Note: Descriptions are shown in the official language in which they were submitted.
CA 02774955 2012-04-20
METHODS AND APPARATUSES FOR ERECTING A STRUCTURAL FRAME -
TECHNICAL FIELD
[0001] This document relates to methods and apparatuses for erecting a
structural
frame.
BACKGROUND
[0002] Wedges are used in structural frame erection to force adjacent columns
open
to allow a new cross beam to be positioned between the columns and secured.
SUMMARY
[0003] A method of erecting a structural frame, the method comprising:
extending a
ram between two structural members, which are spaced and anchored relative to
one another,
to force the two structural members apart; inserting a cross member between
the two
structural members; and removing the ram to allow the two structural members
to converge,
compress, or converge and compress, against the cross member.
[0004] An extendable ram is also disclosed comprising: a structural body; a
first leg
laterally extended from and movably connected to the structural body, the
first leg defining a
first pressure surface; a second leg laterally extended from the structural
body and defining a
second pressure surface opposing the first pressure surface to define a press
axis; and an
actuator between the structural body and the first leg for extending the first
pressure surface
along the press axis.
[0005] An extendable ram is also disclosed comprising: a structural body; a
first
pressure surface and a second pressure surface, both associated with the
structural body and
opposed to one another to define a press axis; a press movably connected to
the structural
body and defining the first pressure surface; an actuator between the
structural body and the
press for extending the first pressure surface along the press axis; a first
stop overhanging the
first pressure surface; and a second stop overhanging the second pressure
surface.
[0006] An extendable ram is also disclosed comprising: an I-beam; a first
pressure
surface and a second pressure surface, both associated with the I-beam and
opposed to one
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another to define a press axis; a press movably connected to the I-beam and
defining the first
pressure surface; and an actuator between the I-beam and the press for
extending the first
pressure surface along the press axis.
[0007] An extendable ram is also disclosed comprising: a structural body; a
first
pressure surface and a second pressure surface, both associated with the
structural body and
opposed to one another to define a press axis; a press movably connected to
the structural
body and defining the first pressure surface; and an actuator mounted to the
structural body
adjacent the press for extending the first pressure surface along the press
axis, in which the
actuator is repositionable to select a pressure point on the press from a
range of pressure
points.
[0008] An extendable ram is also disclosed comprising: a structural body
having a
retainer; a first pressure surface and a second pressure surface, both
associated with the
structural body and opposed to one another to define a press axis; a press
movably connected
to the structural body and defining the first pressure surface; and an
actuator, removably
mounted within the retainer and adjacent the press, for extending the first
pressure surface
along the press axis.
[0009] In various embodiments, there may be included any one or more of the
following features: The method comprises securing the cross member to the two
structural
members. Each of the two structural members further comprise a respective
first member and
a respective second member laterally extending from the respective first
member, in which:
extending further comprises extending the ram between the respective second
members; and
inserting further comprises inserting the cross member between the respective
first members.
The respective first members are columns and the respective second members are
transverse
beams. The structural frame is a metal frame. The method is used for building
construction.
The method is used for pipe rack module construction. The second press leg is
movably
connected to the structural body, and further comprising a second actuator
between the
structural body and the second leg for extending the second pressure surface
along the press
axis. The one or more stops are defined by the structural body; the press
comprises a first leg
laterally extended from the structural body; and the second pressure surface
is defined by a
second leg laterally extended from the structural body. The actuator is
mounted with bolts
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through a set of bolt holes selected from plural sets of bolt holes in the
structural body for
repositioning the actuator. The retainer comprises a cylinder and the actuator
comprises a
hydraulic cylinder.
[0010] These and other aspects of the device and method are set out in the
claims,
which are incorporated here by reference.
BRIEF DESCRIPTION OF THE FIGURES
[0011] Embodiments will now be described with reference to the figures, in
which
like reference characters denote like elements, by way of example, and in
which:
[0012] Figs. 1A-D are a series of perspective and side elevation views that
illustrate a
method of assembling a structural frame using an extendable ram
[0013] Fig. 2. is a side elevation view of an extendable ram with a fixed leg
and a
movable leg for forcing two structural members apart.
[0014] Fig. 3 is a side elevation view of an extendable ram with two movable
legs for
forcing two structural members apart.
[0015] Fig. 4 is cross-sectional view taken along the section lines 4-4 from
Fig. 2.
[0016] Fig. 5 is an end elevation view of an actuator retainer and plate.
[0017] Fig. 6 is a side elevation view of another embodiment of an extendable
ram.
[0018] Fig. 7 is a bottom plan view of the extendable ram of Fig. 6.
[0019] Fig. 8 is a perspective view of the extendable ram of Fig. 6.
DETAILED DESCRIPTION
[0020] Immaterial modifications may be made to the embodiments described here
without departing from what is covered by the claims.
