Full Moment Linked Collar System

Abstract

To propose a full moment connected collar system.SOLUTION: Provided is a method of manufacturing a full moment column collar, including the steps of: forming a collar flange blank; and machining, in the collar flange blank, a beam docking structure corresponding to the dimensions of a selected I-beam flange. The beam docking structure includes a seat configured to contact an I-beam flange.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 62 / 628,807, filed February 9, 2018, the entire contents of which are incorporated herein by reference for all purposes. U.S. Patent No. 7,941,985 B2 is also incorporated herein by reference in its entirety for all purposes. [Background technology]

[0002] Steel building construction requires beam-to-column connections, and moment-resisting connections are necessary for continuous frames. Full moment connection systems, such as collar mounts, offer valuable improvements over field welding techniques. Welds can be performed off-site under controlled conditions, frame members are fixed in the proper spatial orientation when connected by collars, and field construction can be performed more quickly, safely, and efficiently.

[0003] U.S. Patent No. 7,941,985 B2 discloses an exemplary full moment collar mount described as a halo / spider connection. Where the beam and column are connected, a collar flange assembly is welded to the end of the beam. Two collar corners are welded to the corners on each side of the face of the column. To connect, the beam is lowered so that the flange assembly is received between the collar corners, which form a tapered groove. The connections on all faces of the column together form the full moment collar. Summary of the Invention

[0004] In accordance with the present disclosure, systems, devices, and methods for full moment connections are provided. In some embodiments, a full moment post collar can include four collar flange assemblies and four collar corner assemblies. Each collar flange assembly can include an upper lateral element and a lower lateral element connected by a bridge member. Each collar corner assembly can include first and second extensions defining a corner and a standoff extending from the corner, the standoff having a distal T-shaped structure. Each collar corner assembly can be configured to connect two adjacent collar flange assemblies, and each collar corner assembly can have a multi-axis alignment structure extending from a bottom end for vertically positioning the lower lateral element of the respective collar flange assembly.

[0005] In some examples, a method of manufacturing a full moment column collar can include forming a collar flange blank. The method can further include machining a beam docking structure in the collar flange blank corresponding to a selected I-beam flange dimension. The beam docking structure can include a seat configured to contact the I-beam flange.

[0006] In some embodiments, a method of manufacturing a full moment post collar can include forming a collar corner blank having first and second extensions defining a corner and a standoff portion extending from the corner. The standoff portion can have a distal T-shaped configuration. The method can further include machining a stop surface in the collar corner blank configured to contact a surface of a collar flange assembly.

[0007] The features, functions, and advantages may be achieved independently in various embodiments of the present disclosure or may be combined in yet other embodiments, further details of which can be understood by reference to the following description and drawings. [Brief description of the drawings]

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[0022] Various aspects and examples of the full moment interlocking collar system as well as related methods are described below and illustrated in the accompanying drawings. Unless otherwise specified, the interlocking system and / or various components thereof according to the present teachings may, but need not, include at least one of the structures, components, functionality, and / or variations described, illustrated, and / or incorporated herein in connection with the present teachings. Furthermore, unless expressly excluded, the process steps, structures, components, functionality, and / or variations described, illustrated, and / or incorporated herein in connection with the present teachings may be included in other similar apparatus and methods, including interchangeability among the disclosed embodiments. The following description of various embodiments is merely exemplary in nature and is in no way intended to limit the disclosure, its application, or uses. In addition, the advantages provided by the embodiments described below are exemplary in nature, and not all embodiments provide the same advantages or to the same degree of advantages.

[0023] This Detailed Description includes the following immediately following sections: (1) Overview; (2) Examples, Components, and Alternatives; (3) Exemplary Combinations and Additional Examples; (4) Advantages, Features, and Benefits; and (5) Conclusion. The Examples, Components, and Alternatives section is further divided into subsections A through C, each of which is labeled accordingly.

[0024] overview Generally, a full moment collar connection system can connect one or more transverse members to a vertical member. For example, a full moment collar connection system can connect a square box column to four I-beams. Connection systems can also be configured to connect other types of structural members.

[0025] The connection system includes a collar that surrounds a portion of the vertical member. The collar may include a first plurality of components and a second plurality of components. The first plurality of components may be secured to the vertical member and may be referred to as standoffs, column connectors, and / or collar corner assemblies. One or more of the second plurality of components may each be secured to a corresponding transverse member and may be referred to as spans, beam connectors, and / or collar flange assemblies.

[0026] The first and second pluralities of components can be fastened together, e.g., bolted together. The components of the collar can be configured to be connected in a precise spatial configuration. The correct spatial configuration of the collar allows for precise and accurate orientation of the transverse members relative to each other and to the vertical members. Such orientation is important to the successful construction of large structures such as skeletons. By positioning the collar components relative to each other, a desired spatial configuration of the collar can be achieved largely independent of variations in the specifications of the transverse and vertical members.

[0027] The collar components can be manufactured by forming a blank and machining selected features. Forming a blank limits manufacturing costs and allows precision machining to be used only on features critical to achieve the desired spatial configuration. Such manufacturing also allows for stocking of standard blanks and on-demand machining according to selected transverse member dimensions.

[0028] Examples, Components, and Alternatives The following sections describe selected aspects of exemplary full moment articulated collars, as well as related systems and / or methods. The examples in these sections are for illustrative purposes and should not be construed as limiting the overall scope of the disclosure. Each section may include one or more explicit examples, and / or contextual or related information, functionality, and / or structure.

[0029] A. Example full moment column collar As shown in Figures 1-10, this section describes an exemplary collar 10. Collar 10 is one example of the full moment collar connection system described above. In Figure 1, collar 10 is shown connecting a square box column 12 to four I-beams 14 of a building frame. The locations of connections on the column can be referred to as nodes. In some implementations, a column can include multiple nodes, with each node connected to one or more beams by a collar.

[0030] As shown in Figure 1, the collar 10 connects the beams 14 to the post 12 such that opposing beams are parallel, adjacent beams are orthogonal, and all beams are at right angles to the post. In some embodiments, the beams can be nearly orthogonal within some angular tolerance, or can form another angle with respect to adjacent beams and / or the post. The precise location and orientation of the beams relative to the post is achieved by engagement between the components of the collar.

[0031] The column 12 includes four sides or faces 13 and four corners 15. Each beam 14 is attached adjacent to a corresponding face 13 of the column. Each beam 14 includes a web 17 that extends between upper and lower beam flanges 19. The web 17 has a thickness 23 and a height 21, the height being typically referred to as the beam depth of the beam 14. The upper and lower beam flanges 19 each have a width 25. The beam depth 21, web thickness 23, and flange width 25 all vary depending on the weight and size of the beam. The collar 10 can be configured according to the dimensions of the column 12 and beam 14. The collar 10 can be configured to connect four beams of matching dimensions or beams of differing dimensions.

[0032] The collar 10 includes an equal number of flange assemblies 16 and corner assemblies 18. In this embodiment, for a four-sided column, the collar includes four flange assemblies and four corner assemblies. The flange assemblies and corner assemblies are alternated such that each corner assembly engages two flange assemblies and similarly each flange assembly engages two corner assemblies. Each corner assembly 18 is welded to one of the corners 15 of the column 12. In this embodiment, each flange assembly 16 is welded to one of the beams 14. In some embodiments, fewer than four beams may be connected to the column and up to three flange assemblies may be left unwelded to the beams. In some embodiments, other structures or structural members may be connected to one or more of the flange assemblies. For example, a converter for a gravity catch connection may be welded to the flange assemblies.

[0033] As shown in Figure 2, the flange and corner assemblies are fastened together by horizontal bolts 27 that extend through corresponding holes in the assemblies. Each bolt 27 extends through two flange assemblies and a corner assembly. Each corner assembly is fastened with only four bolts, and the collar 10 is fastened with only 16 bolts total.

