US20080028720A1 - An Improved Beam - Google Patents

An Improved Beam Download PDF

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Publication number
US20080028720A1
US20080028720A1 US10/561,185 US56118504A US2008028720A1 US 20080028720 A1 US20080028720 A1 US 20080028720A1 US 56118504 A US56118504 A US 56118504A US 2008028720 A1 US2008028720 A1 US 2008028720A1
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United States
Prior art keywords
web
flange
hollow
flanges
beams
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Abandoned
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US10/561,185
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Inventor
Ross John Bartlett
Ross Ian Dempsey
Russell Lambert Watkins
Alexander Noller
Keiji Yokoyama
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Litesteel Products Pty Ltd
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Smorgon Steel LiteSteel Products Pty Ltd
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Assigned to SMORGON STEEL TUBE MILLS PTY LTD reassignment SMORGON STEEL TUBE MILLS PTY LTD ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DEMPSEY, ROSS I., YOKOYAMA, KEIJI, NOLLER, ALEXANDER, WATKINS, RUSSELL LAMBERT, BARTLETT, ROSS JOHN
Assigned to LITE STEEL TECHNOLOGIES PTY LTD reassignment LITE STEEL TECHNOLOGIES PTY LTD ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SMORGON STEEL TUBE MILLS PTY LTD, TUBE TECHNOLOGY PTY LTD
Assigned to SMORGON STEEL TUBE MILLS PTY LTD reassignment SMORGON STEEL TUBE MILLS PTY LTD CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: PALMER TUBE MILLS (AUST) PTY LTD
Assigned to SMORGON STEEL LITESTEEL PRODUCTS PTY LTD reassignment SMORGON STEEL LITESTEEL PRODUCTS PTY LTD CORRECTIVE ASSIGNMENT TO CORRECT THE SERIAL NUMBER LISTED ON THE CHANGE OF NAME PREVIOUSLY RECORDED ON REEL 019007 FRAME 0515. ASSIGNOR(S) HEREBY CONFIRMS THE SERIAL NUMBER LISTED ON THE CHANGE OF NAME SHOULD BE 10561185. Assignors: LITE STEEL TECHNOLOGIES PTY LTD
Publication of US20080028720A1 publication Critical patent/US20080028720A1/en
Abandoned legal-status Critical Current

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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/29—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces built-up from parts of different material, i.e. composite structures
    • E04C3/292—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces built-up from parts of different material, i.e. composite structures the materials being wood and metal
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
    • E04B5/10—Load-carrying floor structures formed substantially of prefabricated units with metal beams or girders, e.g. with steel lattice girders
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
    • E04C3/06—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal with substantially solid, i.e. unapertured, web
    • E04C3/07—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal with substantially solid, i.e. unapertured, web at least partly of bent or otherwise deformed strip- or sheet-like material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C2003/023—Lintels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
    • E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
    • E04C2003/0408—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by assembly or the cross-section
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
    • E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
    • E04C2003/0408—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by assembly or the cross-section
    • E04C2003/0413—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by assembly or the cross-section being built up from several parts
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
    • E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
    • E04C2003/0408—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by assembly or the cross-section
    • E04C2003/0421—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by assembly or the cross-section comprising one single unitary part
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
    • E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
    • E04C2003/0426—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by material distribution in cross section
    • E04C2003/0439—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by material distribution in cross section the cross-section comprising open parts and hollow parts
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
    • E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
    • E04C2003/0443—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by substantial shape of the cross-section
    • E04C2003/0452—H- or I-shaped
    • E04C2003/0456—H- or I-shaped hollow flanged, i.e. "dogbone" metal beams
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
    • E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
    • E04C2003/0443—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by substantial shape of the cross-section
    • E04C2003/0473—U- or C-shaped
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49616—Structural member making
    • Y10T29/49623—Static structure, e.g., a building component
    • Y10T29/49634—Beam or girder

Definitions

  • This invention is concerned with improvements in structural beams.
  • the invention is concerned particularly, although not exclusively, with a hollow flanged channel wherein opposed hollow flanges along opposite sides of a web extend away from the web in the same direction.
  • United States Design Patents 27394 and 28864 illustrate early forms of an I-beam and C-channel respectively while United States Patent 426558 illustrates early forms of hollow flanged beams, possibly made by a casting process.
