Scaffold assembly and method of manufacture

Abstract

The present invention provides a scaffold assembly, in particular a combination of a conventional tubular scaffold tube or pole and a rosette, type coupling which enables the connection of additional scaffold components to the scaffold assembly, the coupling and tubular element being fixed relative to one another by means of at least one abutment which is cold formed in the tubular element such as to fix the coupling in position relative thereto.

1 . A method of manufacturing a scaffold assembly comprising a hollow tubular element and a coupling circumscribing the tubular element, the method comprising locally outwardly deforming the tubular element to form an abutment positioned to retain the coupling in position. 
     
     
         2 . A method according to  claim 1  comprising the step of forming a pair of abutments axially spaced along the tubular element and between which the coupling is captured. 
     
     
         3 . A method according to  claim 11  comprising the steps of providing a recess in the coupling opening onto an interface between the coupling and the tubular element; and forming at least one abutment as an outward deformation into the recess. 
     
     
         4 . A method according to  claim 11  comprising cold forming each abutment. 
     
     
         5 . A method according to  claim 11  comprising forming each abutment through deformation of the tubular element from an inner wall of the tubular element. 
     
     
         6 . A method according to  claim 11  comprising the step of inserting a forming tool into a hollow interior of the tubular element; and expanding at least a portion of the forming tool in order to form at least one abutment. 
     
     
         7 . A method according to  claim 6  comprising utilising hydraulic pressure in order to effect expansion of the forming tool. 
     
     
         8 . A method according to  claim 6  comprising radially outwardly expanding an annular array of discrete forming elements comprised in the forming tool. 
     
     
         9 . A method according to  claim 8  comprising forcing a conical wedge against the array of forming elements in order to effect the radially outward expansion of the annular array. 
     
     
         10 . A method according to any of  claims 9  comprising securing the tubular element and coupling in a forming jig prior to undertaking deformation of the tubular element. 
     
     
         11 . A method according to  claim 8  comprising forming a pair of abutments axially spaced along the tubular element, with the expanding of the annular array of discrete forming elements.