GB2158122A

GB2158122A - Metal beam, lintel or elongate structural member and method of making same

Info

Publication number: GB2158122A
Application number: GB08510304A
Authority: GB
Inventors: Brian Robinson
Original assignee: BELLHILL Ltd
Current assignee: BELLHILL Ltd
Priority date: 1984-05-03
Filing date: 1985-04-23
Publication date: 1985-11-06
Also published as: GB8510304D0; GB2158122B

Abstract

A metal beam (Figure 3) or lintel (Figures 10-15) is formed in a continuous forming and welding operation from a metal blank 1 which is an elongate strip of metal and has mounting stations 3 for mounting, when the blank is formed in V-shape undulations. Spaced parallel elongate metal elements forming first 4 and second 5 plates or parts of the beam are fixed to the undulating strip at their mounting stations. <IMAGE>

Description

SPECIFICATION Metal beam, lintel or elongate structural member, and method of making same The invention relates to metal beams a blank incorporated therein and a method of making the beam. It will be understood that the term 'metal beam' used herein includes lintels, elongate structural members and the like.

According to the invention there is provided a metal beam as herein defined, comprising a first plate or part for supporting part of a building over an aperture in a wall, a rigid support member of repeating substantially undulating configuration secured to the first plate or part extending longitudinally of the beam and extending from the first plate or part to join with a second plate or part which is substantially parallel with the first plate or part.

The rigid support member may be joined with the second plate or part intermediate the width thereof.

The second plate or part may include guide means for receiving the rigid support member.

The second plate or part may include a recess or rebate for receiving part of a frame such as a door or window frame.

The first and second plates or parts may have substantially the same lateral extent.

The second plate or part may project laterally on one side at least of the beam beyond the lateral extent of the first plate or part on that one side.

The second plate or part may project laterally on both sides of the beam beyond the lateral extremities of the first plate or part.

The second plate or part may include strengthening means spaced apart over the length thereof.

The strengthening means may comprise swages in the second plate or part.

The first andlor second plate or part may be formed from a single sheet of metal.

According to a further aspect of the invention there is provided a metal blank for use in forming a metal beam as herein defined, comprising an elongate metal strip having spaced longitudinally thereof mounting stations for mounting another elongate metal element of the beam, the lateral edges of the strip between the stations being turned out of the plane of the strip.

The mounting stations may each occupy the whole width of the blank and may include spaced transverse fold lines about which the blank can be folded out of the plane thereof.

The fold lines may be substantially parallel.

The edges may be turned out of the plane of the blank in the same direction.

The edges may be substantially parallel and substantially at right angles to the plane of the blank.

According to a yet further aspect of the invention there is provided a metal beam (as herein defined), comprising two spaced elongate metal elements connected together by being secured to respective mounting stations of a metal strip formed from a metal blank comrising an elongate metal strip having spaced longitudinally thereof and mounting stations and the lateral edges of the strip between the mounting stations being turned out of the plane of the strip, the strip being folded alternatively about spaced mounting stations to form an undulating shape the intermediate mounting station being secured to one of the elongate metal elements and the other element being secured to the other mounting stations.

The desired shape may be a 'V' and there may be a plurality of 'V' shapes longitudinally of the beam.

The 'V' shapes may be formed integrally from the blank.

The elongate members may be of channel section with the respective webs thereof being secured to the mounting stations.

The flanges of the respect channel section members may be directed towards one another.

The flanges of the respective channel section members may be directed away from one another.

The flanges of the respective channel section members may be directed in the same direction.

One or both of the spaced metal elements may include means for connection to other articles.

The means may comprise through apertures.

The through apertures may comprise slots and holes. This provides for relatively uniform securing to other articles such as accessories or other beams.

The slots may be in the web of the elongate the or each member.

According to a still further aspect of the invention there is provided a method of making a metal beam as herein defined comprising providing two elongate metal members and a blank as hereinbefore defined, spacing the members and blank apart in substantially the same plane with the blank between the members, forming the blank into a shape whereby alternative mounting stations are in the same plane, contacting the mounting stations and elements and securing the elements and blank together at the mounting stations.

The securing step may comprise welding.

The elements may each be provided in the form of a strip which is formed into a channel shape by passage through a respective roll former in synchronism with the passage of the blank through a 'V' former.

The method may be continuous.

Metal beams embodying the invention are hereinafter described, by way of example, with reference to the accompanying drawings.

