Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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APPARATUS AND METHODS FOR CONNECTING TIMBER FLANGES
FIELD OF THE INVENTION
The present invention is directed to the field of building construction, and
particularly the
construction of multistorey buildings using timber as a major structural
material.
BACKGROUND TO THE INVENTION
The stability of multistorey buildings is typically conferred using steel or
reinforced concrete, or a
combination of the two materials. A steel frame alone may be used in low rise
buildings. For
medium rise buildings either concrete or braced steel cores are typically
used. For high rise
buildings a concrete core may be used to facilitate the construction process.
The core confers
stability as steelwork is erected about the core. In some high rise buildings,
an 'exoskeleton',
may also be used to confer stability, this typically requiring substantial
temporary works as the
final stability system is only complete after a significant number of floors
are erected.
The corrosion of steel as a component of reinforced concrete is a well known
problem in building
construction. Ideally, concrete provides adequate protection to the embedded
steel by way of
the protective alkaline environment provided by fresh concrete to form a
protective coating on the
surface of the steel, which protects it from corrosion. However, over time pH
declines slowly and
the alkaline conditions are lost, leading to increased probability of steel
corrosion. Maintenance
of an alkaline environment can be ensured by providing sufficient cement
content, complete
compaction and proper curing. However, these measures are firstly difficult to
realize in practice
fully and secondly the same are not found to be sufficient in hostile
environments.
Corrosion is also a problem of structural steel beams used in building
construction. Corrosion
may be addressed by the use of a paint system comprising sequential coating
application of paints
or alternatively paints applied over metallic coatings to form a 'duplex'
coating system. Protective
paint systems usually consist of primer, intermediate/build coats and finish
coats. Metallic
coatings may be used such as by the processes of hot-dip galvanizing and
thermal spraying.
Eventually, such coating will break down and expose the underlying structural
steel to the
environment leading to corrosion.
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Quite apart from the problems of corrosion, acceptable quality concrete or
steel may not be
available, or may not be available at an acceptable cost.
Taking into account environmental considerations, it is well known that the
concrete industry is
one of two largest producers of carbon dioxide, creating up to 5% of worldwide
man-made
emissions of this gas, of which 50% is from the chemical process and 40% from
burning fuel.
Clearly, the production of steel is a highly energy-consuming process (mainly
due to the use of
vast amounts of heat energy in smelting) and therefore a substantial
contributor to carbon dioxide
production.
As an alternative to steel and concrete, timber has been used in the
construction of multistorey
buildings. However, timbers having high cross-sectional areas must be used to
provide the load
bearing capacities and spans required. Such timbers are typically very
expensive given the need
to harvest the wood from the prime regions of very mature trees.
More recently, engineered timbers such as laminated veneer lumber (LVL) and
glue laminated
timber have been used in building construction. In producing these products,
layers of wood are
glued (laminated) together with heat, resin binder, and pressure to form a
very strong structural
member that can be produced in regular sizes and lengths. While generally
effective, these wood
products are expensive and therefore not useable in many applications.
Furthermore, there is
significant energy input required in production (mainly in heat energy) and
also the use of
chemicals (such as adhesive and binder).
Engineered timbers must be produced by very precise manufacturing methods,
having rigorous
QA and QC requirements. Accordingly, these products are not widely available
and may need to
be transported long distances to a building site. Where available, these
products are expensive
and may not be cost-effective for many applications.
It is an aspect of the present invention to overcome or ameliorate a problem
of the prior art by
providing materials and methods to construct a multistorey building deriving
primary stability from
neither steel nor concrete. It is a further aspect of the present invention to
provide alternative
materials and methods for building construction.
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The discussion of documents, acts, materials, devices, articles and the like
is included in this
specification solely for the purpose of providing a context for the present
invention. It is not
suggested or represented that any or all of these matters formed part of the
prior art base or were
common general knowledge in the field relevant to the present invention as it
existed before the
priority date of each claim of this application.
SUMMARY OF THE INVENTION
In one aspect of the invention, but not necessarily the broadest aspect, the
present invention
provides a connector for collocating a group of timber flanges, the connector
comprising a main
region, the main region having extending therefrom a plurality of engaging
members each of
which is configured to engage with a timber flange.
In one embodiment of the first aspect, the main region comprises means for
fastening the
connector to a substantially similar or identical second connector.
In one embodiment of the first aspect, the main region comprises means for
connecting the
connector to a building structure.
In one embodiment of the first aspect, the main region comprises a first
substantially planar region
and a second substantially planar region, the first and second planar regions
forming an angle of
about 90 degrees, the first planar region comprising means for connecting the
connector to a
substantially similar or identical second connector, and the second planar
region comprising
means for connecting the connector to a building structure.
In one embodiment of the first aspect, the means for connecting the connector
to a substantially
similar or identical second connector or the means for connecting the
connector to a building
structure is an aperture configured to accept a fastener.
In one embodiment of the first aspect, the main region consists of, or
comprises, a plate.
In one embodiment of the first aspect, the main region comprises a
substantially planar face, and
the group of engaging members extend substantially orthogonal from the planar
face.
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In one embodiment of the first aspect, the engaging members are disposed in an
ordered array
with reference to each other.
In one embodiment of the first aspect, the engaging members form a row, or a
series of rows.
In one embodiment of the first aspect, the engaging members form a grid
arrangement.
In one embodiment of the first aspect, the engaging members form a circle with
a central engaging
member at the origin, or two or more concentric circles.
In one embodiment of the first aspect, each of the plurality of the engaging
members extends at
least about 1 cm, 2cm, 3cm, 4cm, 5cm, 6cm, 7cm, 8cm, 9cm or 10cm from the main
region.
In one embodiment of the first aspect, each of the plurality of engaging
members are substantially
solid and have a cross sectional area greater than that of a 2 gauge nail.
In one embodiment of the first aspect, each of the plurality of engaging
members are substantially
solid and have a cross section area of at least about 0.01 cm2, 0.02 cm2, 0.03
cm2, 0.04 cm2, 0.05
cm2, 0.06 cm2, 0.07 cm2, 0.08 cm2, 0.09 cm2, 0.1 cm2, 0.2 cm2, 0.3 cm2, 0.4
cm2, 0.5 cm2, 0.6 cm2,
0.7 cm2, 0.8 cm2, 0.9 cm2, 1 cm2, 2 cm2, 3 cm2, 4 cm2, 5 cm2, 6 cm2, 7 cm2, 8
cm2, 9 cm2 or 10cm2.
In one embodiment of the first aspect, each of the plurality of engaging
members is a substantially
linear member.
In one embodiment of the first aspect, each of the plurality of engaging
members have
substantially identical morphology.
In one embodiment of the first aspect, the connector comprises at least about
4, 6, 8, 10, 12, 14,
16, 18, 20, 22, 24, 26, 28, 30, 32, 34 or 36 engaging members.
In one embodiment of the first aspect, the main region consists of, or
comprises, a plate and each
of the plurality of engaging members is a dowel or pin extending from the
plate.
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In one embodiment of the first aspect, the connector is fabricated in whole or
in part of a metal.
In one embodiment of the first aspect, the metal is corrosion resistant, or is
treated so as to be
corrosion resistant.
In one embodiment of the first aspect, the connector comprises a support
member extending from
the main region in a direction generally away from the engaging members.
