, 90 located at each end of the members 6, 6a, 7. The operator pulls or pushes the handle 42, 92 towards the second end 28, 78 of the coupling assembly 20, 70 and lifts the end of the member 6, 6a, 7 to release that end from the hub assembly 50. Once released the operator can release the handle 42, 92 and the spring 49, 99 biases the locking pin 43, 93 to the closed position in which the slot 27, 77 is closed by the locking pin 43, 93. This is performed at each end of the members 6, 6a, 7 until all members have been released from the scaffold structure. Figs. 27 and 28 show some further detail of the base assembly. Each base 130 consists of a ground plate 136, a screw-type leveling mechanism 137, a connecting hub 134, bracing 135, pipe 131 and a collar or spigot 133. The ground plate 136 consists of a number of apertures spaced around the ground plate 136 for receiving therein a fastener for securing the ground plate to a supporting structure such as the ground. Each base assembly consists of four bases 130 connected by tube 131 in the shape of the grid structure for the scaffold assembly. At least one of the tubes 131 has a spirit or bubble level 132 to indicate whether the tube 131 is horizontal (level). The screw-type leveling mechanism 137 on each base 130 is adjusted until the tube 131 is level. The collar or spigot 133 receives therein an end of the vertical member 5. As described previously the vertical member 5 at the opposing end to which is connected to the base 130 has a further collar or spigot to facilitate the joining of vertical members 5 from end to end to allow the height of the overall scaffold structure to be easily increased.

Figs. 29 to 31 show the horizontal and diagonal members 6, 6a and 7. Fig. 29 shows the transom or horizontal member 6a, Fig. 30 shows the ledger or horizontal member 6 and Fig. 31 shows the diagonal or bracing member 7. Each ledger or transom 6, 6a has a coupling assembly 20 spaced apart at each end of the tube 11 and each diagonal or bracing member 7 has a coupling assembly 70 spaced apart at each end of the tube 13. The length and diameter of each member 6, 6a and 7 is dependent upon the application or scaffold structure required.

ADVANTAGES

The present invention relates generally to construction scaffolding, and in particular to a coupling system for use in the erection of scaffolding and like temporary structures to support platforms. The coupling system is designed to make scaffolding systems easily assembled and disassembled and provide the scaffolding system with improved functionality.

The present invention provides a coupling system which is easily constructed by a single operator. In particular, the locking mechanism has been designed so that an operator simply places an end of a horizontal or diagonal member on the hub assembly of the vertical member and the biased locking member automatically locks the horizontal or diagonal member to the hub assembly without the need for any tools.

The present invention has also simplified the release mechanism by providing a handle which is either pushed or pulled laterally to allow the end of the horizontal or diagonal member to be released from the hub assembly and the vertical member.

The design of the hub assembly also provides the ability to construct a scaffold structure around any unconventional shaped structure. Each pair of apertures is spaced at angles of approximately 45 degrees around the hub assembly. Each coupling assembly is provided with a first end having a part cylindrical, radially inward bearing surface of a radius equal to an outer peripheral radius of the vertical post and a pair of lateral curved surfaces extending from opposite sides of the part-cylindrical, radially inward bearing surface. In use when an adjacent coupling assembly is placed on the hub assembly the adjacent lateral curved surfaces allow the coupling assemblies to be located in close relation to or abutting against each other. This enables the operator to construct a scaffold with members which are able to be spaced around the hub assembly at intervals of typically 45 degrees around the hub assembly.

The part-cylindrical, radially inward bearing surface also ensures that the coupling assembly when placed on the hub assembly will abut against the outer peripheral surface of the vertical post. This ensures a strong and rigid scaffold structure.

The present invention also provides a number of advantages over the known wedged clamping mortise and tenon assemblies used in constructing scaffolds. In particular, there is no need for an operator to have to install the wedge assemblies. The present invention is in essence a plug and play system, no tools are required to erect a scaffold structure in accordance with the present invention and once the coupling assembly is installed on the hub assembly the structure is rigid and stable. Also, the design of the biased locking member ensures that the coupling assembly will not work free from the hub assembly. This improves the safety for surrounding workers and for the operator installing the scaffold structure.

