WO2007131115A1

WO2007131115A1 - Composite structural framing system and method of erection

Info

Publication number: WO2007131115A1
Application number: PCT/US2007/068152
Authority: WO
Inventors: Housh Rahimzadeh
Original assignee: Diversakore, Llc
Priority date: 2006-05-04
Filing date: 2007-05-03
Publication date: 2007-11-15

Abstract

A structural framing system (10) comprising u-shaped beams (16) that support metal deck flooring components (12) interconnected through the addition of a solidifying material (24), such as poured concrete. Alternatively, a structural framing system (10) is created by anchoring u-shaped beams (16) to vertical columns (14), spanning metal deck floor sections (12) between the beams (15, 16), pouring a solidifying material (24) into the interior of the beams and over the metal deck sections, to form a substantially rigid joint between the beam, floor sections, and columns. Alternative embodiments include an additional bonding layer (24).

Description

COMPOSITE STRUCTURAL FRAMING SYSTEM AND METHOD OF ERECTION

TECHNICAL FIELD

The present invention relates to building construction, and more specifically to a composite steel and concrete framing system that forms a substantially monolithic support structure.

BACKGROUND OF THE INVENTION

In the field of building construction, specifically the erection of multi- story buildings, the framing system constitutes the essential load-bearing structure that provides the stability and integrity of the building. The typical multi-story framing system consists of a plurality of stacked vertical columns interconnected with horizontal support beams. Typically, vertical columns and horizontal beams are composed of structural steel, precast concrete, formed- in-place concrete, or some combination thereof. Further, the horizontal beams typically support flooring sections of precast concrete, metal, or formed-in- place concrete. The framing system is designed to support well in excess of the anticipated loads developed by the structure itself and all live loads placed thereon. The forces generated by these loads are largely borne by the horizontal beams, the vertical columns and the connection members that join the beams and columns.

One known method of erecting a framing system is to pour concrete in place, utilizing suitable forms, to produce vertical columns, horizontal beams, and floor sections. Pouring concrete in place has the advantage of producing buildings that are strong, highly rigid, durable, and highly fire resistant. However, this method requires the use of labor intensive forms and complicated temporary supports that are expensive, easily destroyed and impede efficient work flow. In addition, concrete as a material is, relatively speaking, brittle and not as flexible as steel. Another known method of erecting a framing system is to assemble precast concrete columns, beams and floor sections. This method has the advantage of rapid erection, with little need for temporary supports. However, entirely precast concrete buildings tend to be less rigid than poured-in-place concrete buildings and have other inherent structural limitations. Still another method of erecting a framing system is to assemble steel columns and beams. This method also has the advantage of rapid erection, but all steel frames have inherent structural limitations. Most notably, all steel framing systems are limited by the forces borne by the steel connecting members-- typically the weakest elements of the framing system.

Presently, other than prior framing systems developed by the present applicant, no framing system provides an inexpensive support structure that is both highly rigid and fire resistant - as found with a poured-in-place system, while easy to assemble - as found with a steel system. Thus, there exists a need for an improved, inexpensive, highly rigid, and fire resistant framing structure that can be erected with minimum temporary shoring while overcoming the limitations found in conventional connection methods.

SUMMARY OF THE INVENTION

The various embodiments of the present invention overcome the shortcomings of the prior art by providing an inexpensive system of horizontal composite beams supported by vertical columns, which support flooring components such as formed metal deck sections that receive a pourable bonding layer, such as a plasticized or cementitious material that hardens, tops the flooring components and bonds the flooring components, composite beams, and columns. Each composite beam comprises a steel beam and interior of solidifying material, such as poured concrete. In an exemplary embodiment, the steel beam includes a bottom plate, adjacent containment sides fortified by strap bars, studs, and support angles. Cross beams may be attached to the composite beam. The support angles and cross beams are welded to the containment sides and provide a support surface for the flooring components. The flooring components in this embodiment are positioned so as to be aligned with a longitudinal axis parallel to the steel beam. Moreover, the flooring components are welded to the support angles and the wide flanges before concrete is poured into the steel beam and on top of the flooring components.

In another exemplary embodiment, the steel beam includes a bottom plate, adjacent containment sides fortified by strap bars, studs, and support angles. The support angles are welded to the containment sides and provide a support surface for the flooring components. The flooring components in this embodiment are positioned so as to be aligned with a transverse axis perpendicular to the steel beam. Moreover, the flooring components are welded to the support angles before concrete is poured into the steel beam and on top of the flooring components.

