GB2522039A

GB2522039A - I-beam

Info

Publication number: GB2522039A
Application number: GB1400418.8A
Authority: GB
Inventors: Thomas James Bowman
Original assignee: Dura Composites Ltd
Current assignee: Dura Composites Ltd
Priority date: 2014-01-10
Filing date: 2014-01-10
Publication date: 2015-07-15
Anticipated expiration: 2034-01-10
Also published as: GB201400418D0; GB2522039B

Abstract

A modular I-beam kit 100 comprises a unitary first flange 102. The unitary first flange 102 has two parallel elongate structures 108 that project perpendicularly from the plane of the flange 102. An elongate channel 106 isformed by the two elongate structures 108. The modular I-beam kit 100 further comprises a web 114 and second flange 112. The plane of the web 114 is perpendicular to the plane of the second flange 112. The web 114 has an elongate free edge for receipt within the elongate channel 106 of the unitary first flange 102. The modular I-beam kit 100 can be used to construct an I-beam of a particular height by altering the size of the web 114 prior to assembly.

Description

I-BEAM

The present invention relates to a modular I-beam and a method of manufacturing components for modular I-beams.

I-beams are commonly used in the construction industry to reinforce structures due to their ability to withstand and distribute large forces. However, I-beams are generally "made to measure" and, in cases where the I-beams are oversized for their particular use, it can be difficult to resize those I-beams at the construction site where they are intended to be used. For example, some known I-beams are formed by extruding structural steel. These I-beams have a fixed web height due to their unitary construction and so they cannot be fully resized. Other known I-beams are made from separate structural steel web and flange plates which are welded together. These I-beams do not have unitary construction, and so it is possible to adjust the size of the web of these I-beams before welding. However, structural steel can be very difficult and time consuming to cut and, at some construction sites, it is particularly desirable to reduce the amount of time taken to resize I-beams. For example, some railway track sites such as railway bridges can only be occupied for short periods of time, e.g. overnight, for maintenance and repair. Furthermore, structural steel I-beams tend to be extremely heavy.

It is becoming increasingly common to manufacture unitary I-beams from glass-reinforced plastic (GRP) by pultrusion. These I-beams are generally lighter than their steel equivalents and can more easily be cut to a chosen length. However, GRP I-beams tend not to withstand forces as well as their steel equivalents. Furthermore, GRP I-beams have a fixed web height due to their unitary construction and so they cannot be fully resized. It may be possible to form I-beams from plates of GRA in a similar way to welded plate steel I-beams. However, GRP joints tend not to be as strong as welded steel joints and may need to be reinforced with additional plates.

It is a principal aim of this invention to provide arrangements that overcome the shortcomings of the known I-beam arrangements.

Thus, according to an aspect of this invention there is provided a flange for a modular I-beam, the flange being of unitary construction and having two parallel elongate structures that project perpendicularly from the plane of the flange, an elongate channel for receiving a web of the modular I-beam being formed by the two elongate structures.

It will be appreciated that the flange of the present invention can be used to assemble an I-beam that can be fully resized. In particular, since a channel is provided for receiving a web of the modular I-beam, the web of the I-beam can easily be resized prior to assembly. Furthermore, since the channel is formed by integral elongate structures, the assembled I-beam is able to withstand significant forces without the need, for example, for additional reinforcing plates.

The channel is preferably located substantially along a longitudinal centreline of the plane of the flange. In preferred embodiments, the flange is formed from pultruded material. The flange may be formed from fibre reinforced plastic, such as glass fibre reinforced plastic (GRP). As discussed above, these materials are generally lighter and easier to cut than structural steel.

According to another aspect of this invention there is provided a web and flange for a modular I-beam, the web and flange together being of unitary construction, the plane of the web being perpendicular to the plane of the flange, the web having an elongate free edge for receipt within an elongate channel.

It will also be appreciated that the unitary web and flange of the present invention can be used to assemble an I-beam that can be fully resized. In particular, since the web has an elongate free edge for receipt within an elongate channel, the web of the I-beam can easily be resized. Furthermore, since the web and flange are of unitary construction, the assembled I-beam is able to withstand significant forces without the need, for example, for additional reinforcing plates.

The web preferably meets the flange substantially along a longitudinal centreline of the plane of the flange. In preferred embodiments, the unitary web and flange are formed from pultruded material. The unitary web and flange may be formed from fibre reinforced plastic, such as glass fibre reinforced plastic. As discussed above, these materials are generally lighter and easier to cut than structural steel.

