MODULAR SERVICES SUPPORT SYSTEM

Abstract: A modular services support system for supporting for example, pipes and cables along a tunnel wall, is made up of fibre-reinforced composite structural members connected together by slidably interlocking connector parts (25) in the form of an undercut channel (24) on one member and a complementary head or lug (3) on the other. At least one elongate services support member (20), which may be a channel section providing a tray (4) for the services or a box section (20) through which the services can be passed is connected to extend between wall mounting brackets (35) forming a structural spine for the system. That elongate member can be made up of separate lengths of the appropriate section, disposed and connected end to end.

Description: MODULAR SERVICES SUPPORT SYSTEM This invention relates to a modular system of composite interlocking structural members which provide supports for service pipes and cables, enabling them to be carried on new or existing structures. Service support systems are known in which galvanised steel trays and racking systems are used to support service pipes and cables. These systems have two main disadvantages;- galvanised steel has a limited life, particularly in corrosive environments, without maintenance and the spans of these systems between supports are generally limited to around 1.5 metres. The reason for the former is the large number of edges involved in the designs, some of which are not fully protected by galvanising, at which corrosion breakdown begins and the relatively thin metal sections used. Designs of support systems in glass reinforced plastic are known to have been developed in order to provide better durability. However known systems have low stiffness, making long spans of up to 4 metres or more difficult to accomplish, especially when external environmental loading is present, they are difficult to join to supports and do not provide a flexible system for supporting large numbers of cables in restricted spaces. The problem thus exists of providing a service support system which is economic, highly durable, can span up to 4 metres and more, can support a wide range of service types in a restricted space and is stiff enough to resist extremes of environmental loading, for example, air pressure in high speed rail tunnels. According to this invention we propose a modular services support system of fibre-reinforced composite structural members connected or for connection together by interlocking means comprising an undercut channel on one member and a complementary head or lug, on the other, the system comprising brackets or other support members mounted or adapted to be mounted, at intervals along a wall or other structure by which the services are to be carried, and at least one elongate services support channel which may be a continuous member or formed of two or more members disposed and interconnected end to end. The said elongate services support channel serves as a structural spine for the system. In its simplest form, the system comprises one support channel which extends between the brackets and is in the form of a tray having upstanding flanges between which the services whether they be pipes or cables are received and confined. Alternatively, the support channel may be defined within a spine beam, for example, a box-section member through which the services may extend. This is particularly advantageous for longer spans (between brackets) and also where additional further services support channels in the form of trays or shelves may be disposed and connected on top, beneath or on one side of the spine beam. It will be appreciated that, in this way, system members can be connected together so as to provide a wide range of different secondary support configurations for services over a wide range of spans between supports from the primary structure. The system provides improvements in durability, economy and flexibility in use. In one embodiment an elongate composite fibre reinforced tray has a flat sheet panel of uniform width with two flanges orientated at an angle of 90° to the sheet panel attached to the panel and at least one elongate connecting lug formed integrally with either one flange or with the sheet panel, the elongate connecting lugs running parallel with each other and the axis of the tray having a neck and head-like form for sliding engagement in undercut channels in the support structure. Secondary flanges for retaining services may be attached to the extreme edges of the main flanges lying in planes at right angles to the main flanges. There are preferably at least two elongate connecting lugs on either one main flange or the flat sheet panel. The or each elongate tray is made preferably out of a glass fibre reinforced composite with either a plastic or ceramic matrix using either a moulding or pultrusion process. The trays are supported using discrete composite support brackets having undercut channels in one face for sliding engagement with the connecting lugs on the tray, and suitable attachments on another face for attachment to the primary support structure. The support spine beam preferably is an elongate rectangular cellular composite support spine beam with at least two spaced parallel flanges and two spaced parallel webs, lying in planes at right angels to the planes of the flanges, and with