[0034] The collar 10 includes gravity stop features so that the beam with the flange assemblies attached can be lowered to engage the two corner assemblies of the column and supported by the gravity stop features while the assemblies are bolted together. The gravity stops can also be referred to as alignment guides and can be configured to guide the flange assemblies to a precise vertical and horizontal position. For example, the gravity stops can include curved or angled surfaces. The gravity stops also serve to precisely locate each adjacent flange assembly and corner assembly relative to one another, align corresponding holes in the assemblies, and locate each assembly relative to the collar as a whole.

[0035] Each assembly can include a plurality of components that are welded together, and each component can be manufactured from a formed blank. For example, the blank can be cast, forged, extruded, or additively manufactured. Selected features can be machined into the blank to form the assembly components. The selected features can be those that are important for determining the spatial arrangement and orientation of the assembly when connected to Color 10. For example, bolt holes and engagement functions can be selected to ensure accurate engagement. The machined surfaces of the selected features can be referred to as reference surfaces.

[0036] Figure 3 is a more detailed view of the corner assembly 18. The corner assembly 18 includes a column socket 29 having first and second extensions 30. The extensions extend the length of the assembly and define a corner or intersection 31. The extensions, which can also be called legs, form an interior angle at the intersection, which corresponds to the column 12 (see Figure 1). In this embodiment, the column 12 has a square cross-section and the interior angle is a right angle.

[0037] Each leg 30 is configured to be attached to the face of the column so that the corner assembly is installed at the corner of the column. The standoff 32 extends from the intersection 31 and is directed substantially parallel to the bisector of the interior angle of the leg. The side of each leg 30 facing the standoff can be the main reference plane 30d of the corner assembly 18. Each side surface of the standoff can also be the reference plane 32d. The standoff 32 also includes a T-shaped structure 33 distal from the intersection 31.

[0038] In this embodiment, the corner assembly 18 is composed of an upper section 20, an intermediate section 22, and a lower section 24. Each section can be machined from an individual blank. The sections 20, 22, and 24 are welded together to form the corner assembly. The upper section 20 and the lower section 24 are substantially identical but in a mirror image relationship. Each includes two bolt holes, namely an outer bolt hole 26 and an inner bolt hole 28. The bolt holes are arranged corresponding to the holes in the flange assembly.

[0039] The outer bolt holes 26 and inner bolt holes 28 of the top and bottom sections 20, 24 extend through the standoffs 32. Each of the top and bottom sections includes an inner portion of the standoffs 32 adjacent the mid-section 22 and an outer portion of the standoff distal from the mid-section. Each outer bolt hole 26 is located on an outer portion proximal to the intersection 31. Each inner bolt hole 28 is located on an inner portion, which in this embodiment is distal from the intersection 31. The holes 26, 28 can be described as aligned along a line oblique to the longitudinal axis BB of the corner assembly.

[0040] The location of the outer bolt holes 26 may reduce the mechanical magnification of bending loads from a beam connected to the column, as further described in connection with the flange assemblies 16 and Figures 6 and 7. Such an arrangement may thereby allow the use of only two bolts in each of the upper and lower sections, simplifying the connection of the collar while maintaining connection strength.

[0041] Along the upper and lower sections 20, 24, the height of the standoffs 32 may vary; that is, the distance between the T-shaped structure 33 and the intersection 31 may vary. The channel formed between the leg 30 and the T-shaped structure 33 of the standoff may thus be tapered over the entire length of the corner assembly 18. Note that in Figure 3, the taper is difficult to distinguish due to the small taper angle. The T-shaped structure 33 is shown more clearly in Figure 4.

[0042] While the top section 20 and bottom section 24 are standard sizes, the mid section 22 can be selected from a range of sizes. In this embodiment, the mid section 22 is comprised of multiple identical pieces welded together. The number of pieces included in the mid section can vary depending on the desired length of the corner assembly 18. The length of the corner assembly 18 can be selected to accommodate the size of the flange assembly or beam configuration selected. In embodiments where a minimum size corner assembly 18 is desired, the mid section 22 may be omitted.

[0043] As shown in more detail in FIG. 4, each leg 30 of the lower section 24 includes a multi-axis alignment structure 34 at a bottom end, located distally from the intersection 31 of the legs 30. The alignment structure 34 is configured to position the flange assembly along two axes, a vertical axis and a horizontal axis. For example, the alignment structure may position the flange assembly relative to axes AA and BB shown in FIG. 3. In another embodiment, the alignment structure may position the flange assembly along a column axis and a beam axis defined by the column 12 and adjacent beam 14 shown in FIG. 1.

[0044] Referring again to FIG. 4, the alignment structure 34 is configured to act as a gravity stop to support the flange assembly and precisely position the assembly in the vertical or Z-axis direction. Secondly, the alignment structure is configured to act as a guide to engage the flange assembly and precisely position the assembly in the horizontal or X-axis direction. The channel defined between the leg 30 and the T-shaped structure 33 is similarly configured to precisely position the engaged flange assembly in the horizontal or lateral plane. The alignment and guide functions of the alignment structure 34 are described in more detail below in connection with FIG. 10.

[0045] The structure 34 has a planar top surface 34d that precisely locates the supported flange assembly along the vertical axis or axis of the column. The structure 34 also includes a curved top surface 35 or guide shoulder configured to engage a complementary bottom surface of the flange assembly. The top surface 35 can be described as a gradual surface that slopes downward from the planar top surface 34d. The alignment structure 34 can also be described as having a planar horizontal surface 34d connected to the planar vertical surface by a sloping surface and / or a ramp 35. The ramp can be planar or curved, as in this embodiment. Preferably, the ramp can have an average slope in the range of about 15 to 45 degrees.

[0046] The alignment structure 34 can be configured to effectively transfer loads to the legs 30. For example, the structure can be of sufficient size and / or sufficient cross-sectional dimension to withstand the loads applied by the flange assemblies. The alignment structure 34 can be molded as part of the blank for the lower section 24, which can provide additional structural strength. The planar top surface 34d and the curved upper surface 35 can each be machined from the molded structure.

[0047] The corner assembly 18 is constructed to limit weight by eliminating material unnecessary for structural strength. For this reason, the upper and lower sections 20, 24 have curved contours and include recesses in the standoffs 32. Similarly, the legs 30 include notches in their edges to reduce material. As described below, such a shape can improve the strength-to-weight ratio of the collar.

[0048] 5 is a schematic diagram illustrating the manufacture of the upper and lower sections 20, 24 of the corner assembly 18. A collar corner blank 37 is formed for each section, including the post joints 29 and standoffs 32. The blanks 37 are different for the upper and lower sections 20, 24 because the lower section 24 includes the registration structure 34.

[0049] The reference surfaces of each blank are machined to achieve precise engagement with other components, collars, and / or posts of the corner assembly. The reference surfaces shown in FIG. 5 include bolt holes 26, 28, flat 34d and curved surface 35 of alignment structure 34, leg surface 30d, and standoff surface 32d. In some embodiments, additional reference surfaces can be machined, such as the inner, post-facing surface of each leg 30. The particular size and dimensions at which the machined blank is performed can vary depending on the size of the beam and / or post.

[0050] Non-datum surfaces and / or features can also be machined as needed to conform to tighter specifications than those used in the molding process, to add different features between the upper and lower sections, and / or to create the desired upper or lower sections. For example, as shown in FIG. 3, the inner surface of the T-shaped structure 33 can be machined to a desired smoothness and / or a weld prep recess can be machined on the edge adjacent the middle section 22.

[0051] FIG. 6 shows a flange assembly 16 including upper and lower lateral elements connected by a bridging component. These may be referred to as a top flange 36 and a bottom flange 38 connected by an insert 40. The top and bottom flanges are generally congruent but mirror image relationships. The insert 40 may be a square bar or other elongated member of a length selected depending on the desired size of the flange assembly 16. The flange assembly may be sized to match the depth and weight of an I-beam or other structural member.