Brief description of drawings Figure 1 is a plan view of a blank according to the invention; Figure 2 shows schematically to a smaller scale a method of making a metal beam according to the invention using a blank as shown in Figure 1; Figure 3 shows a perspective view, to a larger scale, of part of a metal beam according to the invention; Figure 4 shows a side elevational view of the beam of Figure 3 to a smaller scale than that Figure; Figures 5A, 5B and 5C show end elevational views of different metal beams according to the invention; Figure 6 shows a perspective view of part of an element of a metal beam; Figure 7 shows an element of Figure 6 connected to a further member; Figure 8 is a schematic end elevational view of a metal beam in the form of one lintel according to the invention;; Figure 9 is a schematic end elevational view of a second embodiment of metal beam in the form of a lintel according to the invention; Figure 10 is a schematic end elevational view of a third embodiment of metal beam in the form of a lintel according to the invention; Figure Ii is a schematic end elevational of a fourth embodiment of metal beam in the form of a lintel according to the invention; Figure 12 is a schematic end elevational view of another lintel according to the invention; Figure 13 is a schematic end elevational view of a further embodiment of lintel according to the invention; Figure 14 is a schematic end elevational view of a yet further embodiment of lintel according to the invention; Figure 15 is a schematic side elevation of a further embodiment of lintel according to the invention, to a smaller scale than Figures 12 to 14; and Figure 16 is a schematic plan view of the bottom plate of the lintels of Figures 12 - 15 to a larger scale than those Figures.

Referring to the drawings, Figure 1 shows a metal blank 1 for use in forming a metal beam 2 (as herein defined) (Figures 2,3,4) comprising an elongate metal strip having spaced longitudinally thereof mounting stations 3 for mounting another elongate metal element in the form of a channel 4 or 5 of the beam 2, the lateral edges 6 of the strip 1 being turned out of the plane of the strip 1.

The upturned edges merge with the ultimate respective edge at the mounting stations 3 so that the parts of the strip 1 between the stations are of channel shape. The turned up edges 6 provide for strength in the blank 1. The mounting stations 3 have spaced substantially parallel fold lines 7 transversely of the strip 1.

In use to form a metal beam 2 in a continuous forming method, two spaced roll formers 8 and 9 are provided, as are two spaced elongate metal elements in the form of strips 4a and 5a and the metal blank 1, which is between the strips 4a and 5a, the strips 4a and 5a and blank 1 lying in the same plane.

The strips are indexed in synchronism with each other and the blank, say from left to right in Figure 2 as viewed. The roll formers 8 and 9 form the respective strips 4a and 5a into channel the channels 4 and 5 which are drawn together with the blank 1 as that passes through a 'V'-former 10 to fold the blank 1 about the fold lines 7 to provide an undulating configuration or shape in the form of the series of connected 'V'-shapes shown, alternative 'V's being inverted. This 'V' configuration provides a series of mounting stations 3 adjacent the element 4 and a series adjacent the element 5 The elements 4 and 5 are then secured to the blank 1 as shown by means such as welding e.g. spot welding at welding heads 11 and 12 as shown.It will be understood that the indexing of the various elements in synchronism from left to right is synchronised with the stroke of the 'V'-former 10 and with the welding head operation at 11 and 12 so that a completely continuous production method, which can be automatic with virtually no operatives in attendance, is provided. In the embodiment shown, Figure 3, the flanges 13 of the channel elements 4 and 5 are directed towards one another (Figure 5A) so the 'V'-formed blank sits within the channels. The mounting stations 3 comprise flat plates which provide a sound and even seating.

The channels 4 and 5 can however be arranged by suitable adjustment of the roll formers so that the flanges thereof point in the same direction (Figure 5B) or in opposite directions (Figure 5C). In all cases however, the welding connection is at the flat mounting stations 3.

The elements 4 and 5 can have securing means such as blind slots 14 and through holes 15 whereby the beam 2 can be connected to another article such as a timber insert 16 (Figure 7) or to other accessories or to a larger structural beam for example. The slots 14 ensure that there is always a space available to pick up or a bolt or other device of an accessory or other beam.

Although a continuous method has been described, the method can be discontinuous. In any production method though the beam is lightweight and has high structural strength, and can be cut to any desired length by severing through a mounting station and the opposite channel, or other shape of elongate element secured to the blank.

Referring to Figures 8 - 11 (like parts having like numerals), the lintel 80 shown in Figure 8 is as sheel metal lintel for use in a wall, comprising a first plate or part 82 for supporting a plurality of building blocks such as bricks, stones, breeze blocks and the like over an aperture (not shown) in the wall (also not shown). The lintel 80 has a rigid support member 83 of undulating configuration (the undulations extending over the length of the lintel), secured as by welding to the first plate or part 82 and extending downwardly therefrom, as viewed and as considered in use, to join with a second plate or part 84 which is substantially parallel with the first plate or part 82, the rigid support member 83 being secured to the second plate or part 84 as by welding intermediate the width thereof.