In some embodiments, the web has a shorter side and a substantially parallel longer side, with the longitudinal length of the flange being substantially the same as the length of one of the shorter or longer sides. These embodiments are particularly useful where one side of the I-beam needs to be shorter so as to avoid contacting other structural components such as existing bridge rivets.

The present invention also extends to kits and assembled I-beams comprising one or more flanges as described above and/or one or more unitary webs and flanges as described above.

In this regard, according to one aspect of this invention there is provided a modular I-beam kit comprising a first flange as described above and a unitary web and second flange as described above, wherein the elongate free edge of the web is sized to fit snuggly within the channel of the first flange. In a related aspect, there is also provided a modular I-beam assembled from this kit, the free edge of the web being within the channel of the first flange, the web preferably being secured in place for example with adhesive and/or with one or more mechanical fixings such as nuts and bolts.

Similarly, according to another aspect of this invention there is provided a modular I-beam kit comprising a first flange as described above, a second flange as described above, and a separate web, a first elongate free edge of the web being sized to fit snuggly within the channel of the first flange and an opposed second elongate free edge of the web being sized to fit snuggly within the channel of the second flange. In a related aspect, there is also provided a modular I-beam assembled from this kit, the first free edge of the web being within the channel of the first flange and/or the opposed second free edge of the web being within the channel of the second flange, the web preferably being secured in place for example with adhesive and/or with one or more mechanical fixings such as nuts and bolts.

In the above kits and assembled I-beams, the web may have a shorter side and a substantially parallel longer side, the longitudinal length of the second flange being substantially the same as the length of one of the shorter or longer sides, the longitudinal length of the first flange being substantially the same as the length of the other of the shorter or longer sides. As discussed above, these embodiments are particularly useful where one side of the I-beam needs to be shorter so as to avoid contacting other structural components such as existing bridge rivets.

The present invention also extends to methods of assembling an I-beam using the kits described above.

In this regard, according to one aspect of this invention there is provided a method of assembling an I-beam using a kit that comprises a first flange as described above and a unitary web and second flange as described above, the method comprising placing the free edge of the web within the channel of the first flange, and preferably securing the web in place for example with adhesive and/or with one or more mechanical fixings such as nuts and bolts.

Similarly, according to another aspect of this invention there is provided a method of assembling an I-beam using a kit that comprises a first flange as described above, a second flange as described above, and a separate web as described above, the method comprising placing the first free edge of the web within the channel of the first flange and/or placing the opposed second free edge of the web within the channel of the second flange, and preferably securing the web in place for example with adhesive and/or with one or more mechanical fixings.

The above methods may comprise cutting to size one or more of: the first flange; the web; and the second flange, so as to provide a desired longitudinal length, height and/or width for the first flange, web and/or second flange. The web may have, or may be cut so as to have, a shorter side and a substantially parallel longer side, the longitudinal length of the second flange may be, or may be cut so as to be, substantially the same as the length of one of the shorter or longer sides, and the longitudinal length of the second flange may be, or may be cut so as to be, substantially the same as the length of the other of the shorter or longer sides. As discussed above, these embodiments are particularly useful where one side of the I-beam needs to be shorter so as to avoid contacting other structural components such as existing bridge rivets.

The present invention also extends to methods of manufacturing components for modular I-beams.

Thus, according to another aspect of the present invention there is provided a method of manufacturing a component for a modular I-beam, the method comprising: forming a flange as described above by pultrusion; and/or; forming a unitary web and flange as described above by pultrusion.

By way of example only, embodiments of the invention will now be described in detail with reference being made to the accompanying drawings in which: Figure 1 shows a modular I-beam kit according to an embodiment of the invention; Figure 2 shows a modular I-beam kit according to another embodiment of the invention; Figure 3 shows a cross-sectional view of an assembled modular I-beam according to an embodiment of the invention; Figure 4 is a side view of the assembled modular I-beam of figure 3; Figure 5 shows a use for an assembled I-beam according to an embodiment of the invention; Figure 6 shows an alternative use for a flange of a modular I-beam according to an embodiment of the invention; and Figure 7 shows the modular I-beam of Figure 5 and the flange of Figure 6 in use.

Figure 1 shows, in cross-section, a modular I-beam kit 100 that comprises a first flange 102 and a unitary web and second flange 110. The components of the kit 100 extend longitudinally into and out of the plane of the paper and are substantially uniform in cross-section. In this embodiment, the height of the I-beam, when assembled, can be up to 363 mm.

