AU2008101086A4

AU2008101086A4 - Sheet Bracing

Info

Publication number: AU2008101086A4
Application number: AU2008101086A
Authority: AU
Inventors: Nicholas John Davidson
Original assignee: Individual
Current assignee: Individual
Priority date: 2007-11-08
Filing date: 2008-11-07
Publication date: 2008-12-11
Anticipated expiration: 2016-11-07

Description

00 -1o SHEET BRACING z O 5 FIELD OF THE INVENTION

INO

00 This invention relates to sheet bracing, and in particular sheet bracing for use in the building industry.

00

BACKGROUND

Winds are a major cause of damage to buildings. Accordingly, buildings in Australia are required to comply with standards regarding wind resistance.

Currently, plywood bracing is the main product available for wind bracing of residential and other low-rise buildings. However, plywood bracing has several disadvantages. It is generally manufactured as a laminated product, with a veneer appropriate to its intended application. It is therefore fairly costly to produce. As a timber product, it may be subject to fungal decay, and also present problems with regard to flammability.

Furthermore, as many plywood products derive from rainforest timber imported from countries such as Indonesia, there are major environmental concerns regarding these products, and also concerns that supplies may be dwindling.

A further disadvantage of plywood bracing and other cladding braces is their thickness, therefore resulting in unsightly bulges in ceilings, wall linings and cladding boards.

Accordingly, there is a need for a product which addresses one or more of the above limitations.

SUMMARY OF THE INVENTION In a first aspect of the invention, there is provided a bracing structure comprising a sheet of a material of appropriate structural strength having a first group of apertures each of which is adapted to receive a fixing member (e.g nail, screw or bolt) and a second group of apertures which allow for passage therethrough of structural members/ utilities such as pipes or wiring. This second group of apertures also allows for more 00 -2economical manufacture of a relatively light-weight product, in that the metal content of N the bracing sheet is reduced.

O

S In a second aspect of the invention, the bracing structure comprises a sheet of material of appropriate structural strength with a grid of intersecting horizontal and vertical elements, and having a plurality of apertures being voids between the horizontal and vertical elements of the grid.

oo00 The sheet may be formed from any appropriate material of sufficient structural strength, including metals, for example iron or aluminium; alloys such as steel; sufficiently durable 00 0 and strong plastic or other synthetic materials such as Kevlar®; carbon fibres or N filaments; or carbon composites or other composite materials. When formed from such materials as metal or carbon fibres or filaments, the sheet may have a woven structure.

The metal fibres or filaments of the woven sheet may be coated with, for example, a plastic coating.

Preferably, the material of the bracing sheet will be capable of providing a bracing value of 1.0 to 10kN per metre when the bracing sheet is attached to an anchored frame. In order to enhance appearance or avoid corrosion, metals such as iron and steel may have a decorative or corrosion-resistant coating such as a galvanized coating, for example Z275 (or similar), ZINCANNEAL® or ZINCALUME®. A dye coating may also be used for extra corrosion resistance, to enhance appearance and/or to prevent or inhibit electrolysis between the metal sheet and any different metal which may contact it. The dye coating may be the only coating on the metal sheet, or may be applied over another coating, such as a galvanized coating.

Preferably, the bracing structure of the present invention will be in the form of a sheet being a grid of intersecting horizontal and vertical elements, with a first group of apertures being a series of apertures located along the horizontal and vertical elements, and a second group of apertures being voids between the horizontal and vertical elements of the grid. For additional strength, the bracing structure may further comprise cross members being longitudinal elements oriented obliquely to the horizontal and vertical elements, and more preferably may comprise two groups of such cross members, the two groups slanting in opposite directions so as to form a diamondshaped structure superimposed on the grid formed by the horizontal and vertical elements. The bracing structure may be easily and economically formed from an appropriately sized sheet of metal by punching out the required pattern of apertures for fixing members such as nails and screws and voids. The pieces of metal which are 00 -3o punched out from the sheet, during this manufacturing process, can readily be recycled C to thereby improve the economic aspects of production.

