U.S. patent application number 12/498420 was filed with the patent office on 2010-01-14 for steel building frame system.
This patent application is currently assigned to King Solomon Creative Enterprises Corp.. Invention is credited to George Abdel-Sayed, Gary J. Bonacci, Arnold A. Davis, Sara E. Ohler-Schmitz, Phillip Ostrowski.
Application Number | 20100005749 12/498420 |
Document ID | / |
Family ID | 41503872 |
Filed Date | 2010-01-14 |
United States Patent
Application |
20100005749 |
Kind Code |
A1 |
Abdel-Sayed; George ; et
al. |
January 14, 2010 |
STEEL BUILDING FRAME SYSTEM
Abstract
A frame assembly for a wide span steel building is disclosed.
The assembly employs columns and rafters formed from two pieces of
webbed channel stock that are joined together at their webs. A
pre-drilled haunch plate connects the column and rafter. A brace
formed from two lengths of channel stock joined together at their
webs extends at an angle between the columns and rafters and each
respective end of the brace is connected to the respective column
and rafter via a brace plate. The brace provides increased strength
in the frame assembly and enables the construction of wide span
steel building from channel stock.
Inventors: |
Abdel-Sayed; George;
(Bloomfield Hills, MI) ; Bonacci; Gary J.;
(Burgettstown, PA) ; Davis; Arnold A.;
(Pittsburgh, PA) ; Ohler-Schmitz; Sara E.; (Moon
Township, PA) ; Ostrowski; Phillip; (Munhall,
PA) |
Correspondence
Address: |
DARBY & DARBY P.C.
P.O. BOX 770, Church Street Station
New York
NY
10008-0770
US
|
Assignee: |
King Solomon Creative Enterprises
Corp.
McKees Rocks
PA
|
Family ID: |
41503872 |
Appl. No.: |
12/498420 |
Filed: |
July 7, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61079328 |
Jul 9, 2008 |
|
|
|
Current U.S.
Class: |
52/650.2 ;
52/655.1; 52/846 |
Current CPC
Class: |
E04B 2001/2472 20130101;
E04B 1/24 20130101; E04B 2001/2469 20130101; E04B 2001/2415
20130101; E04B 2001/2457 20130101; E04B 2001/2487 20130101; E04B
2001/2448 20130101; E04B 2001/2439 20130101 |
Class at
Publication: |
52/650.2 ;
52/655.1; 52/846 |
International
Class: |
E04H 12/10 20060101
E04H012/10 |
Claims
1. A steel frame building, comprising: a plurality of generally
vertical C-channel columns; at least one roof peak element
comprising C-channel rafter elements joined at a first end of each
rafter element to form an oblique angle; a haunch plate joining a
second end of each of the rafter elements to the upper portion of a
respective one of said plurality of columns; a C-channel brace
connected between an upper half of each of said vertical columns
and a portion of each of the rafter elements that is proximate to
the haunch plate; two end wall frames located at opposite ends of
said building and on opposite sides of said columns; a roof
comprising steel roof panels connecting the roof peak element and
the end wall frames; side walls comprising steel wall panels
connecting each column and the end wall frames; and front and rear
end walls at opposite ends of said building comprising steel wall
panels provided on the two end wall frames.
2. The steel frame building according to claim 1, wherein the
oblique angle is between 143 and 175 degrees.
3. The steel frame building according to claim 1, further
comprising: a brace plate joining each end of each brace to each
column and rafter element, respectively.
4. The steel frame building according to claim 1, further
comprising: a peak plate connecting the first ends of the two
rafter elements that comprise the roof peak element.
5. The steel frame building according to claim 1, further
comprising: a plurality of girts extending between each column and
the two end wall frames and joining each column and the steel wall
panels; and a plurality of purlins extending between the roof peak
element and the end wall frames and joining the steel roof panels
and the roof peak element.
6. The steel frame building according to claim 5, further
comprising: a plurality of flange stabilizers extending between the
columns and girts, and the rafters elements and purlins.
7. The steel frame building according to claim 1, wherein each of
the columns, rafter elements, and brace comprise two C-channel
members each having a web and the webs of the two C-channel members
are joined together.
8. The steel frame building according to claim 7, wherein the
haunch plate is disposed between the webs of the two C-channel
members of each column and the two C-channel members of each rafter
element.
9. The steel frame building according to claim 8, wherein the
haunch plate includes a first portion that is narrower than the
width of the column, and a flange extending from the first portion,
the flange being disposed along a side of the column when the first
portion of the haunch plate is disposed between the webs of the two
C-channel members of each column.
10. The steel frame building according to claim 9, wherein the
building has a span of between twenty-five and fifty feet.
11. The steel building according to claim 8, further comprising:
brace plates joining each end of each brace to each column and
rafter, respectively; one of the brace plates being disposed
between the webs of the two C-channel members of the column and the
webs of the two C-channel members of the brace, and another one of
the brace plates being disposed between the webs of the two
C-channel members of the rafter element and the webs of the two
C-channel members of the brace; and a peak plate joining together
the first end of each rafter element, and located between the webs
of the two C-channel members of each rafter element.
12. The steel frame building according to claim 11, wherein the
haunch plate is predrilled with a pre-determined hole pattern.
13. The steel frame building according to claim 7, further
comprising: reinforcing column nesting elements, each reinforcing
column nesting element being joined to the web of one of the two
C-channel members of each column such that the webs of the two
C-channel members of each column are disposed between the
reinforcing column nesting elements; and reinforcing rafter nesting
elements, each reinforcing rafter nesting element being joined to
the web of one of the two C-channel members of each rafter such
that the webs of the two C-channel members of each rafter are
disposed between the reinforcing rafter nesting elements.
14. A metal construction frame for a wide span metal building,
comprising: a first generally vertical C-channel column connected
at one end to a first haunch plate; a first C-channel rafter
element connected at one end to the first haunch plate at an
oblique angle to the horizontal; a first C-channel brace connected
between an upper half of the first column and a portion of the
first rafter element that is proximate to the first haunch plate; a
second generally vertical C-channel column connected at one end to
a second haunch plate; a second C-channel rafter element connected
at one end to the second haunch plate at the same oblique angle to
the horizontal as the first rafter element; a second C-channel
brace connected between an upper half of the second column and a
position on the second rafter element that is proximate to the
second haunch plate; a peak plate connecting, at an obtuse angle,
the first and second rafter elements at an end of each rafter
element that is opposite the end connected to the haunch
plates.