The plane of the web 114 is perpendicular to the plane of the second flange 112, with the web 114 meeting the second flange 112 along the longitudinal centreline of the plane of the second flange 112. The height of the I-beam can be reduced by cutting along the elongate free edge of the web 114.

The first flange 102 comprises two integral parallel elongate structures 108 which project perpendicularly from the plane of the first flange 102. The first flange 102 is 170mm wide and is 75 mm high from the face of the first flange 102 to the tips of the elongate structures 108. The elongate structures 108 form an elongate channel 106 that extends along the longitudinal centreline of the plane of the first flange 102. When the I-beam is assembled, the channel 106 receives the elongate free edge of the web 114. The flanges in this kit 100 are each 10mm thick and the elongate structures 108 in this kit 100 are 8mm thick.

The web in this kit 100 is 12.7 mm thick and so the channel 106 is 12.7 mm wide.

Figure 2 shows an alternative modular I-beam kit 200 that comprises first and second flanges 102, which are similar to the first flange 102 of figure 1, and a separate web 202. The web is again 12.7 mm thick and the assembled I-beam can be up to 363 mm high. When the I-beam is assembled, the channels 106 in the first and second flanges 102 receive respective elongate free edges of the web 202. The height of the I-beam can be reduced by cutting along either or both of the elongate free edges of the web 202.

As will be discussed in more detail below, the components of the kits described above are formed by pultrusion from glass fibre reinforced plastic (GRP).

Figures 3 and 4 show the modular I-beam kit 100 of figure 1 when assembled. Figure 3 is a cross-sectional view of the I-beam through line A-A of figure 4. The I-beam is secured together using a series of bolts 302 and nuts 304 distributed along the longitudinal length of the elongate structures 108 of the first flange 102. Adhesive may also be placed in the channel 106 prior to assembly.

Figure 5 shows a use for the assembled I-beam of figures 3 and 4. The first flange 102 of the I-beam is fixed to a construction component 300 using a series of pairs of bolts 302 and nuts 304 which are distributed along the longitudinal length of the first flange 102 on either side of the elongate structures 108 (only one pair of bolts 302 and nuts 304 of the series is shown).

In this embodiment, the construction component 300 is a GRP slab.

Figure 6 shows an alternative use for the first flange 102 of the modular I-beam kit 100 of figure 1. In this embodiment, the first flange 102 is secured to an existing structural steel flange 400 of a railway bridge using a series of bolts 302 and nuts 304 distributed along the longitudinal length of the elongate structures 108 of the first flange 102 (only one bolt 302 and nut 304 of the series is shown). The I-beam is again fixed to the construction component 300 using a series of pairs of bolts 302 and nuts 304 which are distributed along the longitudinal length of the first flange 102 on either side of the elongate structures 108 (again only one pair of bolts 302 and nuts 304 of the series is shown).

Figure 7 shows the arrangements of figures 5 and 6 when used to reinforce the sides of a railway bridge. Railway bridges are typically constructed from a U-shaped channel which is filled with ballast, with the railway track being placed on top of the ballast. To reinforce or inspect such a railway bridge, the ballast can be removed so as to expose the side walls of the U-shaped channel.

Then a first flange 102 can be secured to the inward-facing free edge of any existing structural steel webs 400 (see also figure 6). One or more modular I-beams can also be cut to size and the second flanges 112 of those I-beams can be placed so as to contact an inward-facing side wall of the U-shaped channel.

In the embodiment of figure 7, the unitary web and flange 110 is also cut so as to have a shorter side that contacts the inward-facing side wall of the U-shaped channel. The shorter side is provided so that the unitary web and flange 110 does not contact the existing rivets of the railway bridge. The first flanges 102 can then be secured to a GRP slab 300 (see also figures 5 and 6) and the U- shaped channel can be re-filled with ballast. The GRP slab 300 and modular I-beams retain the ballast and redistribute the weight of the ballast across the walls of the U-shaped channel.

A method of manufacturing the components for the modular I-beams described above will now be described. First, glass fibres are grouped together into rovings/mats. The rovings/mats are then pulled through a resin bath. The resin coated rovings/mats are then pulled through guides and into a chamber where the resin is cured. The cured component is then pulled through a die which has an opening that is the same shape as the cross-section of the component.