In one embodiment of the first aspect, the connector is configured to end join
a first group of
timber flanges to a second group of timber flanges, the connector comprising a
main region, the
main region having extending therefrom a plurality of engaging members each of
which is
configured to engage with an axial bore of timber flange, the plurality of
engaging members
comprising a first group and a second group, wherein the first group extends
in a first direction
and the second group extends in a second direction.
In one embodiment of the first aspect, the main region comprises opposing
first and second
substantially planar faces, wherein the first group of the engaging members
extend substantially
orthogonal to the first planar face and the second group of engaging members
extend
substantially orthogonal to the second planar face.
In one embodiment of the first aspect, the number of engaging members in the
first group is equal
to the number of engaging members in the second group.
In one embodiment of the first aspect, each of the plurality of engaging
members have
substantially identical morphology.
In one embodiment of the first aspect, the first and/or second group of
engaging members
comprises about 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34 or
36 engaging members.
In one embodiment of the first aspect, the first and second group of engaging
members are
arranged substantially identically, and or have substantially identical
morphology.
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In a second aspect the present invention provides a building component
comprising the connector
according to any embodiment of the first aspect and a plurality of timber
flanges, each of the
timber flanges having an axial bore into which is received an engaging member.
In one embodiment of the second aspect, a longitudinal surface of each of the
plurality of timber
flanges contacts a longitudinal surface of at least one other timber flange.
In one embodiment of the second aspect, each of the plurality of timber
flanges is a pole.
In one embodiment of the second aspect, each of the plurality of timber
flanges is a true round or
a peeler core.
In one embodiment of the second aspect, the longitudinal surface is formed by
removing a
longitudinal segment of each of the contacting flanges so as to provide a
substantially planar
surface.
In one embodiment of the second aspect, the longitudinal surface is formed by
removing a
longitudinal segment of upper and/or lower timber flanges so as to provide a
bearing surface
and/or a mounting surface respectively.
In one embodiment of the second aspect, two contacting timber flanges are
secured together with
a fastener extending at an angle to the long axes of the timber flanges.
In one embodiment of the second aspect, the building component comprises a
second connector
according to any embodiment of the first aspect, a first group of timber
flanges collocated by the
first connector and a second group of time flanges collocated by the second
connector, the first
and group of timber flanges oriented end-to-end, the first and second
connectors being fastened
together so as to form a structurally integral unit.
In one embodiment of the second aspect, the building component comprises a
structural column,
wherein the first and second connectors are disposed on, and fixed to, the
upper face of the
column (or the column top plate, where present) and the first connector is
fastened to the second
connector.
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In one embodiment of the second aspect, the building component comprises the
connector of the
first aspect having a support member as a third connector, the support member
of the third
connector interposed between the first and second connector, and the first
connector is connected
to the second connector (optionally by way of the support member of the third
connector).
In one embodiment of the second aspect, the building component of comprises a
third group of
timber flanges collocated by the third connector.
In one embodiment of the second aspect, the building component comprises the
connector
according to any embodiment of the first aspect as a fourth connector,
In one embodiment of the second aspect, the building component comprises a
fourth group of
timber flanges collocated by the fourth connector.
In one embodiment of the second aspect, the fourth connector is fastened to
the first and second
connectors.
In one embodiment of the second aspect, the first and second group of timber
flanges are
configured as joists, the third group of timber flanges is configured as
column of a (n + 1) storey
of a building, and the fourth group of timber flanges is configured as column
of a (n) storey of the
building.
In a third aspect, the present invention provides a method of constructing a
multistorey building,
the method comprising the steps of providing the building component according
to any
embodiment of the second aspect or a connector of the first aspect.
BRIEF DESCRIPTION OF THE FIGURES
FIG. lA is a diagram in perspective view of paired preferred connectors of the
present invention,
each collocating a series of four preferred stacked timber flanges.
FIG. 1B is an end view of the paired connectors shown in FIG. lA
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FIG. 2A is a diagram in lateral view of a preferred building component of the
present invention
comprising an upper vertical beam, a lower vertical beam and two horizontal
beams. This
embodiment is useful since the space disposed above the horizontal beams
allows for the pouring
of a concrete floor thereon.
FIG. 2B is a plan view of the building component shown in FIG. 2A.
FIG. 3 is a diagram in lateral view of a preferred building component of the
present invention
comprising an upper vertical beam, a lower vertical beam and two horizontal
beams. Flooring
may be laid on top of the horizontal beams.
FIG. 4 is a diagram in plan view of a preferred building structure of the
present invention which
may be used at the corner of a building,
FIG. 5A is a preferred modular building structure of the present invention.
The modular structure
may be repeated as often as required according to the floor space needed.
FIG. 5B shows a similar modular building structure to that shown in FIG. 5A,
although constructed
as two half modules which are bolted together along the median line.
FIG. 50 shows is a diagram in later view showing the formation of a beam
having a ledge, the
ledge support the end of a joist. Such structures may be useful in the modular
embodiments of
the invention shown in FIG. 5A or 5B.
FIG. 5D is a diagram in perspective view of connector plates used to end-join
two sets of
collocated timber flanges. Such means may be used where the flanges must span
relatively long
distances.
FIG. 6 is a diagram in perspective view showing a preferred building structure
of the present
invention configured to join four horizontal beams, an upper column and a
lower column. For
clarity, not all components of the structure are shown in the diagram.
FIG. 7 is a diagram in perspective view showing a connector configured to join
two of more L-
shaped connectors of the type shown in FIG. 1A.
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DETAILED DESCRIPTION OF THE INVENTION
Reference throughout this specification to "one embodiment" or "an embodiment"
means that a
particular feature, structure or characteristic described in connection with
the embodiment is
included in at least one embodiment of the present invention. Thus,
appearances of the phrases
"in one embodiment" or "in an embodiment" in various places throughout this
specification are not
necessarily all referring to the same embodiment, but may. Furthermore, the
particular features,
structures or characteristics may be combined in any suitable manner, as would
be apparent to
one of ordinary skill in the art from this disclosure, in one or more
embodiments.
Similarly it should be appreciated that the description of exemplary
embodiments of the invention,
various features of the invention are sometimes grouped together in a single
embodiment, figure,
or description thereof for the purpose of streamlining the disclosure and
aiding in the
understanding of one or more of the various inventive aspects. This method of
disclosure,
however, is not to be interpreted as reflecting an intention that the claimed
invention requires
more features than are expressly recited in each claim. Rather, as the
following claims reflect,
inventive aspects lie in less than all features of a single foregoing
disclosed embodiment. Thus,
the claims following the Detailed Description are hereby expressly
incorporated into this Detailed
Description, with each claim standing on its own as a separate embodiment of
this invention.
Furthermore, while some embodiments described herein include some but not
other features
included in other embodiments, combinations of features of different
embodiments are meant to
be within the scope of the invention, and from different embodiments, as would
be understood by
those in the art.
In the claims below and the description herein, any one of the terms
"comprising", "comprised of"
or "which comprises" is an open term that means including at least the
elements/features that
follow, but not excluding others. Thus, the term comprising, when used in the
claims, should not
be interpreted as being !imitative to the means or elements or steps listed
thereafter. For example,
the scope of the expression a method comprising step A and step B should not
be limited to
methods consisting only of methods A and B. Any one of the terms "including"
or "which includes"
or "that includes" as used herein is also an open term that also means
including at least the
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elements/features that follow the term, but not excluding others. Thus,
"including" is synonymous
with and means "comprising".