15. The metal construction frame according to claim 14, wherein the
obtuse angle is between 143 and 175 degrees.
16. The metal construction frame according to claim 14, wherein the
first and second braces are connected to the first and second
columns at an acute angle.
17. The metal construction frame according to claim 16, wherein the
acute angle is equal to 1/2(90.degree.-arctan(the oblique angle to
the horizontal)).
18. The metal construction frame according to claim 14, further
comprising: a first brace plate at an end of each of the first and
second braces connecting the end of each of the braces to the
column; and a second brace plate at an opposite end of each of the
first and second braces connecting the opposite end of each of the
braces to the rafter element.
19. The metal construction frame according to claim 18, wherein the
first and second columns, first and second rafter elements, and
first and second braces each comprise two C-channel members each
having a web, wherein the webs of the two C-channel members are
joined.
20. The metal construction frame according to claim 19, wherein
each haunch plate is disposed between the webs of the two C-channel
members of the column and rafter element joined together by such
haunch plate, each first brace plate is disposed between the webs
of the two C-channel members of the column and brace joined
together by such first brace plate, each second brace plate is
disposed between the webs of the two C-channel members of the
rafter element and brace joined together by such second brace
plate, and the peak plate is disposed between the webs of the two
C-channel members of the rafter elements joined together by such
peak plate.
21. The metal construction frame according to claim 19, wherein the
columns and rafter elements are formed of 16 to 10 gauge steel.
22. The metal construction frame according to claim 19, wherein
each haunch plate contains two patterns of pre-drilled holes that
pass through the haunch plate, one of said hole patterns arrayed at
an acute angle to the other of said hole patterns.
23. The metal construction frame according to claim 19 comprising
A653 steel.
24. The metal construction frame according to claim 19, comprising
10 gauge steel.
25. The metal construction frame according to claim 19, wherein the
first and second columns each comprise two reinforcing column
nesting elements, each reinforcing column nesting element being
joined to the web of one of the two C-channel members of each
column such that the webs of the two C-channel members of each
column are disposed between the reinforcing column nesting
elements, and wherein the first and second rafters elements each
comprise two reinforcing rafter nesting elements, each reinforcing
rafter nesting element being joined to the web of one of the two
C-channel members of each rafter such that the webs of the two
C-channel members of each rafter are disposed between the
reinforcing rafter nesting elements.
26. A brace plate for connecting a structural member and a brace
that extends at an angle with respect to the structural member,
wherein the structural member and the brace each comprise a length
of formed metal C-channel stock having a web and two flanges and
the structural member is a member selected from the group
consisting of a column and a rafter, the brace plate comprising: a
plate element having first and second portions; the first portion
of the plate element having a first set of mounting holes and being
adapted to be attached to the web of the structural member; the
second portion of the plate element having a second set of mounting
holes and being adapted to be attached to the web of the brace, the
second portion having an angled edge that extends at an angle
complimentary to the angle at which the brace extends; and a flange
that extends at a angle from the angled edge of the second portion
of the plate element, wherein the flange of the plate element is
adapted to align with a flange of the brace.
27. The brace plate according to claim 26, wherein the angle at
which the flange of the plate element extends is a right angle.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C.
.sctn.119(e) to U.S. Provisional Patent Application No. 61/079,328,
filed on Jul. 9, 2008 and entitled "IMPROVED STEEL BUILDING FRAME
SYSTEM," which is hereby incorporated by reference herein in its
entirety.
TECHNICAL FIELD
[0002] The present invention generally relates to a steel frame
building system, and more specifically to systems for connecting
structural members of a steel frame.
BACKGROUND
[0003] Building systems using steel members tend to be preferred
for many construction applications such as, for example, small
factory buildings, garages, and aircraft hangers. Steel members
such as rafters and beams are stronger than their wood
counterparts, and thus, a smaller steel member can be used in place
of a wooden structural member. In addition, the use of steel
members allows for designs that would not be possible with wood
members. Steel members may also be more durable and resistant to
problems such as infestation and rot. Further, steel building
systems can be provided as prefabricated components that can be
assembled on site.
[0004] Traditionally, in order to provide a steel building having a
wide span, i.e. a span between side walls of the building of more
than approximately 25 feet, cast steel members had to be used for
the columns and rafters. Although cast steel members allow for wide
span buildings, using cast members has several disadvantages. Cast
steel members (e.g. structural I-beams) are heavy, which can
increase the cost and difficulty of transporting, off-loading, and
handling. Cranes are often required to move cast members such as
I-beams within the manufacturing facility. In addition to their
weight, cast steel members require high levels of raw material,
which increases their cost. Further, the lengthy casting
fabrication process can increase the time period between receipt of
an order and shipment of a steel frame building.
[0005] In view of the problems with cast steel members, there has
been a tendency to form steel building components by bending
lighter gauge steel and to use these components as construction
members in steel frame buildings. These light gauge channel members
weigh less than cast members thereby reducing material and
transportation costs. One folded steel member that is widely used
is folded into a C-shaped cross-section and is referred to in the
trade as a C-channel member. Buildings constructed with such
members are often referred to as C-channel buildings. The
advantages of using C-channel construction members as the framing
components include for example, lighter weight, making them easily
transportable, and easier handling on the construction site. These
advantages make such components preferred building materials.
[0006] Although C-channel frame structures offer significant
savings in weight and material costs, it has generally been
difficult to employ them in construction of wide span (width)
buildings. Conventional C-channel steel building systems are
limited to a span (i.e., width of the building) of approximately 25
feet because the lighter gauge C-channel members used in
conventional frame designs are typically not strong enough to
support the building under design wind and snow loads safely.
However, it would be desirable to provide wide span light gauge
steel buildings, for example having spans more than 25 feet and up
to 50 feet, well beyond the limits of customary light gauge steel
building systems.
