AU782491B2 - A mezzanine floor - Google Patents

Description

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Applicant(s): TUBEMAKERS OF AUSTRALIA LIMITED Invention Title: A MEZZANINE FLOOR The following statement is a full description of this invention, including the best method of performing it known to me/us: 2 A MEZZANINE FLOOR FIELD OF THE INVENTION The present invention relates generally to a mezzanine floor structure constructed of metal. The invention also relates to a method of erecting a demountable mezzanine floor and further relates to a load bearing member, bracing member and bracing coupling of a mezzanine floor structure.

BACKGROUND OF THE INVENTION Mezzanine floor structures of a conventional construction are fabricated from steel with load bearing members being of a channel or closed roll formed section.

:The load bearing members are welded to upright posts and floor joists then welded to the load bearers to form the mezzanine floor structure. Wire bracing is arranged 20 diagonally between adjacent posts to stabilise the floor structure. The floor structure can then be clad with an appropriate sheet material to form the mezzanine floor.

e e* SUMMARY OF THE INVENTION S.According to one aspect of the present invention *o e there is provided a demountable mezzanine floor structure *'.".constructed of metal, the mezzanine floor comprising: at least two spaced apart and elongate load bearing S 30 members, each being elevated from the ground via at least two upright posts, each being detachably fixed at an upper end to the corresponding load bearing member; a plurality of spaced apart floor joists, each being detachably fixed and oriented transverse either to the load bearing members or to bridging members connected between and oriented transverse to adjacent load bearing members; a first bracing member mounted to one of the load 3 bearing members at an adjacent post; and a plurality of elongate and diagonally oriented second bracing members, each at opposing ends being detachably coupled respectively to a lower end of one of the posts and to the first bracing member.

According to another aspect of the invention there is provided a method of erecting a demountable mezzanine floor structure constructed of metal, the method comprising the steps of: providing at least two elongate load bearing members, a plurality of posts, a piuraiir-y i fiLit aid .CCnd elongate bracing members, a plurality of floor joists, and a plurality of fasteners; locating the posts in a vertical orientation in predetermined spaced apart positions in two or more rows; ~fixing each load bearing member via one or more of the fasteners to an upper end of a respective post in each of the rows; mounting each first bracing member to one of the load bearing members at an adjacent post; coupling opposing ends of each second bracing member respectively to a lower end of one of the posts and to the oO.o first bracing member; and 25 fixing the floor joists via one or more of the fasteners to the load bearing members, the joists being spaced apart and oriented transverse to the load bearing members.

S 30 Alternatively the floor joists can be fixed to bridging members which are connected between and arranged transverse to adjacent load bearing members.

The first bracing member can be an elongate bracing member fixed and arranged transverse to the load bearing members. Additionally, such an elongate bracing member can be aligned with the underlying upright posts.

4 The fasteners are typically in the form of screws and/or bolts. For example, the fasteners can be in the form of self-tapping screws commercially available in Australia under the tradename TEK screws.

Typically the load bearing members are each fabricated from two channel-shaped members with their respective webs secured in a back-to-back relationship, so that each load bearing member then defines an I-section beam. More typically the channel-shaped members are bolted together in the back-to-back relationship.

Alternatively, the load bearing members can each be defined by a single channel-shaped member, and adjacent such members can be interconnected by transversely extending channel-shaped members.

oo o Typically opposing ends of each second bracing member are threaded and are each adapted to be engaged by a nut 20 to permit adjustment of the effective length of the second bracing member.

The demountable mezzanine floor may further comprise a plurality of bracing couplings, each being detachably 25 fixed to one of the posts at its lower end and either to an upper end of an adjacent post or to the first bracing member. The bracing coupling may include an opening through which a threaded end of a second bracing member passes.

S Typically the bracing coupling includes a cleat mounted to a sleeve which is fixed about the corresponding post or the first bracing member. More typically the opening of the bracing coupling is formed in the cleat.

Alternatively the bracing coupling can be in the form of a U-shaped bracket having opposing flanges integral with an interconnecting web, with the flanges being adapted to detachably fix to the post of the floor, and the web including the opening through which the threaded end of the second bracing member passes.

Typically the posts and/or floor joists are of a rectangular hollow section (RHS) or square hollow section

(SHS)

Typically the mezzanine floor structure is constructed of galvanised steel such as that commercially available in Australia under the trademark DURAGAL.

Typically the mezzanine floor structure is clad with a suitable sheet material to form a mezzanine floor.

