Space frame structure

Abstract: A space frame structure primarily for use as a floor comprises a steel space frame made up of an upper layer (11) of structural members (15), a lower layer (12) of structural members (16) and upright members (14) joining the upper and lower members. An upper concrete layer (50) is poured on to shuttering (41) so that the upper parts of upper structural members (15) are embedded in the concrete.

Description: This invention relates to a space frame structure for use in bridging a space between supports. A space frame is especially suitable for covering a substantial space with support only at the edges, the structure being otherwise self-supporting, with no need for intervening upright supports. A space frame commonly comprises upper and lower grids of structural members, joined by interconnecting members to form a rigid three dimensional structure. A space frame is used, for example, for the roof structure of an exhibition hall or factory, where a large space unencumbered by upright supports is important. It can also be used for the floors and roof of a multi-storey office block. Many space frames have diagonal interconnecting members. Another known space frame structure is described in GB-B 2054694. This structure has upright interconnecting members. The complete structure is also built up from a series of modules each comprising one upright interconnecting member and horizontal upper and lower structural members. On uniting several modules together the upper and lower structural members respectively form the upper and lower grids. It is also known from US Patent 4201023 to provide a structure comprising an upper concrete layer, a grid of lower structural members and upright interconnecting members between the lower grid and the upper layer. With this structure, the lower structural members are of very substantial depth, presumably to provide sufficient strength to allow the lower sub-frame to support the weight of concrete slabs for the upper layer before these slabs have been united to form a structural layer. The lower grid appears to be stronger and heavier and thus more costly than would be required for loads on the completed structure as opposed to loads during the assembly operation. It is also known to provide a layer of concrete above the space frame structure of the aforementioned GB patent. According to the present invention a space frame structure comprising an upper grid of structural members, a lower grid of structural members, interconnecting members extending between the upper grid and the lower grid and joining the grids together to form a space frame, and a concrete layer carried by the upper grid, is characterised in that the structural members of the upper grid are at least partially embedded in the concrete to unite them structurally with the concrete and thus form a composite upper structural layer. Preferably the lower grid of structural members is inherently stronger than the upper grid of structural members. The relatively reduced strength of the upper members allows them to be lighter and thus less costly than members equal in size to the lower members. The upper grid should be sufficiently strong to enable the space frame to support its own weight together with that of freshly deposited concrete and temporary loads during construction. Each lower structural member is preferably of greater cross-section than a corresponding upper structural member but as an alternative there may be a greater number of lower members than of upper members. Preferably permanent shuttering for the concrete is supported within the depth of the upper structural members, the concrete layer being poured on to the shuttering. Each upper structural member may have a lower flange and the shuttering is then supported on these flanges. When the upper structural members have lower flanges supporting shuttering they may also have upper flanges embedded in the concrete, with the lower flanges wider than the upper flanges. The shuttering may be permanent and provide reinforcement for the concrete and may be formed from corrugated steel sheet. The structure may incorporate steel reinforcement rods within the concrete. One set of the rods may be welded to and lie across corrugations of permanent shuttering so that these rods additionally stiffen the shuttering and provide handles for manipulating the shuttering. The space frame constituted by upper structural members, lower structural members and interconnecting members may be assembled from a series of modules, each module comprising one upright interconnecting member, a plurality of upper structural members forming part of the upper grid joined to the top of the interconnecting member and a plurality of lower structural members forming parts of the lower grid joined to the bottom of the interconnecting member, the space frame being formed by joining structural members of adjacent modules end to end at positions remote from the interconnecting members. The upper and lower members may each be such as to form a rectangular grid. The invention also extends to a method of making a space frame structure comprising assembling the complete space frame, applying shuttering for the concrete and subsequently pouring the concrete to form the concrete layer with the upper structural members at least partially embedded therein. Embodiments of the invention will now be described with reference to the accompanying drawings in which: Figure 1 is a perspective view of a space frame structure illustrating a preferred embodiment of the invention but with some parts removed for clarity of illustration; Figure 2 is a diagrammatic perspective view of a series of modules which are assembled together to form part of the structure of Figure 1; Figure 3 is a cross-section through part of the structure of Figure 1 showing greater detail; Figure 4 is a section on line X-X of Figure 3; and Figures 5 and 6 are views corresponding to part of Figure 4 but on a larger scale and showing modifications. The composite space frame structure of Figure 1 incorporates a steel space frame assembled from modules as illustrated in Figure 2. As best seen in Figure 2, a typical module 22 comprises