WO2016040984A1

WO2016040984A1 - A beam module for and method of assembly of composite beams

Info

Publication number: WO2016040984A1
Application number: PCT/AU2015/000561
Authority: WO
Inventors: John Preston
Original assignee: John Preston
Priority date: 2014-09-16
Filing date: 2015-09-15
Publication date: 2016-03-24
Also published as: AU2015318797A1

Abstract

A structural beam module manufactured from angle sections arranged so that the beam comprises top and bottom plates and end surfaces each formed from legs of said angle sections; the beam having a cubic generally elongated shape and including lengths of angle sections forming first and second end members which co operate with the top and bottom angle sections to define ends of the beam module; and intermediate the said first and second end members, at least one web member formed by angle sections which define beam depth; wherein at least the top, bottom and end plates include openings which receive fastening bolts to secure a like modular beam.

Description

A BEAM MODULE FOR AND METHOD OF ASSEMBLY OF

COMPOSITE BEAMS.

BACKGROUND

[0001] The present invention relates to a structural beam and a method of its use and manufacture. The invention has been primarily developed in order to produce a relatively light weight beam of substantially rectangular long-section for use in construction of temporary and pennanent structures. However, although the invention will be described with hereinafter with reference to these applications, it should be appreciated that the invention is not limited to this particular field of use. The invention further relates to a modular beam having a plurality of connecting faces which engage a modular beam of similar construction such that the span, width and height ( depth) of the beam can be selected depending upon structural requirements by connection of beam modules. The invention further relates to a space frame beam which is assembled from a plurality of plates and/or angle sections having arrays of bolt holes which allow connection of the beam to another beam via any face of the beam including side, ends bottom and top. The invention relates to beam construction - i.e. the construction of the particular beam and beam assembly in which the beams or beams are used to form a structure.

PRIOR ART

[0002] There are a variety of beam types used in construction. Such beams include those which are roll formed into various shapes such as channels, angles, box sections, and I beams. One example of a known, light weight construction beam, is produced by joining two roll formed channels of C-shaped cross section to form a beam of rectangular cross-section, sometimes called a box section when flanges oppose and an 1 section when webs oppose. One disadvantage associated with this known beam is that the two channels can slip relative to each other, which can lead to the beam: warping or losing strength. n extreme conditions, the two channels can kink and/or separate from one another, which generally results in the beam failing. Another disadvantage of this known beam is the complexity of construction in roll forming the two C-shaped channels; positioning the two channels in a press; and then performing a pressing operation to join the channels together.

[0003] Another known structural beam comprises a roll formed beam of substantially rectangular cross-section formed from a unitary piece of metal. The beam includes opposed first and second substantially parallel walls formed with at least three adjacent layers of the piece of metal; and opposed third arid fourth substantially parallel walls between the first and second walls, one of the third or fourth walls has a seam joining two opposed longitudinal edges of the piece of metal. The opposed first and second walls are formed with three adjacent layers of said piece of metal.

[0004] More commonly known beams include the widely used I beam which has opposing flanges separated by a web. Another beam used in the field is a standard box section which is roll formed. These are strong beams capable of relatively long spans when the web is deep enough. Another form of known beam is a truss or space frame which is made from a series of struts which are arranged to transmit loads through the beam. Truss beams have a high strength to weight ratio. Other known modular type beams are those which comprise planks which can be bolted together for use in such structures as temporary scaffolding. Construction sites require a variety of temporary structures which are used during construction and dismantled after use. This is a time consuming and costly part of any major building construction. Any streamlining or increased versatility of temporary constructions can result in labour and time savings ultimately reducing the costs of construction.

[0005] The aforesaid known methods and structures have been effective for their purposes but there is a need to further improve the versatility of beams and to provide an alternative to the known beams which are economic to manufacture, has a high strength to weight ratio and is versatile enough to combine with like beams via side end and top and bottom faces.