  • U.S. Pat. No. 1,377,251 is indicative of a cold roll forming process of a hollow flanged trough channel
  • U.S. Pat. No. 3,199,174 describes a method of fabrication and reinforcement of I-shaped beams by welding together separate strips of metal.
  • U.S. Pat. No. 4,468,946 describes a method for fabrication of a beam having a lambda-shaped cross-section by bending a sheet of metal
  • U.S. Pat. No. 4,433,565 describes the manufacture by cold or hot shaping of metal members having a variety of cross-sectional shapes.
  • U.S. Pat. No. 5,692,353 describes a composite beam comprising cold rolled triangular hollow section flanges separated by spaced wooden blocks for use as prefabricated roof and floor trusses.
  • United Kingdom Patent Application GB 2 093 886 describes a cold rolled roofing purlin having a generally J-shaped cross-section
  • United Kingdom Patent Application GB 2 102 465 describes an I- or H-section beam rolled from a single strip of metal.
  • International Publication WO 96/23939 describes a C-section purlin for use in a roof supporting building
  • U.S. Pat. No. 3,256,670 describes a sheet metal joist having a double thickness web with hollow flanges, the web and the flanges being perforated to allow the joist to be incorporated into a cast concrete floor structure.
  • U.S. Pat. No. 6,436,552 describes a cold roll formed thin sheet metal structural member having hollow flanges separated by a web member. This member is intended to function as a chord member in a roof truss or floor joist.
  • Hollow flanged I-beam-like structures with fillet welded connections between the flanges and the web are described in U.S. Pat. No. 3,517,474 and Russian Inventor's Certificate 827723.
  • An extruded aluminium beam shown in Swedish Publication Number 444464 is formed with a ribbed planar web with hollow rectangular flanges protruding from one web face, the hollow flanges being formed by U-shaped extrusions which clip into spaced receiving ribs formed on one face of the web.
  • U.S. Pat. No. 3,698,224 discloses the formation of H- and I-beams and a channel section with hollow flanges by deforming welded seam steel tubing to form a double thickness web between spaced hollow flanges.
  • U.S. Pat. Nos. 6,115,986 and 6,397,550 and Korean Patent Application KR 2001077017 A describe cold roll formed thin steel structural members having hollow flanges with a lip extending from each flange being secured against the face of the web by spot welds, rivets or clinches.
  • the beams described in U.S. Pat. Nos. 6,115,986 and 6,397,550 are employed as wall studs which enable cladding to be secured to the hollow flanges by screws or nails.
  • British Patent No GB 2 261 248 describes hollow flanged torsion resistant ladder stiles formed by extrusion or cold roll forming.
  • U.S. Pat. No. 6,591,576 discloses a hollow flanged channel shaped structural member with a cross-sectionally curved web shaped by press forming to produce a longitudinally arcuate bumper bar reinforcing member for a motor vehicle.
  • 5,501,053 which taught a hollow flange beam with a slotted aperture extending longitudinally of at least one flange to permit telescopic engagement of a flange of one hollow flange beam within a hollow flange of an adjacent beam for use in structural applications as piling, walling, structural barriers or the like.
  • a hollow flange beam is formed as a channel section to act as upper and lower chords of a truss beam with a fabricated web structure secured in the channelled recess in the chord members.
  • the assignee of the present invention is successor in title to the “Dogbone” dual weld hollow flange beam inventions and has conducted an exhaustive survey into actual costs of incorporating a “Dogbone”-type beam into a structure with a view to designing a hollow flange dual welded cold rolled general purpose beam which, between manufacture, handling and transportation and ultimate incorporation in a structure, was more cost effective in a holistic sense than any of the prior art conventional general purpose beams which otherwise overcame several recognized disadvantages in the “Dogbone” beam, namely, connectivity and a capacity for flange crushing with localized loads.
  • a conjoint research methodology was developed to measure the individual product attribute utility for various beam profiles with builders, engineers and architects. These key attributes were then assigned values to produce a utility rating from which a customer value analysis for various types of beams could enable a direct comparison based on many product attributes other than merely cost/unit mass and section efficiency. From this customer value utility analysis, a range of dual welded hollow flange beam configurations in both mild steel and thin gauge high strength steel were devised as potential replacements for hot rolled steel beams such as I- and H-beams and hot rolled channel as well as laminated timber beams.