In erecting the exemplary framing system, substantially concrete vertical columns are provided, each with at least one receiving saddle for supporting the end of a steel beam. The steel beams are raised and the flooring components, which span longitudinally or transversely between adjacent steel beams, are set. Concrete is then poured to fill the interior of the steel beam; the strap bars act to resist the outward forces created by the wet concrete and the studs act to bond the cured concrete to the steel beam. Sufficient concrete is poured to fill the steel beam and to substantially cover the flooring components. Concrete can be added to form a bonding layer and to fill all voids in or around the columns, thereby creating a substantially monolithic layer. Some blocking may be necessary at the columns to stop seepage of the concrete or bonding layer while the concrete is wet.

In an exemplary embodiment, the composite beam is adapted for use along the perimeter of a horizontal level.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a plan view illustrating a typical section of an exemplary framing system, according to the present invention. FIG. 2 is a cross-sectional view of the framing system of FIG. 1. FIG. 3 is a plan view illustrating a typical section of an exemplary framing system, according to the present invention.

FIG. 4 is a cross-sectional view of the framing system of FIG. 3.

FIG. 5 is a cross-sectional view of an exemplary composite beam, positioned at the perimeter of an exemplary framing system.

FIG. 6 is a cross-sectional view of a column and two exemplary beams, illustrating an exemplary connection between a column and beam.

DETAILED DESCRIPTION As required, detailed embodiments of the present invention are disclosed herein. It must be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms, and combinations thereof. As used herein, the word "exemplary" is used expansively to refer to embodiments that serve as an illustration, specimen, model or pattern. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. In other instances, well-known components, systems, materials or methods have not been described in detail in order to avoid obscuring the present invention. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention.

Referring to the drawings, wherein like elements are designated by like numbers, FIG. 1 and FIG. 3 illustrate a top view of a composite structural framing system 10. Generally speaking, the system 10 consists of flooring components 12 that are supported by horizontal composite beams 16 that are connected to vertical columns 14. Vertical columns 14 are located as necessary to support the composite beams 16. Each vertical column 14 is typically connected to and supports at least one composite beam 16. The composite beams 16 support the flooring components 12 which, in the illustrated embodiment, are corrugated metal deck sections. In FIG. 1 , the corrugated metal deck sections are positioned along a longitudinal axis that is substantially parallel to the composite beams 16. As illustrated, the composite beams 16 support cross beams 15, which in turn support flooring components 12. In FIG. 3, the corrugated metal deck sections are positioned along a transverse axis that is substantially perpendicular to the composite beams 16. As explained in detail below, a bonding layer 20 tops the flooring components 12 to join the flooring components 12, the composite beams 16, and the columns 14 to create a substantially rigid joint at each connection. By way of example and not limitation, the bonding layer 20 is a plasticized material, such as concrete or an air-entranced material such as Gyp-Crete^®, or the like, which hardens to provide improved structural integrity between the discrete framing components.

FIG. 2 illustrates a cross-sectional view of an exemplary embodiment of a composite beam 16 supporting metal flooring components 12. The composite beam 16 includes an exterior steel beam 22 sheath and solidifying material 24. In this embodiment, the steel beam 22 includes a bottom plate 26, containment sides 28, means for reinforcement 30, shear studs 32, lower support surfaces 36, and upper support surfaces 38. In this illustrated embodiment, the various components that comprise the beam 16 are shown as individual members that are connected together by known methods, for example, welding. In alternative embodiments the beam 16 is roll-formed or extruded; the method of manufacture not being a limitation or restriction.

Further, FIG. 2 illustrates the containment sides 28 attached inwardly away from the outer edges of the bottom plate 26 to form one or more lower support surfaces 36, but may be attached along the outer edges of the bottom plate 26 and support angles can be positioned to support the bottom of the cross beams 15. To illustrate an alternative configuration, support angles 38 are attached to the containment sides 28 to form a support surface, by welding or other means. These support angles may extend inwardly towards the center of the beam 16 or outwardly away from the beam 16 center. It will be understood that support angles 38 may be oriented on either face of the containment side 28 and at various elevations, the location being merely a design choice. Similar angles may be used to form the lower support surfaces 26. It is also contemplated that the support surface provided by the support angles may be formed by merely thickening the uppermost edge of the containment side 28 to a suitable width or bending the containment side to form a support surface.

Connected to the composite beam 16 are steel cross beams 15 that, with the support angles 38, cooperate to support the metal flooring components 12. The metal flooring component 12 can be attached to the cross beams 15 and composite beam 16 by known methods including welding and/or fasteners.