Furthermore, it is not represented that all embodiments display all advantages
of the invention,
although some may. Some embodiments may display only one or several of the
advantages.
Some embodiments may display none of the advantages referred to herein.
The present invention is predicated at least in part on Applicant's proposal
that relatively small
diameter timbers may be collocated together to form a composite structural
beam using a
connector as described herein. The connector comprises a number of engaging
members, each
of which extends into a small diameter timber flange thereby collocating the
timber flanges into a
composite structural member. Accordingly, in a first aspect the present
invention provides a
connector for collocating a group of timber flanges, the connector comprising
a main region, the
main region having extending therefrom a plurality of engaging members each of
which is
configured to engage with a timber flange.
As will be described more fully infra, the present connectors can take many
forms and may be
used (in combination with timber flanges) to provide column structures, beam
structure, and
combination column/beam structures all of which make use of timber such as
timber rounds and
small diameter peeler cores. Furthermore, the present connectors allow for
timber to be used in
the construction of multistorey buildings. The present invention therefore
represents a significant
departure from prior art construction and hardware which typically rely on
large cross-section
sawn timber or steel members for creating the load bearing structures in a
building.
The composite structural members that may be produced using the present
connectors can be
used as a column, a beam, a half-beam, a bearer, a joist, a brace, a truss or
any other structural
member of a building. As will be more fully discussed infra, the connectors
may be used also to
join composite structural members both as a means for end joining and for
making right-angled
joins between a column and a beam, for example, where the column and beam are
both
collocated timber flanges.
These arrangements allow for the construction of buildings of at least several
storeys having a
frame work predominantly of timber. In some embodiments of the invention, the
building may be
constructed from timber rounds, and even smaller diameter timbers such as
peeler cores
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The present connector is typically formed having main planar region (being a
plate in one
embodiment), and having engaging members extending at 90 degrees therefrom.
The engaging
members may be pins or bars which are generally disposed in a regular manner
so as to be
insertable into an axial bore of each timber flange that is collocated by the
connector. The
combination of plate and engaging members acts to prevent the timber flanges
from acting
individually in so far as one flange may not move (axially, radially or
rotationally) with reference
to another. The collocated timber flanges may therefore act similar to a
unitary structural member
with regard to the transference of load therethrough. Thus, the collocated
flanges may be used
to replace single large cross-section timbers, and even steel members in
building construction.
Unless the contrary is stated, where building structural members are recited
herein (such as
"column" or "beam") it is to be taken that such structural members are formed
by a number of
timber flanges collocated by connection to a connector or the present
invention. Typically, two
connectors will be used: one at each end of the flanges. The number of flanges
collocated
together to form a structural member will depend on the load expected in use.
Broadly speaking,
an increased load will require an increased number of flanges, or flanges
having an increased
cross-sectional area. The flanges may be disposed linearly (i.e. one atop the
other, comprising
2, 3,4, 5, 6, 7, 8, 9 or 10 flanges), or in a grid formation (for example
having 2,3, 4, or 5 rows;
with 2, 3, 4 or 5 columns). In some embodiments the grid formation is a square
(such as 2 rows
x 2 columns), however other formations are contemplated (such as 4 rows x 1
column, or 3 rows
by two columns).
Whilst it is the primary role of the engaging members to locate a fix the
positions of the flange
ends and prevent each flange from acting individually, a secondary role may be
to prevent
crushing of the wood fibres in the flange ends. The engaging members may
transfer at lead some
of any downward load imparted on the connector to regions deeper in the
flange.
In one embodiment, the engaging member may be configured to extend at least
about 1 cm, 2
cm, 3 cm, 4 cm, 5 cm, 6 cm, 7 cm, 8 cm, 9 cm or 10 cm into the flange. To
resist deformation
forces occasioned on the engaging member (for example, by compression due to
overlying
structures or lateral forces) the engaging member may be configured to have a
minimal cross-
sectional area having regard to the expected level of deformation force that
may be applied in a
given application. A member having a cross sectional area greater than that of
a 2 gauge nail is
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useful in many applications, with preferred forms being similar to a rebar
(high yield rebar, high
tensile rebar or mild steel rebar) having diameters of at least about 5 mm, 6
mm, 8 mm, 10 mm,
12 mm, 16 mm, 20 mm, 24 mm, 25 mm, 28 mm, 32 mm, 40 mm or 50 mm.
The engaging members are generally elongate and linear and configured to
insert into a borehole
made centrally and axially into the end of the flange. The dimensions of the
engaging member
and flange may be configured such that a pressure fit is provided.
Alternatively some space may
be left between the two components to allow for the use of an adhesive. In any
event, the growth
rings of the flange (which may be concentric with the engaging member) may act
to resist
deformation of the engaging member and to spread load evenly throughout the
flanges and
connector. Generally the engaging members are identical, however this feature
is not considered
essential to all forms of the invention.
In some embodiments, the engaging member may have profiles which are not
strictly pin-shaped
or bar-shaped. A member may be wedge-shaped, conical or pyramidal for example.
The main region of the connector and the engaging members is typically
fabricated from a
deformation-resistant material such as steel, or a high strength polymer. In
many embodiments,
the main portion of the connector (typically being a plate) and the engaging
members (typically in
the form of pins) are both fabricated from steel. The plate may be separately
fabricated and the
pins attached by welding (or equivalent means of fixation), or the entire
connector may be formed
or moulded as a unitary product. In other embodiments, holes are formed in a
plate and the
engaging members are threaded and screwed through the plate to as to extend
outwardly from
the other side. Given the benefit of the present specification, the skilled
person is amply enabled
to conceive of other suitable methods for forming an engaging member on the
main region of the
connector. In one embodiment, the main region is a plate and the engaging
members extend from
the plate. It is not necessary for the main region to be a continuous
structure, with some
embodiments having cut-outs or other discontinuities therein.
The main region of the connector may or may not be configured to extend beyond
the periphery
of the collocated flanges in any or all directions. In some applications (and
often for fire safety
reasons) the main region is smaller in cross-sectional area than the region
described by the
periphery of the collocated flanges. This allows for horizontal sheeting to be
recessed into and
above the end timber area equally around the main region to abut the sides
thereof. The concrete
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floor or sheeting on the next (upper) storey can be recessed into any under
any timber end grain
area thereby concealing or rebating the connector man region and protecting
both connector and
timber ends from direct heat or flame. A potential disadvantage of this
embodiment is that the
amount of load that can be assumed by the plate is reduced, however this may
be overcome by
the use of more or larger cross-sectional area flanges.
A composite column comprising a connector of the present invention, as
connected to may act in
the a building application as a component of a secondary directed load sharing
system which
depends at least to some extent on the flat end bearing capacity of the end
fibres of the plurality
of timber flanges collocated together (at the top and bottom), and in
particular to the fibres ability
to bear loads in compression from a present connector which is already bearing
a load from a
similarly collocated group of flanges above.
The connector may have engaging members extending in two directions from the
main region. In
.. one embodiment, the engaging members extend from opposed sides of the main
region. Such
embodiments are useful in end joining a first group of flanges to a second
group of flanges.
In another embodiment, the connector is configured to fasten to another
identical or similarly
functioning connector. In this way, a first connector may be used to collocate
a first set of timber
flanges, a second connector may be used to collocate a second set of timber
flanges, and the
first connector is fastened to the second connector so as to form an indirect
structural connection
between the first and second groups of flanges.
