Structural support member, a structural support assembly and a method of manufacturing a structural support member

Abstract

A structural support member, assembly and a method of manufacturing a structural support member is disclosed. The structural support member 100 comprises a hollow, elongate body 110, the body comprisi

Description

The present invention relates to a structural support member, a structural support assembly and a method of manufacturing a structural support member. Background WO202009662 discloses a steel beam and support arrangement. The steel beam comprises a base plate, two web parts and an end plate at each end of the steel beam. The ends of the steel beam comprises a console supporting slot for coupling with a console mounted to a support, such as a column of a building. Summary of the Invention In accordance with a first aspect of the present invention there is provided a structural support member comprising a hollow, elongate body, the body comprising in use, an upper wall, a lower wall, and a first and second side wall which extend between the upper and lower walls, each of the first and second side walls comprising a plurality of apertures formed therein along a length of the body, wherein, the lower wall and a lower portion of the first and second side wall which extends proximate to the lower wall comprises a first thickness, and the upper wall and an upper portion of the first and second side wall which extend proximate the upper wall comprises a second thickness, wherein the first thickness is greater than the second thickness. The hollow section structural support member, having walls with a thickness that is greater at the lower portion than an upper portion thereof, provides for a composite support member with a reduced weight without compromising the structural integrity and strength of the member. Moreover, the reduced weight enables a support member to be formed spanning an increased distance compared with convention support beams, without requiring a support pillar or column. The lower portion of the first and second side wall can comprise a lower half of the first and second side wall respectively, and the upper portion of the first and second side wall can comprise an upper half of the first and second side wall respectively. The apertures within the first side wall are aligned with the apertures formed in the second wall, and the apertures can comprise a substantially hexagonal shape. The apertures are centered substantially midway between the upper and lower walls, along a central region of the respective side wall. A diameter or width of the apertures is at least half the height of the respective side wall. The hollow, elongate body can comprise a substantially rectangular or square cross-sectional shape. In this respect, the upper and lower walls extend substantially perpendicular to the first and second side wall. The structural support member can further comprise a first and second flange which extend outwardly of the body, away from the first a nd second side wall respectively, proximate the lower wall. The first and second flange can extend in a plane substantially parallel with a plane of the lower wall, or within a plane which is coplanar with the plane of the lower wall. The structural support member can further comprise a plate which extends along the member adjacent the lower wall. The plate is rigidly secured to an underside of the lower wall of the body and extends laterally across the body beyond the first and second side wall to form a first and second flange. In accordance with a second aspect of the present invention, there is provided a structural support assembly, the assembly comprising at least two structural support members according to the first aspect and a floor tray which is arranged to extend between the at least two structural support members. The first flange of a structural support member and the second flange of a further structural support member can support a floor tray thereon such that the floor tray can span between the structural support members. The mounting of the floor tray on the flanges provides for a reduced overall height of floor and ceiling cavities which enables more stories to be formed within a given height of a multistorey building. The floor tray can comprise a corrugated cross-sectional shape, forming a plurality of ridges and troughs across the tray. The corrugations in the tray can comprise trapezoidal or rounded corrugations. The apertures formed within the side walls are arranged to extend adjacent a corresponding trough formed in the tray and the ridges are arranged to extend between the apertures within the side walls of the structural support members. The assembly can further comprise a plurality of strengthening bars which extend within the hollow body. The support assembly can further comprise a bracket assembly for fastening the structural support member to a support pillar. The bracket assembly can comprise a first bracket which is arranged to be secured to the support pillar and a second bracket which is arranged to be secured to the support member, the first and second brackets being configured for coupling together. The support assembly can comprise a plurality of support pillars and a plurality of bracket assemblies. The support assembly can further comprise a mesh or grid which is configured to be placed upon the floor tray to reinforce a cementitious product disposed upon the floor tray. In accordance with a third aspect of the invention, there is provided a method of manufacturing a structural support member, the method comprising the steps of: providing a first hollow elongate body comprising an upper wall, a lower wall, and a first and second side wall which extend between the