  • a channel-shaped structural beam comprising:
  • hollow parallel sided flanges extending parallel to each other perpendicularly from a plane of said web along opposite sides thereof, said hollow flanges both extending in the same direction away from said plane of said web, said beam characterized in that a ratio of the width of each said flange between opposite end faces thereof in a direction perpendicular to said plane of said web and the depth of said beam between opposite outer faces of said flanges is in the ratio of from 0.2 to 0.4.
  • the ratio of the width of each said flange to the depth of each said flange is in the range of from 1.5 to 4.00.
  • the ratio of the width of the flange to the thickness of the web is in the range of from 15 to 50.
  • the ratio of said width of each said flange and the depth of said flange is in the range of from 2.5 to 3.5.
  • the ratio of said width of each said flange and said depth of each said flange is in the range of from 2.8 to 3.2.
  • the ratio of the width of each said flange to the depth of said beam may be in the ratio of from 0.25 to 0.35.
  • the ratio of the width of each said flange to the depth of said beam is in the range of from 0.28 to 0.32.
  • the ratio of the width of the flange to the thickness of the web may be in the range of from 25 to 35.
  • the ratio of the width of the flange to the thickness of the web is in the range of from 28 to 32.
  • said beam is fabricated from steel.
  • said beam is fabricated from high strength steel greater than 300 MPa.
  • said beam may be fabricated from stainless steel.
  • the beam may be fabricated from a planar web member with a hollow tubular member continuously welded along opposite sides of said web member to form hollow flanges, each said hollow flange having an end face lying substantially in the same plane as an outer face of said web member.
  • said beam is fabricated from a single sheet of steel.
  • said beam may be fabricated by a folding process.
  • said beam may be fabricated by a roll forming process.
  • free edges of hollow flanges are continuously seam welded to an adjacent web portion to form closed hollow flanges.
  • Said free edges of said hollow flanges may be continuously seam welded to said one face of said web intermediate opposite edges of said web.
  • said free edges of said hollow flanges may be continuously seam welded along respective side boundaries of said web.
  • said structural beam is fabricated in a continuous cold rolling process.
  • said free edges of said hollow flanges are continuously seam welded by a non-consumable electrode welding process.
  • said free edges of said hollow flanges are continuously seam welded by a consumable electrode process.
  • said free edges of said hollow flanges are continuously seam welded by a high frequency electrical resistance welding or induction welding process.
  • said structural beams may be fabricated from sheet steel having a corrosion resistant coating.
  • said structural beams may be coated with a corrosion resistant coating subsequent to welding of said free edges of said flanges.
  • said flange may include one or more stiffening ribs.
  • said web may include stiffening ribs.
  • the stiffening ribs may extend longitudinally of said web.
  • stiffening ribs may extend transversely of said web.
  • FIG. 1 shows a typical configuration of a structural beam according to the invention
  • FIG. 2 shows schematically a cross-sectional view of the hollow flange beam of FIG. 1 ;
  • FIG. 3 shows schematically an alternative embodiment of a fabricated beam
  • FIG. 4 shows a further embodiment of a fabricated beam
  • FIG. 5 shows one configuration of a cold roll formed beam according to the invention
  • FIG. 6 shows an alternative configuration of a roll formed beam according to the invention
  • FIG. 7 shows graphically a comparison of section capacity for HFC (Hollow flange channels) according to the invention
  • UB Hot rolled Universal beam of I-section
  • LUB Low mass hot rolled Universal beams of I-cross-section
  • PFC Hot rolled channels
  • CFC Cold rolled C-sections
  • HFB Hollow flange beams of “Dogbone” configuration i.e., triangular section flanges
  • FIG. 9 shows schematically the configuration of a roll forming mill
  • FIG. 10 shows schematically a flower sequence for direct forming a beam according to one aspect of the invention
  • FIG. 11 shows schematically a flower sequence for forming and shaping a beam according to another aspect of the invention.
  • FIG. 12 shows schematically a cross-sectional view through the seam roll region 17 of the welding station 12 ;
  • FIG. 13 shows schematically a cross-sectional view though the squeeze roll region 18 welding station 12 at the point of closure of the flanges;
  • FIG. 14 shows schematically a forming station
  • FIG. 15 shows schematically a drive station
  • FIG. 16 shows schematically a configuration of shaping rolls in a shaping station
  • FIGS. 17-21 illustrate the flexibility of beams according to the invention
  • FIG. 22 shows a hollow flanged beam with a reinforced flange and a reinforced web
  • FIG. 23 shows an alternative embodiment of FIG. 22 .
  • the beam 1 comprises a central web 2 extending between hollow flanges 3 having a rectangular cross-section.