[0007] There have been some attempts at providing wide span (width)
light gauge steel buildings. One such steel building system
employing light gauge C-channel steel members is disclosed in U.S.
Pat. No. 4,342,177 of Smith. The frames of the building include a
pair of columns and a pair of beams. Smith discloses that the
frames between the end walls have back to back steel members in
which the webs of two C-channel members are bolted together to form
a column or beam. The column-beam connections are provided by a
flat plate that is sandwiched between the two C-channel members of
the column and beam, respectively. Referred to as a haunch plate,
this component has an angled portion that extends between the
column and beam. The angled portion forms a web that occupies the
corner of the frame. The web increases the weight of the haunch
plate, making it more difficult to transport and install.
[0008] The Smith haunch plate design requires extra material to
form the web portion, which increases the weight of the plate and
the material costs. Also, the need to form the haunch plate with
the web portion results in a plate with a more complicated shape,
making manufacturing of the plate more difficult and costly.
Further, the web portion of the haunch plate requires additional
reinforcement from two separate stiffener angles that are attached
to each side of the web portion of the haunch plate. Thus, the
complex shape of the haunch plate and the need to connect
additional reinforcements to the haunch plate makes this type of
haunch plate more costly and difficult to install.
[0009] While Smith discloses that his construction system can be
used to form a steel frame building having a span (width) greater
than 25 feet, in order to achieve this objective, the haunch plate
having the web portion discussed above is required. The Smith
haunch plate is not configured to fit within the profile of the
column and beam, but requires an angled web portion that extends
out beyond the edges of the column and beam and occupies the corner
of the frame, and thereby is considerably heavier and more costly
to make.
[0010] It would be advantageous to provide an improved frame and
corner connection system that would allow the use of light gauge
C-channel steel members, avoid the use of cast metal components,
and would permit construction of steel frame buildings having a
span greater than about twenty-five feet wide.
SUMMARY OF THE INVENTION
[0011] The present invention overcomes the drawbacks of prior art
systems by providing a steel frame construction system that enables
construction of wide span C-channel steel frame structures. (As
used herein, the term wide span means a building span (width) of
between twenty-five and about fifty feet.) According to one aspect
of the present invention, a frame system for a metal frame building
made of formed metal channel stock components includes metal
columns, rafters, a haunch plate configured to fit substantially
within the profile of the column and rafter, and a brace extending
between each column and rafter.
[0012] In a further aspect of the present invention, each column of
the steel frame system comprises two lengths of formed metal
channel stock, each length having a web, two flanges, and two lips.
The two lengths of channel stock of the column have their webs
fastened together to form the column. Each rafter comprises two
lengths of formed channel stock, each having a web, two flanges,
and two lips. The two lengths of channel stock have their webs
fastened together to form each rafter. The rafter is positioned
above the column and the haunch plate is disposed between the two
lengths of formed channel stock of the column and the two lengths
of formed channel stock of the rafter at adjacent ends of the
column and the rafter.
[0013] In a further aspect of the present invention, each brace
comprises two lengths of formed channel stock, each having a web,
two flanges, and two lips. The two lengths of channel stock have
their webs fastened together to form each brace. A first brace
connection plate is disposed at one end of the brace between the
two lengths of channel stock of the column and the two lengths of
channel stock of the brace. At the other end of the brace a second
brace connection plate is disposed between the two lengths of
channel stock of the rafter and the two lengths of channel stock of
the brace. The brace, columns, and rafters formed of channel stock
are employed together with the haunch plate of the invention to
fabricate a wide span steel frame building. Thus, the invention
provides a frame system for a wide span steel building comprising a
brace, haunch plate, and columns and rafters.
[0014] In further aspect of the present invention, the column,
rafter, and brace are all fabricated from C-channel stock.
[0015] According to another aspect, the present invention comprises
a brace plate for connecting a structural member, which includes a
column or rafter, and a brace that extends at an angle with respect
to the structural member. The brace and structural member each
comprise a length of formed channel stock having a web and two
flanges. The brace plate includes first and second portions. The
first portion of the brace plate has a first set of mounting holes
and is adapted to be attached to the web of the structural member.
The second portion of the brace plate has a second set of mounting
holes arranged in an angled configuration with respect to the first
set of mounting holes and is adapted to be attached to the web of
the brace. The second portion of the brace plate extends at the
same angle at which the brace extends with respect to the
structural member. The brace plate also includes a flange that
extends at an angle from the second portion of the plate. The
flange of the plate is adapted to align with a flange of the
brace.
[0016] Further aspects and features of the steel frame building
system disclosed herein can be appreciated from the appended
Figures and accompanying written description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The foregoing and other features of the present invention
will be more readily apparent from the following detailed
description and drawings of illustrative embodiments of the
invention in which:
[0018] FIG. 1 is an exploded perspective view of a frame assembly
in accordance with an embodiment of the present invention;
[0019] FIG. 2 is a perspective view thereof;
[0020] FIG. 3 is a front view thereof;
[0021] FIG. 4 is a cross-sectional view taken along line 4-4 of
FIG. 3;
[0022] FIG. 5 is a close-up view of the corner section of the frame
assembly of FIG. 2;
[0023] FIG. 6 is a plan view of a column channel member of the
frame assembly in accordance with an embodiment of the present
invention;
[0024] FIG. 7 is a plan view of a rafter channel member of the
frame assembly in accordance with an embodiment of the present
invention;
[0025] FIG. 8 is a plan view of a haunch plate in accordance with
an embodiment of the present invention;
[0026] FIG. 9 is a cross-sectional view taken along line 9-9 of
FIG. 3;
[0027] FIG. 10 is a plan view of a brace channel member of the
frame assembly in accordance with an embodiment of the present
invention;
[0028] FIG. 11 is a plan view of a brace plate in accordance with
an embodiment of the present invention;
[0029] FIG. 12 is an isometric view of a spacer in accordance with
an embodiment of the present invention;
[0030] FIG. 13 is a close-up view of the peak connection of the
frame assembly of FIG. 2;
[0031] FIG. 14 is a plan view of a peak plate in accordance with an
embodiment of the present invention;
[0032] FIG. 15 is an isometric view of a base clip in accordance
with an embodiment of the present invention;
[0033] FIG. 16 depicts a steel frame building construction in
accordance with the present invention;
[0034] FIG. 17 is a side view of a column of the frame assembly in
accordance with an embodiment of the present invention;
[0035] FIG. 18 is a side view of a rafter of the frame assembly in
accordance with an embodiment of the present invention;
[0036] FIG. 19 is an isometric view of a reinforcing plate in
accordance with the present invention;
[0037] FIG. 20 is a cross-sectional view of a flange brace
extending between a rafter and a purlin in accordance with the
present invention;
[0038] FIG. 21 is an isometric view of a flange brace in accordance
with an embodiment of the present invention; and
[0039] FIG. 22 is a a view of the corner section of the frame
assembly of FIG. 2, including reinforcing nesting elements;
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0040] Referring now to FIGS. 1-3, there is shown an embodiment of
a steel frame assembly 10 for use in a steel frame building. The
frame assembly 10 can be used in the construction of a
prefabricated C-channel steel building system. The frame assembly
10 includes left and right corner connection assemblies 40 and 41.
