CONSTRUCTION SYSTEM

Abstract: A system for constructing staging or the like comprising beams 2,3,4,5,6 etc. (e.g. timbers) and socket elements 10,11,12,13, etc., with screws or the like to secure the beams to the socket elements. The socket elements each comprise at least three interconnected box sections for slidably receiving the beams, the box sections being open at both ends and arranged such that a first of the beams can pass through a selected one of the box sections, while at least one further beam can pass through further box sections and abut the first beam. The system generally supports cladding sheets 1, for example, for stage flooring.

Description: The present invention is concerned with structural construction systems which may be used, in particular, for theatrical staging or platforms, and also for purposes such as the construction of shuttering for the laying of concrete floors, scaffolding or temporary buildings. In theatrical productions it is often required to provide a temporary stage of a particular size, shape, slope and height. In the past, it has generally been necessary either to construct the required stage in its entirety or to compromise on the stage specification so as to permit the use of existing stage components of predetermined characteristics. With respect to this latter approach, the stage components involved are normally collapsible four-walled box pens with fitting platform members, such components being readily storable. The lack of versatility of the storable stage components can be highly inconvenient and restrictive so that the expensive alternative of constructing a completely new stage for a single production is often adopted. It is an object of the present invention to provide a versatile construction system which can employ readily available construction materials and is suitable for use, inter alia, for constructing stages, and which can be dismantled for storage. GB-A-910183 discloses a construction system having a plurality of structural beams, coupling elements having tubular sockets for receiving the prepared and reduced ends of the beams, and means for securing the beams to the socket elements. BE-A-659715 discloses a construction system which comprises a plurality of structural beams and three-way socket elements for receiving the beams, the socket elements comprising two mutually perpendicular box section members and a third box section member perpendicular thereto, the box section members being open at both ends to allow the beams to pass right through. The present invention is concerned with a construction system of this general type which comprises: (a) a plurality of elongate structural beams; (b) a plurality of multi-way socket elements each comprising at least three interconnected tubular box section members capable of slidably receiving a structural beam, the box section members being open at both ends so as to define unobstructed passages right through each socket; and (c) means for securing beams to the socket elements. According to the invention, each of the box section members is arranged such that a first of the structural beams can pass right through any one of the box section members and also through an open zone at one end of each of the box section members, and further ones of the structural beams can pass through respective further ones of the box section members, such that an end face of any one of the further ones of the structural beams can abut a respective face of the first mentioned structural beam in the open zone. The elongate structural beams used in the construction system are, in some embodiments, all of the same cross-section, which is preferably substantially rectangular. The beams are preferably of timber (although other materials, such as metals, are also envisaged). Typically, such wooden beams measure about 69mmn by 44mm (a standard dimension for planed wooden beams). The socket elements are preferably of metal (such as mild steel), although other materials, such as plastics, are also envisaged. The box section members are preferably of hollow rectangular section such as to snugly receive any one of the structural beams. The use of socket elements of the kind described can avoid the need for shaping the ends of the beams, and the latter abut directly against one another, so that they may be measured and cut to length without reference to the dimensions of the sockets. The system is flexible in that there are no constraints on the length of the beams. Since no shaping of the ends of the beams is necessary, and since a large proportion of the construction can be modular so that the beams are of a standard length, much of the system may be re-used at a later date after dismantling. Securing of the beams to the sockets requires no special tools or expertise. Since the box section members constituting the socket elements used in the construction system according to the invention are fixed in or pivotable to mutually perpendicular orientations, and as the socket elements are internally open, it is possible for the beams to extend therethrough in any one of two mutually perpendicular horizontal directions, or in the vertical direction. Base plates may be provided for the structural beams, for mounting on the ground or floor to function as support columns for the construction. Such base plates may each consist of a metal plate to which is attached a short box section, similar to the box section members of the socket elements, and therefore dimensioned so as to receive the ends of the structural beams. The plate is preferably attached to the box section by hinge means on the end edge of the latter, such that the structural beam forming the support column may be inclined to the ground. When only three box section members are present, the socket elements can generally be used as corner elements, or for edge elements, for a construction such as a staging framework. When four such box section members are employed, the socket element is suitable for use either in the body of the construction, or at the edges thereof. When the socket element has five such box section members, it is suitable for use in the body of the construction. When four or more box section members are employed, it