The present invention provides a coupling assembly for scaffolding systems with a minimum of components, which is simple to construct and reduces the amount of time required to erect and disassemble the scaffolding system. Also, the reduction in the number of tools which the scaffold installer is required to carry reduces the likelihood of injuries to the installer. This is further seen in that as the locking member forms a part of the coupling assembly there is no requirement to install a further locking wedge to shore up the structure. This means a reduction in tools and reduces the likelihood of an onsite dropped tool which can be extremely dangerous to those workers situated below.

The present invention has also been designed to provide a scaffold structure which can take advantage of the maximum lift height for each and every lift above the "first lift". The recommended, and maximum, lift height is two (2) metres. The lift height is taken to also mean the vertical distance between adjacent horizontal members or ledgers or levels of a scaffold structure at which a platform can be constructed. The maximum lift height is stipulated so as to guarantee that the vertical members or standards are capable of supporting the maximum safe working load of the scaffold.

By having a scaffold system which can operate at the maximum lift height of two metres provides a number of advantages over the known scaffold systems. Firstly, each two metre lift is a potential working platform along which the average size person has sufficient headroom to walk without stooping.

Also, providing a two metre lift height in comparison with the current one metre lift heights means a significant reduction in tonnage of components required for a scaffold structure. Also, this means the present invention provides a scaffold structure which is less time consuming and requires less labour personnel to construct.

VARIATIONS

It will be realized that the foregoing has been given by way of illustrative example only and that all other modifications and variations as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of the invention as herein defined in the appended claims.

As used herein the term "and/or" means "and" or "or", or both.

As used herein "(s)" following a noun means the plural and/or singular forms of the noun.

In this specification, adjectives such as first and second, left and right, top and bottom, and the like may be used solely to distinguish one element or action from another element or action without necessarily requiring or implying any actual such relationship or order. Where the context permits, reference to an integer or a component or step (or the like) is not to be interpreted as being limited to only one of that integer, component, or step, but rather could be one or more of that integer, component, or step etc.

The above description of various embodiments of the present invention is provided for purposes of description to one of ordinary skill in the related art. It is not intended to be exhaustive or to limit the invention to a single disclosed embodiment. As mentioned above, numerous alternatives and variations to the present invention will be apparent to those skilled in the art of the above teaching. Accordingly, while some alternative embodiments have been discussed specifically, other embodiments will be apparent or relatively easily developed by those of ordinary skill in the art. The invention is intended to embrace all alternatives, modifications, and variations of the present invention that have been discussed herein, and other embodiments that fall within the scope of the above described invention.

In the specification the term "comprising" shall be understood to have a broad meaning similar to the term "including" and will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. This definition also applies to variations on the term "comprising" such as "comprise" and "comprises".

Claims

1. A coupling system for a scaffold structure, the coupling system comprising: a plurality of horizontally oriented hub assemblies affixed in coaxial alignment to a vertical post, each hub assembly is spaced along the length of the post at intervals corresponding to a grid pattern to be formed for the scaffold structure, each hub assembly comprising: an annular hub body having a periphery with an outer edge and a central opening therethrough for receiving the vertical post; a plurality of first apertures spaced around and extending through the hub body, each first aperture located adjacent the periphery of the hub body; a plurality of second apertures spaced around and extending through the hub body, each second aperture located adjacent the central opening of the hub body; and wherein the first and second apertures form pairs of apertures, each pair is radially aligned in succession around the hub body; a coupling assembly releasably attaching to the pair of apertures on the hub assembly, the coupling assembly comprising: a body have a first end and a second end, the first end having a part-cylindrical, radially inward bearing surface of a radius equal to an outer peripheral radius of the vertical post, and the second end having an attachment member for receiving an elongate scaffold member; a pair of mating elements corresponding to the pair of apertures radially aligned in succession around the hub assembly; a locking member suspended from the body, the locking member having an actuating arm; and a slot located between one of the pair of mating elements and the body;and wherein in use, as the pair of mating elements are located within the pair of apertures of the hub assembly, the actuating arm contacts the outer edge of the annular hub body and the actuating arm is automatically moved in a first direction to allow the outer edge of the hub body to be received within the slot of the coupling assembly, as the actuating arm moves past the hub body the actuating arm automatically moves in a second direction to secure the coupling assembly to the at least one hub assembly.