The first plate or part 82 is of web section as shown, the flanges or limbs 85 of the web extending downwardly as viewed, and flanking the rigid support member 83.

The second plate or part 84 is made of a single sheet of metal by rolling and includes guide means in the form of spaced downwardly open troughs 86 which guide means 86 receive the lower (as viewed) end of the rigid support member 83 between them.

The rigid support member itself may be formed from spaced strips of channel section joined by a series of 'V'-shapes, formed continuously from a blank as considered longitudinally of the blank, alternate 'v's being inverted and being connected by flat mounting station at which the strips are also secured. The first and second plates or parts 82 and 84 are then secured as by welding to respective strips of the support member 83. Alternatively, the strips form the respective first and second plates or parts; in either construction the lintel 80 can be made by a continuous construction method in which strip metal is supplied, formed, advanced in synchronism and welded together to form the lintel.

The lintel 80 shown is used by building up buttresses to a desired height on either side of an aperture to be spanned by the lintel, the lintel is then placed in position over the aperture so that it is supported at each end on the buttresses, which then under the second plate or part 84, and the wall is built up over the aperture, the building blocks of the wall being supported on the second plate or part 84 over the aperture and on the first plate or part 82. The lintel 80 is thus incorporated into the wall.

The guide means 86 also act to strengthen the lintel, as do the flanges or limbs 85 of the first plate or part 82.

Figure 9 shows a lintel 90 similar to Figure 1, the difference being that there is a channel shaped downwardly open (as viewed) recess 91 in the second plate or part in which a head rail of a window or door frame is received in use. The second plate or part 84 is again a single sheet of metal and the rigid support member 83 is received on the web 92 of the channel shaped recess 91.

Figure 10 shows a lintel 100 similar to Figure 9, the difference being that there is in the second plate or part 84 a rebate or step 103, in which a head part of a door or window frame is received to butt against a boundary part 104 of the rebate or step. The second plate or part 84 is again in one piece, through parts 133 and 134 thereof are in spaced vertical (as seen) planes.

Figure 11 shows a lintel 110 in which the second plate or part 84 comprises two L-shape members 141, 142 secured to the opposite sides of the rigid support member 83 and connected by a lower plate 143 which is secured as by being welded to the limbs 144 of the respective members, the other limbs 145 of which are secured as by welded to the rigid support member 83.

The lintels of Figures 9, 10 and 11 are made in similar manner to that described for the lintel of Figure 8.

In every embodiment, the second plate or part has a drip lip 88 which projects downwardly and forwardly at the in use external side of the wall.

Referring now to Figures 12 - 16 of the drawings, in which like parts are again referred to by like reference numerals there is shown a plurality of metal elongate structural components in the form of lintels 120, 130 and 140 (Figures 12 to 14 respectively) each comprising a plate or part 121 for supporting a plurality of buidling blocks over an aperture in a wall, and a rigid member of undulating (V-) configuration 122 secured to the plate or part and extending in use upwardly therefrom.

The plate or part 121 in each case comprises strengthening means in the form of swages 123 which are substantially parallel with one another and which extend substantially at 90 to the respective edges of the plate or part 121. The swages 123 are essentially elongate channel-shaped depressions formed in the plate 121 as by rolling, which depressions are open upwardly or downwardly as considered in use, in other words the swages 123 can be formed either in the top or bottom of the second plate or part as considered in use.

Downwardly open swages 123 are shown in dashed lines in the Figures.

The swages 123 are so spaced as to be half the modular increment of the undulating configuration 122 in other words there is one swage 123 between an apex 124 at the base of a lattice section 122 and the adjacent top apex 125 (Figure 15), an apex 124 or 125 being considered as a change in direction of the zig-zag member forming the lattice 122. This construction provides that there are two swages 123 between any two adjacent bottom apices 124.

In Figure 16, 'X' depicts where adjacent bottom apices 124 would join the plate or part 121.

This arrangement of swages 123 results in the possibility of fully automatic control of production of a lintel as shown. The lattice configuration 122 and bottom plate 121 can be formed individually from suitable blanks, and can then be indexed through stations where they are secured together as by spot welding, the indexing being controlled so that the lower (in use) apices 124 are brought into contact with the lower plate or part at positions 'X' for spot welding in a fully automated production sequence.

The lateral edges of the lower plate or part 121 may have a respective downward lip 126 and an upward lip 127. The lip 126 is a drip lip for shedding water from the outer block work of a wall supported on the left hand limb of the lower plate or part 121, while the lip 127 acts as a strengthener and as a key for mortar, plaster etc to be applied to the inner skin of a wall supported on the right limb of the plate or part 121.