BRIEF DESCRIPTION OF THE DRAWINGS g In order to achieve a better understanding of the nature of the present invention several preferred embodiments of a mezzanine floor structure will now be 20 described, by way of example only, with reference to the accompanying drawings in which: Figure 1 is a perspective view of an embodiment of a mezzanine floor structure; Figure 2 is an enlarged perspective view of a bearing member to column connection together with the associated bracing for the mezzanine floor structure of Figure 1; o Figure 3 is an enlarged perspective view of an o alternative load bearing member to column connection 30 together with the associated bracing; Figure 4 is a perspective view of another embodiment of a mezzanine floor structure together with a "Detail A"; Figure 5 are various cross-sectional and arrangement drawings of the post, bracing, and mezzanine floor of the floor structure of Figure 4; Figure 6 is a perspective view of a further 6 embodiment of a mezzanine floor structure together with a "Detail and Figure 7 are various cross-sectional and arrangement views of the post, bracing, and mezzanine floor of the floor structure of Figure 6.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS As shown in Figure 1 there is a mezzanine floor structure 10 constructed of metal which in this example is galvanised steel. The floor structure 10 is designed to be clad on its upper surface with a sheet material 11 suitable for flooring.

The mezzanine floor structure 10 is demountable and in this embodiment comprises three rows of upright posts such as 12A to 12C, corresponding load bearing members 14A to 14C, a plurality of spaced apart floor joists such as 16, and a plurality of bracing members such as 18. These components of the demountable mezzanine floor 10 are detachably connected to one another as will be described in more detail via one or more fasteners such as screws and/or bolts, for example TEK screws. The demountable mezzanine floor 10 can thus be erected and dismantled with relative speed and ease without the need for specific trade skills.

As shown in Figure 2 each of the load bearing members such as 14B is fabricated from a pair of channel-shaped members such as 20A and 20B with their respective webs secured in a back-to-back relationship wherein the members such as 14B are each in the form of an I-section beam.

The channel-shaped members 20A/B are bolted together in the back-to-back relationship. The floor joists such as 16 are constructed of a rectangular hollow section (RHS) which is fixed to and extends transversely across the three load bearing members 14A to 14C. The floor 41942 7 joists such as 16 of this embodiment are mounted to and equally spaced along the load bearing members 14A to 14C.

In this embodiment the floor joists such as 16B are fixed to the load bearing member 14B via an angled strap or bracket 17.

The mezzanine floor structure 10 also includes a bracing member or strut 19 secured to and extending transversely across the load bearing members 14A to 14C.

The bracing strut such as 19 is located alongside an adjacent floor joist such as 16A at each of the rows of posts, for example, 12A to 12C. The bracing struts such as 19 are constructed of square hollow section (SHS) of the same dimensions as the upright posts such as 12B.

The mezzanine floor structure of Figures 1 and 2 is given added stability with the inclusion of both transverse and longitudinal bracing members such as 18.

The transverse bracing member 18 is in this example formed of steel rod which at opposing ends is threaded. The rod bracing 18 is at opposing ends coupled to a lower end of one of the upright posts such as 12C and the bracing strut 19 adjacent the intermediate post 12B, respectively.

Another bracing member such as 22 is also located diagonally between a lower end of the intermediate post 12B and the bracing strut 19 adjacent the outermost post 12C to form a crossed bracing arrangement. This bracing arrangement is repeated for adjacent posts such as 12A and 12B and extends transversely across the mezzanine floor structure 10. Additionally, the floor structure 10 is braced longitudinally via further bracing members such as 24 which at opposing ends coupled to one of the posts such as intermediate post 12B and one of the load bearing members 14B, respectively. This. longitudinal bracing arrangement is repeated for each of the upright posts such as 12A to 12C.

41942 8 In this embodiment the transverse bracing members such as 18 and 22 are coupled to the post such as 12B and the bracing strut 19 via a bracing coupling 26. The bracing coupling 26 includes a cleat 27 welded to a sleeve 29. The cleat 27 has an aperture 32 in its web 30 which receives and provides for attachment or anchoring of the rod bracing such as 18 or 22. The sleeve 29 is shaped complimentary to and slidably received over the post such as 12B or bracing strut 19 and is fixed thereto via one or more screw fasteners such as 31. The rod bracing such as 18 or 22 includes in a somewhat traditional manner an anchoring nut and a lock nut 33 and 33A, respectively, for securing and adjustment of the rod bracing 18 or 22.