[0006] There is a long felt want to improve modular construction on building sites and in other applications to reduce time, labour costs and building costs generally. There is a need to improve the efficiency of temporary constructions and particularly those which employ structural members which must accommodate a variety of site construction requirements.

INVENTION

[0007] The present invention provides an alternative to the known prior art and the shortcomings identified. The foregoing and other objects and advantages will appear from the description to follow. In the description reference is made to the accompanying representations, which forms a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilised and that structural changes may be made without departing from the scope of the invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is best defined by the appended claims.

[0008] The examples referred to herein are illustrative and are not to be regarded as limiting the scope of the invention. While various embodiments of the invention will be described herein, it will be appreciated that these are capable of modification, and therefore the disclosures herein are not to be construed as limiting of the precise details set forth, but to avail such changes and alterations as fall within the purview of the description. It is an object of the present invention to substantially overcome or at least ameliorate one or more of the above prior art disadvantages. Accordingly, in a first aspect, the present invention provides a beam module for use in a structure made from one or a plurality of like or similar beam modules allowing ease of assembly and disassembly. In attempting to ameliorate or eliminate the prior art limitations and to provide a useful alternative to the known structural beams, the present invention seeks to provide a more efficient alternative modular beam which due to its modularity has the capability of engaging a similar beam module via one or more of its faces, enabling convenient increase in depth, width, length and therefore strength depending upon site and construction requirements.

[0009] It is one object of the present invention to increase the efficiency of beams and particularly a beam formed in the nature of a space frame to enable increased versatility in the use and inter connections of such beams improving strength depending upon the selection of inter engagements of one module with another. This allows for a variety of uses and improved strength to weight ratio.

[0010] In one broad form, the present invention comprises: a structural beam manufactured from angle sections arranged so that the beam comprises top and bottom and end surfaces which are arranged to define a cubic generally elongated shape;

first and second end members which co operate with the top and bottom angle sections to define ends of the beam,

intermediate the said first and second end members are at least one web member formed by angle sections which define beam depth; wherein at least the top, bottom and end plates include openings which receive fastening bolts to secure a like beam to at least one of said, top , bottom and end plates.

[0001 1] According to a preferred embodiment the beam is longer than it is deep and deeper than it is wide. Preferably the angle sections used in the construction of the beams are equal angles. Each connecting face of the beam is formed by one leg of an angle section. According to one embodiment, the width of the beam is equal to an outside length dimension of one leg of said angle section. There are openings in each face of each leg of each angle section, which are aligned along the length of each angle. The openings are disposed along a longitudinal mid line of each leg extending along the length of the angle. The beam comprises a first angle section of longitudinal extent having two equal legs, the first of said legs forming a top plate and the second of said legs forming part of a web of the beam. The beam comprises a first angle section of longitudinal extent having two equal legs, the first of said legs forming a bottom plate and the second of said legs forming part of the web of the beam.

[0012] The structural beam further comprises between the top and bottom plates, ends formed by short lengths of equal angle and web stiffeners. The web stiffeners comprise flat plate including a plurality of openings which enable connection of an adjacent beam. The structural beam can be arranged to form a T shape, square, rectangle.

[0013] According to another embodiment, structural beam comprises a composite beam formed by placing one beam module on top of another like beam module to form a deeper beam. A composite long span beam may be formed by joining beams end to end. A composite wider beam is formed by joining beams side by side.

[0014] In another broad form, the present invention comprises:

a structural beam of substantially rectangular cross-section manufactured from angle sections arranged end to end so that the beam comprises top, bottom plates and end plates; the top and bottom plates and end plates surfaces which are arranged to define a cubic elongated shape;

[0015] In another broad form, the present invention comprises:

a structural beam manufactured from angle sections arranged such that a like structural beam can be connected thereto, each said beam having a plurality of connecting faces which have openings which receive and retain fasteners for the purpose of connecting one beam to another like beam.