upper and lower walls, the walls of the first hollow elongate body comprising a first thickness; providing a second hollow elongate body comprising an upper wall, a lower wall, and a first and second side wall which extend between the upper and lower walls, the walls of the second hollow elongate body comprising a second thickness which is less than the first thickness; forming a cut path within the first and second side wall of the first body, the cut path extending along the length of the body between the upper and lower walls, the cut path defining a cut pattern, to separate the first body into two first body portions, the cut pattern forming a plurality of ridges and troughs within the first and second side walls of each body portion; forming a cut path within the first and second side wall of the second body, the cut path extending along the length of the body between the upper and lower walls, the cut path following the cut pattern to separate the second body into two second body portions; the method further comprising placing a second body portion on top of a first body portion such that the ridges of the side walls of the second body portion are aligned with and extend adjacent to the ridges of the side walls of the first body portion, and such that the troughs of the side walls of the second body portion are aligned with and extend adjacent to the troughs of the side walls of the first body portion; and, coupling the first body portion with the second body portion at regions where the ridges of the side walls of the second body portion contact the ridges of the side walls of the first body portion such that the aligned troughs form apertures in the structural support member. The method is arranged to generate a composite structural support member having, in use, a lower portion with a greater wall thickness than the upper portion. Moreover, the cut pattern and disposition of the separate portions of the first and second bodies adjacent each other provides for a structural support member with a greater overall height than the separate first and second bodies. The method can further comprise forming the cut path along the length of the first and second body such that the cut pattern within each side wall is centered around an axis which extends midway between the upper and lower walls of the respective body. The method further comprises providing a first and second hollow elongate body having substantially the same cross-sectional size and shape. The method can further comprise forming a cut path according to a periodic cut pattern, along a length of the side walls of the first and second body. The periodic pattern can comprise a castellated cut pattern. The coupling of the first body portion with the second body portion can comprise welding at regions where the ridges of the side walls of the second body portion contact the ridges of the side walls of the first body portion. Embodiments of the present invention will now be described by way of example only and with reference to the accompanying drawings in which: Brief Description of the Drawings Figure la is a perspective view of a structural support member according to an embodiment of the present invention; Figure lb is a side view a structural support member showing relative dimensions of the member; Figure 2a is perspective view of a structural support assembly according to an embodiment of the present invention illustrating the placement of a floor tray and strengthening bars; Figure 2b is a perspective view of a structural support assembly shown in figure 2a with a reinforcing mesh positioned upon a floor tray; Figure 3a is a view of the structural support assembly illustrated in figure 2b, with a cementitious product located at one side of the structural support member; Figure 3b is a view of the structural support assembly illustrated in figure 5a, but with the cementitious product located at both sides of the structural support member; Figure 4a is an exploded view of a structural support member, bracket assembly and support pillar; Figure 4b is a perspective view of a structural support member secured to a support pillar and supporting a floor tray and reinforcing mesh; Figure 5 is perspective view of a portion of an assembled structural support assembly with several support pillars omitted for clarity; Figure 6 is a flow chart illustrating the steps associated with a method of manufacturing a structural support member according to an embodiment of the present invention; and Figure 7 is a diagrammatic representation of the steps associated with the method illustrated in figure 6. Detailed Description of Embodiments of the Invention Referring to figure 1 of the drawings, there is illustrated a structural support member 100 according to an embodiment of the present invention. The member 100 is used when constructing buildings and principally for supporting floors within a multistorey building (not shown), for example. The member comprises an elongate hollow body 110 which can be formed of steel for example. The body 110 can comprise a rectangular or square cross-sectional shape and comprises a lower and an upper wall 111, 112 which extend along the length of the body, and a first and second side wall 113,114 which extend between the lower and upper walls 111, 112, along the length of the body 110. The member 100 further comprise a plurality of apertures 120 formed in the side walls 113, 114. The apertures 120 are spaced along the length of the body 110, and the spacing may be a constant spacing such that the apertures 120 are disposed at regular positions along the body 110. Moreover, the apertures 120 in the first and second side wall 113, 114 are located at the same longitudinal positions along the body 110, such that the