The left corner connection assembly 40 includes left column 12,
left rafter 16, a haunch plate 42, and a brace 72. The right corner
connection assembly 41 includes right column 14, right rafter 18, a
haunch plate 42, and a brace 72. This arrangement enables the
construction from C-channel stock of wide span steel frame
buildings having a roof span of up to 50 feet or more. The frame
assembly 10 with corner connection assemblies 40 and 41, having
their particular combination of structural members that is further
described below, surprisingly allows for the use of light gauge
steel formed members that can be used to fabricate wide span steel
frame buildings.
[0041] Each column 12 and 14 comprises two lengths of channel stock
20. As can best be seen in FIG. 4, the lengths of channel stock 20
are formed into a C shape channel (sometimes referred to in the
trade as C-channel or Cee-channel). Each length of channel stock 20
has a web 22, two flanges 24 at substantially right angles to the
web 22, and two lips 26 at substantially right angles to the
flanges 24. Each column 12 and 14 is formed by joining the webs 22
of the two lengths of channel stock 20 together, as further
described below.
[0042] Similarly, each rafter 16 and 18 comprises two lengths of
channel stock 30. The channel stock 30 is also formed, preferably
into a C-channel shape. As can best be seen in FIG. 13, each length
of channel stock 30 has a web 32, two flanges 34 at substantially
right angles to the web 32, and two lips 36 at substantially right
angles to the flanges 34. Each rafter 16 and 18 is formed by
joining the webs 32 of the two lengths of channel stock 30
together, as further described below.
[0043] The channel stock members 20 and 30 are made from formed
light gage steel sheets. Typical members are formed of steel
between 16 gauge and 10 gauge. The gauge thickness is selected
depending on the designed wind load, snow load, and span of the
building. Heavier (thicker) gauge materials are used to construct
buildings requiring the ability to withstand heavier wind or snow
loads. In one embodiment, the channel stock members 20 and 30 are
formed from 10 gauge steel. Steel, sold under the trade
designations A653, A570, or A792 may be used in constructing the
frame members of the present invention. In one embodiment, channel
stock members 20 and 30 conform to the requirements of ASTM A-653
with a minimum yield point of 55 ksi. The channel stock for the
columns and rafters can have the same profile shape and size. In
other embodiments, the shape of the columns and rafters is not
limited to Cee-channels, and other shapes, such as U-channels, may
be used.
[0044] Referring now to FIGS. 1 and 5, the left column-rafter
connection assembly 40 is shown. FIG. 5 illustrates the connection
of the left column 12 and left rafter 16. For ease of description,
the connection is described with respect to the left column 12 and
rafter 16 although the connection assembly 41 on the right side of
the frame assembly 10 is constructed in a similar manner but in the
mirror image. Referring to FIGS. 5 and 8, left column 12 and left
rafter 16 are joined together by a haunch plate 42. Haunch plate 42
is pre-drilled with a pattern of seven holes 44 at one end and a
pattern of seven holes 46 at the other end (FIG. 8). Each web 22 of
the two channel stock members 20 that form the column 12 is
provided with a pattern of seven column-haunch connection holes 52
at one end (FIG. 6) that correspond to the holes 44 provided in the
lower portion of the haunch plate 42. The haunch plate 42 is placed
between the webs 22 of the two channel stock members 20 that form
the column 12. The pattern of seven column-haunch connection holes
52 on each of the two channel stock members 20 of the column 12
accepts a group of seven fasteners 68, which also pass through the
holes 44 in the haunch plate 42 to join the column 12 to the haunch
plate 42 (FIGS. 3 and 5). Similarly, each web 32 of the two channel
stock members 30 that form the rafter 16 is provided with a pattern
of seven rafter-haunch connection holes 60 (FIG. 7) that correspond
to the holes 46 provided in the upper portion of the haunch plate
42. The haunch plate 42 is also positioned between the webs 32 of
the two channel stock members 30 that form the rafter 16. The
pattern of seven rafter-haunch connection holes 60 on each of the
two channel stock members 30 of the rafter 16 accepts a group of
seven fasteners 70, which also pass through holes 46 in the haunch
plate 42 (FIG. 5). With the fasteners 68 and 70 in place, the
adjacent ends of the column 12 and rafter 16 are connected via the
haunch plate 42.