is particularly preferred that three are of the same rectangular cross-section such as to admit the structural beams, the three members being joined to form a T in the plane of the smaller transverse edge of the respective box section members. In this embodiment, a fourth box section memberprojects at right angles to the junction of the T, the central region of the socket being open so that a first structural beam may be passed through it in any one of three mutually perpendicular directions, with other beams being inserted into other arms of the socket element so as to abut against the first structural beam at right angles. The box section members may be rigidly interconnected to form the socket element, in which case the interconnection is such that all the socket elements are mutually perpendicular. However, an alternative form of socket element will be described which is adaptable for both left and right hand use and which can also be used where the angle is other than a right angle. In this form of socket element, at least one further box section may be provided with meeting hinge components at either end of a respective face to enable it to be coupled at a respective side of the centre. The socket elements described above may be provided with hinge components to enable them to be linked directly to the other hinge component of a base plate in the case where the staging slopes down to ground level. The lengths of the box section members are preferably at least equal to the larger transverse dimension of the beams. However, some of the box section members, and in particular preferably the standard of the T, may be longer, for example, of twice this length, to allow two beams to be abutted together end to end while being securely held within the box section member. To facilitate this, the longer box section member may be provided with a pair of holes through which an aligning pin may be inserted. In assembling the staging a beam is inserted into a box section member until it rests against the aligning pin, the other beam is inserted from the other side until it also rests against the pin, and the beams are secured to the sockets, by, for instance, screws, bolts, nails, rivets, staples, wedges or the like fastening means. Such fixing means may alternatively be installed through the tops of the socket arms. The aligning pin may either be withdrawn, or may be left in place. The invention will now be further described with reference to the accompanying drawings, in which: Figure 1 is a partly cut away section showing a platform constructed from a construction system according to the present invention and decked over with cladding sheet material. Figures 2a to 2e are diagrams showing in elevation various constructions with systems according to the invention. Figure 3 is a socket for use where four or more beams meet. Figure 4 is a base plate. Figure 5 is a modified form of socket for use in structures where a continuous vertical post is required or where long lengths of timber are required to be joined. Figure 6 is a socket suitable for use as a corner element or edge. Figure 7 shows a socket similar to that of Figure 3 but provided with hinge elements. Figure 8 is an alternative form of corner socket incorporating hinges and suitable for use where the angle of the corner is other than 90° and Figure 8a is a diagram showing the utilization of this socket. Figure 9 shows a two-way socket with a hinge fitting suitable for use where a change of slope of the staging is required and Figures 9a and 9b are diagrams illustrating its operation. Figure 10 shows the socket of Figure 9 used in conjunction with that of Figure 8 to allow for both vertical and horizontal inclination of the beam and Figures 10a and 10b are diagrams illustrating the mode of movement allowed by this socket. Figure 1 shows a platform constructed from a system according to the invention, together with a supported decking panels 1, of , for example, plywood. The platform comprises longitudinal beams 2 and 3 running the whole length of the platform, and transverse beams 4,5,6, which extend between beams 2 and 3. Further transverse beams 7,8,9, extend between beam 3 and the next adjacent longitudinal beam (not shown). Where the transverse beams meet the longitudinal beams in a non-corner position, they are coupled by sockets 10,11,12,13, of a kind which will be described in more detail with reference to Figures 3 and 7. At the corners, a different type of socket 14 is used as will be described below with reference to Figures 5 and 8. Each of the sockets 10,11,12 and 13 has a downward projecting arm which receives a beam acting as a support of the platform; each of these supports enters a base plate unit such as 54 which will be described in more detail with reference to Figure 4. Additional strengthening beams 15,16 etc. are provided to span between longitudinal beams 2 and 3, parallel to beams 4,5,6 etc.; these additional beams both make the structure more rigid and provide additional support for the decking panels 1. These additional beams are supported from the longitudinal beams by brackets 17,18 of conventional shape. As indicated above, the decking panels 1 are laid on top of the beams to form the decking. The panels may be laid directly on top of the beams and sockets as shown, the slight irregularities caused by the thickness of the metal of the socket arms being acceptable for many purposes. However, preferably strips of material such as rubber or felt are laid on the beams between the ends of the socket arms to provide a uniform support for the decking panels in order to serve the additional purpose of helping to deaden sound and vibration. As further indicated above, the decking panels are typically of plywood sheets. Plywood sheets are generally available in Britain in a standard size of 8ft by 4ft (approximately 244 x 122 cm). Accordingly, where a large area of staging is required, it may be constructed to a module of about 122 cm, the longitudinal beams being an exact multiple of this modular length and the transverse beams being cut to this length less the width of one beam. Such a modular construction ensures that after a stage has been dismantled, the beams are largely suitable