[0016] According to a preferred embodiment, the connecting faces of each beam include at least part of a top, bottom, end and side faces. The connecting faces are abutting parts and can comprise the whole dimension of each face.

[0017] In a broad form of the method aspect the present invention comprises:

a method of construction using a structural beam of substantially rectangular cross-section manufactured from angle sections arranged end to end so that the beam comprises top, bottom plates and end plates; the top and bottom plates and end plates surfaces which are arranged to define a cubic elongated shape;

intermediate the said first and second end members are at least one web member formed by angle sections which define beam depth; wherein at least the top, bottom and end plates include openings which receive fastening bolts to secure a like beam to at least one of said, top , bottom and end plates;

the method comprising the steps of;

a) taking a first beam and joining the beam to a corresponding face of a like second beam via a top, bottom, end or side face

b) inserting fasteners through openings in each beam which align when each said beams are engaged in opposing relationship. The method comprises the further optional step of joining at least one other beam to the first and/or second beam via top or bottom or side or end faces to form a higher or wider or longer beam made from a plurality of said beam modules. Additional angle section members are placed between the top and bottom plates to increase stiffness for the modular beam.

[0018] In another broad form of a method aspect, the present invention comprises:

a method of forming a beam of substantially rectangular cross-section from a plurality of angle or planar plate sections by welding or bolting the plates or angles.

[0019] In another broad form of the method aspect the present invention comprises:

the method comprising the steps of;

a) taking a first beam of a pre selected length, thickness and depth and securing the beam to a fixed support structure to form a beam span of predetermined length spanning a space between the support structure;

b) inserting fasteners through openings in the beam which align with corresponding openings in the structure at any location along the beam . [0020] The method comprises the further optional step of joining at least one other beam to the first and/or second beam via top or bottom or side or end faces to form a higher or wider or longer beam made from a plurality of said beam modules.

[0021] The present invention provides an alternative to the known prior art and the shortcomings identified. The foregoing and other objects and advantages will appear from the description to follow. In the description reference is made to the accompanying representations, which forms a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilised and that structural changes may be made without departing from the scope of the invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is best defined by the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The present invention will now be described in more detail according to a preferred but non limiting embodiment and by way of example only with reference to the accompanying drawings wherein;

[0023] Preferred embodiments of the invention will now be described, in relation to the accompanying drawings in which:

Figure. 1 shows a perspective view of one side of a modular beam according to a preferred embodiment.

Figure 2 shows a perspective view of the beam of figure 1 from an opposite side.

Figure 3 shows a perspective view of a wider span modular beam according to an alternative embodiment. Figure 4 shows a perspective view of the beam of figure 3 from an opposite side and rotated 180 degrees.

Figure. 5 shows a perspective view of the beam of figure 3 mounted on the beam of figure 4 via opposing respective top and bottom flanges .

Figure 6 shows a perspective view of the beam of figure 1 engaging the beam of figure 2 via opposing side faces.

Figure 7 shows a perspective view of the beam of figure 1 engaging end to end with the beam of figure 2.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0024] The examples referred to herein are illustrative and are not to be regarded as limiting the scope of the invention. While various embodiments of the invention have been described herein, it will be appreciated that these are capable of modification, and therefore the disclosures herein are not to be construed as limiting of the precise details set forth, but to avail such changes and alterations as fall within the purview of the description. Although the method and apparatus aspects of the invention will be described with reference to their application to heavy and light building construction, it will be appreciated that the invention has alternative applications.

[0025] The modular beam is able to span longer distances than a correspondingly sized beam and the beam has improved torsional rigidity compared to the known beams of a corresponding size. The beams can be produced by one person which results in lower labour costs, lower plant costs and reduced manual handling. The beams can be produced from a variety of materials, including aluminium, steel, pre coated metal products which require no further surface finishing, Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms. [0026] Figure. 1 shows a perspective view of one side of a modular beam

1 according to a preferred embodiment. Beam 1 is constructed as a space frame comprising top and bottom plates 2 and 3 respectively formed from equal angle sections. It will however, be appreciated by persons skilled in the art that a beam module according to the present invention could be constructed using unequal angles. Beam module 1 further comprises, end plates 4 and 5 and intermediate therebetween web plates 6, 7 and 8 which act as web stiffeners, contributing to bending and torsional force resistance.