  • the opposite sides 4 , 5 of each flange 3 are parallel to each other and extend away from web 2 in the same direction perpendicular to the plane of web 2 .
  • End faces 6 , 7 of flanges 3 are parallel to each other and end face 6 lies in the same plane as web 2 .
  • FIG. 2 shows a cross-sectional view of the beam of FIG. 1 to demonstrate the relationship between the width Wf of the flanges 3 , the depth Df of the flanges, the depth Db of the beam and the thickness t of the steel from which the beam is fabricated.
  • FIG. 3 shows schematically a structural beam according to the invention wherein the beam 1 is fabricated from separate web and flange elements 2 , 3 respectively.
  • Web 2 is continuously seam welded along its opposite edges to radiussed corners 3 a at the junction between sides 5 and end faces 6 .
  • Weld seam 8 may be formed in a continuous operation by high frequency electrical resistance or induction welding. Alternatively, in a semi-continuous operation, the weld seam 8 may be formed utilizing a consumable welding electrode in a MIG, TIG, SMAW, SAW GMAW, FCAW welding process laser or plasma welding or the like. Where a semi-continuous consumable welding electrode process is utilized, it is considered that a post welding rolling or straightening process may be required to remove thermally induced deformations.
  • the continuous weld seam 8 is a full penetration weld which creates an integrally formed planar web member 2 extending between outer sides 4 of flanges 3 .
  • a beam Whilst semi-continuous fabrication is quite inefficient compared with a continuous cold rolling process, it may be cost efficient for a short run of a specially dimensioned non-standard beam.
  • fabrication of a beam from separate preformed web and flange elements permits the use of elements of differing thickness and/or strength.
  • such a beam may comprise flanges of a thick high strength steel and a web of thinner lower grade steel.
  • FIG. 4 shows an alternative process for fabrication of discrete beam lengths by shaping the hollow flanged beam from a single strip of metal by folding in a press brake or the like (not shown).
  • a closed flange may be formed by progressively folding side 5 relative to end face 7 , then folding end face 7 relative to side 4 and then finally folding side 4 relative to web 2 until a free edge 5 a contacts an inner surface 2 a of the channel-like beam so formed.
  • a full penetration weld seam 8 is then formed between free edge 5 a and web 2 to form a unitary structure, again with a continuous planar web member 2 extending between outer sides 4 of flanges 3 .
  • FIG. 5 shows one configuration of a beam according to the invention when made by a continuous cold rolling process, which process is preferred because of its high cost efficiency and the ability to maintain small dimensional tolerances to produce beams of consistent quality.
  • the end faces 7 of hollow flanges 3 are formed as radiussed curves.
  • the section efficiency of this configuration is inferior to a rectangular cross-section flange although there may be applications for this cross-sectional configuration.
  • it may be shaped further to form a flat end face with radiussed curves.
  • a full penetration weld seam 8 is formed between the free edges 5 a of sides 5 and an inner surface 2 a of web 2 by a high frequency electrical resistance or induction welding process as described generally in U.S. Pat. No. 5,163,225.
  • the resultant beam is an integrally formed member which relies upon the ability to transmit load between outer flange sides 4 via a continuous web element 2 extending therebetween.
  • FIG. 6 illustrates an alternative technique for forming a cold rolled beam according to the invention.
  • a free edge 6 a of end face 6 of hollow flange 3 is welded to the radiussed junction 10 between web 2 and side 5 by high frequency electrical resistance or induction welding to form a full penetration weld seam 8 which effectively creates a substantially continuous planar outer surface 2 b of a load bearing element comprising end faces 6 and web 2 whereby the load bearing element extends between outer flange sides 4 .
  • the lack of smoothness in the curves for all but hot rolled channel sections arises from the selection of a variety of web depths and flange widths which manifests with overlapping values for each section on an increasing mass based axis.
  • hot rolled universal beams (UB), low mass universal beams (LUB) and hot rolled channels (PFC) are quite inferior to cold rolled C-shaped purlin sections (CFC) and hollow flanged (HFB) beams such as the “Dogbone” beam with triangular-shaped flanges and the hollow flange channels (HFC) according to the present invention.
  • CFC cold rolled C-shaped purlin sections
  • HFB hollow flanged
  • the graphs clearly illustrate the superior section capacity of the HFC hollow flange channel over all other comparable beams and exhibits superior moment capacity over longer lengths.