Turning now to FIG. 4, there is shown a cross-sectional view of an exemplary embodiment of a composite beam 16 supporting flooring components 12. The composite beam 16 includes an exterior steel beam 22 sheath and solidifying material 24. In this embodiment, the steel beam 22 includes a bottom plate 26, containment sides 28, means for reinforcement 30, shear studs 32, and support angles 38. The containment sides 28 are attached to the bottom plate 26, by welding or other means, and extend upwardly.

In addition, FIG. 4 illustrates the containment sides 28 attached along the outer edges 35 of the bottom plate 26, but may be attached inwardly away from the outer edges to form one or more lower support surfaces (not shown). Support angles 38 are attached to the containment sides 28 to form a support surface 34, by welding or other means. These support angles may extend inwardly towards the center of the beam 22 or outwardly away from the beam 22. The support angles 38 provide a support surface 34 for floor components 12. It will be understood that support angles 38 may be oriented on either face of the containment side 28 and at various elevations, the location being merely a design choice. It is also contemplated that the support surface provided by the support angles may be formed by merely thickening the uppermost edge of the containment sides 28 to a suitable width or bending the containment side to form a support surface.

In the illustrated embodiments, means for reinforcement 30 are attached at one end to the inside face of a first containment side and at the opposite end to the inside face of a second containment side. Placed approximately four feet on-center; one purpose of the means for reinforcement 30 is to restrain the containment sides 28 from outwardly splaying or otherwise laterally moving. In addition, the means for reinforcement resist concentric loading and create a more rigid box structure during erection of the system. By way of example and not limitation, the means for reinforcement 30 illustrated are strap bars. It will be understood that equally suitable means for reinforcement include, but is not limited to, restraining/reinforcement devices such as strap bars, interior or exterior mounted ribs, fins, stiffening plates, angles, bands, and the like. Various means for reinforcement may be positioned at differing locations.

In the illustrated embodiment, means for joining 32 are attached to the bottom plate approximately one foot on-center; one purpose of the means for joining 32 is to anchor the cured concrete to the steel beam 22. By way of example and not limitation, the means for joining 32 illustrated are shear studs. It will be understood that equally suitable means for joining include, but is not limited to, shear/joining devices such as studs, ribs, fins, anchor bolts, rebar, and the like. Various joining means may be positioned at differing locations. Further, an abundance of means for reinforcement may serve the combined function of reinforcing devices and joining devices. In addition, means for joining function to fully engage the steel and concrete elements for full composite development. Advantages of attaining full composite development is that the beam profile 15 is lowered, that is, the beam could be made shorter, and the beam span to depth ratio is increased.

In the illustrated embodiments, the bottom plate 26, containment sides 28, means for reinforcement 30, means for joining 32, and support angles 38 are formed from known shape steel. Nevertheless, it is contemplated that as a design choice, steel may be substituted with other materials that meet minimum performance characteristics. It is also contemplated that the steel beam 22 illustrated and described above may be formed as a single, substantially monolithic unit, such as by roll forming and/or extruding methods.

The steel beam 22 supports the bottom surface of the floor component 12 with the support angles 38. Reinforcing members 42 may be added to provide additional force bearing capacity to the composite beam 16, and are located according to design criteria. Reinforcing members 42 may be reinforcing members such as rebar or post tensioned cables.

In erecting the framing system 10, the foundation (not shown) and vertical columns 14 are constructed according to methods well known by those skilled in the art. In the illustrated embodiments, the columns are concrete, either precast or formed-in-place, and are provided with a receiving saddle 44, as best shown in FIG. 6. In alternative embodiments, hollow steel columns of various shapes (e.g., square or circular) are filled with concrete. In such embodiments the steel column is provided with an external receiving saddle 44. The saddles 44, which are approximately the height of the composite beam 16 and approximately 1" wider and approximately 3" deep, receive and support the end of the composite beam 16. The end of each composite beam 16 is further secured to the column by methods well known to those skilled in the art.

It is contemplated that a plurality of columns 14 are erected that receive and support at least one steel beam 22. Any temporary intermediate supports required may now be installed. The steel beams 22 then receive and support flooring components 12, such as corrugated metal decking, along the support surface 34 provided by the support angles 38 and/or the cross beams 15. Although the present invention requires much less shoring as compared to other framing systems that incorporate poured concrete beams, the shoring here minimizes deflection while providing for longer spans of a fully developed composite beam. FIG. 2 and FIG. 4 best illustrate flooring components 12, supported by the steel beam 22, which in turn is supported by columns 14. Next in the process of erecting the framing system 10 a solidifying material 24, such as but not limited to concrete, is poured into the steel beam 22 where it fills the cavity created by the bottom plate 26 and containment sides 28. By way of illustration and not limitation, the solidifying mixture 24 that creates the bonding layer 20 is poured concrete. Equally suitable solidifying materials include, but are not limited to, well known plastic bonding materials that solidify to realize increased performance characteristics such as cement, grout, Gyp-Crete^®, and similar performance enhanced compounds. The means for reinforcement 30 act to resist the outward forces exerted by the wet concrete 24 and the means for joining 32 act to fully engage the cured concrete 24 to the steel beam 22.