2. A coupling system as claimed in claim 1, wherein the scaffold structure is formed from: a plurality of vertical posts with one end of each vertical post connected to a base plate which helps distribute the weight each vertical post bears in the scaffold structure, another end of each vertical post has a socket which is adapted to receive the one end of a further vertical post to allow a height of the scaffold structure to be extended vertically; a plurality of horizontal and/or diagonal elongate scaffold members which are fastened to respective horizontally oriented hub assemblies on the vertical posts, each elongate scaffold member having the coupling assembly attached at opposite ends thereof to connect the respective elongate scaffold member to the annular hub body; and wherein the horizontal and/or diagonal elongate scaffold members and the vertical posts are connected to form the grid pattern for the scaffold structure.

3. A coupling system as claimed in any one of the preceding claims, wherein the hub assembly has a planar top surface spaced apart from a planar bottom surface, each aperture and the central opening extending through the hub body between the top surface and the bottom surface.

4. A coupling system as claimed in claim 3, wherein each first aperture is formed as a cylindrical aperture extending through the hub body.

5. A coupling system as claimed in claim 3 or claim 4, wherein each second aperture is formed as a slotted aperture extending through the hub body, each slotted aperture having a pair of curved sides extending between semicircular ends.

6. A coupling system as claimed in any one of claims 3 to 5, wherein the pairs of apertures radially aligned in succession around the hub body are spaced radially apart from adjacent pairs of apertures by an angle of between 30 to 60 degrees.

7. A coupling system as claimed in any one of claims 3 to 5, wherein the pairs of apertures radially aligned in succession around the hub body are spaced radially apart from adjacent pairs of apertures by an angle of approximately 45 degrees.

8. A coupling system as claimed in claim 1, wherein the first and second ends of the coupling assembly are aligned on a central axis passing longitudinally through the body of the coupling assembly.

9. A coupling system as claimed in claim 8, wherein the pair of mating elements are located adjacent the first end of the body.

10. A coupling system as claimed in claim 8 or claim 9, wherein the pair of mating elements extend downwardly from the first end of the body.

11. A coupling system as claimed in any one of claims 8 to 10, wherein the second end has a cylindrical body with an opening for receiving therein an end of the elongate scaffold member.

12. A coupling system as claimed in any one of claims 8 to 11, wherein the coupling assembly is adapted to attach to horizontal elongate scaffold members.

13. A coupling system as claimed in claim 1, wherein the second end of the coupling assembly extends at an angle with respect to a central axis passing longitudinally through the body of the coupling assembly.

14. A coupling system as claimed in claim 13, wherein the angle which the second end extends with respect to the central axis is between 20 and 60 degrees.

15. A coupling system as claimed in claim 13, wherein the angle which the second end extends with respect to the central axis is approximately 45 degrees.

16. A coupling system as claimed in any one of claims 13 to 15, wherein the second end of the coupling is adapted to form a mounting pad for an elongate scaffold member.

17. A coupling system as claimed in claim 16, wherein the mounting pad is formed at the angle with respect to the central axis passing longitudinally through the body of the coupling assembly.

18. A coupling system as claimed in any one of claims 16 to 17, wherein the mounting pad has an aperture passing through the body of the coupling assembly and the mounting pad, the aperture is adapted to receive therein a fastener for attachment to an end of the elongate scaffold member.

19. A coupling system as claimed in claim 18, wherein the coupling assembly is adapted to attach to diagonal elongate scaffold members.