Alternatively, the connector may be configured to fasten to a building, or a
part of building during
construction thereof. For example, the connector may be configured to connect
to a prior art
building component such as a column, a beam, a bearer, a joist, a truss or any
other frame
member of a building. Configuration may also be provided to connect to non-
timber building
components such as a steel frame component, a concrete component, or a masonry
component.
As a further alternative, configuration may be provided to connect to building
hardware such as a
bracket, a brace, a plate a cap or similar contrivance. As a further option,
the connector may be
configured to fasten to a structural member formed by the collocation of a
number of timber
flanges with a connector of the present invention.
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In a form configured so as to facilitate fastening, the connector may comprise
one or more
apertures dimensioned to receive a bolt or similar fastener. A bolt may extend
through the
apertures of two connectors with a nut being used to make the fastening semi-
permanent. As an
alternative, a clamping mechanism may be used to fasten a first connector to a
second connector
or other building component. In another version, threaded pins may be used to
fasten the present
connector to another connector or other building component. Given the benefit
of the present
specification, the skilled person is enabled to conceive of other fastening
means and configure
the connector accordingly.
The engaging members may be configured to be driven directly into the flanges
in a manner
similar to a nail such that the act of driving in the engagement member forms
a borehole in the
flange. In some circumstances, this may lead to splitting of the flanges in
which case alternative
means are used. Preferably, each of the engaging members is configured as a
pin configured to
be inserted into a pre-formed bore of the flange. An adhesive may be injected
into the bore before
.. insertion of the engaging member so as to provide for a more dependable
union.
Typically, the flanges are of equal length, and a connector is applied to both
ends of the flanges.
Thus, the flanges are bound together at both ends and the flanges are
substantially incapable of
radial movement relative to each other or axial movement relative to each
other.
As discussed supra, the present connector has advantage in so far as multiple
wood flanges of
relatively small diameter may be collocated to form a unified composite
structural member.
Suitable flanges include timber rounds. Timber rounds are described in Section
6 of Australian
Standard 1720, and are typically produced from softwood trees grown
commercially as renewable
forest plantation timber. These timbers are typically fast growing, easily
harvested, and have a
low natural defect rate.
Various species of timber are suitable to form the true rounds, particularly
those types of species
that tend to have a relatively constant diameter for a considerable portion of
their length to
minimise waste during the trimming and circularising processes. Plantation
pine materials, such
as slashpine or Carribaea hybrids, tend to form suitable true rounds. Other
materials that might
be considered include Douglas fir, and various eucalypt species.
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True rounds are particularly strong since the natural strength of the timber
fibres is not disrupted
by sawing or other treatment. The integrity of the round is maintained, and
the trimming process
required to circularise the round does not greatly affect the overall strength
of the round. The
natural characteristics of timber are that the central core or pith of the
round is relatively soft and
has low structural strength. The periphery of the timber, on the other hand,
is much harder and
the timber fibres are able to carry a high tensile load. Also, this hard outer
layer is more resistant
to water absorption and attack by insects, and thus by keeping the outer
circumference of the
timber largely intact in the process of preparing a true round, the structural
integrity of the timber
is maintained
The rounds in some forms of the invention do not strictly conform to
Australian Standard 1720,
and may be of a smaller diameter such that the Standard is not satisfied.
However, by the
fastening of at least three rounds together a required load bearing capacity
may be nevertheless
attained.
In some embodiments, the timber flanges are "peeler cores". As is understood
by the skilled
person, a peeler core is a round pressure treated post. A peeler core has been
turned in a milling
machine to the point that substantially all the soft wood has been removed
(for plywood
manufacturing), leaving the hardwood core which is typically dense and
inflexible. The milling
process peels off the bark, cambium layer, sapwood, and even some of the
heartwood to make
veneer panels. This leaves no sapwood on the post.
The hardwood core of a peeler core does not absorb the pressure treatment and
preservatives
as well as the softwood resulting in an inferior post that will typically not
last as long as a post with
treated softwood on the exterior.
Applicant has discovered an economically and technically viable use for peeler
cores in that the
cores may be used in a composite timber product such as that disclosed herein.
The use of
multiple peeler cores (and even those with a diameter down to about 70, 60, 50
or 40 mm) can
produce a member which is useful in construction and yet is highly cost-
effective. Peeler cores
are often considered a waste product of forestry, having little value in the
market. In one
embodiment, the present invention is directed to timber structural members
that are comprised of
peeler cores only in combination with a present connector.
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Given the low diameters of peeler cores, it will be appreciated that a greater
number of rounds
may be required to achieve any desired structural property. For example, while
a structural
member composed only of larger diameter rounds may only require 2 or 3 rounds,
the use of
peeler cores may require 4, 5, 6, 7 or 8 cores to achieve a useful result.
Typically, the flanges and connector are configured so as to ensure that the
surface of each
flanges makes contact with all neighbouring flanges. Thus, the diameter of the
flanges and the
spacing of the engaging members may be configured so as to ensure flange-to-
flange contact.
As will be appreciated, the diameters of timber rounds can be variable and the
spacing of
engaging members is generally fixed. Accordingly, some embodiments of the
invention provide
for opposing longitudinal segments to be removed (by a chamfering process)
from each flange
so as to provide opposing substantially planar surfaces which can act as a
contact interface
between flanges.
The amount of wood removed from a flange may be varied from flange to flange
so as to provide
a fixed distance between the flange centre and substantially planar surface.
Thus, when two so-
formed flanges are stacked on their long axes, the centre-to-centre distance
is fixed. The fixed
distance is concordant with the distance between the engaging members of the
connector and
the so-formed composite structural member is therefore assembled easily and
with the avoidance
of unforeseen forces acting on any of the flanges or engaging members that may
be caused by
poorly fitting components.
In some embodiments, the flanges are laminated together by an adhesive
disposed between the
regions of contact between two flanges. In addition or alternatively, the
flanges have fasteners
extending therethrough, and generally across the long axis. For example, the
fasteners may be
steel rods inserted into bore holes made at alternating acute and obtuse
angles to form a
repeating V-pattern along the length of the flanges. This arrangement of
fasteners provides a
trussing effect to afford greater resistance of the composite timber member to
bending, and is
therefore particularly useful where the flanges are used to form a composite
floor joist or similar.
The flanges may be laminated together according to any of the various means
disclosed in any
of the following international patent specifications, the contents of which
are herein incorporated
by reference: WO/2015/176125, WO/2015/031957, and WO/2010/057243,
WO/2009/094696,
WO/2016/086275, Australian provisional patent application 2016902472 (filed 23
June 2016).
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In one embodiment, the main region of the connector has a support member
extending therefrom
and generally in the direction opposite to that of the engaging members.
Preferably, the main
region is a plate disposed horizontally, the engaging members extending
upwardly and vertically
from the main region plate, the support member being a plate extending
generally downwardly
from the centre of the main region plate. This modified version of the
connector allows for the
collation of group of flanges into an upwardly extending column, with the
column being supported
above a surface by the vertical plate support member.
In another embodiment, the connector is configured such that the main region
is a plate that forms
an angle (typically an angle of about 90 degrees) such that a horizontal
portion of the plate is (in
use) disposed upon an underlying structure, the surface acting to support
and/or stabilise the
vertically extending portion of the main region, the vertically extending
portion having the
engaging members extending horizontally therefrom. The horizontal portion may
be configured
to fasten to the underlying structure, and may have for example apertures
allowing for a fastener
(such as a bolt or a screw) to pass through and extend into the underlying
structure.