O

S It is envisaged that the bracing structures of the present invention will be produced in standard sizes. However, a standard-sized sheet can, if so desired, readily be cut to a more appropriate size by the customer, to thereby produce a product more suited to the customer's specific application. For example, a metal sheet having a width of 1200mm 00 and a length of 2400mm can be cut into smaller sized braces. This can easily be done by the tradesperson on site. Smaller sized braces will of course have a lesser resistance (kilonewton, kN) value.

oo00 C In a preferred option, one of the horizontal elements adjacent the periphery of the sheet, hereinafter referred to as the first retained end, will be of substantially greater width than others of the horizontal elements of the sheet. Similarly, one of the vertical elements adjacent the periphery of the sheet, hereinafter referred to as the second retained end, will be of substantially greater width than others of the vertical elements of the sheet.

These retained ends enhance the strength and rigidity of the sheet and, if the sheet is to be cut to size by the customer, it is recommended that the cut lines be positioned so as to retain these elements (or, at least, portions thereof). The sheet can be cut using metal snip shears, powered shears, side grinders or other appropriate cutting tools.

BRIEF DESCRIPTION OF THE DRAWINGS AND PHOTOGRAPHS Figures 1 to 7 Figure 1 shows a metal bracing sheet according to a first embodiment of the present invention; Figures 2A to C illustrate how the metal bracing sheet of Figure 1 can be folded or bent according to requirements; Figure 3 shows a second embodiment of a metal bracing sheet according to the present invention; Figure 4 shows a third embodiment of a metal bracing sheet according to the present invention; Figure 5 shows a fourth embodiment of a metal bracing sheet according to the present invention; Figure 6 shows a further embodiment of metal bracing sheets according to the present invention, where they are being used to form structures such as composite floor bearers, joists, and composite ceiling and roof rafters; 00 -4- O Figure 7 shows a yet further embodiment of a metal bracing sheet according to the C present invention, where it is being used as a lintel support; S Photographs C 5 Photograph 1 compares a bracing sheet according to the present invention (left-handside of photograph) with previously used bracing structures (right-hand-side of the CO photograph the prior art bracing structures are the solid brown features shown in use o00 on the frame of a house); C Photograph 2 shows a wall prior to attachment of a bracing sheet; oo Photograph 3 shows a corner brace (as per the description on page 6 of Figures 2A and B) in use; and Photographs 4 and 5 illustrate how a bracing sheet according to the present invention is attached to a wall a wall as shown in Photograph 2).

3 In various of the above photographs, a paper model is illustrated in place of the actual bracing sheet of the invention.

The embodiments illustrated in Figures 3 and 4 are substantially identical, except that the metal bracing sheet of Figure 4 has additional apertures 19 on horizontal elements 11 and vertical elements 12. The embodiment of Figure 5 has a more open lattice structure than the embodiments of Figures 3 and 4.

The lattice structure may be symmetrical (as in Figures 3 and 4) or asymmetrical (as in Figure DETAILED DESCRIPTION OF AN EMBODIMENT OF THE INVENTION The metal bracing sheet 10 of the embodiment depicted in Figure 1 has a grid-like structure formed from intersecting horizontal elements 11 and vertical elements 12. The voids 14 in the structure allow for easy penetration of structural members/utilities such as pipes and wiring.

The metal bracing sheet 10 of each of the embodiments depicted in Figures 3, 4 and has a similar grid-like structure formed from intersecting horizontal elements 11 and vertical elements 12, together with cross brace members 13.

00 SThe version shown in Figure 5 has a more open lattice structure than the versions of N Figures 3 and 4, with fewer horizontal and vertical members 11 and 12 in the lattice.