[0052] As shown for bottom flange 38 in FIG. 7, each of the top and bottom flanges includes a body portion 42 having first and second end portions 45 and a central span 44. End portions 45 extend generally parallel to central span 44. Angled wing portions 48 extend from the first and second end portions. A beam-facing side 54 of each end portion is a primary datum surface 45d. Each datum surface 45d contacts a datum surface of a corresponding corner assembly in an assembled collar. The beam-facing side 54 of each wing portion 48 may also be a datum surface 48d.

[0053] 6, in each flange, a brace or cross member 46 extends generally perpendicularly from the body portion 42 and the wing portion 48. Each wing portion 48 has an outer portion and an inner portion separated by the cross member 46. The outer portion includes the outer bolt hole 26 and the inner portion includes the inner bolt hole 28. In this embodiment, the outer bolt hole 26 is proximal to the central axis BB of the flange assembly and the inner bolt hole 28 is distal from the central axis. The holes 26, 28 may also be described as being aligned along a line oblique to the central axis BB. The central axis BB may be parallel to the insert 40 and may bisect the central span 44.

[0054] In an assembled collar, the bolts that extend through the inner and outer bolt holes transfer loads between the collar components, especially bending loads from the attached beam. The bolts on the outer portion of each flange may bear a greater percentage of the load. The distance of each bolt from the central axis of the beam may determine the moment arm and therefore the mechanical magnification. Reducing the number of bolts on each wing portion may result in failure of the collar if the mechanical magnification is too great.

[0055] Thus, the outer bolt holes 26 are positioned to minimize the moment arm. As shown in FIG. 7, the outer bolt holes are positioned directly adjacent the end portion 45 of the body portion 42. In this embodiment, the inner bolt holes 28 are positioned proximate the distal edge 62 of the wing portion 48. Such positioning of the inner bolt holes allows access for tools used to install and tighten the bolts. Depending on the tool and / or bolt, the insert 40 may get in the way if the inner bolt holes 28 were closer to the central axis BB. In some embodiments, a fastener may be used that allows the inner bolt holes 28 to be positioned in vertical alignment with the outer bolt holes 26 directly adjacent the end portion 45.

[0056] Such an arrangement of bolt holes 26, 28 allows for only two bolts to be used for each wing section, simplifying the connection of the collar while maintaining connection strength. Reducing the number of bolts can reduce machining time for the bolt holes, reduce material costs for the bolts, and improve installation time. Some examples may include three bolt holes (as described below in Example C), the number of holes in different wing sections may vary, and / or other numbers of holes may be used in other configurations to achieve the desired load transfer.

[0057] The top and bottom flanges 36, 38 are constructed to limit weight by eliminating material unnecessary for structural strength. Together with the weight-reducing shape of the collar corner assembly, this can improve the strength-to-weight ratio of the collar. For example, the collar can achieve a ratio of 5,000-9,000 pounds of force per pound of mass (i.e., 2,200-4,000 kilograms of force per kilogram of mass). For this reason, the wing portions 48 and cross members 46 have curved profiles, notches such as recesses 43. The outer portion of each wing 48 is smaller than the inner portion, and the beveled corners have an angled boundary distal to the center span 44.

[0058] As shown for bottom flange 38 in FIG. 7, end portions 45 of body portion 42 narrow from wing portions 48 to center span 44. Center span 44 may be described as having a height 47 that is less than a height 49 of wing portions 48. The top and bottom flanges may also be described as being asymmetrical and / or butterfly shaped relative to cross member 46. The rounded contours of the flanges also facilitate easy assembly of the collar beam mount and may guide a slightly misaligned flange assembly into correct alignment.

[0059] 1, the column-facing side 54 of the mid-span 44 is adjacent to the face 13 of the column 12, but is spaced from the column. Each beam 14 is attached to the flange assembly 16 with the beam flanges 19 in contact with the beam-facing sides 56 of the cross members 46 of the top and bottom flanges 36, 38, and the beam webs 17 in contact with the inserts 40 of the flange assemblies.

[0060] The contact between the top flange 19 of the beam 14 and the cross member 46 of the top flange 36 is shown in more detail in Figure 8, which depicts the beam in a transparent view. The contact between the beam and the bottom flange 38 is similar and mirror imaged, so the following description applies to the described features on both the top and bottom flanges. The cross member 46 of the top flange 36 includes a beam docking structure 58 on a side 56 facing the beam that is configured to receive an end portion of the beam 14.

[0061] The docking structure 58 includes a recess on the outer side of the cross-member 46 defined by a planar seat 59 and an angled wall 61. The seat 59 is configured to support a portion of the upper beam flange 19. Proximate a central portion of the seat 59, a projection 63 extends from the beam-facing side 56 of the cross-member 46. A slot 60 in the projection 63 is configured to receive an end portion of the web 17 of the beam 14.

[0062] The seat portion 59 and the slot 60 of the docking structure 58 can support and stabilize the end portion of the beam 14 during welding to the flange assembly. Such stability can simplify the welding and improve its safety. The docking structure 58 is also shaped to accommodate a filling material used when welding the beam 14 to the top flange 36. Such a filling material may be enclosed between the beam end and the inclined wall 61.

[0063] The docking structure 58 is dimensioned to correspond to the beam 14. FIG. 8 also depicts another possible docking structure 58a (see FIG. 1) suitable for a heavier beam with a larger web thickness 23 and flange width 25, shown by dashed lines. When the upper flange 19 is machined from a blank, the size of the beam can be selected, and the docking structure 58, 58a, or any suitable docking structure can be machined into the cross member 46 of the blank.

[0064] The cross member 46 extends beyond the flange 48 on the side 56 facing the beam. The cross member 46 can be described as having an extended depth 51 measured in the direction of the beam from the outermost part of the flange 48. The depth 51 may be sufficient for the beam docking structure 58 to be disposed in the beam direction of the flange. This extension of the cross member can strengthen each of the top and bottom flanges against bending loads from the beam 14.

[0065] As shown in FIG. 6, each cross member 46 of the top flange 36 and the bottom flange 38 has an inner surface 53 close to the inner part of the flange 48 and an outer surface 55 close to the outer part of the flange. The outer surface 55 of the bottom flange 38 is clearly shown in FIG. 10, and the inner surface 53 of the upper flange 36 is clearly shown in FIG. 8. In each flange, the cross member 46 is tapered towards the side 56 facing the beam. In other words, each taper of the cross member 46 can help alleviate the increased manufacturing complexity caused by extending the cross member by the depth 51.

[0066] As shown in FIG. 8, the flanges 19 of the connecting beam 14 may define a plane. The inner surface 53 and the outer surface 55 may be described as inclined relative to the beam flange plane. The outer surface 55 may be disposed at a greater angle than the inner surface 53. For example, the outer surface 55 may be inclined in the range of 2-10 degrees and the inner surface 53 may be inclined in the range of 5-15 degrees. The angle may be large enough to simplify shaping of the blanks for the upper and lower flanges, particularly if the blanks are to be forged. The angle may be small enough so as not to adversely affect the strength of the cross member 46 and / or interfere with precise spatial placement of the collar components.

[0067] Also shown in FIG. 8 is the collar corner assembly 18 engaging with the collar flange assembly 16. The corner and flange assemblies are shown in an ideal engaged position. The datum surface 45d of the body portion 42 of the flange assembly contacts the datum surface 30d of the leg 30 of the corner assembly. The wing surface 48d is separated from the standoff surface 32d by a gap 68. When assembled to the collar 10 as shown in FIG. 1, this position can provide an ideal load path and clamping of the column 12. Bending loads on each beam 14 can be transferred through the collar, around the column to the other beams.