This combination of connectors having (i) right-angled main regions and (ii)
support regions can
be used to unify an upwardly extending column, a downwardly extending column,
a beam
extending horizontally to the left and a beam extending horizontally to the
right. By way of
construction, the downwardly extending column is installed in place firstly
with the main region
plate collating the flanges which comprise the downwardly extending column
being set
horizontally. The beams extending left and right horizontally are then mounted
on the horizontal
plate of the upwardly extending beam with the horizontally extending portions
of the plates of
each connector of each beam being mounted on and bolted to the underlying
plate. A space is
left between the vertically extending portions of the plates of each connector
of each beam. The
function of this space is to snugly accept the vertical plate support member
of the connector of
the upwardly extending column. Bolts extend through (i) the vertical plates of
the connectors of
the beams and (ii) the vertical plate support member sandwiched between the
aforementioned
vertical plates. By this arrangement, a rigid unification of all components is
provided.
The present invention may comprise the combination of a number of flanges with
a connector to
form a structural column capable of resisting compressive forces expected in
building
construction. In some embodiments, a connector is present on one of both ends
of the flanges.
In any event, where a downwardly acting force bears on an upwardly presented
face of the
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connector, the connect acts to transfer the force downwardly and into the
underlying collocated
flanges.
In other embodiments one or more connectors are used to join two groups of
flanges end-to-end
so as to provide an extended length column. Without wishing to be limited by
theory in any way,
it is believed that where the connector forms end-grain connections between an
upper group of
collocated flanges and a lower group of collocated flanges so as to form an
extended height
column, the ends of the upper flanges transfers the vertical load component
through the connector
and onto the ends of the lower flanges. The engagement pins engage the flanges
(both upper
and lower) and provide composite action in the nodal zone. For any given
building application,
and according to any relevant building code with reference to the final load
to be assumed by the
column, it will be possible to determine the number of flanges and the cross-
sectional area of
each flange so as to satisfy the application.
A present connector may be used in the construction of a multistorey building.
For example, a
connector may be disposed at the interface between two floors of the building
such that the lower
group of collocated flanges together define a beam traversing the floor to
ceiling of the first storey,
and the lower group of collocated flanges together define a beam traversing
the floor to ceiling of
the second storey. This arrangement can be repeated such so as to provide a
third storey, fourth
storey, fifth storey etc. In applications for multistorey buildings, it may be
necessary to use flanges
having a higher cross-sectional area (or more flanges in total) as columns on
the lower storeys of
the building so as to support the vertical load imparted by multiple upper
storeys of the building.
Typically, in use the flanges are of equivalent length and are collocated at
both ends with a
connector of the present invention. The collocation of flanges at both ends
with connectors of the
present invention prevents independent behaviour of flanges across the entire
length of the
collocated flanges. This prevents buckling or warping of the flanges when
placed under load by
minimizing any moment bias in any given lateral direction perpendicular to the
collocated flanges.
Much of the load may be orientated along the centroid of the column, thereby
minimising or
lessening the tendency of the flanges to buckle by virtue of either unstable
moment bias due to
inherent eccentricity of loading to the centroid, imperfections in timber
cross-section, non-
uniformity of timber material and the like. To minimise the prospect for
buckling, flanges having
a symmetrical shape are preferred, and moreover the regular disposition of
flanges into a defined
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group or matrix is preferred. Furthermore, flanges should preferably make
contact with other
flanges as far as possible along their lengths so as to provide a more highly
stabilised structural
member.
In order to further minimise column failure by buckling the flanges may be
optionally connected
at one or more points such as by extending a retaining band about the
circumference of the
collocated flanges, and/or by an adhesive disposed at point of contact between
two flanges,
and/or by insertions of fasteners (such as steel dowels, optionally inserted
al alternative angles
along the flanges) through two or more flanges. In addition or alternatively
to these measures,
the flanges may be modified to increase the flange-to-flange contact area. For
example, round
flanges may be chamfered along their length such that each flange has a large
contact surface
suitable for contacting a similarly formed chamfer on an adjacent flange.
Methods of chamfering
and laminating flanges are discussed in Applicant prior published patent
document
WO/2015/176125, WO/2015/031957, and WO/2010/057243, WO/2009/094696,
WO/2016/086275, Australian provisional patent application 2016902472 (filed 23
June 2016), the
contents of which are incorporated herein by reference.
The present connectors may be used as a means for connection of collocated
flanges, each group
of collocated flanges extending outwardly in 2, 3, 4 or 4 directions.
Typically, an angle of
.. substantially 90 degrees or 180 degrees exists between any two flange
collocations. Where two
flange collocations are concerned the connector and flange collocations may
form a linear shape
(the connector being disposed between the two groups of flanges which are
coaxial).
Alternatively, the two collocated flanges may form an L-shape with the
connector disposed at the
angle of the L. Where three flange collocations are concerned, the flanges may
form a T-shape
with the connector disposed at the intersection of the T. Where four flange
collocations are
concerned, a cruciform structure may result with the connector being located
at the centre of the
cross.
Such combinations of connector and flange collocations is that an inter-storey
cavity space
between floor levels for housing can be created. Collocated flanges which
function as beams can
be connected before or at the same time that the next level of columns are
installed for an
overlying storey such that a complete storey can be completed before
commencing construction
of the next. The zone provided can be used as a cavity into which services
(such as air
conditioning conduit, water, electrical cabling and the like) can be disposed.
It is further proposed
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that this method of construction is more cost-effective ad requires shorter
periods of time for which
workers must operate at heights.
In another embodiment of combination connector/flange collocations, there is
provided the
combination of an upper connector plate (having engaging pins extending
upwardly therefrom)
which bolts directly to an opposing mirror image lower connector plate (having
engaging pins
extending downwardly therefrom) with the plates having means for laterally
joining one or more
horizontal beams (each of the beams being collocated flanges). Such means may
comprise a
plate having laterally extending engaging members. The plate may be bolted
vertically
downwardly to the lower connecting plate.
The present invention may provide for rapid methods for constructing pre-
formed panels on the
ground of the building site or in a dedicated factory environment. The panels
may be comprised
of joists consisting of two half-beam bearers with a plurality of cross-joists
are 450 to 600 mm
centres. The panels are lowered onto the top corners of 4 columns with only
the connector plates
(previously engaged therewith) and the corner connections secured. When
another panel is
lowered the two side-by-side half-beams are simply bolted together to form a
whole beam. The
resultant grids can be quickly sheeted with timber flooring, for example, or
prepared for a slab as
described infra.
Such panels or grids may comprise at least two joists acting a half-beam
bearers (say, 5 members
high) cross joined by a plurality of similar joists (say, 4 members high) at
suitable spacing of
between say 45 Omm to 600 mm to form a 4.8 m x 6 m grid or a6mx6m grid for
example. The
joists may joined in the same plane and the joists ends may be collocated by a
present connector,
I which case the engaging members may be wither Y bar or threaded bar. In
addition the ends
may be radially cut so as to engage the rounded sides of the joists and be end
bolted through the
bearer joists in a non-moment bolted connection or be laminated on site in the
case of a Y bar
end connection.
A further advantage of the present connectors and collocated flanges is that a
composite
concrete-to-timber slab may be poured without the need the screw in numerous
shear connectors
into the tops of the joists and bearers. This is achieved in-factory be
extending the rebar engaging
members up above the joists and bearers. The bottom formwork or ply layer is
designed to be
recessed into the joists and bearers such that the tops of both are level.