20. A coupling system as claimed in claim 18 or claim 19, wherein each end of the diagonal elongate scaffold member is provided with a flat tang having a cylindrical bore through which the fastener passes.

21. A coupling system as claimed in any one of claims 3 to 20, wherein the coupling assembly further comprises a pair of lateral curved surfaces extending from opposite sides of the part-cylindrical, radially inward bearing surface located at the first end of the body, in use when coupling assemblies are placed in adjacent pairs of apertures radially aligned in succession around the hub body the adjacent lateral curved surfaces on each coupling assembly allow the adjacent coupling assemblies to be located in close relation to or abutting against each other.

22. A coupling system as claimed in any one of the preceding claims, wherein the locking member further comprises a spring to allow the actuating arm to be biased to move automatically in the first and second directions.

23. A coupling system as claimed in claim 22, wherein in use, when the pair of mating elements are located within the pair of apertures of the hub assembly, the actuating arm contacts the annular hub body and the movement of the actuating arm in the first direction compresses the spring to allow the outer edge of the hub body to be received within the slot of the coupling assembly, as the actuating arm moves past the outer edge of the hub body the spring moves the actuating arm in the second direction to secure the coupling assembly to the at least one hub assembly.

24. A coupling system as claimed in claim 22 or claim 23, wherein when the actuating arm is moved in the second direction the actuating arm is positioned adjacent the planar bottom surface of the hub assembly, the actuating arm securing the outer edge of the hub assembly within the slot of the coupling assembly to secure the coupling assembly to the hub assembly.

25. A coupling system as claimed in any one of claims 22 to 24, wherein the actuating arm is a longitudinally extending member which has a first end and a second end, the first end is positioned abutting the spring and the second end extends across the slot to substantially close the slot.

26. A coupling system as claimed in claim 25, wherein the second end of the actuating arm is tapered to aid in the movement of the actuating arm in the first direction as it contacts the outer edge of the hub assembly.

27. A coupling system as claimed in any one of claims 22 to 26, wherein the locking member further comprises a handle attached to the actuating arm, the handle allowing the actuating arm to be moved manually to compress the spring and move the actuating arm in the first direction to allow the coupling assembly to be released from the hub assembly.

28. A coupling system as claimed in claim 27, wherein the handle allows the actuating arm to move laterally to release the outer edge of the hub assembly from within the slot of the coupling assembly.

29. A coupling system and claimed in claim 27 or claim 28, wherein the handle is attached to the actuating arm at an angle perpendicular to a central axis extending longitudinally through the actuating arm.

30. A coupling system as claimed in any one of the preceding claims, wherein one of the pair of mating elements corresponding to the pair of apertures radially aligned in succession around the hub assembly is a removable pin.

31. A coupling system as claimed in claim 30, wherein the removable pin is received within a threaded opening extending through the body of the coupling assembly.

32. A coupling system as claimed in any one of the preceding claims, wherein the spacing of the adjacent pairs of apertures around the hub body in combination with the coupling assemblies as claimed in any one of claims 1 to 12 allows horizontal elongate scaffold members to be positioned around any shaped structure.

33. A coupling system as claimed in claim 32, wherein the combination further comprising the coupling assemblies as claimed in claims 1 to 7 and 13 to 20 allows the connection of diagonal scaffold members to further reinforce the scaffold structure.

34. A coupling system as claimed in any one of the preceding claims, wherein in use, the coupling assembly is placed onto, and thereby mounted on, the hub assembly in such a manner that the pair of mating elements enter the corresponding pair of apertures in the top planar surface of the hub body and extend therethrough to be positioned below the planar bottom surface of the hub assembly, as the pair of mating elements pass through the corresponding pair of apertures the actuating arm of the locking member passes over and around the outer edge of the hub body and is positioned adjacent the planar bottom surface of the hub assembly, the actuating arm securing the outer edge of the hub assembly within the slot of the coupling assembly to secure the coupling assembly to the hub assembly, wherein the coupling assembly and the hub assembly form a rigid structural assembly.