  • the attributes of the hollow flange channel over the compared standard sections generate a utility rating which is surprisingly superior to the UB and LUB hot rolled I-beams and the HFB triangular hollow flange “Dogbone” beams.
  • the aggregated utility scores for the HFC beam were about 2.5 times that of the UB hot rolled I-beam at a 60% price premium over the UB hot rolled beam.
  • Table 3 represents a utility value comparison with laminated timber beams wherein the aggregate utility value of HFC hollow flange channels according to the invention were about 2.5 times that of the laminated timber beams.
  • FIG. 9 shows schematically a typical configuration of a roll forming mill which may be employed in the manufacture of hollow flange beams according to the invention and as exemplified in FIGS. 5 and 6 .
  • the mill comprises a forming station 11 , a welding station 12 and a shaping station 13 .
  • Forming station 11 comprises alternative drive stands 14 and forming roll stands 15 .
  • Drive stands 14 are coupled to a conventional mill drive train (not shown) but instead of employing contoured forming rolls to assist in the forming process, plain cylindrical rolls are employed to grip steel strip 16 in a central region corresponding to the web portion of the resultant beam.
  • the forming roll stands 15 are formed as separate pairs 15 a , 15 b each equipped with a set of contoured rollers adapted to form a hollow flange portion on opposite sides of the strip of metal 16 as it passes through the forming station.
  • forming roll stands 15 a , 15 b do not require coupling to a drive train as in conventional cold roll forming mills, forming roll stands 15 a , 15 b are readily able to be adjusted transversely of the longitudinal axis of the mill to accommodate hollow flange beams of varying width.
  • the formed strip 16 When formed to a desired cross-sectional configuration, the formed strip 16 enters the welding station 12 wherein the free edges of respective flanges are guided into contact with the web at a predetermined angle in the presence of a high frequency electrical resistance or inductor welding (ERW) apparatus.
  • ERW electrical resistance or inductor welding
  • the formed strip is directed through seam guide roll stands 17 into the region of the ERW apparatus shown schematically at 17 a. After the flange edges and the weld seam line on the web are heated to fusion temperature, the strip passes through squeeze roll stands 18 to urge the heated portions together to fuse closed flanges.
  • the welded hollow flange section then proceeds through a succession of drive roll stands 19 and shaping roll stands 20 to form the desired cross-sectional shape of the beam and finally through a conventional turk's head roll stand 21 for final alignment and thence to issue as a dual welded hollow flange beam 22 according to the invention.
  • the high frequency ERW process induces a current into the free edges of the strip and respective adjacent regions of the web due to a proximity effect between a free edge and the nearest portion of the web. Because the thermal energy in the web portion is able to dissipate bi-directionally compared with a free edge of the flange, additional energy is required to induce sufficient heat into the web region to enable fusion with the free edge.
  • the “sweeping” effect caused by the rotation of the flange in the squeeze rolls of the welding station avoided the problem of inducing heat into an unnecessarily wide path extending away from the desired weld line as the free edge swept into alignment with the desired weld line.
  • FIGS. 10 and 11 show typical flower shapes for the forming, welding and shaping of hollow flange beams as illustrated in FIGS. 5 and 6 respectively.
  • the flower shape leading to the configuration shown in FIG. 6 is preferred in practice as there is less of a tendency to accumulate mill coolant fluid in the channel between the hollow flange sections in the region of the welding station.
  • visibility of the weld to the mill operator is improved.
  • the problems posed by accumulation of mill coolant in the region of the flange seam welds may be overcome by providing suction nozzles and/or mechanical or air curtain wiper blades to keep the weld seams clear of coolant in the induction region of the welding station.
  • Another alternative is to invert the section profile and form the weld seam under the web outer surface.
  • a still further alternative is to operate the rolling mill with the beam web oriented in a vertical or upright position.
  • FIG. 10 shows schematically the development of a hollow flange in a cold roll forming operation by what is known as a direct forming process through an entry point where the flat steel strip 30 enters the mill and a final stage 10 at which edge welding occurs. While not impossible to weld in a continuous cold roll forming process, maintenance of weld stability and section shape is very difficult.
  • Direct formed hollow flange beams of this type may be welded by a consumable electrode process either during the roll forming process or subsequently utilizing automated or semi-automated processes and/or low cost labour. With consumable electrode welding processes, a post welding straightening process is likely to be required to remove warping and local deformations due to the greater heat input. Whether an automated, semi-automated or manual welding process is employed, it is important to employ a continuous weld seam to close the hollow flange formations in order to maintain the greatest structural integrity of the beam so formed.