[0045] The haunch plate 42 is formed from solid steel plate. In one
embodiment, the haunch plate 42 is formed from 1/4 inch thick
steel; however, the thickness of the plate can range between about
3/16 inch to about 1/4 inch. Referring to FIG. 8, the pattern of
holes 46 is arranged on the upper part of haunch plate 42 at an
acute angle to the bottom edge 45 of the lower part of the haunch
plate 42. This acute angle corresponds to the angle at which the
rafter 16 extends from column 12 above the horizontal. Arranging
the pattern of holes 46 at an angle enables rafter 16 to be mounted
at an angle with respect to the column 12 without having to form
the rafter-haunch connection holes 60 at an angle with respect to
the flange edges of the webs 32 (the edges of the web 32 from which
the flanges 34 extend) of the channel stock 30 of the rafter 16
after the components have been configured in the frame
construction. Forming the rafter-haunch connection holes 60 in a
rectangular pattern that is aligned with the flange edges of the
webs 32 permits the rafter-haunch connection holes 60 to be
positioned at a uniform distance from the flange edges of the webs
32 of the channel stock members 30 of rafter 16. The haunch plate
42 also includes a section that is bent up at approximately 90
degrees with respect to the flat portion 43 of the haunch plate 42
along bend line 48 to form a flange 50, as shown in FIG. 5. The
flange 50 helps to reinforce the haunch plate 42. The flange 50
also assists with the proper positioning of the haunch plate 42
between the webs of the channel stock 20 and 30 of the column 12
and rafter 16. The haunch plate 42 is configured to fit
substantially within the profile of the column 12 and rafter 16 and
does not extend out beyond the edges of the column 12 or the rafter
16. Only the flange 50, which is disposed along side the column 12
as can be seen in FIG. 5, extends beyond the edges of the column 12
and rafter 16 towards the corner area 38.
[0046] In addition to connection via the haunch plate 42, the
column-rafter connection assembly 40 also includes a brace 72. The
brace 72 extends at an angle between the column 12 and rafter 16.
The brace 72 extends at an acute angle A with respect to column 12
and at an acute angle B with respect to rafter 16, as shown in FIG.
3. Preferably the angle A between the brace 72 and the column 12
and the angle B between the brace 72 and the rafter 16 are equal.
In a preferred embodiment, the angle A between the brace 72 and the
column 12 and the angle B between the brace 72 and the rafter 16
are equal to one half of the angle of 90 degrees minus the angle at
which the rafter 16 extends above the horizontal, i.e.,
1/2(90-angle at which rafter 16 extends above the horizontal). As
can be seen in FIG. 3, the rafter 16 extends at an angle above the
horizontal. Thus, the angles A and B at which the brace 72 extends
from the rafter 16 and column 12 are equal to 1/2(90-arctan(rise of
rafter/run of rafter)). In one embodiment the rise over run of the
rafter 16 is approximately 2/12 (inches/inches), and thus the
angles A and B of the brace 72 are 1/2(90-arctan( 2/12)), which
equals approximately 40 degrees with respect to the column 12 and
rafter 16.
[0047] Referring to FIG. 9, it can be seen that the brace 72
comprises two lengths of C-channel stock 74. Each length of
C-channel stock 74 has a web 76, two flanges 78 at substantially
right angles to the web 76, and two lips 80 at substantially right
angles to the flanges 78. The C-channel stock 74 forming the brace
72 is smaller than the channel stock 20 and 30 that forms the
columns 12 and rafters 16. The channel stock 74 of the brace 72
need not be the same size and shape as the channel stock 20 and 30
of column 12 and rafter 16. In one embodiment, the channel stock
member 74 is formed from 12 gauge steel.
[0048] Referring to FIGS. 1 and 5, one end of the brace 72 and
column 12 are joined together by a brace plate 83. As can be seen
in FIGS. 3 and 5, the brace plate 83 is positioned along an upper
portion of the column 12 to connect one end of the brace 72 to the
upper portion of the column 12. As shown in FIG. 11, the brace
plate 83 is pre-drilled with a pattern of eight holes 86 in angled
portion 87 of the brace plate 83 and a pattern of eight holes 88 in
non-angled portion 81 of the brace plate 83. As shown in FIG. 10,
each web 76 of the two channel stock members 74 that form the brace
72 is provided with a pattern of eight brace connection holes 82 at
one end that correspond to the holes 86 arrayed in the angled
portion 85 of the brace plate 83. As shown in FIGS. 1, 5, and 9,
the brace plate 83 is placed between the webs 76 of the two channel
stock members 74 that form the brace 72. The pattern of eight brace
connection holes 82 in each of the two channel stock members 74 of
the brace 72 accepts a group of eight fasteners 92, which also pass
through the holes 86 in the brace plate 83 to join the brace 72 to
the brace plate 83 (FIGS. 3 and 5). Referring to FIG. 6, each web
22 of the two channel stock members 20 that form the column 12 is
provided with a pattern of eight column-brace connection holes 54
that correspond to holes 88 provided in the non-angled portion 81
of the brace plate 83. As shown in FIGS. 1, 5, and 9, the brace
plate 83 is disposed between the webs 22 of the two channel stock
members 20 that form the column 12. The column-brace connection
holes 54 accept a group of eight fasteners 90, which also pass
through holes 88 in the brace plate 83. Thus, with the fasteners 90
and 92 in place, one end of the brace 72 is connected to the column
12.
[0049] Referring to FIG. 22, each column 12 may be reinforced with
a set of reinforcing nesting elements 165. Each nesting element has
a web 168 and two flanges 169 at substantially right angles to the
web 168. Each nesting element 165 is pre-drilled with a pattern of
eight holes 166 that correspond to the column-brace connection
holes 54 provided in each of the two channel stock members 20.
Additional holes 167 are provided in each nesting element 165 that
correspond to the additional holes 56 provided in the webs 22 of
the channel stock members 20.
[0050] If nesting elements are included, each nesting element 165
is positioned within the channel created by the flanges 24 (FIG. 4)
of the corresponding channel stock member 20 so that the web 168 of
the nesting element 165 is located adjacent the web 22 of the
channel stock member 20. The flanges 169 of each nesting element
165 are thereby located adjacent the flanges 24 of the
corresponding channel stock member 20 and the lips 26 (FIG. 4) of
the channel stock member 20 cover the ends of the flanges 169 of
the nesting element 165. Additionally, each nesting element 165 is
positioned so that the pattern of eight holes 166 lines up with the
column-brace connection holes 54 provided in the corresponding
channel member 20, and the additional holes 167 provided in the
nesting element line up with the additional holes 56 provided in
the web 22 of the corresponding channel member 20. The fasteners 90
(FIG. 5), which connect the one end of the brace 72 to the column
12, along with the fasteners 102 (FIG. 5) that join the webs 22 of
the channel members 20 also secure the nesting elements 165 to the
channel stock members 20.