35. A coupling system as claimed in any one of the preceding claims, wherein in use, when the coupling assembly is mounted onto the hub assembly of the vertical post the part-cylindrical, radially inward bearing surface of the first end of the coupling assembly is positioned to bear radially inward against the vertical post in surface-to-surface contact therewith.

36. A scaffold system comprising: a plurality of first vertical posts, each first vertical post having a lengthwise axis extending between a first end and a second end, each first vertical post comprising: a base plate connected to each first end, the base plate helps distribute the weight each vertical post bears in the scaffold system; and a plurality of horizontally oriented hub assemblies affixed in coaxial alignment to the vertical post, each hub assembly is spaced along the length of the post at intervals corresponding to a grid pattern to be formed for the scaffold system; a plurality of horizontal elongate scaffold members, each horizontal scaffold member having a pair of opposite end coupling assemblies for fastening to respective horizontally oriented hub assemblies on the vertical posts; wherein each one of the horizontally oriented hub assemblies comprises: an annular hub body having a periphery with an outer edge and a central opening therethrough for receiving the vertical post; a plurality of first apertures spaced around and extending through the hub body, each first aperture is located adjacent the periphery of the hub body; a plurality of second apertures are spaced around and extending through the hub body, each second aperture is located adjacent the central opening of the hub body; and adjacent first and second apertures form pairs of apertures radially aligned in succession around the hub body; wherein each end coupling assembly comprises: a body have a first end and a second end, the first end having a part-cylindrical, radially inward bearing surface of a radius equal to an outer peripheral radius of the vertical post, and the second end having an attachment member for receiving an elongate scaffold member; a pair of mating elements corresponding to the pair of apertures radially aligned in succession around the hub assembly; a locking member suspended from the body, the locking member having an actuating arm; and a slot located between one of the pair of mating elements and the body; wherein the horizontal elongate scaffold members and the first vertical posts are connected to form the grid pattern for the scaffold system by: positioning each pair of mating elements on each end coupling assembly of a horizontal scaffold member within the pair of apertures of each aligned hub assembly on adjacent vertical posts; and pressing downwardly on each horizontal scaffold member so that the actuating arm within each end coupling assembly contacts the annular hub body and the actuating arm is automatically moved in a first direction to allow the outer edge of the hub body to be received within the slot of the coupling assembly, as the actuating arm moves past the hub body the actuating arm automatically moves in a second direction to secure the coupling assembly to the hub assembly.

37. A scaffold system as claimed in claim 36, wherein the scaffold system further comprises a plurality of diagonal elongate scaffold members, each diagonal scaffold member having a pair of opposite end coupling assemblies for fastening to respective horizontally oriented hub assemblies located at different vertical positions on adjacent vertical posts.

38. A scaffold system as claimed in claim 36 or claim 37, wherein a socket is located in the second end of each vertical post, the socket is adapted to connect the first end of another vertical post to allow a height of the scaffold system to be extended vertically.

39. A scaffold system as claimed in any one of claims 36 to 38, wherein each hub assembly has a planar top surface spaced apart from a planar bottom surface, each first and second aperture and the central opening extending through the hub body between the top surface and the bottom surface.

40. A scaffold system as claimed in claim 39, wherein each first aperture is formed as a cylindrical aperture extending through the hub body and each second aperture is formed as a slotted aperture extending through the hub body, each slotted aperture having a pair of curved sides extending between semicircular ends.

41. A scaffold system as claimed in claim 39 or claim 40, wherein the pairs of apertures radially aligned in succession around each hub body are spaced radially apart from adjacent pairs of apertures by an angle of between 30 to 60 degrees.

42. A scaffold system as claimed in any one of claims 39 to 41, wherein the pairs of apertures radially aligned in succession around each hub body are spaced radially apart from adjacent pairs of apertures by an angle of approximately 45 degrees.

