CLIENT: SkyClimber (2008)

PROJECT: SkyMaster Scaffolding Hoist Stage Mass Climber

Newer buildings often don't have access from the roof to allow for scaffolding. SkyClimber, the most recognized manufacturing name in suspended access solutions, created a concept for an innovative new scaffolding system that could scale the exterior of a building from the ground up. They asked us to help them refine their concept and engineer a production solution. Further challenges included using their existing "stage" (the part people stand on) and meeting all safety regulations for OSHA, UL, & CE.

The system, called the Sky Master, features a hybrid solution with ground mounted support extrusion columns that suspend a center stage. The system allows the user to increase the height of the scaffolding by stacking aluminum extruded rails on the top ends of the extrusion columns as the center stage raises. Our task was to engineer an innovative proprietary mechanical system to connect the stage to the extrusions, create a way to tie the support extrusions to the buildings exterior walls and create a base to support the extrusion columns.

Our engineers also added several innovative safety features to the Sky Master including mechanical tilt limiters that do no allow the stage to tilt more than 7 degrees, mechanisms that detect and lock the stage in place in the event of cable breakage, and mechanisms that prevent stage movement in the case of weight overload.

Our engineers developed the climber in a 3D CAD environment using SolidWorks software. Then, full FEA structural analysis was conducted to ensure the product could support the loads without failure. Lastly, our engineers coordinated outside vendors to produce a working prototype.

The result of our work for SkyClimber was a working prototype which they showed to potential customers at the 2007 World of Concrete show. The prototype was well received and encouraged SkyClimber to proceed with production.

Our contributions to this project included research, 2-D and 3-D design development, 3D CAD modeling & engineering, and prototyping.

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