for re-use in constructing subsequent stages. Labour and material wastage is thus very much reduced and cutting and shaping operations required by previously known methods are thus largely avoided. Figures 2a to 2e show in sectional elevation various forms of staging constructed using the system of the invention. Figure 2a is a construction in which a horizontal platform 18 is extended as a sloping ramp 19. Where the two portions join the change of slope is accommodated by a hinged socket 20 which will be described below in more detail with reference to Figure 9. Figure 2b shows a sloping stage on level ground, the lengths of the beams forming the supports are graded and the base plate units 14 are hinged as will be explained below with reference to Figure 4, to allow the ground plate itself to stand firmly on the ground although the leg is at an angle. Figure 2c shows a level staging constructed on uneven ground. Figure 2d is a construction extending to a considerable height with two levels of decking and in which for strength it is desirable that long through beams should be used for the uprights such as 21. The construction permits intermediate levels of decking directly below an upper level, as seen in the lower part of Figure 2d. To accommodate the through upright beams a modified socket 22 is used and this will be described below with reference to Figure 5. Figure 2e is a plan view of staging in which one edge 23 is oblique. Where this joins the rectangular components of the staging a modified socket 24 with hinge elements is employed and this will be described with reference to Figure 8. Figure 3 shows the construction of the sockets 10,11,12 of Figure 1. The socket comprises four tubular arms, of rectangular cross section, welded together at right angles, the arms 40,42,44 forming a letter T and the arm 46 projecting downwards at right angles to them. The joints are strengthened by triangular plates such as 48,49,50,51. The socket arms are cut away so that it is possible to pass a beam through the socket in any one of the three mutually perpendicular directions. When the staging is constructed, the horizontal beams will have their longer cross section vertical for strength, so the socket will be used in the position shown in Figure 3 with the arm 46 projecting downwards and receiving the beam which forms an upright or a support leg. The arm 40 in normal use will receive a longitudinal through beam, and preferably is made longer than the others. Where two consecutive longitudinal beams abut, the junction may then be positioned in the middle of this longer section where it will be well supported. For this purpose small holes may be provided in the middle of the top and bottom of the arm 40 for an aligning pin to be inserted against which the ends of such beams may be positioned. Screw holes and/or bolt holes (not shown) are preferably provided in the socket arms so that screws or bolts may be inserted to secure the beams to the sockets for added strength. Alignment marks such as 52 may be engraved or punched on the top surfaces at the centres of the widths of the socket arms to serve as measuring points to assist in positioning the sockets and beams during assembly. Figure 4 is a base plate unit corresponding to the unit 54 of Figure 1. It consists of a rectangular ground plate 55 bearing hinge elements 56,56′ and a rectangular box section socket 58 bearing a cooperating hinge element 60. The upright beam forming a leg of the staging is inserted in the socket 58 and attached by bolts, and the hinge is typically assembled by inserting a socket cap screw (not shown) through the hinge elements 56,56′,60. Where the beam inserted in the socket 58 is at a small angle to the horizontal the position of the socket on the ground plate may be reversed so that it abuts against the edge of the ground plate. An additional hinge element 62 may be provided where a beam needs to be supported inclined to the vertical in a plane parallel to its shorter side. The ground plate may also be provided with alignment marks 52 to assist in positioning it during assembly of the staging. The socket element, being hinged, may also be rotated to enable the support element to be passed through the socket so that the decking surface can extend over an edge of an existing stage as shown for example in Figure 2a by reference numeral 51. Figure 5 shows a socket similar to that of Figure 3 (and like parts are denoted by like reference numerals), but with a further box section member 47 such that the socket is suitable for use in situations such as that illustrated in Figure 2d where for strength it is desirable that the through beams of the construction should be the verticals. The socket also enables consecutive beams to abut in the middle of the socket as with the long-armed version of the socket of Figure 3. The socket consists of four horizontal rectangular section arms 40,42,44,47 and a downwardly depending vertical socket arm 46, the centre of the socket being kept clear in such a way that a beam may be passed through it in any of the threemutually perpendicular directions. Alignment marks 52 and screw holes may be provided as described with reference to Figure 3. Figure 6 shows an exemplary socket according to the invention, as used for corners or edges of a staging construction and corresponds to the socket 13 of Figure 1. It consists essentially of the socket of Figure 3 with the arm 42 omitted. Figure 6 shows screw holes 61 and bolt holes 63 by means of which the beams can be secured to the sockets. In the embodiment shown in Figure 6, the triangular support plates 48', 49', 50' are spaced from the ends of the socket arms. Figure 7 shows the socket of Figure 3 with the addition of two hinge elements, one of them 74 being provided at the lower end of the socket arm 46 and the other 76 on the outward-facing vertical face of the socket arm 42. The hinge element 74 permits this socket to be hinged directly to the ground plate 55 of Figure 4 by inserting a socket cap screw into the hinge, as, for example, in the case of the socket 11 of Figure 1. The hinge element 76 provides for the attachment of a further socket to be described with reference to Figure 9 where a change in the