[0068] However, maintaining the gap 68 when the collar 10 is fastened together by the horizontal bolts 27 requires stringent manufacturing standards and robust, heavy collar components. On the other hand, eliminating the gap 68 would increase the mechanical magnification of the beam 14 relative to the collar 10, increasing the moment arm. Such an increase could be sufficient to cause failure of the collar components.

[0069] As disclosed herein, the collar 10 is configured to be used without the gap 68 and without damage to the collar. Several features and characteristics can be combined to achieve such a configuration. The location of the bolt holes 26, 28 described above in connection with FIG. 7 can reduce bolting loads. The extension 51 of the cross member 46 described above in connection with FIG. 8 can increase the strength of the flange assembly. The collar 10 can include a more flexible material, have a reduced weight as described above in connection with FIGS. 3 and 7, and can be configured for lighter beams for a given desired span. By allowing the gap 68 to close during installation due to manufacturing or construction inaccuracies, manufacturing and installation standards can be less stringent. Such standards can in turn reduce costs, increase manufacturing speeds, and allow for additional options for manufacturing methods.

[0070] 9, the bottom flange 38 and the top flange 36 each include an interface structure configured for connection of the insert 40. The interface structure includes a raised flat 50 on the inner surface 53 of the cross member 46 and an adjacent upstanding surface 52 of the central span 44. The raised flat is centrally located on the inner surface of the cross member 46, and a protrusion 63 extends from the beam-facing end of the flat.

[0071] The raised flat 50 contacts the end face 41 of the insert 40, and the raised face 52 contacts the post-facing surface of the insert. The insert 40 can be described as a square prism and / or a square bar having first and second planar ends. Thus, the raised flat and the raised faces are each planar. Such planar interfaces allow the insert 40 to be cut to a desired length from the square bar stock without additional shaping.

[0072] The raised flats 50 and raised faces 52 can be machined into the molded flange blank and precisely located relative to the bolt holes 26, 28. The insert 40 can thereby be precisely located relative to the bolt holes in the top and bottom flanges 36, 38 to ensure precise spacing between the bolt holes in the top and bottom flanges.

[0073] Bottom flange 38 is also configured to engage with a corresponding corner assembly alignment structure. As shown in FIG. 7, bottom flange 38 includes a curved bottom surface 64 recessed into end portion 45 of body portion 42. Bottom surface 64 has a horizontal flat portion 64d at the apex of the curvature. Bottom surface 64 may be machined into a molded flange blank.

[0074] 10 shows the flange assembly 16 with the bottom flange 38 engaged with the lower section 24 and received between two corner assemblies 18. The post-facing side 54 of the center span 44 contacts the adjacent leg of each lower section. The post-facing side 54 of each wing portion 48 may contact the standoff 32 of the corresponding corner assembly or may be separated from the standoff by a gap, as described above. The inner and outer bolt holes 26, 28 of the bottom flange 38 and lower section 24 are aligned.

[0075] The alignment features 34 of the corner assembly 18 extend below the end portion 45 of the body portion 42 of the bottom flange 38. The planar portion 64d of the bottom surface 64 of the mid-span rests on the planar surface 34d of each alignment feature. The bottom flange 38, and thus the flange assembly, is thereby precisely positioned vertically relative to the corner assembly.

[0076] The bottom surface 64 can be described as an inverted version of the alignment structure 34. In particular, the bottom surface can include a curved, sloped, or gradated surface that is complementary to the top surface 35 of the alignment structure. Once the flange assembly 16 is received in the correct position, the curved portion of the bottom surface 64 is spaced from the curved surface 35 of the alignment structure 34. The two curved surfaces engage as the flange assembly descends between the corner assemblies, guiding the flange assembly to the correct horizontal position. That is, when the corner of the bottom surface 64 contacts the curved surface 35, the bottom flange 38 can be adjusted horizontally as the corner slides downward along the curved surface to the correct position.

[0077] 11 is a schematic diagram illustrating the manufacture of the top and bottom flanges 36, 38 of the flange assembly 16. A collar flange blank 65 is formed, including the center span 44, cross members, and wing portions 48. The top and bottom flanges 36, 38 can be made from the same blank, although the machining differs between the flanges.

[0078] The reference surfaces of the blank are machined to achieve precise engagement with other components, collars, and / or beams of the flange assembly. For example, the reference surfaces shown in FIG. 11 include the bolt holes 26, 28; the raised flats 50 and upstanding surfaces 52 of the insert interface; and the seats 59 and slots 60 of the docking structure 58. Other reference surfaces on the post-facing side of the flange, shown in FIG. 7, include the body end portion surface 45d and the wing surface 48d. On the bottom flange 38, the bottom surface 64d is also machined.

[0079] Referring again to FIG. 11, the bolt holes 26, 28 can be machined to align with corresponding holes in the mating corner assembly. The insert interfaces 50 and 52 allow the insert to be precisely positioned to locate the top and bottom flanges along a vertical axis relative to one another. The docking structure 58 surfaces contact the corresponding beams to precisely locate the beams relative to the flange assemblies. The post-facing surfaces 45d, 48d contact the corner assembly reference surfaces to precisely locate the flanges in a horizontal plane or a plane perpendicular to the posts. The bottom surface 64d allows the flange assembly to be precisely positioned along both the vertical and horizontal axes relative to the corner assembly alignment structure 34. The relative position of each of these surfaces is also important to the correct overall spatial configuration of the flange assemblies and collars.

[0080] In some examples, additional datum surfaces can be machined into one or both of the flange blanks, such as the post-facing side of each wing portion 48 and a surface adjacent the wing portion 48 on the post-facing side of the midspan 44. These surfaces can contact datum surfaces on the corner assemblies to position the flanges in a horizontal plane or a plane perpendicular to the columns. The particular sizes and dimensions at which the machinables are performed can vary depending on the size of the beam and / or column.

[0081] Non-datum surfaces and / or features can also be machined as needed to add different features between the top and bottom flanges and / or to create the desired top or bottom flanges to conform to tighter specifications than those used in the molding process. For example, as shown in FIG. 7, each wing portion 48 has a side edge 62. The side edge can be machined at an angle to the insert 40 or to the vertical axis of the flange assembly. This angle is not mirrored between the top and bottom flanges, resulting in a generally tapered flange assembly. This taper corresponds to the tapered channel of the corner assembly. For example, in another embodiment, as shown in FIG. 6, each bolt hole 26, 28 includes a counterbore 70 on the beam-facing side 54 of the flange assembly. The flange blank can include recesses molded in the appropriate locations, which can be machined to the counterbore 70.

[0082] 12 is another schematic diagram illustrating the manufacture of flange assembly 16. Component inventory 66 includes collar flange blanks 37 and a range of sizes of inserts 40. In some embodiments, the inventory may include standard length bar stock that can be cut to selected lengths for inserts 40. In some embodiments, the inventory may include a single type of collar flange blank, may include blanks specific to the top and / or bottom flanges, and / or may include blanks of a range of sizes.

[0083] The flange assemblies 16 can be manufactured from stock 66 components for a selected size beam 14. As shown in FIG. 1, each beam has a beam depth 21, a web thickness 23, and a flange width 25. These dimensions can be varied independently or interdependently. The flange assemblies 16 can be independently configured for each of the three dimensions. FIG. 12 illustrates three flange assemblies 16 manufactured for three different sizes of beam 14.

[0084] To match the beam diameter 21 of the beam 14, a corresponding size insert 40 can be selected or cut. In another embodiment, the insert 40 can be cut to the appropriate length for a W12-22, 12 inch beam, but can also be cut for a W21-65, W12-65, or W18-40 beam. To match the web thickness 23 and flange width 25, an appropriate size beam docking structure can be machined into the collar flange blank 37. For example, the collar flange blank 37 can be wide enough to be machined to accept a W12-22, 22 lbs per linear foot width flange I-beam, but can also be machined to accept a W21-65, W12-65, or W18-40 beam.