[0051] Referring to FIG. 5, the opposite end of the brace 72 is
connected to the rafter 16 in a similar manner. A second brace
plate 84 is positioned along the portion of the rafter 16 that is
proximate to the haunch plate 42. The second brace plate 84 is
positioned between the webs 76 of the two channel stock members 74
of brace 72 and the webs 32 of the two channel stock members 30 of
rafter 16. Brace plate 84 is similar to brace plate 83 but is
rotated so that it can join the opposite end of brace 72 and rafter
16. The webs 76 of the channel stock members 74 of the brace 72 are
provided with a pattern of eight brace connection holes 91 at the
other end. The webs 32 of the channel stock members 30 of the
rafter 16 are provided with a pattern of eight rafter brace
connection holes 62. The holes 91 of the brace 72 and the holes 62
of the rafter 16 correspond to holes 86 and 88 in brace plate 84,
respectively. Holes 91 accept a group of eight fasteners 94, which
also pass through holes 86 in the angled portion 85 in the brace
plate 84 to join the brace 72 to the brace plate 84. Holes 62 of
the rafter 16 accept a group of eight fasteners 96, which also pass
through holes 88 in the non-angled portion 81 in the brace plate 84
to join the rafter 16 to the brace plate 84. Thus, the brace 72 is
joined to the rafter 16 via brace plate 84. In addition, the
fasteners 92 and 94 that connect brace 72 to brace plates 83 and 84
also function to join the webs 76 of the two individual lengths of
channel stock 74 forming brace 72 together.
[0052] Referring to FIG. 22, each rafter 16 may be reinforced with
a set of reinforcing nesting elements 170. Each nesting element has
a web 173 and two flanges 174 at substantially right angles to the
web 173. Each nesting element 170 is pre-drilled with a pattern of
eight holes 171 that correspond to the rafter brace connection
holes 62 provided in each of the two channel stock members 30.
Additional holes 172 are provided in each nesting element 170 that
correspond to the additional holes 66 provided in the webs 32 of
the channel stock members 30.
[0053] If nesting elements are included in the rafter 16, each
nesting element 170 is positioned within the channel created by the
flanges 34 (FIG. 13) of the corresponding channel stock member 30
so that the web 173 of the nesting element 170 is located adjacent
the web 32 of the channel stock member 30. The flanges 174 of each
nesting element 170 are thereby located adjacent the flanges 34 of
the corresponding channel stock member 30 and the lips 36 (FIG. 13)
of the channel stock member 30 cover the ends of the flanges 174 of
the nesting element 170. Additionally, each nesting element 170 is
positioned so that the pattern of eight holes 171 lines up with the
rafter brace connection holes 62 provided in the corresponding
channel member 30, and the additional holes 172 provided in the
nesting element line up with the additional holes 66 provided in
the web 32 of the corresponding channel member 30. The fasteners 96
(FIG. 5), which join the rafter 16 to the brace plate 84, along
with the fasteners 102 (FIG. 5) that join the webs 32 of the
channel stock members 30 secure the nesting elements 170 to the
channel stock members 30.
[0054] Referring to FIG. 11, a detailed view of brace plate 83,
which is formed from steel plate can be seen. In one embodiment,
brace plate 83 is formed from 1/4 inch thick steel; however, the
thickness of the plate can range between about 3/16 inch to about
1/4 inch. Section 85 of brace plate 83 is disposed at an angle to
bottom edge 89 of brace plate 83 and holes 86 in section 85 are
arranged in a pattern at an angle to bottom edge 89. The holes 86
are arranged at an angle so that brace 72, to which the brace plate
83 is joined, can be mounted at an angle with respect to the column
12 without having to form holes 82 in the webs 76 of the channel
stock members 74 of brace 72 in a pattern at an angle with respect
to the flange edges of the webs 76. Forming the holes 82 in a
rectangular pattern that is aligned with the flange edges of the
webs 76 permits the holes 82 to be positioned at a uniform distance
from the flange edges of the webs 76 of the channel stock members
74 of brace 72. As can be seen in FIG. 3, when brace plates 83 and
84 are positioned on column 12 and rafter 16 such that brace 72
connects to column 12 and rafter 16 at the same angle (i.e., when
angle A and B are the same), brace plates 83 and 84 have the same
shape. As stated above, brace plate 84 is similar to brace plate 83
but is rotated. As shown in FIGS. 5 and 11, brace plates 83 and 84
also include a portion that is bent up from flat angled portion 87
at approximately 90 degrees along bend line 98 to form a flange
100. Flange 100 helps to reinforce the brace plates 83 and 84 and
also assists with proper positioning of brace plates 83 and 84
between the webs 76 of the channel stock members 74 of brace
72.
[0055] Use of brace 72 results in an improved reinforcement for the
column 12 and rafter 16. The attachment points for brace 72 can be
changed without significantly altering the design of brace 72 by
moving the attachment point of brace plate 83 vertically along
column 12 and brace plate 84 laterally along rafter 16. The ability
to change the attachment points of brace 72 affords improved
flexibility in design, permitting the brace 72 to be optimally
positioned based on the design loads of the structure created with
the framing system of the present invention. Also brace 72
eliminates the need for an angled haunch plate that includes a web
portion and also eliminates the haunch plate material that would
occupy the corner between the column 12 and rafter 16. As can be
seen in FIG. 3, with the use of brace 72 to provide reinforcement
corner area 38 is left open. Haunch plate 42 does not extend out
beyond the edges of the column 12 or the rafter 16 into corner area
38 except for small flange 50 that extends along side the column
12. This design of haunch plate 42 affords a considerable savings
in the steel material needed to fabricate the haunch plate 42.