[0021] Construction of a steel frame building or other structure generally
begins by
assembly of one or more cranes on-site for lifting the steel columns, beams,
and girders
required to erect the structure. To hoist the steel, structural ironworkers
may use cables
connected to the crane to lift the beams onto the steel columns, and taglines
may be attached
to the beams so the ironworker can control the beams if necessary.
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[0022] During construction, the crane hoists the steel into place, and
ironworkers
position the beams in place with spud wrenches to align bolt holes. Afterwards
the beams are
bolted to the steel columns. This process is continued until there are no
beams or columns
left to construct the structure. Structural ironworkers may also erect joist
girders, bar joists,
trusses and install metal decking.
[0023] To begin frame erection, spaced columns may first be positioned and
anchored. Next, cross beams are connected between the columns in rows to
provide lateral
stability and make up the frame. Rows of cross beams are added one above the
other until
the structure is completed.
[0024] To position a new cross beam between adjacent columns, the adjacent
columns are first forced open to allow entry of the cross beam. Opening
adjacent columns to
install a cross beam above an existing lower cross beam proceeds in several
steps. First, one
end of the lower cross beam is left loosely attached to one of the columns,
for example by
connecting the lower beam to a bolt plate on the column via several untorqued
bolts with
plenty of slack. Next, a wedge is driven between the loosely attached end of
the lower beam
and the column.
[0025] The force of the wedge is transferred through the beam to both columns,
spreading the columns open. Once the columns are opened, the new beam is
lowered into
place and secured between the columns. After the new beam is installed, the
wedge is
removed and the lower beam is leveled and torqued securely in place.
[0026] Referring to Fig. 1A, a method of erecting a structural frame 10 is
illustrated.
In the example shown, the structural frame 10, for example a metal frame, is
composed of
two or more structural members 12, which are spaced and anchored relative to
one another.
Relative anchoring may or may not involve a direct connection, for example
with beam 20,
between members 12 and in some cases members 12 are independently anchored
within a
foundation or ground. Each structural member 12 may comprise a respective
first member,
such as a column 14, and a respective second member, such as a transverse beam
16,
laterally extending from the column 14. As shown, each structural member 12
may form part
of a respective wall structure 18 as shown, and the wall structures 18 may be
connected via
one or more cross beams 20.
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[0027] Referring to Figs. 1 B-C, and 2, in one stage a ram 22 is extended
between the
two structural members 12 to force the two structural members 12 apart. In
another stage a
cross member such as beam 24 is inserted between the two structural members
12. In the
example shown, the ram 22 is extended between the transverse beams 16 (Figs. 1
B-C, and
2), and the beam 24 inserted between the two columns 14 (Figs. 1 C and D). In
some
embodiments, however, the ram 22 may be extended between the columns 14 or
another
suitable pressure point on structural members 12.
[0028] Referring to Fig. 1 D, the ram 22 is subsequently removed, for example
by
retracting the ram 22 and lifting ram 22 from the structural frame 10, to
allow the two
structural members 12 to converge, compress, or converge and compress, against
the beam
24.
[0029] In another stage, the beam 24 may be secured to the two structural
members
12. For example, the beam 24 may be secured to both columns 14 while the ram
22 is
extended. In other cases the beam 24 is secured after the ram 22 is removed.
In further cases
the beam 24 is secured partially while the ram 22 is extended and partially
when the ram 22
is removed. Securing may include leveling and bolting, as may be required.
Securing may be
done through intermediate components such as brackets, legs, extensions, and
other suitable
components.
[0030] Referring to Fig. 1D, the structural frame 12 may form part of a pipe
rack
module 26, for supporting one or more pipes 28. A pipe rack module 26 is a
structural frame
fitted with for example pipes, cable trays, and miscellaneous equipment. Pipe
rack modules
26 are used for example in the oil and gas industry as such modules are
reusable, may be
remotely constructed in a controlled environment, and may be transported to a
remote work
site. Additionally, pipe rack modules 26 may be constructed at the same time
as the
foundation is constructed, in order to save time in assembly. Other types of
structural frames
12 may be constructed with the methods and rams 22 disclosed herein, for
example buildings
such as skyscrapers.
[0031] Referring to Figs. 1 A and 1 D, the disclosed methods and rams 22 are
advantageous over the wedge method of installing cross members 24. For
example, the
disclosed methods remove the need to re-level and torque the lower beam 20
after installing
CA 02774955 2012-04-20
the new beam 24. Thus, with the disclosed methods the lower beam 20 may be
fully secured
in place before beam 24 is installed at all. This is particularly advantageous
when erecting a
pipe rack module or other structure that requires erection of scaffolding (not
shown) or other
obstacles after installing and before removing the wedge, because such
scaffolding may have
to be removed before the wedge can be accessed for removal itself and the
lower beam 20
secured. The removal alone of the extra step of securing the lower beam 20
after installing
the new beam 24 is expected to amount to a substantial cost savings in
construction costs and
a reduction in project duration.