[0085] Such versatile configurations can be easily manufactured by maintaining an inventory of formed flanges and bar stock on hand and / or machining and / or cutting them to create flange assemblies as needed for each particular building project.

[0086] B. Exemplary Methods for Manufacturing Full Moment Colors This section describes the steps of an exemplary method 200 for manufacturing a full moment collar (see FIG. 13). Aspects of the collars, components, and / or blanks described above may be utilized in the method steps described below. Where appropriate, reference may be made to components and systems that may be used to perform each step. These references are for illustrative purposes and are not intended to limit the possible manner in which any particular step of the method may be performed.

[0087] 13 is a flow chart illustrating steps performed in an exemplary method, although a complete process or all steps of the method may not be listed. Various steps of method 200 are described below and illustrated in FIG. 13, although the steps need not all be performed, and in some cases may be performed simultaneously or in a different order than that shown.

[0088] At step 210, the method includes forming a collar flange blank. The blank can be cast, forged, extruded, additively manufactured, and / or formed by any effective method. The blank can also be referred to as a transverse element and can include a central span with wing portions at each end. The transverse can divide the blank into two portions, an outer portion and an inner portion.

[0089] Step 212 of the method includes machining a beam docking structure. The beam docking structure can be machined into the cross member of the collar flange blank and can correspond to the selected I-beam dimensions. The docking structure can include a seat and an angled wall, the angled wall forming an angle of greater than 90 degrees with the seat.

[0090] The docking structure can be configured to receive an end of a flange of a selected I-beam. When received, an inner or web-adjacent side of the flange of the I-beam may contact a seat of the beam docking structure. The beam docking structure may further include a protrusion extending outwardly from a central portion of the seat. A slot in the protrusion can be configured to receive the web of the I-beam.

[0091] Step 214 of the method includes drilling a pair of holes. The pair of holes may be drilled in one of the wing portions of the collar flange blank. Each hole may be sized to receive a fastener, such as a bolt. Step 214 may be repeated for the other wing portion of the blank such that the holes are symmetrical and a total of four holes are drilled. In some embodiments, no more than two holes may be drilled in each wing portion.

[0092] The holes can be drilled at precise locations relative to the docking structures machined in step 212. In embodiments where step 214 is performed before step 212, the docking structures can be machined at precise locations relative to the drilled holes. Each pair of holes can be located along an axis that is oblique to the cross member and / or to the lateral extension of the blank. In other words, the line extending between the two holes is inclined relative to the blank.

[0093] In some embodiments, the method 200 may further include additional machining steps. Other surfaces and / or features may be machined into the collar flange blank. Examples of such features include web insert interfaces and alignment structure engagement surfaces. Additional processing of the blank, such as cleaning, may also be performed. Once processing is complete, the collar flange blank may be referred to as a collar flange.

[0094] Method step 216 includes welding the collar flange into the collar flange assembly. Steps 210-214 may be repeated to create a second collar flange. One of the collar flanges may be configured as a top flange and one as a bottom flange. The top flange may be welded to a first end of the web insert and the bottom flange may be welded to a second end of the web insert. In some embodiments, additional processing of the collar flange assembly may be performed after welding. For example, the collar flange assembly may be galvanized.

[0095] Method step 218 includes welding the collar flange assembly to the end of the beam. In some embodiments, step 218 may be omitted. Each flange of the beam may be received by one beam docking structure of the collar flange of the collar flange assembly. The web of the beam may be received in both docking structures. With the beam supported and stabilized by the docking structures, the collar flange assembly may be welded to the beam.

[0096] Step 220 of the method includes forming a collar corner blank. The blank can be formed by casting, forging, extrusion, additive manufacturing, and / or any effective method. The blank can also be referred to as a lower section and can include a post joint and a standoff portion. The post joint can include first and second extensions that define a corner portion, and the standoff portion can include a distal T-shaped structure.

[0097] Method step 222 includes machining a stop surface into the blank. The stop surface can be a flat and / or curved surface on top of the alignment structure. The alignment structure can extend from a bottom portion of the first or second extension and can be located distal to the standoff. The stop surface can be orthogonal to an adjacent surface of the respective extension.

[0098] Step 224 of the method includes drilling a pair of holes in the blank. The pair of holes may be drilled in one of the wing portions of the collar flange blank. Each hole may be sized to receive a fastener such as a bolt. The holes may be drilled in a precise location relative to the stop surface machined in step 222. In embodiments where step 224 is performed prior to step 222, the stop surface may be machined in a precise location relative to the drilled holes. The pair of holes may be located along an axis oblique to a corner defined by the first and second extensions and / or to a longitudinal direction of the blank. In other words, a line extending between the two holes may be inclined relative to the blank. In some embodiments, the pair of holes may be the only holes drilled in the standoff of the blank.

[0099] In some embodiments, the method 200 can include additional machining steps. Other surfaces and / or features can be machined into the collar corner blank. Examples of such features include a post-engaging surface of each of the first and second extensions and a post-engaging surface of the standoff. The blank can also undergo additional blank processing, such as galvanizing. Once processing is complete, the collar flange blank can be referred to as the lower section.

[0100] Step 226 of the method includes welding the bottom section to the collar corner assembly. Steps 220 and 224 can be repeated to create the top section, and an appropriately sized middle section can be selected. The top, middle, and bottom sections can be welded together to form a collar corner assembly having a post joint with first and second extensions and a standoff portion with a distal T-shaped structure. The collar corner assembly can include two pairs of drilled holes in the standoff portion, or a total of four pairs.

[0101] Step 228 includes welding the collar corner assembly to the corner of the post. First and second extensions of the collar corner assembly may be welded to first and second faces of the post adjacent the corner of the post at selected longitudinal locations of the post. Steps 220-226 may be repeated to create three additional collar corner assemblies, and step 228 may include welding all four collar corner assemblies to the post. The collar corner assemblies may be precisely positioned relative to one another prior to welding to the post.

[0102] Steps 210-218 may be performed in a shop or other staging area prior to transport to the job site. Steps 210-218 may be performed multiple times to create a desired number of collar flange assemblies, which may or may not be welded to the beam. Steps 220-228 may also be performed in a shop or staging area. Steps 220-228 may be performed in parallel with steps 210-218, prior to steps 210-218, or after steps 210-218. Steps 210-228 may be completed in their entirety before the material is transported to the job site and step 230 is performed.

[0103] At step 230, the method 200 includes assembling the prepared collar flange assembly and collar corner assembly into a collar. The column can be positioned as desired at the job site, for example, fastened to a foundation. A first beam can be positioned adjacent to the column with the column-facing side of the mid-span of the attached flange assembly generally parallel to the face of the column, and over two corner assemblies attached to adjacent corners of the column.

[0104] The beam may be lowered along the column so that the wing portions of the bottom flanges of the flange assemblies are received by the adjacent corner assemblies. The beam may be lowered until the underside of the bottom flange contacts the alignment structure of the corner assembly. The bolt holes in each wing portion of the top and bottom flanges may then be aligned with corresponding bolt holes in the corner assembly.

[0105] A second beam can then be lowered in a similar manner on the second face of the column, and so on for the third and fourth beams until a complete collar is formed by the flange assemblies and corner assemblies. When connecting three or fewer beams to a column, flange assemblies without attached beams can be lowered on one or more faces of the column.

[0106] In the upper section of each corner assembly, three pairs or sets of bolt holes may be aligned. Similarly, in the lower section, three pairs or sets of bolt holes may be aligned. A bolt may be secured to each set of the three aligned holes for a total of 16 bolts secured to the collar. Each wing section may thereby be attached through the corner assembly to the wing section of the adjacent flange assembly. The collar may be precisely positioned prior to bolting and may be bolted to maintain proper alignment and support additional load transfer.