  • welding is effected at the final stage illustrated and the subsequent processing through the shaping section of a mill merely effects a straightening of any warpage or deformations.
  • FIG. 11 a shows a flower representing the progression of planar steel strip 30 through the forming section of a cold roll forming mill between an entry point through to the edge seam alignment in the welding station just prior to entry into the squeeze rolls of the mill where the free edges of the flanges are brought into contact along the respective side boundaries of web 2 .
  • FIG. 11 b shows a flower progression from the squeeze roll stand in the welding station through the shaping station to the turk's head final straightening.
  • FIG. 12 shows schematically a seam roll stand 17 comprising a support frame 35 , a pair of independently mounted, contoured support rolls 36 , 36 a each journalled for rotation about aligned rotational axes 37 , 37 a and seam guide rolls 38 , 38 a rotatably journalled on respective inclined axes 39 , 39 a.
  • Seam guide rolls 38 , 38 a serve to guide the free edges 16 a , 16 b of strip 16 into longitudinal alignment with a desired weld seam line as the shaped strip 16 approaches the squeeze roll region of the welding station.
  • FIG. 13 shows schematically the squeeze roll stand 18 comprising a cylindrical top roll 40 and a cylindrical lower roll 41 with contoured edges 41 a, each of rolls 40 , 41 being rotatably journalled about respective rotational axes 42 , 43 .
  • Squeeze rolls 44 a, 44 b, rotatable about respective inclined axes 45 a , 45 b are adapted to urge the heated free edges 16 a , 16 b of hollow flanges 3 into respective heated weld line regions along the opposed boundaries of web 2 to effect fusion therebetween to create a continuous weld seam.
  • the free edges 16 a , 16 b are urged toward respective weld lines in a linear fashion perpendicular to the respective rotational axes 45 a , 45 b of squeeze rolls 44 a , 44 b without a transverse “sweeping” action thereby maintaining stable induction “shadows” or pathways on or at the desired position of the weld seams between respective free edges 16 a , 16 b and the opposed boundaries of web 2 .
  • FIG. 13 a shows schematically in phantom an enlarged perspective view of the relationship of the squeeze rolls 44 a , 44 b to upper and lower support rolls 40 , 41 as the free edges 16 a , 16 b of strip 16 are guided into fusion with the boundaries of web 2 .
  • lower support roll 41 is illustrated as separately journalled roll elements, each with a contoured outer edge 41 a.
  • FIG. 14 shows schematically a shaping roll stand 50 comprising independent shaping roll stands 51 slidably mounted on a mill bed 52 .
  • Roll stands 51 each support a complementary pair of shaping rolls 53 , 54 to progressively impart shape to the outer edge regions of steel strip 16 as illustrated generally by the forming flower pattern illustrated in FIG. 11 a.
  • shaping rolls 53 , 54 are undriven idler rolls.
  • FIG. 15 shows schematically a drive roll stand 60 which may be employed with either of the forming station 11 or shaping station 13 as shown in FIG. 9 .
  • Drive roll stand comprises spaced side frames 61 mounted on a mill bed 61 a, the side frames 61 rotatably supporting upper and lower driven shafts 62 , 63 on which are mounted cylindrical drive rolls 64 , 65 respectively to engage the upper and lower surfaces of the web portion 2 of a hollow flanged member as it is guided through the forming and shaping regions of the cold rolling mill shown generally in FIG. 9 .
  • Universal joints 66 , 67 couple driven shafts 62 , 63 to output shafts 68 , 69 of a conventional mill drive train (not shown).
  • the roll stand 60 may be fitted with strip edge rolls 70 , 71 to maintain alignment of strip 16 through the mill.
  • the edge rolls may be plain cylindrical rolls or they may be contoured as shown.
  • Rolls 70 , 71 are adjustably mounted on roll stands 61 to accommodate hollow flange beams of varying widths.
  • FIG. 16 shows schematically a configuration of shaping rolls in a shaping mill stand.
  • Shaping of the flanges 3 is effected by a respective shaping roll set 75 positioned on each side of web 2 .
  • a flange 3 is subjected to shaping pressures from roller 76 mounted for rotation on a horizontal axis 81 , roller 77 mounted for rotation on a vertical axis 82 and roller 78 mounted for rotation on an inclined axis 83 .