Claims

CLAIMS1. A flange for a modular I-beam, the flange being of unitary construction and having two parallel elongate structures that project perpendicularly from the plane of the flange, an elongate channel for receiving a web of the modular I-beam being formed by the two elongate structures.
2. A flange as claimed in claim 1, wherein the channel is located substantially along a longitudinal centreline of the plane of the flange.
3. A flange as claimed in claim 1 or 2, wherein the flange is formed from pultruded material.
4. A flange as claimed in claim 1, 2 or 3, wherein the flange is formed from fibre reinforced plastic, such as glass fibre reinforced plastic.
5. A web and flange for a modular I-beam, the web and flange together being of unitary construction, the plane of the web being perpendicular to the plane of the flange, the web having an elongate free edge for receipt within an elongate channel.
6. A web and flange as claimed in claim 5, wherein the web meets the flange substantially along a longitudinal centreline of the plane of the flange.
7. A web and flange as claimed in claim 5 or 6, wherein the web and flange are formed from pultruded material.
8. A web and flange as claimed in claim 5, 6 or 7, wherein the web and flange are formed from fibre reinforced plastic, such as glass fibre reinforced plastic.
9. A web and flange as claimed in any one of claims 5-8, the web having a shorter side and a substantially parallel longer side, the longitudinal length of the flange being substantially the same as the length of one of the shorter or longer sides.
10. A modular I-beam kit comprising: a first flange as claimed in any one of claims 1 -4; and a unitary web and second flange as claimed in any one of claims 5-9; wherein the elongate free edge of the web is sized to fit snuggly within the channel of the first flange.
11. A modular I-beam assembled from the kit of claim 10, the free edge of the web being within the channel of the first flange, the web preferably being secured in place for example with adhesive and/or with one or more mechanical fixings.
12. A modular I-beam kit comprising: a first flange as claimed in any one of claims 1-4 and a second flange as claimed in any one of claims 1-4; and a separate web, a first elongate free edge of the web being sized to fit snuggly within the channel of the first flange and an opposed second elongate free edge of the web being sized to fit snuggly within the channel of the second flange.
13. A modular I-beam assembled from the kit of claim 12, the first free edge of the web being within the channel of the first flange and/or the opposed second free edge of the web being within the channel of the second flange, the web preferably being secured in place for example with adhesive and/or with one or more mechanical fixings.
14. A modular I-beam kit as claimed in claim 10 or 12 or the modular I-beam as claimed in claim 11 or 13, the web having a shorter side and a substantially parallel longer side, the longitudinal length of the second flange being substantially the same as the length of one of the shorter or longer sides, the longitudinal length of the first flange being substantially the same as the length of the other of the shorter or longer sides.
15. A method of assembling an I-beam using the kit of claim 10, the method comprising placing the free edge of the web within the channel of the first flange, and preferably securing the web in place for example with adhesive and/or with one or more mechanical fixings.
16. A method of assembling an I-beam using the kit of claim 12, the method comprising placing the first free edge of the web within the channel of the first flange and/or placing the opposed second free edge of the web within the channel of the second flange, and preferably securing the web in place for example with adhesive and/or with one or more mechanical fixings.
17. A method as claimed in claim 15 or 16, comprising cutting to size one or more of: the first flange; the web; and the second flange, so as to provide a desired longitudinal length, height and/or width for the first flange, web and/or second flange.
18. A method as claimed in claim 15, 16 or 17, wherein the web has, or is cut so as to have, a shorter side and a substantially parallel longer side, the longitudinal length of the second flange being, or being cut so as to be, substantially the same as the length of one of the shorter or longer sides, the longitudinal length of the second flange being, or being cut so as to be, substantially the same as the length of the other of the shorter or longer sides.
19. A method of manufacturing a component for a modular I-beam, the method comprising: forming a flange as claimed in any one of claims 1-4 by pultrusion; and/or; forming a unitary web and flange as claimed in any one of claims 5-9 by pultrusion.
20. A flange for a modular I-beam substantially as hereinbefore described with reference to and as illustrated in one or more of figures 1-7.
21. A unitary web and flange for a modular I-beam substantially as hereinbefore described with reference to and as illustrated in one or more of figures 1-7.
22. A modular I-beam kit substantially as hereinbefore described with reference to and as illustrated in one or more of figures 1-7.
23. A modular I-beam substantially as hereinbefore described with reference to and as illustrated in one or more of figures 1-7.
24. A method of assembling an I-beam substantially as hereinbefore described with reference to and as illustrated in one or more of figures 1-7.
25. A method of manufacturing a component for a modular I-beam substantially as hereinbefore described with reference to and as illustrated in one or more of figures 1-7.