slope of the staging occurs. Figure 8 shows a specialised form of socket corresponding to the socket 24 of Figure 2e which can also be used where beams of the staging meet at an angle other than a right angle. It comprises a horizontal and a vertical socket arm 80,82 respectively, welded together at right angles, the construction being optionally made rigid by a triangular strengthening plate 48. The vertical socket arm is provided with a pair of hinge elements one of which 84 is visible and one or other of these is used in cooperation with a hinge element 86 provided on a further socket arm 88 to allow that socket arm to have an extended degree of rotational movement so as to accommodate a beam at an oblique angle to that in the socket arm 80. Optional strengthening brackets 90,92 welded to the upright socket arm 82 help to support the weight carried by the socket arm 88. As shown in Figure 8, a hinge element 74 may be provided on the vertical socket 82 for coupling to a ground plate, and a hinge element 76 may be provided on the socket arm 88 for coupling to the socket to be described with reference to Figure 9. Figure 8a is a diagram showing in plan view the hinging movement available with the socket of Figure 8. Figure 9 shows a socket allowing hinging movement in a vertical plane such as where a change of slope is required in a staging, and corresponds to the socket 20 of Figure 2a. The socket comprises two socket arms 94,96 welded together at right angles with triangular strengthening plates 48,49. The socket arm 94 carries a hinge element 98, and in the embodiment of Figure 9 this can be secured by means of a socket cap screw or the like to the hinge element 76 of the socket of Figure 7 (shown in dotted lines). By means of this hinge a beam inserted into the socket arm 96 may be retained in the same vertical plane as a beam in the socket arm 40 but may be inclined to it. The action of this hinge arrangement is illustrated in elevation, and in plan respectively, in the diagrams of Figures 9a and 9b. Figure 10 shows the socket of Figure 9, but this time hinged instead to the hinge element 76 of the socket of Figure 8 (shown in dotted lines). In view of the foregoing description the action of this arrangement will be self evident. It allows rotation of a beam inserted into the socket arm 96 about two mutually perpendicular axes, namely those defined by the hinge elements 98 and 86. The sketches of Figures 10a and 10b show these movements diagrammatically respectively in elevation and in plan. The construction system according to the invention has been described primarily with reference to staging constructions; the system can however be used for other types of construction, such as exhibition display stands, scaffolding, curtain walling, temporary or permanent constructions such as buildings and the like.

Claims: A construction system which comprises: (a) a plurality of elongate structural beams (2,3,4,5,6); (b) a plurality of multi-way socket elements (10,11,12) each comprising at least three interconnected tubular box section members (40,42,44,46) capable of slidably receiving a said structural beam, three or said box section members (40,42,44) being fixed in, or pivotable to, mutually perpendicular orientations; said box section members being open at both ends so as to define unobstructed passages right through each socket element in mutually perpendicular directions; and (c) means for securing said beams to said socket elements; characterised in that each of said box section members is arranged such that a first of said structural beams can pass right through any one of said box section members and through an open zone at one end of each of said box section members, and further ones of said structural beams can pass through respective further ones of said box section members, such that an end face of any one of said further ones of said structural beams can abut a respective face of said first structural beam in said open zone. A construction system according to claim 1, characterised in that the elongate structural beams are timbers of substantially rectangular cross-section. A construction system according to claim 1 or 2, characterised in that the box section members are fixed in, or pivotable to, mutually perpendicular orientations. A construction system according to any of claims 1 to 3, characterised in that three of said box section members are joined to form a T-shaped body in the plane of the smaller transverse edge of each of said three box section members, a fourth box section member projecting at right angles to the junction of the T, the central region of the socket being open so that a first said beam may be passed therethrough in any one of three mutually perpendicular directions, with other beams being insertable into other arms of said socket element so as to abut against said first mentioned beam at right angles thereto. A construction system according to any of claims 1 to 4, characterised in that said system further comprises a plurality of base plates each comprising a rigid support to which is hinged a box section member capable of slidably receiving a said structural beam. A construction system according to any of claims 1 to 5, characterised in that the means for securing said beams to said socket elements comprise fasteners arranged to pass through apertures in said box section members. A construction system according to any of claims 1 to 6, characterised in that said system further comprises at least one socket comprising two box section members secured to one another at right angles, so as to leave an open central region through which a said beam may be passed, at least one of these box section members being provided with hinge components in combination with a further box section member provided with matching hinge components at either end of one face so as to enable it to be coupled at one or other side of said central region. A construction system according to any of claims 1 to 7, characterised in that said system further comprises cladding sheet material to be supported by said structural beams.

Inventors: CAVANAGH, SEAN
Applicants: CAVANAGH, SEAN
Application year: 1986
Main classification: E04B1
IPC codes: E04B1