apertures 120 in the first side wall 113 are laterally aligned across the body 110 with a corresponding aperture 120 within the second side wall 114. The apertures 120 illustrated in figure 1 comprise a hexagonal shape, although the skilled reader will recognize that other aperture shapes, such as circular and rectangular, may also be used. The apertures 120 are centered along an axis 116 which extends midway along the respective side wall 113,114, between the lower and upper walls 111, 112. Upon referring to figure lb of the drawings, the apertures 120 typically comprise a diameter or width which is substantially 2 / 3 of the overall height H of the side walls 113,114 and are located at periodic locations along the respective side wall 113, 114, where the spacing period can typically correspond with the height H of the respective side wall 113,114. The member 100 further comprises a base plate 130 which is rigidly secured to an underside of the lower wall 111. The plate 130 comprise a substantially rectangular shape and extends along the length of the body 110, slightly beyond each longitudinal end, and also laterally beyond the first and second side walls 113,114 to form a first and second flange 131, 132 at each side of the body 110. The first and second flange 131,132 extend in a plane which is substantially parallel with the lower wall 111 of the body 110, however in an alternative embodiment, the first and second flange 131, 132 may comprise separate items which are rigidly secured to the lower wall 111 along each longitudinal edge thereof, and extend in a plane which is coplanar with the lower wall 111. The member 100 comprises a substantially composite body whereby the walls of a lower body portion 110a, and the walls of an upper body portion 110b comprise a different wall thickness. Specifically, the lower wall 111 and a lower portion of the first and second walls 113,114, which collectively form the lower body portion 110a, comprise a first thickness, and the upper wall 112 and an upper portion of the first and second walls 113, 114, which collectively form the upper body portion 110b, comprise a second thickness which is less than the first thickness. The lower portion of the first and second walls 113,114 can comprise the lower half of the first and second side walls 113, 114, and the upper portion of the first and second side walls 113,114can comprise the upper half. Referring to figure 2 of the drawings, there is illustrated a structural support assembly 200 according to an embodiment of the present invention. The assembly 200 comprises at least two structural support members 100 as described above, and a floor tray 210. The assembly 200 is used to form a floor in a multistorey building (not shown) with the members 100 supporting the floor tray 210 therebetween. The floor tray 210 can be formed of steel and comprises a generally corrugated profile comprising a series of ridges 211 and troughs 212 across a width of the tray. The corrugations may comprise a square or rounded shape, for example although the illustrated example shows a trapezoidal shape. The tray 210 is supported between the members 100 by positioning one longitudinal end of the tray 210 on a first flange 131 of one member and an opposite longitudinal end of the tray 210 on a second flange 132 of a further member 100. In this respect, the tray 210 is supported on the flanges 131, 132 of the members 100, rather than on the upper wall 112, and this provides for a lower overall height of a floor / ceiling cavity within a multistorey building (not shown). The tray 210 is disposed upon the flanges 131,132 of the members 100 and positioned relative to the members 100 such that the troughs 212 in the corrugated profile are located adjacent an aperture 120 and so that the ridges 211 in the corrugated profile are located between the apertures 120, namely adjacent a solid section of the respective side wall 113, 114. The floor tray 210 and the members 100 of the assembly 200 are arranged to receive and support a cementitious slurry 300 which is poured thereon. Referring to figure 3 of the drawings, the slurry 300 is arranged to pass into the body 110 of each member 100 through the apertures 120 in one side wall 113 and out from the body 110 through the apertures 120 in the other side wall 114. The slurry is thus arranged to extend to trays 210 disposed either side of a member 110 such that a cementitious floor can be formed in a single continuous slurry pour. To reinforce the cementitious floor, strengthening members 220 such as steel rebars may be positioned within the body 110 of each member 100 and a steel mesh 230 can be positioned upon each floor tray. Referring to figures 4 and 5 of the drawings, the support assembly 200 further comprises a plurality of support pillars 240 or columns which are arranged to support the members 100 and floor trays 210. The members 100 are secured to the pillars 240 using a bracket assembly 250 comprising a first 260 and second bracket 270. The first bracket comprises a substantially U-shape cross-section having a base 261 and opposing walls 262 which extend from the base 261. The first bracket 260 is disposed upon a support platform 280 which extends around the pillar 240 and which is secured thereto, and the base 261 is rigidly secured to the pillar 240 by welding or similar. The second bracket 270 similarly 11 comprises a U-shape having a base 271 and opposing side walls 272 and the base 271 is rigidly secured to each end of the body 110 of the member 100, effectively closing the body 110, with the opposing side walls 272 of the second bracket 270 extending outwardly away from the body 110. The side walls 272 of the second bracket 270 are separated by a distance which enables the opposing