This is to facilitate use by tradespeople erecting the bracing sheet 10. It will make the Scorner brace lighter and easier to bend if being used as corner brace (see the description on page 6 of Figures 2A and However, there will be a trade-off with bracing strength the greater the number of horizontal and vertical members 11 and 12, the greater the bracing strength. More horizontal and vertical members will achieve oo00 greater mathematical bracing values but will result in the bracing sheet being heavier and slightly harder to bend. Selection of the optimum configuration of the bracing sheet and its lattice structure may depend on the testing of prototypes to determine the best 00 Sproduct for a particular use. It may also depend on cost factors, such as the quantity of 0 material (preferably, steel) to be used in each bracing sheet The sheet 10 may, for example, have dimensions of 2400mm x 1200mm, with a thickness of 0.8mm, 1.0mm, 1.2mm or 1.4mm. In particular, an appropriate thickness for the bracing sheet can be about that of a tin can. For ease of manufacture, the metal bracing sheet 10 can be cut or punched from, for example, a large (2400mm x 1200mm) metal sheet. That sheet can be rolled under a sheet metal guillotine punch which, with a single action, stamps metal bracing sheet 10 out of the sheet, leaving behind a rectangular outer frame 13 and numerous smaller pieces to form lattice voids 14.

The sheet can readily be cut to a desired size, by cutting (for example) centrally through each void 14 located between an adjacent pair of horizontal elements 11 or vertical elements 12. Possible cut line positions are indicated by the arrows 18 at the top and to the right-hand-side of the metal sheet 10, as shown in Figures 3 and 4. Preferably, one of the horizontal elements adjacent the periphery of the sheet, being the first retained end 15, will be of substantially greater width than others of the horizontal elements of the sheet. Similarly, one of the vertical elements adjacent the periphery of the sheet, being the second retained end 16, will be of substantially greater width than others of the vertical elements of the sheet. These retained ends 15 and 16 enhance the strength and rigidity of the sheet, and possible cut lines are therefore positioned so as to retain these elements (or, at least, portions thereof) the cut lines are preferably positioned to retain the portions of these ends 15 and 16 which extend at least as far as the cut-off points indicated by the arrows 15a and 16a respectively.

A series of apertures 19 (as shown in Figures 3 and which are preferably spaced evenly along the horizontal elements 11 and vertical elements 12, are provided as fixing 00 -6- 0 holes whereby the bracing sheet can be attached to timber pine or hardwood) C framing or metal studwork (having spacings of, for example, 300mm, 450mm or 600mm) for walls, or (at, for example, 1200mm or 900mm centres or spacings) to Sceilings, rafters or trusses using fixing members such as nails 30mm x 2.8mm galvanized reinforced head nails or clouts), screws Type 10, 12, 14 or 17 flat-head screws) or bolts. Air-driven Duo-Fast®, Bostitch® or Paslode® coil nails are typically the preferred option for carpenters and builders, as (with suitable pressure) they allow for oo00 rapid fixing of the bracing sheets, where pinpoint accuracy in aligning nails with the apertures 19 is not required a nail can penetrate the metal surrounding the aperture without any adverse effect on the performance of the bracing sheet. Indeed, this fixing 00 method may actually achieve a marginal increase in the resistance/bracing value (kN) of 0 the sheet. Typically, when used as bracing structures for wall panels, the bracing sheets of the present invention are fixed, at distances of no more than 9 metres apart, to external corners of the building.

The bracing sheets can also be fixed to internal walls. In fact, the bracing sheets of the present invention can be fixed to almost any wall, on either the inside or outside of the frame, thus eliminating the need for external building scaffolding to fix bracing sheets.

Metal bracing sheets according to the present invention can provide bracing values of 1.0 to 10 OkN per metre when attached to standard pine frames. The frames are typically anchored at the bottom plate with M12 bolts. In general, increasing the thickness of the bracing sheet will increase the kN (bracing) value (subject to engineering specifications and testing).