an upright hollow square section structural member 14 with four upper members 15 extending horizontally at right angles to one another from an upper joint 10 and four further lower structural members 16 extending in corresponding directions from a lower joint 13. Each horizontal structural member is an I-section beam and the lower members 16 are of greater cross-sectional area and thus strength than the upper members 15. The members of the module are welded together. Each joint is reinforced by a square reinforcing plate 20 which has a square central aperture through which the upright 14 passes. Plate 20 is welded to the upright 14 and has one corner welded to each of the four horizontal members 15 or 16. Reinforcing plates 20 are provided at all upper and lower joints but some are omitted from Figure 2 to simplify the drawing. Figure 2 also illustrates two edge modules 26 and a corner module 25. These edge and corner modules correspond to module 22 except for having only three or two horizontal members projecting from them and having truncated reinforcing plates 20. Each module is assembled by welding in a jig in a factory and is subsequently transported to the site where it is to be joined with other modules in building up a complete structure. Adjacent modules are joined together with the free ends of their horizontal structural members placed end to end. Upper members 15 have their webs 30 joined by plates 31 and bolts 37 as illustrated more clearly in Figures 3 and 4 but some plates 31 are shown in Figure 2. Similarly plates 32 join lower webs 33 of lower members 16. Figures 1 and 2 are on too small a scale to show full details of the plates 31 and 32. In practice the plates are each welded to one side of one of the structural members of a joint during assembly of the module. The welding of the plates to the structural members is preferably carried out at the factory as part of the construction of the module. Assembly of one module to another is by bolting through the webs and plates. A complete space frame built up from sixteen such modules is illustrated in Figure 1, some of the modules being hidden from view by other parts of the structure to be described subsequently. The resulting structure is in the form of an upper grid 11 of upper structural members 15, a lower grid 12 of lower structural members 16 and vertical interconnecting structural members 14 extending between the upper and lower grids and joining the grids together to form a space frame. In practice a typical structure may be made up of a very much larger number of modules, possibly running to some hundreds of modules. The modular construction is particularly convenient for assembly of the structure on site, for example as a floor or roof. Some groups of modules may be assembled together at ground level or at another convenient site such as a previously constructed floor to form a sub-structure. The size of the sub-structure depends in part on the lifting capacity of an available crane. The sub-structure is then raised into position and mounted in its permanent position on a steel frame or similar basic building structure. Subsequent sub-structures are raised one at a time and joined either to the building framework or to adjacent sub-structures or both. A suitable pattern of working might be to start from one or more corners and work towards the centre. An alternative construction procedure would be to build up the structure one module at a time. The modular structure thus facilitates assembly of the space frame. The space frame made up of structural members is only a part of the complete space frame structure. As shown in Figures 1, 3 and 4, permanent corrugated steel shuttering 41 is installed on the upper layer constituted by the structural members 15. This shuttering is carried by the lower flanges 35 (Figure 4) of the I-section members 15 so that it lies within the depth of the upper structural members but the webs 30 of these members extend well above the shuttering and in particular the upper flanges 36 are positioned well above the shuttering. Figure 1 shows steel reinforcing rods 42, intended as concrete reinforcement, positioned on the shuttering across the corrugations. These rods may be welded to the shuttering to help unite adjacent sections of shuttering and also to increase the rigidity of the shuttering. Rods 42 also act as handles and facilitate manipulation of the shuttering. The reinforcement rods 42 are also well below the upper edge of the structural members 15. Further steel reinforcement 43 in the form of conventional welded mesh is positioned on the top flanges of the structural members 15. Concrete 50 is then poured on to the shuttering to such a depth that it extends above the top of the structural members 15 and also covers the upper layer 43 of reinforcement. In this way, members 15 become partially embedded in the concrete with the upper flanges forming a key between the members 15 and the concrete. When the concrete has cured, the reinforced concrete adds to the strength of the upper structural members 15 of the space frame to provide an upper layer for the structure which is much stronger than the strength provided by members 15 alone. The structural members 15 are selected to give sufficient strength in the upper grid of the structure to provide a self-supporting steel space frame and to support the weight of shuttering, reinforcement, freshly poured concrete and other construction loads including the weight of operatives. In a typical case, this load requirement is about one quarter to one third of the strength required in use of the structure. The concrete after curing provides the additional strength. The embedding of the upper members 15 is particularly important because the concrete then supports these members against buckling, thereby increasing their contribution to the overall strength of the structure. The top surface of the concrete may be used as a floor and the lower surface of the structure can be clad to provide a ceiling. One advantage of the complete structure is that the reduced cross-section of the upper members 15 compared with the lower members 16 reduces the weight of steel required in the whole