[0027] Each of the aforesaid plates, are adapted with a plurality of like openings 9 which enable the beam to be connected to an adjacent beam using fasteners ( not shown) which penetrate openings 9. Typically fasteners used to connected beam modules are heavy duty mild steel bolts. Other forms of joining may be employed such as welding or clamping.

[0028] Openings 9 can be distributed according to particular requirements with the numbers depending upon the number of points of fixation required. In practice, it is expedient to manufacture the angle members with a plurality of openings so there are always a sufficient number even if there are redundant openings provided. Opening sizes can also be adjusted according structural requirements. Preferably, the plates used to construct the beam are equal angle sections, although beams constructed from unequal angles are feasible. The angle sections are arranged so that beam width is dictated by the length of one of the legs of the angle sections. The top and bottom plates

2 and 3 can be of any practical length and the depth to length ratio is variable according to particular structural requirement of the beam including those dictated by span and anticipated live and dead loads. Beam 1 is essentially a space frame of a predetermined length and depth which is reinforced by stiffeners 6, 7 and 8 which also function to transmit forces through a beam web formed by ends 4 and 5 and stiffeners 6, 7 and 8.

[0029] The beam is braced when in isolation by fastening bolts which connect the plates and web stiffeners. Bolting of connections between top and bottom plates, the end plates and webs maintains bracing and avoids the need for diagonal braces as would be found in a truss beam.

[0030] Figure 2 shows with corresponding numbering a perspective view of the beam 1 of figure 1 from an opposite side rotated 180 degrees. Webs 6, 7 and 8 are preferably formed from angle sections but fiat plates can be employed as an alternative.

[0031] Figure 3 shows a perspective view of a longer span beam 20 according to an alternative embodiment. Figure 4 shows a perspective view of the beam 20 of figure 3 from an opposite side and rotated 180 degrees. . Beam 20 is approximately twice the length of beam 1 and comprises a space frame comprising top and bottom plates 21 and 22 respectively, end plates 23 and 24 and intermediate therebetween web plates 25, 26 and 27. Each of the angle or plate sections are adapted with a plurality of like openings 28 distributed along the length of each member and which enable the beam to be connected to an adjacent beam, via top and bottom, end to end or side by side. Openings 28 can be distributed according to particular requirements with the numbers depending upon the number of points of fixation required.

[0032] Figure. 5 shows with corresponding numbering a perspective view of the beam of figure 3 mounted on the beam view of figure 4 via opposing respective top and bottom flanges. This shows that one beam in one orientation can be connected to a like beam in an opposite orientation. Likewise two like beams in the same orientation can be connected one on top of the other. The engagement shown shows asymmetry about an engaging centre of span axis, but according to an alternative embodiment top and bottom beams would show a mirror image about that axis. An asymmetrical engagement of one beam to another would contribute to a centre of gravity of the composite beam along a central axis. This would avoid eccentricities and unwanted torsional movements when beams are under load. One beam module can engage a like beam in a variety of orientations. Engaging beams can be in alignment vertically ( lying along the same axis) or they can be angled to each other such as crossed or T shaped. Bolted connectors are preferred, with the bolt numbers dependent upon shear and other loadings to be resisted. Bracing of each beam can be introduced as required. The beams can be assembled from a kit to form a first beam which can then be connected to another beam assembled from a kit then joined to the first beam as required. Beams can be joined side by side, end on end and on top of one another. Intermediate stiffeners may be spaced equally or unequally with the number of stiffeners adjusted according to strength requirements.