[0032] Referring to Fig. 2, an embodiment of a ram 22 used in the method
disclosed
above is illustrated. Ram 22 comprises a structural body 30, a first pressure
surface 32, a
second pressure surface 34, and an actuator 39.
[0033] Structural body 30 may be an I-beam 31 or other suitable structure. I-
beams
are generally cheaper than other potential structural bodies. In addition, I-
beams and other
building materials may be found on site, meaning that in some cases only the
non I-beam
parts of ram 22 need be brought to the work site and assembled with the I-beam
31, reducing
cost. In some cases structural frame 10, for example columns 14, beams 20, 16,
and legs 44,
38, and 66, is partially or wholly assembled by I-beams. Other structural
members may be
used.
[0034] Pressure surfaces 32 and 34 are associated with the structural body 30
and
opposed to one another to define a press axis 36. The first pressure surface
32 may be
defined by a press 37 movably connected to the structural body 30. In some
cases the press
37 may be a first leg 38 extended from and movably connected to the structural
body 30. For
example, first leg 38 is connected to slide across the structural body 30, for
further example
if an upper flange 40 of first leg 38 wraps around and rests on a lower flange
42 of I-beam
31. Leg 38 may be stopped (see for example stop 91 in the embodiment of Fig.
8) or
temporarily attached, for example bolted against movement with removable bolts
(not
shown), during positioning or transport to prevent leg 38 from inadvertently
sliding off of
structural body 30. In other cases first leg 38 is connected to pivot relative
to structural body
30. A second leg 44 may laterally extend from the structural body 30 and
define the second
pressure surface 34. Legs 38 and 44 allow the ram 22 to be assembled using a
conventional
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structural body such as an I-beam 31, in order to reduce the cost of ram 22
and ensure that
ram 22 possesses sufficient rigidity to force structural members 12 apart.
[0035] Actuator 39 may be positioned between the structural body 30 and the
press
37 for extending the first pressure surface 32 along the press axis 36.
Actuator 39 may
comprise a hydraulic cylinder 46 connected to a power source 49 such as a hand
pump 50.
Power source 49 may be mounted on structural body 30 or remotely connected to
cylinder
46. Power sources other than those shown may be used. A hand pump 50 and
cylinder 46 is
advantageous because such pump 50 can be operated using human power only while
still
reaching pressures of up to a hundred tons and more.
[0036] Referring to Figs. 2 and 4, actuator 39 may be mounted to the
structural body
30 adjacent the press 37 and repositionable to select a pressure point 52 on
the press 37 from
a range of pressure points. Actuator 37 may be mounted with bolts 54 through a
set of bolt
holes 56 (Fig. 4) selected from plural sets 58 of bolt holes 56 in the
structural body 30 for
repositioning the actuator 39. Repositionability may be achieved by a variety
of other
suitable ways, such as using a track (not shown) or ratchet system (not
shown). Actuator 39
may be repositionable about one or more axes of repositionability. Leg 38 may
be reinforced
along selectable pressure points, for example by thickening with welded
material (not
shown).
[0037] Allowing repositionability of the pressure point 52 is advantageous
because it
allows a user to position the actuator to ensure that a lateral and not a
twisting force is
produced against the structural member 12. For example, beam 16 may be an I-
beam 17, and
actuator 39 may be repositioned to apply a force vector into the center 60 of
the I- beam 17
to avoid twisting the I-beam 17. Repositioning the actuator 39 may also be
advantageous
when using spreader 22 to press against beams 16 of different widths.
[0038] Referring to Figs. 2 and 5, structural body 30 may have a retainer 62,
which
actuator 39 may be removably mounted within. The retainer 62 may comprise a
whole or
semi cylinder 64 (Fig. 5), for example mounted to a support leg 66 laterally
extended from
the structural body 30. Retainer 62 may be mounted to ensure that actuator 39,
when
mounted, is aligned, for example parallel with an axis of I-beam 31, to
deliver a force against
press 37 across a desirable press axis 36, which may be a level axes when body
30 is level.
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Thus, retainer 62 is advantageous because it reduces the chance of
inadvertently bending
structural member 12 by misdirecting force against structural member 12, while
allowing
actuator 39 to be quickly and accurately assembled from a kit after transport
to the work site
in parts. Retainer 62 may be mounted to structural body 12 using suitable
methods such as
welding to a bolt plate 71 (Fig. 5).