[0056] Surprisingly, the inclusion of brace 72 in the frame
assembly 10, which includes columns 12 and 14, rafters 16 and 18,
and haunch plates 42, permits the construction of buildings having
spans of up to 50 feet or more. Thus, a frame assembly 10 that
includes brace 72 permits the construction of wide span steel
buildings using C-channel members. C-channel steel frame buildings
of similar construction but without the brace 72 of the present
invention are generally limited in the distances that they can
span. A typical C-channel steel building constructed without the
brace 72 of the present invention is limited to a roof span (width)
of about 25 feet. Such a building is customarily designed with bays
of 15 feet, snow loading of about 30 pounds per square foot, and
wind loads of about 90 mph. A similar steel building that includes
the brace 72 of the present invention can achieve much larger
spans, for example a 40 foot span with bays of 15 feet, and will
withstand snow loads and wind loads equal to or greater than that
of the smaller span building. Thus, a corner connection 40 that
includes a haunch plate 42 and brace 72 as described above permits
construction of buildings with larger roof spans designed to
withstand equivalent snow and wind loading characteristics without
significantly increasing the cost or difficulty of
manufacturing.
[0057] Referring now to FIGS. 1, 3, and 13, the left rafter 16 and
the right rafter 18 are joined together via a peak plate 106 to
form a complete frame assembly 10. Rafter sections 16 and 18 are
joined at their adjacent ends to form a roof peak element 147.
Rafters 16 and 18 are joined at an obtuse angle C with respect to
each other. Rafters 16 and 18 are preferably joined at an angle
between approximately 143 and 175 degrees, and even more preferably
at approximately 161 degrees. Peak plate 106 is disposed between
the webs 32 of the channel stock members 30 that form each of the
rafters 16 and 18. The peak plate 106, as shown in FIG. 14, is
pre-drilled with two hole patterns, one on each side of the peak
plate 106, each consisting of nine holes 108 disposed at an angle
to the horizontal. Webs 32 of the rafters 16 and 18 are each
provided with a pattern of nine peak plate fastening holes 64 that
correspond to holes 108 in peak plate 106 (FIG. 7). Each pattern of
nine peak plate fastening holes 64 in each rafter 16 and 18 accept
a group of nine fasteners 109, which pass through the holes 108 in
the peak plate 106 to join adjacent ends of the rafters 16 and 18
(FIG. 13). Thus, rafters 16 and 18 are joined via peak plate
106.
[0058] Peak plate 106 is formed from steel plate which can range in
thickness between about 3/16 inch to about 1/4 inch. Peak plate
106, brace plates 83 and 84, and haunch plate 42 should preferably
be the same thickness in order to maintain uniform spacing between
the channel stock members 20 and 30 of the columns 12 and 14 and
rafters 16 and 18. As shown in FIG. 14, the two hole patterns each
consisting of nine holes 108 in the peak plate 106 are disposed at
an angle to the horizontal. This angle corresponds to the angle at
which the rafters 16 and 18 extend. This permits rafters 16 and 18
to be connected to peak 106 without the need to form the holes 64
in the webs 32 of the channel stock of the rafters 16 and 18 in an
angled pattern with respect to the flange edges of the webs 32.
Forming the holes 64 in a rectangular pattern that is aligned with
the edges of the webs 32 permits the holes 64 to be positioned at a
uniform distance from the flange edges of the webs 32 of the
channel stock members 30 of rafters 16 and 18. Referring to FIGS.
13 and 14, peak plate 106 also includes two portions that are bent
up at approximately 90 degrees from flat portion 107 along bend
lines 110 and 112 to form flanges 114 and 116. Flanges 114 and 116
help to reinforce the peak plate 106 and also assist with the
proper positioning of the peak plate 106 between the webs 32 of the
two channel stock members 30 of each rafter 16 and 18.
[0059] As discussed above and depicted in FIG. 1, column 12 is
formed from two lengths of channel stock 20 joined together by
their webs 22 and rafter 16 is formed from two lengths of channel
stock 30 joined together by their webs 32. As shown in FIGS. 3, 5,
and 13, the fastener groups 68, 70, 90, 96, and 109, also provide
connection between the webs 22 and 32 of each of the two lengths of
channel stock 20 and 30 that form the column 12 and rafter 16,
respectively. In addition to fastener groups 68, 70, 90, 96, and
109, fasteners 102 are employed to join the webs 22 and 32 of each
of the two length of channel stock 20 and 30 that form the column
12 and rafter 16, respectively. Additional holes 56 and 66 are
provided in the webs 22 and 32 of the channel stock 20 and 30
(FIGS. 6 and 7). As shown in FIG. 12, spacers 104 are also provided
with pre-drilled holes 105 that correspond to the holes 56 and 66
in the webs 22 and 32. Spacers 104 are disposed between the webs 22
and 32 of channel stock members 20 and 30 and have the same
thickness as the haunch plate 42, brace plates 83 and 84, and peak
plate 106. This allows webs 22 and 32 to be connected without
deforming channel stock members 20 and 30 of the column 12 and
rafter 16. Fasteners 102 are passed through the holes 56 and 66 in
the webs 22 and 32 and the holes 105 in spacers 104 to join these
components together. Thus, the webs 22 and 32 of each of the two
lengths of channel stock 20 and 30 are joined to form the columns
12 and 14 and rafter 16 and 18, respectively.
[0060] In one embodiment, depicted in FIGS. 1, 4, 9, and 13, all
main frame connections are provided with fasteners such as bolts
160 with nuts 164 and two washers 162 in which one washer is on the
bolt side and the other is on the nut side. The bolts 160 can be
high strength bolts and the nuts 164 are hex nuts. Further, all the
holes in the channel stock 20, 30, and 74 of the columns 12 and 14,
rafters 16 and 18, and braces 72, respectively, can be pre-drilled
so that the frame assembly 10 can be easily constructed on a job
site.
[0061] Referring now to FIGS. 1, 15, and 16, base clips 118 attach
the columns 12 and 14 to a support surface 126. Two base clips 118,
one on each side of columns 12 and 14, are provided. Four fastening
holes 120 are pre-drilled in the upper portion of each base clip
118, which correspond to holes 58 (FIG. 6) in each web 22 of the
channel stock 20 of each column 12 and 14. Fastening holes 120 also
correspond to the holes provided in the column spacers 124, so that
fasteners can be passed through the holes to secure the base clips
118 to columns 12 and 14. The lower portion 123 of base clips 118,
which is substantially at a right angle to the upper portion 121,
has pre-drilled holes 122 to enable the base clips 118 to be
fastened to support surface 126. The support surface 126 (which
may, for example, be a concrete slab or cinder block foundation)
serves as a foundation upon which a building can be erected.