Figure 3 illustrates an alternative embodiment of the mezzanine floor structure including a rectangular hollow section (RHS) as the load bearing member such as 14B instead of the back-to-back channel-shaped members of Figure 2. In this example, the load bearing members such as 14B are mounted to the corresponding post 12B via an adjustable fitting designated generally as 34. The adjustable fitting 34 is similar in construction to the oooo adjustable stump fittings disclosed in the applicants Australian patent no. 719750, the disclosure of which is S 25 to be included herein by way of reference. Otherwise, the 0 mezzanine floor structure 10 is of similar construction to the preceding embodiment and, in order to avoid repetition and for ease of reference, similar components have been designated with the same reference numerals.

00 The longitudinal bracing members such as 24 of e Figures 2 and 3 are connected to the corresponding load oooo bearing member 14B via another bracing coupling 35. In the preferred embodiment of Figure 2 the bracing coupling 35 includes another cleat 37 welded to a mounting plate 39 together with a pair of clamp plates such as 41. Adjacent lower flanges of the perspective channel-section members 9 and 20B are clamped between the mounting plate 39 and the clamp plates such as 41 where upon the longitudinal bracing member 24 is fixed to the load bearing member 14B.

In the bracing coupling 35 of Figure 3 there is provided a U-shaped bracket 43 which is fixed to opposing sides of the RHS load bearing member 14B. The U-shaped bracket 43 includes an opening 44 through which a threaded end of the rod bracing 24 passes, and at which it is secured by anchoring and lock nuts 46, 46A respectively.

Figure 4 illustrates another embodiment of the mezzanine floor structure designated generally as 100. In order to avoid repetition and for ease of reference similar components of this floor structure have been designated with an additional For example, the floor joist has been designated as 160. The floor structure 100 is in essence the same as that of Figure 1 with the exception of the bracing details.

The mezzanine floor structure 100 of Figure 4 is given added stability with the inclusion of both O transverse and longitudinal bracing members such as 180.

The transverse bracing member 180 is in this example formed of steel rod which at opposing ends is threaded.

The rod bracing 180 is at opposing ends coupled to a lower :.Sao. and an upper end, respectively, of adjacent posts such as 120A and 120B. Another bracing member such as 220 is also located diagonally between adjacent posts such as 120A and 120B to form a crossed bracing arrangement. This bracing arrangement is repeated for adjacent posts such as 120B and 120C and extends transversely across the mezzanine floor structure 100. Additionally, the floor structure 00 is braced longitudinally via further bracing members such as 240 which, at opposing ends, couple to one of the posts such as 120A and one of the load bearing members 140A, respectively. This longitudinal bracing arrangement is repeated for each of the upright posts such as 120A to 10 120C.

"Detail A" of Figure 4 depicts an alternative form of a bracing coupling such as 260 which is mounted to the post, in this instance 120B, and detachably couples to the bracing rod 180. The bracing coupling 260 is of a Ushaped configuration having opposing flanges fitted and fixed to opposing sides of one of the posts such as 120B via one or more fasteners such as TEK screws. The flanges such as 280 are formed integral with an interconnecting web 300 which includes an opening through which a threaded end of the rod bracing 180 passes. The bracing coupling 260 is also provided with a stiffening element in the form of an inverted U-shaped stiffening plate 320 which is designed to seat within the U-shaped coupling 260. The stiffening plate 320 includes an aperture aligned with the opening in the coupling 260. A nut such as 340 threadingly engages the end of the rod bracing 180 and bears against the stiffening plate 320. Thus, the nut 340 and threaded bracing rod 180 allow for adjustment of the effective length of the rod bracing 180.

Importantly, the rod bracing 180 is relatively inextensible under normal loading of the mezzanine floor structure 100. Therefore, it is generally not necessary 25 to pre-tension the rod bracing 180 to resist outward splaying of the posts such as 120A when the mezzanine floor structure 100 is loaded. Although not illustrated in detail the longitudinal bracing members 240 are '"detachably fitted to the post and load bearing member such as 120A and 140A, respectively, via brackets or other :ooosuitable fittings.

coo* Figure 5 illustrates other specific detail views of the mezzanine floor structure 100 of Figure 4. "Detail B" clearly shows bolting of the channel-shaped members such as 200A and 200B in a back-to-back relationship via bolts such as 360. The floor joist such as 160C of this example 11 is formed from two RHS sections joined end to end via a conventional bracket such as that used in pergola construction. The floor cladding 400 is laid across and fixed to the series of floor joists 160 via appropriate fasteners such as TEK screws.