Sufficient concrete 24 is poured to fill the steel beam 22 and to substantially cover the flooring components 12 to at least create a sub-floor. It is contemplated that concrete 24 can continue to be added to form the bonding layer 20 and to fill any voids in or around the columns 14. In other words, the solidifying material 24 and bonding layer 20 may be of the same plasticized material. The bonding layer 20 creates a substantially monolithic layer that connects and unites each horizontal level of flooring components 12, composite beams 16 and columns 14 together to form a substantially rigid joint.

During erection of the framing system 10, the steel beam 22 initially provides support to the floor components 12. Thereafter, the steel beam 22 acts as a form to accept the concrete 24. Finally, the steel beam 22 becomes an integral part of the composite beam 16. Some of the advantages realized by providing the steel beam 22 taught herein include: the virtual elimination of temporary shoring, the virtual elimination of temporary forms, and isolating concrete pouring to a single critical step per horizontal level. Some of the advantages realized by providing the composite beam 16 taught herein include: a structural beam with greatly improved performance characteristics in spans of at least sixty feet in length, a substantially more rigid frame 10 by interlocking the flooring components 12, composite beams 16 and columns 14 of each horizontal level together with a bonding layer 20, and, it is believed, the composite beam taught herein, including the means for joining 32, means for reinforcement 30, and reinforcing members 42, provides a structural member that achieves a fire-resistant rating without fire proofing that is as high as a steel beam sized for the same loads with fire-proofing. Individually and together these advantages reduce construction related expense and time.

FIG. 5 depicts an exemplary embodiment of a perimeter composite beam 50 adapted for use along the perimeter of a horizontal level. The composite beam 50 includes an exterior containment side 52 that extends upwardly from the bottom plate 26. In the illustrated embodiment, the upper edge 54 terminates and returns at the elevation of the bonding layer 20. It will be understood that the configuration, even the existence, of the return position 56 is a design choice and may be replaced with a support angle for the purpose of attaching walls, windows, rails or other building components. The remaining components illustrated in FIG. 5, together with their advantages, are substantially similar to the steel beam 22 and composite beam 16 described above. FIG. 6 illustrates a cross-section of a typical concrete column 14 supporting one end each of two steel beams 22. Flooring components 12 are also shown supported by the steel beams 22 and cross beams 15. The vertical column 14 illustrated is a formed-in-place concrete column, constructed in a manner well known by those skilled in the art. It is also contemplated that the column 14 may be configured with precast concrete or a steel beam. The support column 14 illustrated includes two receiving saddles 44 to support the steel beams 22. The location and number of receiving saddles 44 is a design choice, as is any additional means for attachment between the beam 22 and column 14. From the configuration of the horizontal level illustrated in FIG. 6, the next step in constructing the framing system is to pour solidifying material 24 into the steel beam 22 to form the bonding layer 20, or pour both a solidifying material 24 and a bonding layer 20. The selection of solidifying material 24 and bonding layer 20 is a design choice governed by structural design criteria and construction timing requirements. It will be understood that some blocking (not shown) may be necessary around the columns 14 to stop seepage of the material 24 or bonding layer 20 and that some temporary intermediate supports will be required to support the steel beam 22 while the concrete is wet, but the need for intermediate supports is ultimately a design choice.

The law does not require and it is economically prohibitive to illustrate and teach every possible embodiment of the present claims. Hence, the above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Variations, modifications, and combinations may be made to the above-described embodiments without departing from the scope of the claims. All such variations, modifications, and combinations are included herein by the scope of this disclosure and the following claims.

Claims

CLAIMSWhat is claimed is:

1. A composite framing system (10), comprising: a plurality of columnar members (14) vertically erected; at least one composite structural member (16) supported between adjacent columnar members, said at least one composite structural member comprising; an exterior sheathing, comprising: a bottom plate (26); a plurality of containment sides (28) extending upwardly from said bottom plate, wherein at least one of said plurality of containment sides includes at least one support surface (36, 38); and an interior cavity formed by said plate and sides, configured to receive a solidifying material (24); a cross-beam (15) attached to at least one of said containment sides; and at least one metal deck section (12) positioned substantially parallel to said composite structural member, comprising: a top surface; and a bottom surface opposite said top surface and supported by said cross beam, wherein said metal deck is attached to said structural member.