  • FIG. 17 illustrates one application of beams according to the invention.
  • a pair of beams 90 can be secured back to back by any suitable fasteners such as a spaced nut and bolt combination 91 , a self-piercing clench fastener or the like 92 or a self-drilling self-tapping screw 93 through webs 90 a .
  • a support bracket 94 for a utilities conduit 95 may be secured to flange 96 with a screw 97 .
  • duct for cables may be formed by securing a metal channel section 98 to a flange 99 by a screw 100 or the like to form a hollow cavity 101 to enclose electrical or communications cables 102 .
  • FIG. 18 shows a hollow flange channel 103 functioning as a floorjoist.
  • Floorjoint 103 is supported on another hollow flange channel 104 functioning as a bearer.
  • Timber flooring 105 is secured to an upper flange 106 by a nail 107 or the like.
  • the intersection of respective flanges 106 , 108 of hollow flange channels is secured by an angle bracket 109 anchored by screws 110 to respective adjacent flanges 106 , 108 .
  • FIG. 19 shows a composite structure 115 in the form of a hollow flange channel 111 and an angle section 112 secured thereto by a screw 113 or the like.
  • Composite structure 115 thus can act as a lintel-like structure to support a door or window opening in a cavity brick structure whereby bricks 120 can rest upon angle section 112 but otherwise be secured to the web 114 of channel 111 by a brick tie 116 having a corrugated portion 116 a anchored in a mortar layer 117 and a mounting tab 116 b anchored to web 114 by a screw 118 .
  • FIG. 20 shows the formation of a cruciform joint between hollow flange channels according to the invention.
  • a hollow flange channel 120 may be secured perpendicular to an outer face 121 of a similar sized channel 122 by an angle bracket 123 secured to respective webs 124 , 125 by rivets, screws or any other suitable fasteners 126 .
  • a smaller hollow flange channel 127 is nestably located between the flanges 128 of channel 122 and is secured therein by an angle bracket 129 attached to webs 125 , 130 of channels 122 , 127 respectively by screws or other suitable fasteners 131 .
  • adjacent flanges 128 , 132 of channels 122 , 127 respectively could be attached by an angle bracket 133 secured by screws 134 .
  • adjacent flanges 128 , 132 could be secured by a screw-threaded fastener 135 extending between flanges 128 and 132 .
  • the hollow interior 128 a of the flanges may be employed as ducting for electrical cables 138 or the like.
  • FIG. 21 shows yet another composite beam 140 wherein a timber beam 141 is secured to an outer face of web 142 by mushroom headed bolts 148 and nuts 144 to increase section capacity and/or to provide a decorative finish.
  • hollow flange channel beams according to the invention not only provide an excellent moment capacity/mass per metre ratio compared with other structural beams, they offer ease of connectivity, ease of handling and flexibility in application which greatly enhances “usability”. Taking into account all of the factors which contribute to an in situ installation value or cost, hollow flange channel beams offer significant utility of up to 2.5 times conventional hot rolled beams and laminated timber beams and have moment capacities that permit superior performances over similar sized cold rolled open flange purlins over longer lengths.
  • FIG. 22 shows an alternative embodiment of the hollow flange beam according to the invention.
  • the beam is formed with longitudinally extending alternating ribs 150 and troughs 151 to provide greater resistance to longitudinal bending in web 2 .
  • flanges 3 may also have formed therein longitudinally extending stiffening ribs 152 .
  • FIG. 23 shows yet another embodiment of reinforced web hollow flange beam according to the invention.
  • transversely extending spaced ribs 153 provide greater resistance to transverse bending in web 2 .

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US10/561,185 2003-06-23 2004-06-23 An Improved Beam Abandoned US20080028720A1 (en)

Applications Claiming Priority (3)

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AU2003903142A AU2003903142A0 (en) 2003-06-23 2003-06-23 An improved beam
AU2003903142 2003-06-23
PCT/AU2004/000824 WO2004113637A1 (en) 2003-06-23 2004-06-23 An improved beam

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US12/555,877 Continuation US20100005758A1 (en) 2003-06-23 2009-09-09 Beam

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US12/555,877 Abandoned US20100005758A1 (en) 2003-06-23 2009-09-09 Beam
US13/048,706 Expired - Fee Related US8181423B2 (en) 2003-06-23 2011-03-15 Beam

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IL172543A (en) 2011-02-28
AU2003903142A0 (en) 2003-07-03

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