walls 262 of the first bracket 260 to nest within the opposing walls 272 of the second bracket 270. Support pillars 240 positioned centrally of a building storey (not shown) can comprise a plurality of first brackets 260, for example four first brackets 260, angularly spaced around the respective pillar 240, by 90° for example. Similarly, support pillars 240 positioned at a corner of a building (not shown) can comprise two first brackets 260 angularly spaced by 90°. The support members 100 are secured to the pillars 240 by placing a longitudinal extending portion of the base plate 130 upon the support platform 280 and nesting the opposing walls 262 of the first bracket 260 within the opposing walls 272 of the second bracket 270. The opposing walls 262, 272 of the first bracket 260 and second bracket 270 further comprise a plurality of apertures 263, 273, and when the first bracket 260 is nested within the second bracket 270, the apertures 263, 273 align for receiving fasteners, such as bolts (not shown) for securing the brackets 260, 270 together, and thus the support member 100 to the support pillar 240. Referring to figure 6 of the drawings there is illustrated a method 400 of manufacturing a structural support member 100 according to an embodiment of the present invention. The method comprises providing a first and second hollow elongate body 1101,1102 at step 401, each body comprising a lower wall 111, an upper wall 112, and a first and second side wall 113, 114. The first and second body can comprise a square or rectangular cross-sectional shape for example, and the separation of the side walls 113,114 is the same for both the first and second body 1101,1102. The first and second body 1101,1102 can be formed of steel, and the walls of the first and second body 1101,1102 respectively comprise a first and second thickness, whereby the second thickness is less than the first thickness. In this respect the second body 1102 can be lighter than the first body 1101. The method further comprises forming a cut path 140 within the first and second side wall 113,114 of each body 1101,1102 at step 402. The cutting of the first and second side wall 113,114 can take place via various methods known in the art, such as laser cutting, plasma cutting, flame cutting and also with the use of a saw. The cut path 140 extends along the length of the side walls 113, 114 between the lower and upper walls 111, 112 of the respective body, and the cut path 140 is arranged to follow a predefined cut pattern centered around the axis 116 at step 403, which extends substantially midway between the respective lower and upper walls 111, 112. The pattern may comprise a wave cut pattern, such as a castellated pattern, which is repeated with a defined period, along the respective side wall 113, 114, and is arranged to separate each body 1101, 1102 into two body portions, namely a lower body portion 1101a, 1102a and an upper body portion 1101b, 1102b at step 404. The lower body portion 1101a, 1102a comprises the lower wall 111 of the respective body and a lower portion of the respective side walls 113,114. The cut pattern formed in the first and second side wall 113, 114 of each body is mirror reflection of each other such that the pattern formed in the first side wall 113 is identical to the pattern formed in the second side wall 114, and as such the side walls 113, 114 of each lower body portion 1101a, 1102a terminate with a shape according to the cut pattern and thus comprise a plurality of ridges 141 and troughs 142 along the length thereof. Similarly, the side walls 113, 114 of the upper portion 1101b, 1102b terminate with a shape according to the cut pattern and thus comprise a plurality of ridges and troughs 141,142 along the length thereof. This is illustrated in figure 7a of the drawings. The method further comprises placing a body portion 1102a, 1102b of the second body 1102 upon a body portion 1101a, 1101b of the first body 1101 at step 405 such that the ridges 141 of the side walls 113, 114 of the second body portion 1102a are aligned with and extend adjacent to the ridges 141 of the side walls 113, 114 of the first body portion 1101a, and such that the troughs 142 of the side walls 113, 114 of the second body portion 1102a are aligned with and extend adjacent to the troughs 142 of the side walls 113,114 of the first body portion 1101a at step 406. This is illustrated in figures 7b of the drawings. Once the first and second body portions 1101a, 1102a have been aligned, the side walls 113, 114 are brought into contact, as illustrated in figure 7c of the drawings, and coupled together such as with a weld at step 407, to rigidly secure the body portions 1101a, 1102a together. The composite structural member 100 thus formed comprises a plurality of apertures 120 formed in the side walls thereof, the shape of which is determined by the desired cut pattern. In a final step, a rectangular base plate 130 is provided and rigidly secured to the underside of the lower wall 111 of the composite member at step 408. The base plate 130 is sized such that when the structural member 100 is positioned substantially centrally on the base plate 130, the base plate 130 extends laterally beyond the side walls 113, 114 and the longitudinal ends of the composite body 110, forming a first and second flange 131,132 which extends along each lateral side of the composite body 110. The structural member formed according to the above-described method comprises an increased height, namely an increased separation between the upper and lower walls compared with the separate first and second body, and thus enables structural members to 14 be formed with different dimensions compared with the dimensions of a given stock of hollow elongate bodies.