2. The framing system of claim 1 further comprising: a bonding layer (24) that connects and unites at least one of said columnar members, said metal deck section, and said at least one composite structural member.

3. The framing system of claim 1 , wherein each of said columnar members includes at least one saddle (44) to receive and support said at least one composite structural member.

4. The composite framing system of claim 1 , wherein said exterior sheathing further comprises at least one means for reinforcement (30) attached to said plurality of containment sides, and a plurality of means for joining (32) attached to said bottom plate.

5. The composite framing system of claim 1 , wherein said solidifying material substantially fills said interior cavity and is disposed upon said top surface of said metal deck section.

6. The composite framing system of claim 1 , wherein said at least one formed metal deck section is corrugated.

7. The composite framing system of claim 1 , wherein said at least one formed metal deck section is non-corrugated.

8. A composite framing system (10), comprising: a plurality of columnar members (14) vertically erected; at least one composite structural member (16) supported between adjacent columnar members, said at least one composite structural member comprising; an exterior sheathing, comprising: a bottom plate (26); a plurality of containment sides (28) extending upwardly from said bottom plate, wherein at least one of said plurality of containment sides includes at least one support surface (36, 38); and an interior cavity, formed by said plate and sides, configured to receive a solidifying material (24); and at least one metal deck section (12) positioned substantially perpendicular to said composite structural member, comprising: a top surface; and a bottom surface opposite said top surface and supported by said at least one support surface, wherein said metal deck is attached to said at least one support surface.

9. The framing system of claim 8 further comprising: a bonding layer (24) that connects and unites at least one of said columnar members, said metal deck section, and said at least one composite structural member.

10. The framing system of claim 8, wherein each of said columnar members includes at least one saddle (44) to receive and support said at least one composite structural member.

11. The composite framing system of claim 8, wherein said exterior sheathing further comprises at least one means for reinforcement (30) attached to said plurality of containment sides, and a plurality of means for joining (32) attached to said bottom plate.

12. The composite framing system of claim 8, wherein said solidifying material substantially fills said interior cavity and is disposed upon said top surface of said metal deck section.

13. The composite framing system of claim 8, wherein said at least one formed metal deck section is corrugated.

14. The composite framing system of claim 8, wherein said at least one formed metal deck section is non-corrugated.

15. A method of erecting a framing system, comprising: erecting a plurality of columnar members (14); supportively connecting a composite structural member (16) to at least two of said plurality of columnar members, wherein said composite structural member includes: a bottom plate (26), a plurality of containment sides (28) attached to said bottom plate, at least one support surface proximate to at least one of said containment sides (36, 38), an interior cavity configured to receive a solidifying mixture (24); attaching a cross beam (15) to at least one of said containment sides; spanning at least one metal deck section (12) substantially parallel to said composite structural member, said metal deck section including a top surface, a bottom surface opposite said top surface and supported by said support surface and said cross beam; attaching said metal deck to said support surface and to said cross beam; and pouring solidifying material to substantially fill said interior cavity and to substantially cover said top surface of said at least one metal decking section.

16. The method of claim 15, further comprising the step of: disposing a bonding layer (24) over said solidifying material, over said at least one metal deck section and around said plurality of columnar members to form a substantially rigid joint.

17. The method of claim 15, wherein said at least one formed metal deck section is at least one corrugated metal decking section.

18. The method of claim 15, wherein said at least one metal decking section is at least one non-corrugated metal decking section.

19. A method of erecting a framing system, comprising: erecting a plurality of columnar members (14); supportively connecting a composite structural member (16) to at least two of said plurality of columnar members, wherein said composite structural member includes: a bottom plate (26), a plurality of containment sides (28) attached to said bottom plate, at least one support surface proximate to at least one of said containment sides (26, 28), an interior cavity configured to receive a solidifying mixture (24); spanning at least one metal deck section (12) substantially perpendicular to said composite structural member, said metal deck section including a top surface, a bottom surface opposite said top surface and supported by said support surface; attaching said metal deck to said support surface; and pouring solidifying material to substantially fill said interior cavity and to substantially cover said top surface.

20. The method of claim 19, further comprising the step of: disposing a bonding layer (24) over said solidifying material, over said at least one metal deck section and around said plurality of columnar members to form a substantially rigid joint.

21. The method of claim 19, wherein said at least one formed metal deck section is at least one corrugated metal decking section.

22. The method of claim 19, wherein said at least one metal decking section is at least one non-corrugated metal decking section.