This can be safely
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achieved with sheets that are fitted between joists from below, say of 400 mm
to remain level with
the joist tops at 450 mm spacings. When the slab is poured with its multiple
opposite-facing shear
connectors the concrete slab becomes essentially composite with the timber and
therefore
unlikely to separate.
Before the slab is poured, pods or anchors may be strategically positioned
around the column or
grid edges and running down to the third or fourth bearer or joist member to
create further shear
resistance for the slab. This arrangement may be used at the corners of a
building.
In some embodiments, the rapid installation methods of the present invention
involve the use of
any one or more of the following.
(i) Joists, which are in many embodiments collocated flanges. The flanges are
collocated by each
of the flanges having an axial bore hole into which inserts an engaging member
(which may be a
Y bar or a threaded bar). The ends of the joists may have ends which are
radially cut so as to
engage the rounded sides of adjacent rounded structures such beams formed from
timber rounds
which act as bearers. In some embodiments, the beams to which the joists are
configured to
attach take the form of half beam bearers as further described.
(ii) Half beam bearers have the engaging members of the connector glued into
the joist ends to
form a half-beam bearer. The connectors are further attached to column
collector plates by bolting
down onto top connector plates on site.
(iii) Full beams are two half-beam bearers cross bolted or laminated together
to form a full beam.
These can be used as cross beams between columns where required.
(iv) Top connector plates which are configured to be embedded (via the
engaging members) and
laminated into the tops of columns, so as to collocate the individual flanges
to form a column. The
top connector plate may be welded with two vertical plates in the centre
configured to receive and
sandwich therebetween the downward facing flange of a column above which is
through bolted
together as well as to receive and support a connector plate from up to four
directions by bolting
down through the plate. To avoid nuts or boltheads on the bottom, these may
just be bolt threads
extending upwardly from the top of the connector plates to screw the nuts down
onto.
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(v) Bottom connector plates having a welded flange vertical to the connector
plate on the opposite
side of the engaging members. A columns in embedded onto the engaging members.
The
connector plate and column can be lowered into position onsite for through-
bolting to other
connector plates.
(vi) Corner connector plates for corners of a building. These may have a
flange plate running the
same as for a normal connection or with the vertical flange plate at 45
degrees in either orientation
or the vertical flange plate in the shape of a cross or just as a half-cross
as a box section.
A preferred method of building is as follows. Four columns are lowered into
place firstly. Each
column is a set of flanges collocated with a connector plate. Grid-like
building modules (each
comprised of intersecting joists and beams) are lowered down onto the
connector plate and
between the corners of the four column tops. From an under-platform or
scaffold, workers secure
connector plates with nuts and washers. All other half-beam bearers and full
beams are secured
in this way.
The grids are then sheeted by passing appropriately-sized (say 400 mm x 2400
mm) ply sheet up
through the spaces between joists and allowing them to rest in preformed
rebates. From above,
concrete is poured onto the ply to form a slab floor.
New columns are then lowered into the connection zone such that the vertical
portion of the
connector plate is sandwiched between the connector plates at the top of the
underlying column
and bolt through to fix.
This basic method may be repeated so as to form a multistorey building
framework.
The present invention will be more fully described by reference to the
following non-limiting
preferred embodiments.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Reference is made to FIG. 1 which shows a perspective view of paired
connectors (each
connector marked as 10) of the present invention having a main region, being a
vertical plate 12
in this embodiment, the plate 12 having extending at a right angles thereform
a series of cylindrical
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pins 14 each of which is an engaging member configured to be received by an
axial bore (not
shown) made in each of a series of chamfered timber flanges 16. In this
embodiment each
connector 10 has a stacked series of four flanges 16. It will be noted that
each of the flanges 16
abut each other at the interface between the chamfered surfaces 17 so as to
prevent any free
play or rotation. Minor chamfering is applied also to the inside surfaces 19
of the flanges 16 for
the same reason. The chamfered inside surfaces of the flanges are more clearly
shown at FIG.
6.
The plate 12 has a first series of bolt holes (not shown) into which of each a
bolt 18 inserts to
.. allow for fastening of the connector 10 to a second identical connector set
behind (not shown in
this drawing), such that the plates of the two connectors are parallel and the
pins for the first
connecter extend in the opposite direction to those of the first connector. In
other embodiments,
the bolt ends may insert into another type of connector or any other building
structure.
The plate 12 has a lower horizontal extension 20 extending at right angles
therefrom to form an
L-shaped bracket. This lower extension 20 functions so as to support the
bottom flange 16A, but
also to provide means to fasten the connector 10 to an underlying connector
(not shown in this
drawing) or to an underlying building structure (not shown in this drawing).
In particular the lower
extension 20 comprises a second series of bolt holes (not shown) through which
a second series
.. of bolts 22 which facilitate such fastening to another connector or
structure. It will be understood
that it is not necessary for the connector to have bolt holes passing through
both the vertical plate
and the horizontal plate, although in this embodiment both are provided. It is
to be further
understood that it is not necessary for the connectors to be paired as shown
in this drawing. In
some embodiments a single connector may be used, optionally with bolt holes
disposed lateral to
both sides of the flanges 16.
The flanges 16 in the foreground are collocated by the connector in the
foreground, with the
flanges 16 in the background being collocated by the connector in the
background.
The connectors 10 are shown in end-on view in FIG. 2, whereby the minor
chamfering on the
inside abutting surfaces 19 of the flanges is more clearly shown. In some
applications, it will be
preferable for the portions of the plate 20 that sit immediately below the
flanges 16A to be removed
such that the flanges 16A are able to directly contact an underlying support
surface. In this way,
the overall height profile of the combination of the connector 10 with flanges
16 is lowered.
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Typically, the areas of plate 20 lateral to the flanges 16A remains as a means
for accepting the
bolts 22.
Use of the paired connectors 10 in a first application is shown in FIG. 2A
(lateral view) and FIG.
2B (top view). In FIG. 2A the second of the paired connectors 10 is disposed
immediately behind
the first (forward most, as drawn) connector and is therefore obscured.
As shown most clearly in FIG. 2A, there is shown a cruciform building
structure providing a vertical
column and horizontal beam arrangement. This arrangement structurally connects
an upper
column 100, a lower column 200, a left lateral beam 300 and a right lateral
beam 400. Each of
the columns 100, 200 and beams 300, 400 are comprised of chamfered timber
flanges 16 as
those shown in FIG. 1. The cruciform building structure comprises L-shaped
connectors 500,
510 which are disposed back-to-back in a mirror-image arrangement.
Each connector 500, 510 comprises a series of pins 14 each of which engages
with a flange 14
by way of an axial borehole (not shown) in the flange end. Each connector has
a series of vertical
bolt holes and horizontal bolt holes to accept a series of bolts. The vertical
bolt holes of each
connector 500, 510 are aligned so as to be fastenable together by horizontal
bolts 18.
Together the flanges 16 collocated by the connector 500 form the left hand
laterally extending
beam 300, and the flanges 16 collocated by the connector 510 form the right
hand laterally
extending beam 400.
As is shown clearly in the plan view of FIG. 2B, the connector 500 has a
paired connector 502 set
adjacently thereto. In addition, the connector 510 has a paired connector 512
set adjacently
thereto.