43. A scaffold system as claimed in claim 36, wherein the first and second ends of the coupling assembly on each horizontal scaffold member are aligned on a central axis passing longitudinally through the body of the coupling assembly.

44. A scaffold system as claimed in claim 43, wherein the pair of mating elements on the coupling assembly are located adjacent the first end of the body and extend downwardly from the body.

45. A scaffold system as claimed in claim 43 or claim 44, wherein the second end has a cylindrical body with an opening for receiving therein an end of the horizontal elongate scaffold member.

46. A scaffold system as claimed in claim 36 and when dependent from claim 37, wherein the second end of the coupling assemblies of each diagonal elongate scaffold member extend at an angle with respect to a central axis passing longitudinally through the body of the coupling assembly.

47. A scaffold system as claimed in claim 46, wherein the angle which the second end extends with respect to the central axis is between 20 and 60 degrees.

48. A scaffold system as claimed in claim 47, wherein the angle which the second end extends with respect to the central axis is approximately 45 degrees.

49. A scaffold system as claimed in any one of claims 46 to 48, wherein the second end of the coupling assembly has a mounting pad with an aperture passing through the body of the coupling assembly and the mounting pad, the aperture is adapted to receive therein a fastener for attachment to an end of the diagonal elongate scaffold member.

50. A scaffold system as claimed in claim 49, wherein each end of the diagonal elongate scaffold member is provided with a flat tang having a cylindrical bore through which the fastener passes.

51. A scaffold system as claimed in any one of claims 36 to 50, wherein each coupling assembly further comprises a pair of lateral curved surfaces extending from opposite sides of the part-cylindrical, radially inward bearing surface located at the first end of the body, in use when coupling assemblies are placed in adjacent pairs of apertures radially aligned in succession around the hub body the adjacent lateral curved surfaces on each coupling assembly allow the adjacent coupling assemblies to be located in close relation to or abutting against each other.

52. A scaffold system as claimed in any one of claims 36 to 51, wherein the locking member of each end coupling assembly further comprises a spring to allow the actuating arm to be biased to move automatically in the first and second directions.

53. A scaffold system as claimed in claim 52, wherein in use, when the pair of mating elements are located within the pair of apertures of the hub assembly, the actuating arm contacts the annular hub body and the movement of the actuating arm in the first direction compresses the spring to allow the outer edge of the hub body to be received within the slot of the coupling assembly, as the actuating arm moves past the outer edge of the hub body the spring moves the actuating arm in the second direction to secure the coupling assembly to the at least one hub assembly.

54. A scaffold system as claimed in claim 52 or claim 53, wherein when the actuating arm is moved in the second direction the actuating arm is positioned adjacent the planar bottom surface of the hub assembly, the actuating arm securing the outer edge of the hub assembly within the slot of the coupling assembly to secure the coupling assembly to the hub assembly.

55. A scaffold system as claimed in any one of claims 52 to 54, wherein the actuating arm is a longitudinally extending member which has a first end and a second end, the first end is positioned abutting the spring and the second end extends across the slot to substantially close the slot.

56. A scaffold system as claimed in claim 55, wherein the second end of the actuating arm is tapered to aid in the movement of the actuating arm in the first direction as it contacts the outer edge of the hub assembly.

57. A scaffold system as claimed in any one of claims 52 to 56, wherein the locking member further comprises a handle attached to the actuating arm, the handle allowing the actuating arm to be moved manually to compress the spring and move the actuating arm in the first direction to allow the coupling assembly to be released from the hub assembly.

58. A scaffold system as claimed in claim 57, wherein the handle allows the actuating arm to move laterally to release the outer edge of the hub assembly from within the slot of the coupling assembly.

59. A scaffold system and claimed in claim 57 or claim 58, wherein the handle is attached to the actuating arm at an angle perpendicular to a central axis extending longitudinally through the actuating arm.

60. A scaffold system as claimed in any one of claims 36 to 59, wherein one of the pair of mating elements corresponding to the pair of apertures radially aligned in succession around the hub assembly is a removable pin.