[0039] Referring to Figs. lB and 2, ram 22 may further comprise a first stop
68
overhanging the first pressure surface 32, and a second stop 70 overhanging
the second
pressure surface 34. As shown, stops 68 and 70 may be defined by the
structural body 30 or
by other components. Stops.68 and 70 allow ram 22 to be stably positioned over
transverse
cross beams 16 before extension. Stops 68 and 70 are advantageous,
particularly when ram
22 is used to impart force against horizontally oriented beams 16, because
stops 68 and 70
allow ram 22 to be lifted and deposited by crane to rest by gravity upon beams
16, freeing
the same crane to subsequently lift beam 24 into place (Fig. 1 C). Thus, stops
68 and 70 allow
one crane instead of two to be used in the disclosed methods, resulting in a
substantial cost
savings. For the purpose of lifting via crane (not shown), body 30 may have
one or more
lifting lugs 72. In some cases, stops 68, 70 may be provided with sufficient
respective
overhang to ensure that stops 68, 70 overhang surfaces 32, 34, respectively
after full
extension of ram 22. Stops 68, 70 may be adjustable in overhang extension.
Stops 68, 70
may have hooks (not shown) for hooking onto wall beams 16.
[0040] Referring to Fig. 3, the second press leg 44 may be movably connected
to the
structural body 30 for example in the same fashion as first leg 38 is movably
connected to
structural body 30. Thus, a second actuator 76 may be provided between the
structural body
30 and the second leg 44 for extending the second pressure surface 34 along
the press axis
36. The ability to press from both legs 38 and 44 may be advantageous in some
applications,
for example when opening heavy gauge columns. Like actuator 39, second
actuator 76 may
be mounted to a support leg 67 extended from body 30. Second actuator 76 may
also be
repositionable like first actuator 39, and may have some or all of the
features described
herein for first actuator 39.
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[0041] Referring to Figs. 2 and 3, body 30 may be reinforced against twisting
and
bending via a reinforcing bar 74. Other forms of reinforcement may be used,
for example
knee braces 78 against legs 44, 66 and 67.
[0042] Referring to Figs. 6-8, another embodiment of an extendable ram 22 is
illustrated. Instead of knee brace 78, legs 44 and 66 are reinforced with knee
plates 83. Each
leg 44, 66, and 38 may be connected, for example through welding, to a plate
85 that
connects to structural body 30. Plates 85 may have bolt holes 93 in the case
of stationary legs
44 and 66, for connection to body 30 via bolts 89. Stationary legs 44 and 66
may be bolted
through a set of holes 87 selected from plural sets of holes 87 in structural
body 30 as shown,
to allow the spacing between surfaces 32 and 34 to be adjusted by adjusting
leg separation to
fit a range of separations between structural members 12 in use. Each of legs
44, 66, and 38
may have an upper flange 40 that wraps around and rests on lower flange 42 of
body 30, in
order to allow legs 44, 66, and 38 to be slid into position during assembly. A
removable or
permanent stop 91 may limit slide travel of leg 38.
[0043] Embodiments of the methods disclosed herein contemplate elastic
deformation of structural members 12 by use of ram 22. However, in some cases
permanent
deformation may occur. If permanent deformation is not desired, ram 22 or
another suitable
device may be used to permanently deform structural member 12 back to the
desired shape.
[0044] Ram 22 may be provided partially or wholly in kit form. As described
above,
an exemplary kit may include all required parts except the structural body 30,
which may be
found at the worksite. In other cases, all of the parts of ram 22 including
structural body 30
may be provided in kit form. For ease of assembly, parts connecting at or near
a first end 82
of structural body 30 may be color coded differently than parts connecting at
or near a
second end 84 of structural body 30 (Fig. 2). Other installation location
identifiers may be
used other than color coding.
[0045] Although ram 22 is illustrated in Figs. 1A-D as opening vertical
columns 14,
in some cases ram 22 may be used to open horizontal or angled columns 14 or
beams 16. In
fact the use of the words vertical, horizontal, transverse, up, down, lateral,
and all other
directional language, is relative and it should be understood that the methods
and rams 22
disclosed herein may be used to separate any two structural members 12
regardless of
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absolute directional orientation of members 12 relative to the surface of the
earth. In
addition, beam 24 inserted between columns 14 may be inserted transverse,
parallel, or
angled relative, to columns 14. The use of terms such as column or beam are
also relative,
and may refer to studs, bents, joists, ties, and other suitable structural
members. Additionally,
references to bolting or bolts are exemplary and it should be understood that
other
connection methods may be used. The methods and rams 22 disclosed herein may
be used
for disassembly as well as assembly of a structural frame 10.
[0046] In the claims, the word "comprising" is used in its inclusive sense and
does
not exclude other elements being present. The indefinite articles "a" and "an"
before a claim
feature do not exclude more than one of the feature being present. Each one of
the individual
features described here may be used in one or more embodiments and is not, by
virtue only
of being described here, to be construed as essential to all embodiments as
defined by the
claims.