[0033] Figure 6 shows a perspective view of the view of beam 1 of figure 1 engaging the beam view of figure 2 via opposing side faces. Due to the construction of each beam, and such is their versatility, it will be appreciated that the beams can be opposed via the same or opposite faces, which allows beams to be turned and reoriented. A preferred embodiment would have the beams joined so that a beam on one side of a composite beam is a mirror image of the beam orientation on the opposite side.

[0034] Figure 7 shows a perspective view of the beam of figure 1 engaging end to end with the beam view of figure 2. This shows one method of joining but if the figure 2 view is rotated 180 degrees, it would show the identical face to that shown in figure 1. In some cases that may be preferred in which case that would show a mirror image of the view of figure 1. Each beam module can be joined to anther like module via any face and from any orientation depending upon structural requirements.

[0035] The present invention provides a useful alternative to the known beams and provides additional choice for a potentially unlimited number of customers. Although the invention has been described with reference to specific examples, it would be appreciated by those skilled in the art that the invention may be embodied in many other forms. Although the method and apparatus aspects of the invention have been described with reference to their application to modular beams used in construction sites, it will be appreciated that the invention has alternative applications. [0036] The beam modules described herein are preferably manufactured from steel but other materials may be employed such as heavy duty plastics materials and aluminium. One advantage of the invention described herein is that the connecting joint methodology imparts high strength with shear bolts which also provide high resistance to shear bending and tension. Although the drawings show bolt hoes in each connection, it will be appreciated that a variety of bolt sizes ( length and diameters) and bolt configurations can be employed depending upon beam size and design loading requirements. The holes in the beams are, according to a preferred embodiment, in a square grid of 80mm x 80mm in every direction including X, Y and Z directions. Arranging the holes in a grid pattern allows the faces of the beams to engage with the holes in alignment to receive fasteners. In that case the maximum adjustment distance that is required to align beams is the centre to centre distance of the holes. Other grid patterns are envisaged when beam dimensions change or the number of required fasteners decreases or increases.

[0031] It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLLOWS:

1. A structural beam manufactured from angle profile sections arranged as a space frame to form a structural beam module; the beam module including at least one abutting surface which is capable of engagement with an opposing abutting surface of a co operating beam, such that one structural beam manufactured from said angle sections, can be connected to at least one other beam.

2 A structural beam according to claim 1 wherein each beam module comprises a plurality of connected angle sections each having a web and a flange which each provide abutting surfaces.

3. A structural beam according to claim 2 wherein, each said beam module when formed has a plurality of abutting surfaces which are connectable with a corresponding abutting surface of a second beam module.

4. A structural beam according to claim 3 wherein the abutting surfaces provide connecting faces.

5. A structural beam according to claim 4 wherein the connecting faces comprise top, bottom, side and end faces and include openings which receive and retain fasteners for the purpose of connecting one beam to another like beam via one of said faces.

6. A structural beam according to claim 5 wherein the beam module is longer than it is deep and deeper than it is wide.

7. A structural beam according to claim 6 wherein the angle sections used in the construction of the beams are equal angles.

8. A structural beam according to claim 7 wherein, each connecting face of the beam is formed by one leg of a length of angle secti on.

9. A structural beam according to claim 8 wherein the width of the beam approximates an outside length dimension of one leg of said angle section.

10. A structural beam according to claim 9 wherein, there are openings in each face of each leg of each angle section, which are aligned along the length of each angle.

11. A structural beam according to claim 10 wherein the openings are disposed along a longitudinal mid line of each leg extending along the length of one said angled profile sections.

12. A structural beam according to claim 1 1 wherein, the beam module includes a first angle section of longitudinal extent having first and second ends and two equal legs, the first of said legs forming a top plate and the second of said legs forming part of a web of the beam.

13. A structural beam according to claim 12 wherein the beam modules includes a first angle section of longitudinal extent having first and second ends and two equal legs, the first of said legs forming a bottom plate and the second of said legs forming part of the web of the beam.