61. A scaffold system as claimed in claim 60, wherein the removable pin is received within a threaded opening extending through the body of the coupling assembly.

62. A method of coupling a vertical post to an elongate scaffold member to form a scaffold structure, the method comprising the steps of: a) providing a plurality of horizontally oriented hub assemblies affixed in coaxial alignment to the vertical post, each hub assembly having a plurality of first apertures spaced around and extending through the hub body, each first aperture located adjacent the periphery of the hub body, and a plurality of second apertures spaced around and extending through the hub body, each second aperture located adjacent the central opening of the hub body, and the first and second apertures form pairs of apertures, each pair is radially aligned in succession around the hub body; b) providing the elongate scaffold member with at least one coupling assembly, the coupling assembly having a body with a first end and a second end, the first end having a part-cylindrical, radially inward bearing surface of a radius equal to an outer peripheral radius of the vertical post, and the second end having an attachment member for receiving an elongate scaffold member, a pair of mating elements corresponding to the pair of apertures radially aligned in succession around the hub assembly, a locking member suspended from the body, the locking member having an actuating arm, and a slot located between one of the pair of mating elements and the body; and c) connecting the elongate scaffold member to the vertical post by: i) positioning the pair of mating elements of the coupling assembly within the pair of apertures of the hub assembly; ii) contacting the annular hub body with the actuating arm to automatically move the actuating arm in a first direction; iii) allowing the outer edge of the hub body to be received within the slot of the coupling assembly; and iv) moving the actuating arm past the hub body to allow the actuating arm to automatically move in a second direction to secure the coupling assembly to the hub assembly.

63. A method as claimed in claim 62, further comprising any one of the features of the coupling system of claims 2 to 35.

64. A method of erecting a scaffold system comprising the steps of: a) providing a plurality of first vertical posts, each first vertical post having a lengthwise axis extending between a first end and a second end, and a plurality of horizontally oriented hub assemblies affixed in coaxial alignment to each first vertical post, each hub assembly is spaced along the length of the post at intervals corresponding to a grid pattern to be formed for the scaffold system; b) connecting a base plate to each first end of each first vertical post, the base plate helps distribute the weight each first vertical post bears in the scaffold system; c) providing within each one of the plurality of horizontally oriented hub assemblies: i) a central opening therethrough for receiving the vertical post; ii) a plurality of first apertures spaced around and extending through a hub body, each first aperture is located adjacent the periphery of the hub body, iii) a plurality of second apertures spaced around and extending through the hub body, each second aperture is located adjacent the central opening of the hub body; and iv) adjacent first and second apertures form pairs of apertures, each pair is radially aligned in succession around the hub body; d) providing a plurality of horizontal elongate scaffold members for fastening to respective horizontally oriented hub assemblies on the vertical posts; e) providing each end of each horizontal scaffold member with an end coupling assembly, each end coupling assembly comprising: i) a body have a first end and a second end, the first end having a part-cylindrical, radially inward bearing surface of a radius equal to an outer peripheral radius of the vertical post, and the second end having an attachment member for receiving an elongate scaffold member; ii) a pair of mating elements corresponding to the pair of apertures radially aligned in succession around the hub assembly; iii) a locking member suspended from the body, the locking member having an actuating arm; and iv) a slot located between one of the pair of mating elements and the body; f) positioning each end of the horizontal scaffold member on a hub assembly on adjacent first vertical posts so that the pair of mating elements are aligned with the pairs of apertures in the hub assembly; g) securing each end of the horizontal scaffold member to the hub assemblies by automatically activating the locking member as the actuating arm contacts the annular hub body the actuating arm is automatically moved in a first direction to allow the outer edge of the hub body to be received within the slot of the coupling assembly, as the actuating arm moves past the hub body the actuating arm automatically moves in a second direction to secure the coupling assembly to the hub assembly; and h) repeating steps f) and g) to form the grid pattern for the scaffold system.

65. A method as claimed in claim 64, further comprising any one of the features of the scaffold system of claims 37 to 61.