[0062] As shown in FIG. 16, the frame assembly 10 forms a part of
steel building 130. The steel building 130 may include multiple
frame assemblies 10 spaced along the length of the building
depending on the overall length of the building. End walls 132 of
the building 130 comprise a frame that has rafters 134 and columns
136, each formed from a single length of channel stock. A double
channel stock design is not needed for the end walls because extra
support is provided by intermediate columns 138.
[0063] Girts 140 are provided on the outside of columns 12 and 14
to structurally reinforce the building and to provide support for
the outer wall sheathing 142. The girts 140 and outer wall
sheathing 142 join the columns 12 and 14 to the two end walls 132.
The girts 140 are attached to the columns 12 and 14 via holes 144
provided in the flanges 24 of the columns (FIG. 17). Purlins 146
are attached to the rafters 16 and 18 via holes 148 provided in the
flanges 34 of the rafters (FIG. 18). The purlins 146 provide
support and the roof sheathing 150 is attached to the purlins 146.
The purlins 146 and roof sheathing 150 join the rafters 16 and 18
of the roof peak element 147 to the end walls 132. In one
embodiment, the sheathing panels 142 and 150 are attached to the
girts 140 and purlins 146 using screws (for example No. 12
self-drilling screws) and are located adjacent major ribs in the
panel. The sheathing panels 142 and 150 preferably have major ribs
spaced twelve inches apart and minor ribs spaced four inches
apart.
[0064] Referring now to FIGS. 16, 20, and 21, compression flange
stabilizers 141 (also known as flange braces) may be used to
connect the columns 12 and 14 to the girts 140. Flange stabilizers
141 may also be employed to connect the rafters 16 and 18 to the
purlins 146. The flange stabilizers 141 serve to stabilize the
structural elements (columns 12 and 14 and rafters 16 and 18). The
flange stabilizers 141 may be formed from bent right angle stock or
rolled angle stock. The right angle stock can be 1/8 inch thick
steel. One flange at each end 151 and 153 of the flange stabilizer
141 is cut short, leaving the other flange longer to form a tab
143. The tab 143 at the end of the flange stabilizer 141 that
connects to the rafter 16 is bent to mate with the rafter 16 as
shown in FIG. 20. A hole 149 is provided in the tab 143 at end 151
so that the flange stabilizer 141 may be attached to rafter 16
using fasteners. A hole 145 is also provided in the flange at the
opposite end 153 of the flange stabilizer 141 so that the flange
stabilizer 141 can be attached to the purlin 146 with fasteners
(not shown). In one embodiment, the flange stabilizers 141 are
connected a with bolt 160, two washers 162, and a nut 164. The
flange stabilizers 141 extending between the rafters 16 and 18 and
the purlins 146 are connected between the holes 66 in the rafters
closest to the inside (compression) flange at one end 151 and to
holes 155 in the purlins at the other end 153. The flange
stabilizers 141 extending between the columns 12 and 14 and the
girts 140 are connected between the holes 56 in the columns closest
to the inside (compression) flange at one end 151 and to holes in
the girts at the other end 153. The flange stabilizers 141 are
connected at approximately 45 degree angles. Flange stabilizers 141
are located as needed by design and limit the out of plane
displacement along the length of the member. This increases the
load carrying capacity of the columns 12 and 14 and rafters 16 and
18.
[0065] In one embodiment, the wall sheathing panels 142 and the
roof panels 150 attached to the girts 140 and purlins 146 are 26 or
29 gage structural roof and wall panel (known in the trade as PBR
panel). PBR panels are formed with transverse major (large ribs
which may be 11/2 inches high) and minor (small which may be 3/16
inches high). Known in the trade as "through-fastened panels,"
panels 142 and 150 are fabricated from cold-formed steel.
[0066] Referring to FIGS. 5, 8, 13, and 14, slots 152 are provided
in the main frame members (columns, rafters, haunch plates, and
peak plate) of the structure so that building 130 can be reinforced
with cables or rods. Longitudinal stability of building 130 is
provided by cable or rod bracing (not shown) in the plane of the
rafters and in the wall planes. These are respectively known as
roof bracing and sidewall bracing. The cables or rods of the
bracing comprises tension members which transfer wind and
earthquake forces to the foundation 126. Such cable or rod bracing
can be provided in the form of cross-bracing (not shown). Slots 152
are provided in the webs 22 and 32 of the channel stock members 20
and 30 of the columns 12 and 14 and rafters 16 and 18 of the frame
assembly 10. Corresponding slots 152 are provided in the haunch
plates 42, peak plate 106, and reinforcing plates 154. The slots
152 in the haunch plates 42 and the peak plate 106 allow passage of
the cable from one side of the column or rafter to the other. The
haunch plate 42 and peak plate 106 also function to distribute the
load applied to the web of the channel stock of the column and
rafter from the cables or rods. The plates 42 and 106 increase the
resistance to the cables or rods damaging the webs 22 and 32 of the
columns 12 and 14 and rafters 16 and 18. Where slots 152 are
provided in the webs 22 and 32 of the channel stock members 20 and
30 in locations that do not have haunch or peak plates, reinforcing
plates 154 are provided. The reinforcing plates 154 function in a
similar manner as the haunch and peak plates to increase the
resistance to failure of the webs of the channel stock members. In
addition, the columns and rafters of the end walls 132 have slots
152 and reinforcing plates 154 for attachment of cables or
rods.
[0067] The steel framing system of the present invention permits
the design and construction of wide span metal frame buildings
using lightweight, inexpensive C-channel stock. The wide span
structures constructed with the framing system of the invention can
withstand wind and snow loads at least equal to those of structures
having narrower spans while utilizing inexpensive lightweight
materials that are inexpensive to fabricate, transport, and
install.
[0068] While the invention has been particularly shown and
described with reference to preferred embodiments thereof, it will
be understood by those skilled in the art that various changes in
form and details may be made therein without departing from the
spirit and scope of the invention.
* * * * *