[0107] In some embodiments, the bolting can leave a gap between each wing portion and the adjacent standoff. In such embodiments, the collar can achieve ideal load transfer by fully tightening the collar. In some embodiments, the bolts can be sufficiently tightened to bring some or all of the wing portion into contact with the adjacent standoff. The collar can be configured to withstand expected loads without damage despite partial tightening of the post resulting from such contact. By performing this bolting step without having to leave a gap, the time and cost required to manufacture and assemble the collar can be reduced.

[0108] C. Example of stiffened full moment column collar This section describes another embodiment of the full moment collar connection system described above, as shown in Figures 14 and 15. This embodiment is suitable for structures or other applications that include larger beams or require a higher load capacity.

[0109] FIG. 14 shows a flange assembly 116 configured to mate with three other flange assemblies and four corner assemblies to form a collar. The flange assembly 116 is substantially identical to the flange assembly 16 of the collar 10 described above, but includes additional holes to allow for the use of a greater number of horizontal bolts. The additional bolts, when positioned as described in further detail below, provide additional load transfer between the beam and column connected by the collar. The total number of bolts required for the collar of this embodiment can still be reduced from the number of fasteners required for known full moment connections. It is preferable to use the minimum number of bolts possible for speed and ease of construction, and the collar of this embodiment can be selected only for connections requiring reinforcement.

[0110] The flange assembly 116 includes a top flange 136 and a bottom flange 138 connected by an insert 140. The flange assembly can be sized to match the depth and weight of an I-beam or other structural member by both selecting an insert of the appropriate length and forming a beam docking structure 158 of the appropriate dimensions. The top flange 136 and bottom flange 138 can be made from a formed blank, with critical surfaces such as the beam docking structure 158 being precisely machined into the blank.

[0111] Top flange 136 and bottom flange 138 are generally identical, but many features are mirror images and some features are different. Each flange includes a body having angled wing portions 148 extending from first and second end portions 145 and a cross member 146. Each wing portion includes an outer portion and an inner portion separated by cross member 46. For top flange 136, the outer portion can be described as an upper portion and the inner portion can be described as a lower portion. In contrast, for bottom flange 138, the outer portion can be described as a lower portion and the inner portion can be described as an upper portion. The outer portion of each flange includes an outer bolt hole 126. The inner portion of each flange includes two inner bolt holes 126, a proximal inner bolt hole 127 and a distal inner bolt hole 128.

[0112] Bolt holes 126, 127, and 128 can be described as being disposed at a right angle corner. The two proximal bolt holes, outer bolt hole 126, and proximal inner bolt hole 127 are stacked vertically. Bolt holes 126 and 127 can be described as being aligned on a vertical axis BB, where axis BB is parallel to the longitudinal axis of flange assembly 116. The two inner bolt holes 127 and 128 are horizontally adjacent. Distal inner bolt hole 128 and outer bolt hole 126 can be described as being aligned along a line oblique to axis BB.

[0113] As described above with respect to embodiment A, the bolts extending through the inner and outer bolt holes transfer loads between the components of the assembled collar, particularly bending loads from the attached beam. The distance of each bolt from the central axis of the beam determines the moment arm and therefore the mechanical magnification. Thus, the outer bolt hole 126 and the proximal inner bolt hole 127 are positioned to minimize the moment arm. The outer bolt hole and the proximal inner bolt hole are each positioned directly adjacent to the end portion 145 of the body 142.

[0114] The flange assembly 116 can be fastened to two further flange assemblies via two adjacent corner assemblies of the collar. Each corner assembly can include three bolt holes in an upper section and three bolt holes in a lower section corresponding to bolt holes 126, 127, 128 of the flange assembly 116. The flange assemblies and corner assemblies can be fastened by a number of horizontal bolts. In this embodiment, each corner assembly can be fastened by six bolts and the collar can be fastened by a total of 24 bolts.

[0115] Exemplary Combinations and Additional Examples This section describes additional aspects and features of the apparatus and methods for connecting a full moment connection collar system to an elongate member, presented without limitation as a series of paragraphs, some or all of which may be designated alphanumeric for clarity and efficiency. Each of these paragraphs may be combined in any suitable manner with one or more of the other paragraphs and / or with the disclosure elsewhere in this application, including material incorporated by reference in cross-references. Some of the following paragraphs explicitly refer to and further limit other parameters, providing, without limitation, some examples of suitable combinations.

[0116] A. forming a collar flange blank; machining a beam docking feature into the collar flange blank corresponding to a selected I-beam flange dimension; Including, the beam docking structure includes a seat configured to contact an I-beam flange; Manufacturing method for full moment column collar.

[0117] A1. The method of paragraph A, wherein the seat is configured to contact an upper surface of an I-beam flange.

[0118] A2. The method of paragraph A or A1, wherein the seat is configured to contact a bottom surface of the I-beam flange.

[0119] A3. The method of any of paragraphs A-A2, wherein the beam docking structure includes a protrusion extending outwardly from a central portion of the seat, the protrusion having a slot configured to receive a web portion of an I-beam.

[0120] A4. The method of any of paragraphs A-A3, wherein the collar flange blank has a pair of wing portions, and further comprising the step of drilling a pair of holes in each wing portion at locations precisely related to the beam docking structure.

[0121] A5. The method of paragraph A4, wherein the pair of holes in each wing portion are disposed along an oblique axis.

[0122] A6. The method of paragraphs A4 or A5, wherein the pair of holes in each wing portion are the only holes in the respective wing portion.

[0123] A7. The method of paragraphs A4 or A5, further comprising drilling a third hole in each wing portion.

[0124] A8. The method of any of paragraphs A-A7, wherein the beam docking structure has an angled wall extending from the seat.

[0125] A9. The method of paragraph A8, wherein the angled wall forms an angle of greater than 90 degrees with respect to the seat.

[0126] A10. The method of any of paragraphs A-A9, further comprising machining a bridge component interface structure into the collar flange blank, the interface structure including first and second planar surfaces.

[0127] A11. The method of any of paragraphs A-A10, further comprising cutting a bridging component of a selected length from a standard length elongated member.

[0128] B. forming a collar corner blank having first and second extensions defining a corner and a standoff extending from the corner, the standoff having a distal T-shaped configuration; machining a stop surface on the collar corner blank configured to contact a surface of a flange assembly; Including, Manufacturing method for full moment column collar.

[0129] B1. The method of paragraph B, further comprising the step of drilling a pair of holes in the standoff portion at locations precisely related to said stop surface.

[0130] B2. The method of paragraph B1, wherein the pair of holes are disposed along an oblique axis.

[0131] B3. The method of paragraphs B1 or B2, wherein the pair of holes in the standoff portion are the only holes in the standoff portion.

[0132] B4. The method of paragraphs B1 or B2, further comprising drilling a third hole in the standoff portion.

[0133] B5. The method of any of paragraphs B-B4, further comprising machining a curved or angled guide surface adjacent said stop surface.

[0134] B6. The method of paragraph B5, wherein the guide surface and the stop surface are machined into alignment features of the collar corner blank.

[0135] C. an upper transverse element; A lower transverse element; a bridging component connecting the upper transverse element and the lower transverse element; 1. A flange assembly comprising: A flange assembly, wherein each transverse element has an intermediate portion connecting a first wing portion and a second wing portion, said intermediate portion being connected to said bridging component, and each wing portion having fewer than four bolt holes configured for attachment to the wing portion of an adjacent flange assembly.

[0136] C1. A flange assembly as described in paragraph C, wherein each wing section has three or less bolt holes.

[0137] C2. A flange assembly as described in paragraph C or C1, wherein each wing section has no more than two bolt holes.