Claims

1. A structural support member comprising a hollow, elongate body, the body comprising, in use, an upper wall, a lower wall, and a first and second side wall which extend between the upper and lower walls, each of the first and second side walls comprising a plurality of apertures formed therein along a length of the body, wherein, the lower wall and a lower portion of the first and second side wall which extends proximate to the lower wall comprises a first thickness, and the upper wall and an upper portion of the first and second side wall which extend proximate the upper wall comprises a second thickness,wherein the first thickness is greater than the second thickness.

2. A structural support member according to claim 1, wherein the lower portion of the first and second side wall comprise a lower half of the first and second side wall respectively, and the upper portion of the first and second side wall comprise an upper half of the first and second side wall respectively.

3. A structural support member according to claim 1 or 2, wherein the apertures within the first side wall are aligned with the apertures formed in the second wall.

4. A structural support member according to any preceding claim, wherein the apertures comprise a substantially hexagonal shape.

5. A structural support member according to any preceding claim, wherein the apertures are centered substantially midway between the upper and lower walls, along a centralregion of the respective side wall.

6. A structural support member according to any preceding claim, further comprising a first and second flange which extend outwardly of the body, away from the first and second side wall respectively, proximate the lower wall.

7. A structural support member according to claim 6, wherein the first and second flange extend in a plane substantially parallel with a plane of the lower wall.

8. A structural support member according to claim 6, wherein the first and second flange extend in a plane which is coplanar with the plane of the lower wall.

9. A structural support member according to any of claims 1-6, further comprising a plate which extends along the member adjacent the lower wall.

10. A structural support member according to claim 9, wherein the plate is rigidly secured to the lower wall of the body and extends laterally across the body beyond the first and second side wall to form a first and second flange.

11. A structural support assembly, the assembly comprising at least two structural support members according to any preceding claim and a floor tray which is arranged to extend between the at least two structural support members.

12. A structural support assembly according to claim 11, wherein the floor tray comprises a corrugated cross-sectional shape, forming a plurality of ridges and troughs across the tray.

13. A structural support assembly according to claim 12, wherein the corrugations comprise trapezoidal or rounded corrugations.

14. A structural support assembly according to claim 12 or 13, wherein the apertures formed within the side walls are arranged to extend adjacent a corresponding trough formed in the tray and the ridges are arranged to extend between the apertures within the side walls of the structural support members.

15. A structural support assembly according to any of claims 11-14, further comprising a plurality of strengthening bars which are arranged to extend within the body of the at least two structural support members.

16. A structural support assembly according to any of claims 11-15, further comprising a bracket assembly for fastening the structural support member to a support pillar.

17. A structural support assembly according to claim 16, wherein the bracket assembly comprises a first bracket which is arranged to be secured to the support member and a second bracket which is arranged to be secured to the support pillar, the first and second brackets being configured for coupling together.

18. A structural support assembly according to claim 16 or 17, comprising a plurality of support pillars and a plurality of bracket assemblies.

19. A structural support assembly according to any of claims 11-18, further comprising a mesh or grid which is configured to be placed upon the floor tray to reinforce a cementitious product disposed upon the floor tray.

20. A method of manufacturing a structural support member, the method comprising the steps of:providing a first hollow elongate body comprising an upper wall, a lower wall, and a first and second side wall which extend between the upper and lower walls, the walls of the first hollow elongate body comprising a first thickness;providing a second hollow elongate body comprising an upper wall, a lower wall, and a first and second side wall which extend between the upper and lower walls, the walls of the second hollow elongate body comprising a second thickness which is less thanthe first thickness;forming a cut path within the first and second side wall of the first body, the cut path extending along the length of the body between the upper and lower walls, the cut path defining a cut pattern, to separate the first body into two first body portions, the cut pattern forming a plurality of ridges and troughs within the first and second side walls of each body portion;forming a cut path within the first and second side wall of the second body, the cut path extending along the length of the body between the upper and lower walls, the cut path following the cut pattern to separate the second body into two second body portions;the method further comprising placing a second body portion on top of a first body portion such that the ridges of the side walls of the second body portion are aligned with and extend adjacent to the ridges of the side walls of the first body portion, and such that the troughs of the side walls of the second body portion are aligned with and extend adjacent to the troughs of the side walls of the first body portion; and, coupling the first body portion with the second body portion at regions where the ridges of the side walls of the second body portion contact the ridges of the side walls of the first body portion such that the aligned troughs form apertures in the structural support member.

21. A method according to claim 20, further comprising forming the cut path along the length of the first and second body such that the cut pattern is centered around an axis which extends midway between the upper and lower walls of the respective body.

22. A method according to claim 20 or 21, comprising providing a first and second hollow elongate body having substantially the same cross-sectional size and shape.

23. A method according to any of claims 20-22, comprising forming a cut path according to a cut pattern which is a periodic pattern, along a length of the side walls of the first and second body.

24. A method according to claim 23, wherein the periodic pattern can comprise a 5 castellated cut pattern.

25. A method according to any of claims 20-24, wherein the coupling of the first body portion with the second body portion comprises welding at regions where the ridges of the side walls of the second body portion contact the ridges of the side walls of the first body portion.10

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