The plate or part 121 may also have longitudinally extending means such as U-shaped channels 128 which strengthen the plate or part and form seatings for the lattice configuration structure 122 (Figures 13 and 14).

Claims

1. A metal beam as herein defined, comprising a first plate or part for supporting part of a building over an aperture in a wall, a rigid support member of repeating substantially undulating configuration secured to the first plate or part extending longitudinally of the beam and extending from the first plate or part to join with a second plate or part which is substantially parallel with the first plate or part.

2. A metal beam, according to Claim 1, the rigid support member is joined with the second plate or part intermediate the width thereof.

3. A metal beam according to Claim 1 or Claim 2, the second plate or part including guide means for receiving the rigid support member.

4. A metal beam according to any preceding Claim, the second plate or part including a recess or rebate for receiving part of a frame such as a door or window frame.

5. A metal beam according to any preceding Claim, the first and second plates or parts having substantially the same lateral extent.

6. A metal beam according to any of Claims 1 to 5, the second plate or part projecting laterally on one side at least of the beam beyond the lateral extent of the first plate or part on that one side.

7. A metal beam according to Claim 6, the second plate or part projecting laterally on both sides of the beam beyond the lateral extremities of the first plate or part.

8. A metal beam according to Claim 6 or Claim 7, the second plate or part including strengthening means spaced apart over the length thereof.

9. A metal beam according to Claim 8, the strengthening means comprising swages in the second plate or part.

10. A metal beam according to any preceding Claim, the first andlor second plate or part being formed from a single sheet of metal.

11. A metal beam as herein defined, substantially as hereinbefore described with reference to the accompanying drawings.

12. A metal blank for use in forming a metal beam as herein defined, comprising an elongate metal strip having spaced longitudinally thereof mounting stations for mounting another elongate metal element of the beam, the lateral edges of the strip between the stations being turned out of the plane of the strip.

13. A blank according to Claim 12, the mounting stations each occupying the whole width of the blank and including spaced transverse fold lines about which the blank can be folded out of the plane thereof.

14. A metal blank according to Claim 13, the fold lines being substantially parallel.

15. A metal blank according to any of claims 12 - 14, the edges being turned out of the plane of the blank in the same direction.

16. A metal blank according to Claim 15, the edges being substantially parallel and substantially at right angles to the plane of the blank.

17. A metal blank for use in forming a metal beam, substantially as hereinbefore described with reference to the accompanying drawings.

18. A metal beam as herein defined, comprising two spaced elongate metal elements connected together by being secured to respective mounting stations of a metal strip formed from a metal blank comprising an elongate metal strip have spaced longitudinally thereof and mounting stations and the lateral edges of the strip between the mounting stations being turned out of the plane of the strip, the strip being folded alternatively about spaced mounting stations to form an undulating shape, the intermediate mounting station being secured to one of the elongate metal elements and the other element being secured to the other mounting station.

19. A metal beam according to Claim 18, in which the undulating shape is a 'V' and in which there is a plurality of 'V' shapes longitudinally of the beam.

20. A metal beam according to Claim 19, the 'V' shapes being formed integrally from the blank.

21. A metal beam according to any of the Claims 18 to 20, the elongate members being of channel section with the respective webs thereof being secured to the mounting stations.

22. A metal beam according to Claim 21, the flanges of the respective channels section mem- bers being directed towards one another.

23. A metal beam according to Claim 21, the flanges of the respective channel section members being directed away from one another.

24. A metal beam according to Claim 21, the flanges of the respective channel section members being directed in the same direction.

25. A metal beam according to any of Claims 18 to 24, one or both of the spaced metal elements including means for connection to other articles.

26. A metal beam according to Claim 25, the means comprising through apertures.

27. A metal beam according to Claim 26, the through apertures comprising slots and holes.

28. A metal beam according to Claim 27, the slots being in the web of the elongate the or each member.

29. A metal beam, substantially as hereinbefore described with reference to the accompanying drawings.

30. A method of making a metal beam as herein defined comprising providing two elongate metal members and a blank according to Claim 12, spacing the members and blank apart in substantially the same plane with the blank between the members, forming the blank into a shape whereby alternative mounting stations are in the same plane, contacting the mounting stations and elements and securing the elements and blank together at the mounting stations.

31. A method according to Claim 30, the securing step comprising welding.

32. A method according to Claim 30 or Claim 31, the elements each being provided in the form of a strip which is formed into a channel shape by pasage through a respective roll former in synchronism with the passage of the blank through a 'V'-former.

33. A method according to any of Claims 30 to 32, which is continuous.

34. A method according to Claim 30, substantially as hereinbefore described with reference to the accompanying draws.