[0138] C3. The flange assembly of paragraph C2, wherein the bolt holes in each wing portion are aligned along a first axis oblique to the longitudinal axis of the bridge component.

[0139] C4. The flange assembly of any of paragraphs C-C3, wherein one of the bolt holes is directly adjacent to the intermediate portion.

[0140] C5. The flange assembly of any of paragraphs C1-C4, wherein each wing portion has an inner portion and an outer portion, the inner portion having a bolt hole distal from the intermediate portion and the outer portion having a bolt hole proximal from the intermediate portion.

[0141] C6. The flange assembly of any of paragraphs C1-C5, wherein each wing portion has an inboard portion and an outboard portion, the outboard portion having a bolt hole immediately adjacent the intermediate portion.

[0142] C7. The flange assembly of any of paragraphs C-C5, wherein the upper and lower lateral elements are comprised of forged metal and the bolt holes are machined into the forged metal.

[0143] C8. The flange assembly of any of paragraphs C-C7, wherein the upper and lower lateral elements each include a brace portion and a central portion extending perpendicularly from the wing portions, and first and second bolt holes are located on either side of the brace portion in each wing portion.

[0144] C9. The flange assembly of paragraph C8, wherein the brace section tapers toward the beam.

[0145] C10. The flange assembly of paragraphs C8 or C9, wherein the brace section includes an outer surface and an inner surface, each surface disposed at an angle to the flange of a beam connected to the flange assembly.

[0146] C11. The flange assembly of paragraph C10, wherein the outer surface is disposed at an angle ranging from about 2 degrees to 10 degrees and the inner surface is disposed at an angle ranging from about 5 degrees to 15 degrees.

[0147] C12. The flange assembly of any of paragraphs C-C11, wherein the bridging component is a rectangular prism.

[0148] C13. The flange assembly of any of paragraphs C-C12, wherein each transverse element includes an interface structure configured to interlock with the bridging component, the interface structure including two orthogonal planes.

[0149] C14. The flange assembly of any of paragraphs C-C13, wherein the intermediate portion includes a central span and first and second end portions, the first and second end portions each tapering from the wing portions toward the central span.

[0150] C15. The flange assembly of paragraph C14, wherein the center span has a vertical height less than a vertical height of the wing portions.

[0151] C16. The flange assembly of any of paragraphs C-C15, wherein the transverse element has a curved profile configured to reduce material weight.

[0152] C17. The flange assembly of any of paragraphs C-C16, wherein the flange assembly has a bending load-to-weight ratio of about 5,000-9,000 pounds of force per pound of weight.

[0153] D. a post joint having first and second extensions defining a corner; a standoff portion extending from the corner portion; the standoff portion having fewer than eight bolt holes. Color corner assembly.

[0154] D1. The collar corner assembly of paragraph D, wherein a first axis is parallel to the corner portion and the standoff portion has two sets of holes, each set of holes being aligned along a second axis oblique to the first axis.

[0155] D2. The collar corner assembly of paragraph D or D1, wherein at least two bolt holes are located immediately adjacent to the standoff portion.

[0156] D3. A collar corner assembly as described in any of paragraphs D-D2, wherein the column joint portion and the standoff portion each have a standard upper section and a standard lower section connected by a selectable middle section corresponding to the beam configuration, and each of the upper section and the lower section includes a set of holes.

[0157] D4. The collar corner assembly of paragraph D3, wherein each set of holes includes three or less holes.

[0158] D5. A collar corner assembly as described in paragraph D3 or D4, wherein each set of holes includes no more than two holes.

[0159] D6. The collar corner assembly of any of paragraphs D3-D5, wherein the upper and lower sections each have an inner portion and an outer portion, the inner portion having a bolt hole distal to the corner and the outer portion having a bolt hole proximal to the corner.

[0160] D6. The collar corner assembly of any of paragraphs D3-D5, wherein the upper and lower sections each have an inner portion and an outer portion, the outer portion having a bolt hole immediately adjacent the standoff portion.

[0161] D8. A collar corner assembly as described in parameter D6 or D7, wherein the upper and lower sections are comprised of forged metal and the bolt holes are machined into the forged metal.

[0162] E. four flange assemblies, each including an upper transverse element, a lower transverse element, and a bridging component connecting the upper and lower transverse elements; four collar corner assemblies, each including a post joint having first and second extensions defining a corner and a standoff extending from the corner, the standoff having a distal T-shaped configuration; A full moment beam connection system comprising: Each collar corner assembly extends from a corner of the column and connects two adjacent flange assemblies via seven or less bolts, collectively configured to form a full moment connection that encircles the column. Full moment beam connection system.

[0163] E1. The connection system of paragraph E, wherein each collar corner assembly is configured to connect two adjacent flange assemblies via two pairs of bolts, each pair of bolts being aligned along a non-vertical axis.

[0164] E2. The connection system of paragraph E, wherein each collar corner assembly is configured to connect two adjacent flange assemblies via two pairs of bolts, one of the bolts in each pair configured to minimize the mechanical magnification of bending loads applied to the system.

[0165] E3. The connection system of paragraphs E1 or E2, wherein each pair of bolts includes an inner bolt and an outer bolt, the inner bolt being distal from the post and the outer bolt being proximal from the post.

[0166] E4. The connection system of any of paragraphs E-E3, wherein the system includes 24 or fewer bolts.

[0167] E5. The connection system of any of paragraphs E-E4, wherein the system includes 16 or fewer bolts.

[0168] E6. The connection system of any of paragraphs E-E5, further comprising a beam secured to one of the four flange assemblies.

[0169] F. a post joint having first and second extensions defining a corner; a standoff extending from the corner, the standoff comprising a distal T-shaped configuration; Equipped with The first extension has an alignment structure adjacent a bottom end.

[0170] F1. The collar corner assembly of paragraph F, wherein the alignment structure is located distal to the corner.

[0171] F2. The collar corner assembly of paragraph F1, wherein the alignment structure has a planar top surface configured to contact a bottom surface of the lower lateral element of the flange assembly.

[0172] F3. The collar corner assembly of paragraph F2, wherein the collar corner assembly is comprised of forged metal and the planar top surface of the alignment structure is formed by machining the forged metal.

[0173] F4. The collar corner assembly of paragraphs F2 or F3, wherein the alignment structure has a curved surface configured to mate with a complementary portion of a bottom surface of the lower lateral element of the flange assembly.

[0174] F5. A collar corner assembly as described in any of paragraphs F-F4, wherein the column joint and the standoff each have a standard upper section and a standard lower section connected by a selectable middle section corresponding to a beam configuration.

[0175] F6. The collar corner assembly of any of paragraphs F-F5, wherein the first extension has a plane and the alignment structure extends perpendicularly from the plane.

[0176] F7. The collar corner assembly of any of paragraphs F-F6, wherein the first extension has a first surface configured to contact a face of a post and a second surface opposite and parallel to the first surface, and the alignment structure protrudes from the second surface.

[0177] F8. The collar corner assembly of any of paragraphs F-F7, wherein the first extension and the second extension are orthogonal, each extension making an angle of approximately 45 degrees with respect to the standoff portion.

[0178] F9. The collar corner assembly of any of paragraphs F-F8, wherein the second extension has an alignment structure adjacent the bottom end.

[0179] F10. The collar corner assembly of any of paragraphs F-F9, wherein the standoff portion is traversed by a plurality of holes.

[0180] G. four collar flange assemblies, each collar flange assembly comprising an upper lateral element, a lower lateral element, and a bridging component connecting the upper and lower lateral elements; four collar corner assemblies, each including a post joint having first and second extensions defining a corner and a standoff extending from the corner, the standoff having a distal T-shaped configuration; Equipped with Each collar corner assembly is configured to connect two adjacent flange assemblies, each collar corner assembly having an alignment structure extending from a bottom end for positioning a lower lateral element of a respective flange assembly; Full moment beam connection system.