"Detail C" of Figure 5 depicts one of the posts such as 120B anchored to a floor slab 420 via masonry anchor bolts 440. The anchor bolts 440 pass through apertures in a base plate 460 which is welded to a lower end of the post 120B. An upper end of the post 120B is similarly fixed to the load bearing member 140B via bolts 480.

"Detail D" of Figure 5 shows in end view the "Detail A" of Figure 4.

The demountable mezzanine floor structure 10 (or 100) can be erected in the following general manner: the upright posts such as 12A to 12C are located on the floor slab 42 at their predetermined positions; (ii) the load bearing members such as 14A to 14C are fixed to the upper ends of the respective row of posts such as 12A to 12C; (iii) the other bracing struts such as 19 are mounted transversely across the load bearing members 14A Sgto 14C; 00 00 (iv) adjacent posts are braced both transversely and longitudinally via bracing members such as 18 and 24; the floor joists such as 16 are fixed to and oooo g 30 extend transversely across the load bearing members such e00e as 14A to 14C; and (vi) the mezzanine floor structure 10 is clad with :an appropriate sheet flooring material.

0 35 It should be appreciated that the order and specific detail of these steps may vary depending on the preferred or most efficient manner of erecting the mezzanine floor 12 structure 10. For example, the lateral bracing such as 18 may be fitted prior to location and fixing of the load bearing members such as 14A to 14C.

Figures 6 and 7 illustrate another embodiment of a mezzanine floor structure 100'. In order to avoid repetition and for ease of reference, similar components for this embodiment have been designated with the same reference numerals as Figure 4. For example, the posts have been designated as 120A to 120C.

The load bearing members 140A to 140C are in this particular construction of the mezzanine floor structure 100 formed simply of a channel-shaped section, as best shown in "Detail The floor joists 160 extend longitudinally rather than transversely along the flooring structure 100. The flooring structure 100 includes bridging members such as 11OA/B and 130A/B which are connected between and oriented transverse to adjacent of the load bearing members such as 140A and 140B. The bridging members are also formed simply of channel-shaped section. The floor joists such as 160 are fixed to and extend transverse to the bridging members lIOA and 130A.

25 Figure 7 in "Details B1, B2 and B3" shows fixing of the bridging members such as 130A and 130B to the load bearing member 140B. "Detail Bl" shows an end elevation, "Detail B2" shows a front elevation and "Detail B3" shows a side elevation. In this embodiment angle brackets 150A 30 and 150B are bolted to either side of the channel-section of the load bearing member 140B. The brackets 150A and 150B are bolted to adjacent ends of the respective bridging members 130A and 130B. The floor joist 160 is fixed to the bridging member such as 130A via a tie 35 connector of a conventional construction such as 170. The floor cladding 400 is screwed or otherwise fixed to the joists 160 as described in the preceding embodiment.

13 Otherwise, these two embodiments of the invention are similar in construction.

In Figure 7, "Detail C" shows a similar view to Figure 5C and "Detail D" shows a similar view to Figure 5D. Like references numerals are used to describe similar or like parts.

The mezzanine floor structure and bracing detail of Figures 1 to 3 are preferred. In these embodiments the transfer of load from the floor material such as 11 to the posts such as 12A to 12C is not through the upper connection of the posts 12A to 12C to the load bearing member such as 14A to 14C. It is understood that this avoids distortion of the load bearing member, for example the web of the back-to-back channel section members and 20B of the embodiment of Figure 4 may laterally distort. In the preferred embodiment of Figures 1 to 3 the load is transferred from the flooring material 11 to the underlying joists such as 16 to the load bearing member such as 14B via the angled bracket 17 to the bracing strut 19 and finally to a lower end of one of the posts such as 12C via the rod bracing such as 18. In this manner transverse loads from the mezzanine floor 10 are transferred to the posts such as 12A to 12C whilst S" 25 minimising forces at the connection of the posts to the corresponding load bearing members.

oa The mezzanine floor structures 10 and 100 and in particular the posts, joists, load bearing members, and 30 bridging members can be constructed of a steel o o manufactured and sold in Australia under the trade mark DURAGAL. Strip steel is formed in a continuous forming/galvanising process which is the subject of further patents/patent applications of the applicant, for example US patent No. 5895534.

13a Now that several preferred embodiments of the invention have been described in some detail it will be apparent to those skilled in the art that the demountable mezzanine floor has at least the following advantages: the demountable mezzanine floor can be erected and dismantled with relative ease and minimal trade skills; (ii) the demountable mezzanine floor provides a f *o f o* *o ft ft 14 relatively stable platform; (iii) the demountable mezzanine floor is formed from galvanised steel which is corrosion and weather resistant; (iv) the demountable mezzanine floor structure can be supplied and transported in a kit form; and the demountable mezzanine floor is capable of being "free standing".

Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described.

For example, the specific constructional features of the flooring structure may vary provided it is of a S 15 demountable configuration. The materials need not be limited to steel but may for example extend to aluminium alloy and other metals depending on the load requirements.

All such variations and modifications are to be 20 considered within the ambit of the present invention the nature of which is to be determined from the foregoing description.

41942

Claims (12)

1. A demountable mezzanine floor structure constructed of metal, the mezzanine floor comprising: at least two spaced apart and elongate load bearing members, each being elevated from the ground via at least two upright posts, each being detachably fixed at an upper end to a corresponding load bearing member; a plurality of spaced apart floor joists, each being detachably fixed and oriented transverse either to the load bearing members or to bridging members connected between and oriented transverse to adjacent load bearing members; a first bracing member mounted to one of the load bearing members at an adjacent post; and a plurality of elongate and diagonally oriented second bracing members, each at opposing ends being •g detachably coupled respectively to a lower end of one of the posts and to the first bracing member. A demountable mezzanine floor structure as defined in claim 1 wherein the first bracing member is an elongate bracing member fixed and arranged transverse to the load bearing members. A demountable mezzanine floor structure as defined in claim 2 wherein when the first bracing member is elongate extends transverse to the load bearing members so as to be aligned with the underlying upright posts. S"

4. A demountable mezzanine floor structure as defined in claim 2 or 3 wherein the first bracing member is of rectangular or square hollow section.

5. A demountable mezzanine floor structure as defined in any one of the preceding claims wherein the load bearing members are each defined by two channel-shaped members 16 with their respective webs secured in a back-to-back relationship such that the load bearing members then each define an I-section beam.

6. A demountable mezzanine floor structure as defined in claim 5 wherein the channel-shaped members are bolted together in the back-to-back relationship.

7. A demountable mezzanine floor structure as defined in any one of claims 1 to 4 wherein the load bearing members are each defined by a single channel-shaped member.

8. A demountable mezzanine floor structure as defined in claim 7 wherein adjacent load bearing members are interconnected by transversely extending channel-shaped members. *ooo A demountable mezzanine floor structure as defined in any one of the preceding claims wherein opposing ends of S 20 each second bracing member are threaded to enable engagement by a respective nut to permit adjustment of the effective length of the second bracing member. o *o •10. A demountable mezzanine floor structure as defined in 25 any one of the preceding claims further comprising a plurality of bracing couplings, each being detachably fixed to one of the posts at its lower end and to either an upper end of the adjacent post or the first bracing 3 member.

11. A demountable mezzanine floor structure as defined in claim 10 wherein each bracing coupling includes a cleat mounted to a sleeve which is fixed about a corresponding post or the first bracing member.

12. A demountable mezzanine floor structure as defined in any one of the preceding claims wherein the posts and/or 17 floor joists are of a rectangular hollow section (RHS) or square hollow section (SHS).

13. A demountable mezzanine floor structure as defined in any one of the preceding claims wherein the floor structure is clad with a suitable sheet material to complete the mezzanine floor.

14. A demountable mezzanine floor structure substantially as herein described with reference to the accompanying drawings. A method of erecting a demountable mezzanine floor structure constructed of metal, the method comprising the steps of: providing at least two elongate load bearing members, :a plurality of posts, a plurality of first and second ::..elongate bracing members, a plurality of floor joists, and a plurality of fasteners; S 20 locating the posts in a vertical orientation in predetermined spaced apart positions in two or more rows; S.fixing each load bearing member via one or more of the fasteners to an upper end of a respective post in each oO*. of the rows; 25 mounting each first bracing member to one of the load 0 *o :bearing members at an adjacent post; coupling opposing ends of each second bracing member respectively to a lower end of one of the posts and to the first bracing member; and 30 fixing the floor joists via one or more of the fasteners to the load bearing members, the joists being spaced apart and oriented transverse to the load bearing members.

16. A method of erecting a demountable mezzanine floor as defined in claim 15 wherein the floor joists are fixed to bridging members which have been connected between and 18 arranged transverse to adjacent load bearing members.

17. A method of erecting a demountable mezzanine floor structure substantially as herein described. Dated this 2 3 rd Day of May 2005 ONESTEEL TRADING PTY LTD By its Patent Attorneys GRIFFITH HACK *fee