As shown in Figures 2A to C, the bracing sheets of the present invention can be folded or bent according to requirements. In particular, the sheets can be bent or folded (as exemplified by Figures 2A and B) to form corner braces.

For use with external walls, a corner brace can, for example, be constructed by fixing one side or end of the bracing sheet 10 to the wall forming one side of the corner.

The remaining width or length of the bracing sheet (the return) is then pushed into place around the corner bend where the walls meet, and is then flattened, straightened, and the return is fixed to the wall forming the other side of the corner.

The inventor is unaware of any other type of brace that can be fixed in this way to two walls meeting to form a corner.

00 -7- A corner brace for an internal corner can be formed and utilized in a similar manner.

O However, it may be necessary for the bracing sheet to be bent or folded on the ground Sor on a work platform to form the shape of the corner prior to installing and fixing the bracing sheet in place.

O Bending of a sheet to form a corner brace is easily achieved because the bracing sheet 00 has been manufactured as a lattice of metal to facilitate folding at the intervals indicated by arrows 18 on Figures 3 and 4. These fold points are typically located on the side or between horizontal and vertical members 11 and 12.

oo00 C In order to facilitate better understanding of the invention, the present invention has been described in terms of preferred embodiments, and with regard to the particular elements and/or features described or depicted therein. It should however be appreciated that various modifications can be made without departing from the principles of the invention. Therefore, the invention should be understood to include all such modifications within its scope.

For example, in a further embodiment (not shown), several metal bracing sheets can, if so desired, be combined vertically and/or horizontally to provide different lengths and/or widths 4800mm x 1200mm, 2400mm x 2400mm), being multiples of the dimensions of a single sheet 10. This can be done so as to increase the overall length or width of the bracing structure, or to provide additional strength and support, and may be achieved by butting sheets together and fixing to a single or double stud arrangement. For example, three sheets, each having a width of 1200mm, can be butted together, side by side, to produce a bracing structure having an overall width of 3600mm.

In a yet further embodiment (not shown), several bracing sheets 10 may be combined, one on top of another, so as to increase the overall thickness as desired, or to provide additional strength and support. This may be achieved by any appropriate fixing technique which is known to the relevant skilled person, or by merely overlaying two or more of the bracing sheets.

An additional embodiment is shown in Figure 6, where the bracing sheets of the present invention are used to form such structures as composite floor bearers, joists, and composite ceiling and roof rafters. For example, two 100mm x 50mm hardwood 00 -8- O members 20 can be fixed together with bracing on both sides, being the two sheet c bracing pieces 21.

SAlso, although the bracing sheet of the present invention has been described with respect to its use as a bracing structure for walls, ceilings, rafters, trusses and the like, it can similarly be used to provide lintel supports for openings such as doorways or windows. Referring to Figure 1, any size down to the smallest cut piece of bracing sheet 00 10 would be suitable for use as a lintel support. As shown in Figure 7, a metal brace sheet 22 (which may have been cut off from a larger bracing sheet 10) is fixed to the stud framing 23 above an opening such as a doorway or window. The metal brace 00 sheet 22 may either be single-sided, or double-sided for greater strength.

Furthermore, as described above (on page 2 of this specification), the bracing sheet of the present invention is not necessarily made of metal, but may instead be formed from Sother appropriate materials of sufficient structural strength, such as sufficiently durable and strong alloys; plastic or synthetic materials; carbon fibres or filaments; or carbon composites or other composite materials.

Claims

3. A bracing structure according to Claim 2, said bracing structure further comprising longitudinal cross members oriented obliquely to the horizontal and vertical elements.
4. A bracing structure according to any one of Claim 1 to 3, wherein the material of 3 appropriate structural strength is selected from metals; alloys; plastic or synthetic materials; carbon fibres or filaments; and carbon composites or other composite materials. A bracing structure substantially as described herein and with reference to any one of the attached drawings and photographs.