[0181] G1. A full moment beam connection system as described in paragraph G, wherein each two adjacent flange assemblies connected by a collar corner assembly are secured by a horizontal bolt extending through corresponding holes in the collar corner assembly and each of the flange assemblies.

[0182] G2. The full moment beam connection system of paragraph G or G1, wherein each alignment structure has a planar top surface configured to contact the bottom surface of the lower transverse element of an adjacent one of the four flange assemblies and vertically position the contacted flange assemblies.

[0183] G3. A full moment beam connection system as described in paragraph G2, wherein each alignment structure includes a shoulder surface configured to contact a complementary surface of the lower lateral element of an adjacent one of the four flange assemblies to urge the contacted flange assemblies into the correct horizontal position.

[0184] G4. A post having four corners, one of four collar corner assemblies being fixed to each of the corners of the post; a beam having an end fixed to one of the four flange assemblies; The full moment beam connection system of any of paragraphs G-G3, further comprising:

[0185] G5. A full moment beam connection system as described in paragraph G4, wherein each alignment structure extends perpendicular to an adjacent face of said column.

[0186] H. positioning a first flange assembly adjacent a first face of the post extending between a first corner and a second corner of the post, a first collar corner assembly secured to the first corner and a second collar corner assembly secured to the second corner, the first flange assembly secured to an end of a beam; aligning the first flange assembly over a first channel defined between the first and second collar corner assemblies and the first face of the post; lowering the first flange assembly along the first channel; contacting a bottom surface of a lower lateral element of the first flange assembly with a top surface of a first alignment structure protruding from the first collar corner assembly; fastening the first flange assembly to the first collar corner assembly; Including, How beams are connected to columns.

[0187] H1. The method of paragraph H, wherein the top surface of the alignment structure is planar.

[0188] H2. The method of paragraph H or H1, wherein each collar corner assembly includes a post joint having first and second extensions defining a corner, and a standoff portion extending from the corner, the standoff portion having a distal T-shaped configuration.

[0189] H3. positioning a second flange assembly adjacent to the post second surface extending between the first corner and a third corner, a third collar corner assembly being secured to the third corner; aligning the second flange assembly over a second channel defined between the first and third column corner assemblies and the second face of the post; lowering the second flange assembly along the second channel; contacting a bottom surface of a lower lateral element of the second flange assembly with a top surface of a second alignment structure protruding from the first collar corner assembly; fastening together the first flange assembly, the second flange assembly, and the first collar corner assembly; The method of any of paragraphs H-H2, further comprising:

[0190] H4. The method of paragraph H3, wherein said fastening step includes the step of tightening nuts onto bolts to bring wing portions of lateral elements of a flange assembly into contact with standoff portions of an adjacent collar corner assembly.

[0191] J. four collar flange assemblies, each collar flange assembly comprising an upper lateral element, a lower lateral element, and a bridging component connecting the upper and lower lateral elements; four collar corner assemblies, each collar corner assembly including first and second extensions defining a corner and a standoff portion extending from said corner, said standoff portion having a distal T-shaped configuration; Equipped with Each collar corner assembly is configured to connect two adjacent collar flange assemblies, each collar corner assembly having a multi-axis alignment structure extending from a bottom end for vertically positioning a lower lateral element of the respective collar flange assembly. Full moment pillar collar.

[0192] J1. The full moment column collar of paragraph J, wherein the alignment structure has a planar top surface configured to contact a bottom surface of a lower lateral element of an adjacent one of the four collar flange assemblies.

[0193] J2. The full moment post collar of paragraph J1, wherein the alignment structure has a graduated surface that slopes downwardly from the planar top surface.

[0194] J3. The full moment post collar of paragraph J2, wherein the gradation surface is curved.

[0195] J4. The full moment post collar of paragraph J2 or J3, wherein the grading surface is an inclined surface.

[0196] J5. The full moment column collar of any of paragraphs J-J4, wherein the alignment device is configured to align the lower lateral element of each collar flange assembly along the z axis and an axis perpendicular to the z axis.

[0197] J6. A full moment column collar as described in any of paragraphs J-J5, wherein each alignment structure has a locating surface and each lower lateral element has a machined surface that is an inverse shape to the locating surface of the respective alignment structure.

[0198] J7. The full moment pillar collar of paragraph J6, wherein at least a portion of the machined surface is curved.

[0199] J8. The full moment post collar of any of paragraphs J-J7, wherein each alignment structure is formed from a respective collar corner assembly.

[0200] Advantages, Features, and Benefits The various embodiments of the full moment connection collar system described herein provide several advantages over known solutions for connecting one or more lateral structural members to vertical members. For example, the exemplary embodiments described herein allow for precise connection of beams to columns of a structure.

[0201] Additionally, among other advantages, the exemplary embodiments described herein utilize alignment structures to provide precise vertical and horizontal positioning of the lateral members and support during collar connection.

[0202] Additionally, among other advantages, the exemplary embodiments described herein simplify collar connections by minimizing assembly steps and time, and arranging fastening bolts to achieve desired connection strength with a reduced number of bolts.

[0203] Additionally, among other advantages, the exemplary embodiments described herein utilize a beam docking structure to achieve stable support of the lateral structural members during fastening of the collar components.

[0204] Additionally, among other advantages, the exemplary embodiments described herein enable the production of color components on demand from blank inventory for use in building projects with a variety of specifications and dimensional requirements.

[0205] Moreover, among other advantages, the exemplary embodiments described herein provide precise spatial orientation of structural members largely independent of tolerances or other variations in the structural members.

[0206] Known systems or devices are not capable of performing these functions, particularly with such high precision. Accordingly, the exemplary embodiments described herein are particularly useful in steel building construction. However, not all embodiments described herein necessarily provide the same advantages or the same degree of advantages.

[0207] Conclusion The disclosure described above encompasses a number of distinct embodiments having independent utility. While each of these is disclosed in its preferred form, the specific embodiments disclosed and illustrated herein should not be considered in a limiting sense, as numerous variations are possible. Where section headings are used within this disclosure, such headings are for organizational purposes only. The disclosed subject matter includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions, and / or properties disclosed herein. The following claims particularly point out certain combinations and subcombinations that are regarded as novel and non-obvious. Other combinations and subcombinations of features, functions, elements, and / or properties may be claimed in applications claiming priority to this or a related application. Such claims are also deemed to be within the scope of the disclosed subject matter, whether broader, narrower, equal, or different in scope than the original claims.

Claims

1. A step of forming a first collar flange blank and a second collar flange blank, wherein the first collar flange blank and the second collar flange blank are identical. machining a first beam docking structure in the first collar flange blank corresponding to dimensions of a selected first size I-beam flange; machining a second beam docking structure in the second collar flange blank corresponding to dimensions of an I-beam flange of a selected second size, wherein the second size is different from the first size; 16. A method for manufacturing a plurality of full moment column collars, comprising:

2. The method described in claim 1, wherein each of the seats of the beam docking structures is configured to contact an inner surface of an I-beam flange.

3. The method of claim 1 , wherein each of the beam docking structures includes a projection extending outwardly from a central portion of a seat, the projection having a slot configured to receive a web portion of an I-beam.

4. The method of claim 1 , further comprising machining a bridge component interface structure into each of the collar flange blanks, the interface structure including first and second planar surfaces.

5. 2. The method of claim 1, wherein each of the collar flange blanks has a pair of wing portions, the method further comprising drilling a pair of holes in each wing portion at locations precisely related to the beam docking structure.

6. The method of claim 5 , wherein the pair of holes in each wing portion are disposed along an oblique axis.

7. The method of claim 5 , wherein said pair of holes in each wing section are the only holes in the respective wing section.

8. The method of claim 1 , wherein each of the beam docking structures has an angled wall extending from the seat.

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