A third connector 520 comprises a horizontal plate 522 from which a series of
pins 14 each of
which extend so as to engage an axial bore (not shown) in each of the upper
column 100 flanges
16. Together the flanges 16 collocated by the connector 510 form the upper
column 100.
Extending downwardly from the horizontal plate 522 is a vertical plate 524
configured to snugly fit
between the vertical plates of the connectors 500, 510. The vertical plate 524
comprises bolt
holes (not shown) positioned to accept the horizontal bolts 18.
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A fourth connector 530 comprises a horizontal plate from which a series of
pins 14 extend
vertically and downwardly therefrom. Each of the pins 14 engage with an axial
borehole (not
shown) in each flange 16. Together the flanges 16 collocated by the connector
530 form the
lower column 200. The horizontal plate 532 comprises a series of bolt holes
positioned so as to
align with the bolt holes of the horizontal plate of connector 500 and
connector 510.
The flanges 16 which form the columns 100 and 200 are chamfered in a similar
manner to the
flanges shown in FIGS. lA and 2B
In the embodiment of FIG. 2A, the vertical flanges 16 of column 100 form a
column of an upper
storey of a building, while the column 200 forms the column of an immediately
lower storey of the
building. The flanges 16 are disposed in a 4 x 4 matrix, and accordingly the
pins 14 extending
from the horizontal plates 522 and 532 are disposed in a 4 x 4 matrix such
that each pin engages
with an axial borehole of its corresponding flange 16.
In the course of construction, the connectors 500, 510 and 530 (each with its
respective column
or beam already engaged) are bolted together. The third connector (with its
column attached) is
lowered into the space between the horizontal plates of connectors 500 and
510. The connectors
500 and 510 are then bolted together.
Ply may be laid on top of the upper flanges 16 of beams 300, 400 and concrete
poured thereon.
FIG. 2B shows a plan view of the cruciform building structure of FIG. 2A.
Reference is now made to FIG. 3 which shows an alternative cruciform building
structure which
is similar to that of FIG. 2A and 2B, the main difference being that the upper
vertical column 100
is disposed between the connectors 500 and 510 with there being no requirement
for a vertical
plate (524 of FIG. 2A) to extend between connectors 500 and 510. In the
structure of FIG. 3, two
L-shaped connectors 600, 610 are provided having horizontally extending pins
14. The horizontal
plates of each connector 600, 610 have a series of horizontal bolt holes (not
shown) configured
to accept the vertical bolts 612. There are no bolt holes on the vertical
plates of connectors 600,
610 in this embodiment.
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A third connector 700 comprises a horizontal plate with upwardly and
vertically extending pins 14
each of which engages with a corresponding flange 16 of the upper column 100.
Bolt holes are
disposed so as for the fourth connector of FIG. 2A, the position of bolt holes
shown as for FIG.
2B.
A fourth connector 800 comprises a horizontal plate from which pins 14 extend
vertically and
downwardly, each of which engages a flange of the lower column. The fourth
connector has bolt
holes positioned so as to align with the bolt holes of the first 600, second
610 and third connector
700. In this embodiment, the lower column (with connector) is placed firstly,
and the upper column
100 (with connectors 600 and 610 attached) then lowered downwardly thereon.
The two L-
shaped connectors 600, 610 (each with a collocated beam 300, 400 attached) are
then positioned
so as to sit on the connectors 700, 800 with the horizontal plates of all four
connectors being
bolted together.
The plan view of the structure of FIG. 3 will be the same as for FIG. 2B.
In this arrangement, each of the horizontal beams 300, 400 may be considered a
half-beam upon
which flooring (not shown) may be laid.
FIG. 4 shows an alternative embodiment useful at a corner of a building. Show
in plan view is
the upper surface of a first connector plate 900 having a central region 905
extending from which
is a first extended region 910 and a second extended region 920. The extended
regions 910 and
920 support first L-shaped connector 930 and a second L-shaped connector 940
which are
disposed on top of the fist connector 900. The extended region 910 and L-
shaped connector 930
have aligned bolt holes to facilitate fastening to each other with vertical
bolts 905. The extended
region 920 and L-shaped connector 940 have aligned bolt holes to facilitate
fastening to each
other with vertical bolts 905
Extending downwardly and vertically from the central region 905 is a series of
pins (not shown)
each of which engages with a borehole in a flange, each flange being a
component of a column.
Each L-shaped connector 930 and 940 has a series of pins 14 extending from its
vertical
component, each of the pins engaging with a flange 16, the flanges being
collocated into beams
950 and 960.
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Extending upwardly and vertically from the central region 905 of the first
connector 900 is an L-
shaped plate 970 which is welded to the upper surface of first connector 900.
Bolts 908 are
provided to fasten together the horizontal components of the L-shaped plate
970 with L-shaped
connectors 930 and 940.
The arrangement of connectors 930, 940 and plate 970 leaves an L-shaped space
allowing for
the lowering of a box-shaped vertical flange 980 downwardly and onto the
central region 905 of
the connector 900. The box-shaped flange 980 originates from a column disposed
above (not
shown) and extends from a connector plate having pins extending upwardly so as
to collocate a
number of flanges to form the column.
The box-shaped vertical flange 980 has bolt holes which align with bolt holes
of the vertical
components of the L-shaped connectors 930, 940 and the L-shaped plate 970.
Bolts are inserted
through these bolt holes as a final step so as to secure the corner structure.
Thus, it will be apparent that by this arrangement the beams 950 and 960 form
a right angle at to
the column at a corner of a building.
Reference is made to FIG. 5A showing the use of the corner structures shown in
FIG. 4 in the
context of an entire building floor. Each of the corner structures 1000, 1100,
1200, 1300 has
extending therefrom two beams 1400 at right angles. The beams have inside
ledges 1410
allowing for the disposition of a series of flooring joists 1500 thereon. In
this embodiment, the
beams 1400 are constructed from true rounds, chamfered and stacked four
flanges high, and
then abutting the four-stacked flanges are two-stacked flanges as is shown in
FIG. 50. The ledge
1410 is shown more clearly in FIG. 50. It is not necessary for the ledge 1410
to be continuous
as shown in the drawings. Instead, for example, a simple block-like support
may be affixed to the
beam 1400 only where necessary to support a joist 1500. Neither beam 1400D nor
1400B has
any ledge in this embodiment.
Each joist 1 500 is comprised of a stack of three, four or five chamfered
timber flanges, which may
be laminated together by any method deemed suitable by the skilled person. In
addition or
alternatively, the flanges may be collocated using a connector of the present
invention, being
generally a plate having outwardly extending pins inserting into a borehole of
each flange. The
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joists may be comprised of peeler cores which are collocated with a connector
comprising a plate
having pins extending therefrom and into an axial borehole in each flange as
generally taught
herein.
In the building structure of FIG. 5A the beams 1400D and 1400B are pre-fitted
to their respective
supporting corner columns. On site, the beams 1400A and 14000 are assembled
with joists
1500. Each joist 1500 (being timber flanges collocated by a connector of the
present invention)
may be bracketed or cleated or otherwise attached to the beam 1400A and 14000.
Once
assembled, the combination of beams and joists (forming a grid-like building
module) is lowered
onto and secured to the columns upon which each beam rests. Building
structures that can be
assembled on site at least to some extent, are advantageous in that transport
of the unassembled
components is typically easier and less expensive than for assembled modules.