14. A structural beam according to claim 13 further comprising between the top and bottom plates, lengths of equal angle forming web stiffeners

15. A structural beam according to claim 14 wherein the web stiffeners comprise flat plate including a plurality of openings which enable connection of an adjacent beam.

16. A structural beam according to claim 15 further comprising at said first and second ends of said top and bottom plates, a length of equal angle extending between said top and bottom plates and forming respective of said beams.

17. A structural beam according to claim 16 wherein a plurality of like beam modules are be arranged to form shapes including a T shape, square, rectangular or elongated composite beam.

18. A structural beam according to claim 16 wherein a composite beam is formed by placing one beam module on top of another like beam module to form a deeper beam.

18. A structural beam according to claim 16 wherein a composite long span beam is formed by joining beams end to end.

19. A structural beam according to claim 16 wherein a composite wider beam is formed by joining beams side by side.

20. A structural beam module manufactured from angle sections arranged so that the beam comprises top and bottom plates and end surfaces each formed from legs of said angle sections; the beam having a cubic generally elongated shape and including lengths of angle sections forming first and second end members which co operate with the top and bottom angle sections to define ends of the beam module; and intermediate the said first and second end members, at least one web member formed by angle sections which define beam depth; wherein at least the top, bottom and end plates include openings which receive fastening bolts to secure a like modular beam.

21. A structural beam according to claim 20 wherein a bottom plate of one modular beam is connected to a top plate of at least a second like modular beam to form a deeper composite beam.

22. A structural beam according to claim 20 wherein an end plate of one modular beam is connected to an opposing end plate of at least a second like modular beam to longer composite beam.

23. A structural modular beam of substantially rectangular cross- section manufactured from angle sections arranged end to end so that the beam comprises top, bottom plates and end plates; the top and bottom plates and end plates surfaces which are arranged to define a cubic elongated shape;

first and second end members which co operate with the top and bottom angle sections to define ends of the beam, and intermediate the said first and second end members, at least one web member each formed by a length of angle section which define beam depth; wherein at least the top, bottom and end plates include openings which receive fastening bolts to secure a like modular beam to at least one of said, top, bottom and end plates.

24. A structural beam according to claim 23 wherein, connecting faces of each beam include at least part of a top, bottom, end and side faces.

25. A structural beam according to claim 24 wherein abutting parts of separate beams comprise a joining face.

26. A method of construction using a modular structural beam of substantially rectangular cross-section manufactured from angle sections arranged end to end so that the beam comprises top, bottom plates and end plates; the top and bottom plates and end plates surfaces which are arranged to define a cubic elongated shape;

intermediate the said first and second end members are at least one web member formed by angle sections which define beam depth; wherein at least the top, bottom and end plates include openings which receive fastening bolts to secure a like modular beam to at least one of said, top , bottom and end plates;

the method comprising the steps of;

a) taking a first beam and joining the beam to a corresponding face of a like second beam via a top, bottom, end or side face; b) inserting fasteners through openings in each beam which align when each said beams are engaged in opposing relationship;

27. A method of construction using a modular structural beam according to claim 26 comprising the preliminary step of engaging the beam modules to form either a longer beam or deeper beam.

28. A method of construction using a structural beam of substantially rectangular cross-section manufactured from angle sections arranged end to end so that the beam comprises top, bottom plates and end plates; the top and bottom plates and end plates surfaces which are arranged to define a cubic elongated shape;

the method comprising the steps of;

b) inserting fasteners through openings in the beam which align with corresponding openings in the structure at any location along the beam.

22. A method according to claim 21 comprising the further optional step of joining at least one other like beam to the beam via top, bottom, side or end faces to form a higher or wider or longer beam made from a plurality of said beam modules.

23. A method according to claim 22 comprising the further step of adding web members which provide stiffeners for the beams.