structure. The relatively light upper structure also allows it to contract slightly during shrinkage of the curing concrete, thus reducing the tendency towards cracks and further strengthening the overall structure. Another advantage is that because the concrete layer and the upper members 15 occupy substantially the same vertical space, less vertical height is required between floor and ceiling thin for other structures so a greater number of floors can be installed in a building of a given height. The inherently strong and light efficient structure can allow further depth reduction at the design stage. The particular choice of space frame structure also provides clear straight runs within the depth of the structure for services such as pipework, ducting and cables. Avoiding a requirement for service space below the structure further assists in reducing the required total depth of floor, ceiling and service space. When used as a roof the whole structure may be cambered or the upper layer may be pitched at a small angle to the horizontal to provide drainage. For a pitched roof slight variations in module height can be achieved with an adjustable jig. One modification of the structure is illustrated in Figure 5. The lower flange 35a of the upper structural members 15 is extended laterally to facilitate support for the shuttering 41. Figure 6 shows a further modification with member 15 fabricated from a 'T' section and an 'Angle' section. The lower flat flange 35b again projects further than the upper angled flange 36b. In a further modification, a different form of steel space frame could be employed. For example, it does not need to be of modular construction and it could have interconnecting members which are angled instead of upright. Similarly, some other pattern than a rectangular grid of upper and lower members could be employed. The cross-sectional shapes of the structural steel members are not critical. The upright members could be round tubes. Alternative forms of shuttering could be employed and the shuttering need not be an integral part of the structure. The shuttering could be set below the upper members allowing them to be completely embedded in the concrete. For specialist applications the structural members of the space frame could be of some material other than steel, for example a lighter material such as aluminium. Reinforcing plates 20 could be omitted or replaced by plates of a different shape or individual plates for each horizontal member. It is not necessary for all lower or all upper horizontal structural members to be of the same dimensions. For example the members in one direction could be heavier than those in the other direction. For a structure supported solely by columns there may be lines of stronger modules running directly from column to column.

Claims: A space frame structure comprising an upper grid (11) of structural members (15), a lower grid (12) of structural members (16), interconnecting members (14) extending between the upper grid and the lower grid and joining the grids together to form a space frame, and a concrete layer (50) carried by the upper grid, characterised in that the structural members of the upper grid are at least partially embedded in the concrete to unite them structurally with the concrete and thus form a composite upper structural layer. A space frame structure according to Claim 1 characterised in that the lower grid (12) of structural members is inherently stronger than the upper grid (11) of structural members. A space frame structure as claimed in Claim 2 wherein each lower structural member (16) is of greater cross-section than a corresponding upper structural member (15). A space frame structure according to any one of the preceding claims further comprising permanent shuttering (41) supported within the depth of the upper structural members (15), the concrete layer being poured on the shuttering. A space frame structure according to Claim 4 wherein each upper structural member has a lower flange (35) and the shuttering is supported on these flanges. A space frame structure according to Claim 5 wherein the upper structural members (15) also have upper flanges (36) embedded in the concrete and wherein the lower flanges (35a - Figure 5) are wider than the upper flanges. A space frame structure as claimed in Claim 4 or Claim 5 wherein the shuttering is permanent and provides reinforcement for the concrete. A space frame structure as claimed in any one of Claims 4 to 7 wherein the shuttering is formed from corrugated steel sheet. A space frame structure as claimed in any one of the preceding claims incorporating steel reinforcement rods (42, 43) within the concrete. A space frame structure as claimed in Claim 9 incorporating corrugated permanent shuttering wherein steel reinforcement rods (42) are welded to and lie across the corrugations. A space frame structure as claimed in any one of the preceding claims wherein the space frame constituted by upper structural members (15), lower structural members (16) and interconnecting members (14) is assembled from a series of modules (22, 25, 26 - Figure 2), each module comprising one upright interconnecting member (14), a plurality of upper structural members (15) forming part of the upper grid (11) joined to the top of the interconnecting member and a plurality of lower structural members (16) forming parts of the lower grid (12) joined to the bottom of the interconnecting member, the space frame being formed by joining structural members of adjacent modules end to end at positions remote from the interconnecting members. A method of constructing a space frame structure in accordance with any one of the preceding claims, the method comprising assembling the complete space frame (11, 12, 14), applying shuttering (41) for the concrete and subsequently pouring the concrete (50) to form the concrete layer with the upper structural members (15) at least partially embedded therein.

Inventors: KUBIK LESZEK ALEKSANDER, KUBIK MARIAN LESZEK, KUBIK, LESZEK ALEKSANDER, KUBIK, MARIAN LESZEK
Applicants: KUBIK LESZEK A, KUBIK, LESZEK ALEKSANDER, KUBIK, MARIAN LESZEK
Application year: 1990
Main classification: E04B1
IPC codes: E04B1