Alternatively,
structures comprising all four beams 1400A, 1400B, 14000, 1400D and all joists
1500 may be
fabricated on site as a module and lowered onto the columns at the corners
1000, 1100, 1200,
1300. As an alternative to on-site fabrication, such building modules may be
fabricated in an off-
site factory and transported fully assemble to the building site.
Further advantage is provided where a building structure does not require any
gluing to be
performed on site. In some embodiments, flanges are collocated without the
need for gluing, in
which case a pressure fit is typically formed between a pin of a connector and
an axial bore hole
of a timber flange. The avoidance of glue saves a considerable amount of time
in construction
given there is no need to (i) apply glue and (ii) allow sufficient time for
the glue to cure before
moving assembled modules.
Reference is now made to FIG. 5B which is directed to an alternative building
structure to that
shown in FIG. 5A. It will be noted that the joists 1500 are about one-half the
length of those shown
in FIG. 5A and accordingly requires a median beam 1510 disposed one-half way
between the
beams 1400A and 14000.
The median beam 1510 rests on the ledges 1410B and 1410D and spans across
beams 1400B
and 1400D. Median beam 1510 functions so as to support and transfer load from
the joists 1500,
and then to beams 1400D and 1400B. In turn, load force is transferred from
1400D and 1400B
to the columns at each corner 1000, 1100, 1200, 1300. The median beam 1510 may
be
comprised of chamfered timer flanges collocated using a connector of the
present invention. In
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the embodiment shown in FIG. 5B two sets (1510A and 1510B) of stacked flanges
are cross-
bolted together with bolts 1515.
Thus, in the construction of the 6000 mm x 4800 mm module shown in FIG. 5B,
two half-modules
each of 6000 mm x 2400 mm may be fabricated on-site or prefabricated in a
factory. The first
half-module comprises beams 1400A and 1510A with half-joists 1500 extending
therebetween,
and the second half-module comprises beams 14000 and 1510B with half-joists
1500 extending
therebetween. The half-joists 1500 may be end grain pinned into the median
beam 1510.
The two half-modules may be fastened together with bolts 1515 either before or
after being
lowered into position on beams at corners 1000, 1100, 1200, 1300. A
supplementary beam (not
shown) may be sandwiched between 1510A and 1510B so as to provide increased
strength if
required.
With regard to the embodiment of FIG. 5B it will be noted that a ledge 1410B
is provided along
beam 1400B, and a further ledge 1410D provided along beam 1400D, these ledges
providing
support for the median beam 1510.
Reference is made to FIG. 50 which shows an exemplary arrangement of a joist
1500 resting on
a ledge 1410. A cross-pin 1530 is inserted into a bore hole drilled through
the stacked flanges.
As will be appreciated, this arrangement is exemplary only, with many other
variations being utile.
Where it is required to end join any beam or joist in order to span a required
distance across a
building, an arrangement as shown in FIG. 50 may be used whereby two connector
plates 1560,
1570 having pins extending therefrom to collocate the individual chamfered
flanges 16 are end
fastened with bolts 1575 so as to form a structurally integral joist or beam.
The plates 1560, 1570
may be configured so as to sit on or attach to other building components as
required. This is a
relatively simple form of the connector of the present invention, being a
single plate with a series
of pins extending therefrom.
The building modules shown in FIGS. 5A and 5B can be fabricated onsite or
offsite as required
and lifted into position, with sequential floors being placed on top of the
other so as to create a
multistorey building.
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Any of the beams or joists in a building structure of the present invention
may be fabricated
according to WO/2015/176125, WO/2015/031957, WO/2010/057243 WO/2009/094696,
WO/2016/086275, Australian provisional patent application 2016902472 (filed 23
June 2016), the
contents of which are herein incorporated into the specification by reference.
The structure of FIGS. 5A or 5B may be considered modular in nature, and
therefore amenable
to be substantially repeated and extended in all directions (x, y) as required
according to the area
of the building footprint. For example, beam 1400A may have an identical beam
bolted to its rear
face (i.e. the face opposed to the !edged face), with the identical beam
having a ledge extending
in the opposite direction to the ledge 1410A. This arrangement provides a beam
having an
inverted T-shaped cross-section. The ledge on the identical beam in turn
supports one end of a
further series of joists identical to those marked 1500. Typically, the beam
1400A and its abutting
identical beam will be bolted together at a number or points along their
lengths.
In this description of FIGS 5A and 5B, all columns, beams and joists are
comprised of collocated
timber flanges. In some embodiments, prior art timbers (such as square sawn
lumber, any
laminated timber or otherwise engineered timber) may be used for at least some
of the columns,
beams or joists. In some circumstances, the expense of prior art timbers may
be justified for
reasons of strength, ease of use or local building regulations.
In some building applications, it may be necessary to form a join between four
beams, with upper
and lower beams being disposed at the intersection of the beams. A suitable
arrangement of
connectors is shown in FIG. 6. The arrangement comprises a cruciform plate
2000, each of the
four arms of the plate 2000 being to support a beam formed from collocated
chamfered timber
flanges, of the type marked 2010. Two upwardly extending parallel plates 2020,
2030 are welded
onto the centre portion of the plate 2000. The space between the plates 2020,
2030 is
dimensioned so as to accept the vertical plate 524. The plates 2020 and 2030
are used so as to
afford greater overall strength as compared with the arrangement shown in FIG
2A whereby the
connector plates 500 and 510 are bolted directly to the vertical plate 524. As
such the plates
2020 and 2030 are optional.
The vertical plate 524 is joined to a horizontal plate (not shown) and
collocated upper column
flanges (not shown) as drawn in FIG. 2A (see components 524, 520, 522, 100).
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In this arrangement, there are four beams (only one of which is shown as 201 0
for clarity) each
of which extend outwardly from the centre at the 12 o'clock, 3 o'clock, 6
o'clock and 9 o'clock
position. The beam shown as 2010 is formed from flanges collocated using the L-
shaped
connector 2040. The connector 2040 contacts the plate 2030 upon assembly. A
mirror image of
the connector 2040 and beam 2010 contacts the plate 2020 upon assembly. The
two beam which
extend at 90 degrees to beam 2010 are similarly collocated with an L-shaped
connector, with the
vertical components of the connectors abutting the edges of plates 2020 and
2030, with the
horizontal components of the L-shaped connectors bolting downwardly to the
plate 2000 (bolt
holes not shown). A lower beam (not shown) is formed of flanges collocated by
a connector
similar to that marked 530 in FIG 2A.
As will be appreciated, an arrangement suitable for joining three beams in a T-
formation may be
provided by modifying the cruciform plate 2000 to exhibit a T-shape.
Reference is now made to FIG. 7 which shows an H-shaped connector 2100 having
two parallel
plates 2110 and 2120. The bottom edge of each plate 2110 and/or 21 20 may be
welded to a
lower connector plate. Each of plates 2110 and 2120 has a series of bolt holes
2130 allowing
bolting of L-shapes connector plates (such as that shown as 10 in FIG. 1A) to
the outwardly
directed faces of plates 2110 and 2120. Bolts holes are also formed in the
cross-plate 2140 allow
for the attachment of further connector plates. The cross-plate 2140 may be
not be required in
some embodiments, in which case the connector comprises simply one of plates
2110 and 2120.
In the description provided herein, numerous specific details are set forth.
However, it is
understood that embodiments of the invention may be practiced without these
specific details. In
other instances, well-known methods, structures and techniques have not been
shown in detail
in order not to obscure an understanding of this description.
In the following claims, any of the claimed embodiments can be used in any
combination.
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