undercut channels in one or more of the outer flanges and webs. There are preferably at least two undercut channels in one of the outer flanges and one web. The flanges of the spine beam may be outstanding from the planes of the webs and may incorporate secondary flanges for retaining services placed directly onto the flange. The section is preferably formed by moulding or pultrusion as an integral member. The spine box beam is preferably reinforced with glass fibres surrounded by a plastic or ceramic matrix. The undercut channels enable discrete sections of trays described above or continuous lengths of the same trays to be attached by sliding engagement into the channels to form supports for services radiating around the spine. Also the undercut channels enable fibre reinforced composite moulded support members having connecting lugs with head and neck-like features to be attached by sliding engagement at any position along the spine box length. For interconnecting spine beam lengths we propose a composite spine box beam connector comprising a web with two spaced outstanding flanges in planes at right angels to the plane of the web joined to the web edges and at least one connecting lug attached to the inner face of the web and each flange, the lugs having head and neck-like features for sliding engagement into undercut channels in the spine box beam. In cases where loads and stresses in the box beam are high, the connector may additionally have two secondary flange outstands connected one to each of the main flange edges in planes at right angels to the main flange planes. These secondary flanges will each also have at least one connecting lug attached to the inner face. The connector is preferably reinforced with glass fibres surrounded by a plastic or ceramic matrix and will be preferably formed in a moulding or pultrusion process as an integral section. The modular system of composite trays of different shapes, composite spine box beams and composite support brackets provides good durability through the use of fibre reinforced plastic or ceramic materials. The trays can be used on their own to span between discrete support brackets to support services over spans up to 1.5 metres and the spine box beams with their superior bending and torsional strength and stiffness can be used as the main support for services in spans up to 4 metres and over. An array of discrete service support members cut from trays can be arranged around each spine box to provide a compact and adaptable array of support members to suit almost any arrangement of services. Also services can be placed inside the spine box beam with access through gaps at the spine box connections. Connections provide structural continuity between ends of spine boxes improving stiffness and economy of material, while leaving gaps for access to services. Spine boxes, trays and supports can be coloured through the thickness of the member, using pigments in the matrix, and this enables service runs to be colour coded for easy identification in complex installations. It will be understood, that as an alternative to the services support members themselves having interlocking undercut channels and complementary head or lug members separate connector members may be provided to intervene and interconnect the service support members. Embodiments of the invention will now be described by way of example with reference to the drawings in which:- Figure 1 is a cross-section of an elongate tray; Figures 2 and 3 are cross-sections of elongate trays with secondary flanges; Figure 4 is a detail of a bracket to support the trays shown in Figures 1 to 3; Figure 5A to F are cross-sections of various support spine box beams; Figure 6 is a cross-section of a spine box beam connector; Figure 7 is a cross-section of a spine box connector with secondary flanges; Figures 8 and 9 are alternative details for brackets to support the spine box beam in Figure 5A; Figure 10 is a spine beam with an assembly of elongate trays fitted; Figure 11 is an isometric view of the connection between spine box sections; Figure 12 is a cross-section of another elongate tray with secondary flanges (of Figures 2 and 3); and Figure 13 is a cross-section of a spine box beam with outstanding flanges; and Figure 14 is a perspective view of one embodiment modular services support system. Figure 1 shows an elongate tray 4 being a flat sheet panel 1 with two flanges 2A, 2B at each extremity. Two connecting lugs 3 are located on the sheet panel. Figure 2 shows an elongate tray 9A in the form of a flat sheet 5 with two flanges 6A, 6B at each extremity. The flanges 6A, 6B have secondary flanges 7A, 7B, 8A, 8B at the extremities which are used to retain service cables or pipes placed on the flanges. Two connecting lugs 3 are located on one face of the flange 6B. Figure 3 shows an alternative tray 9B, similar to 9A, but the flange 6A is positioned to one side of the panel 5 and secondary flanges 7B and 8B are not used. Another elongate tray 9C shown in Figure 12 comprises a sheet panel 5, with flanges 6A at one extremity and a flange 6B projecting at a distance from the extremities. The flanges have secondary flanges 7A, 7B. Two connecting lugs 3 are located on the sheet panel 5. The trays 4, 9A, 9B, 9C referred to above are produced by the pultrusion process to produce a continuous length by a moulding process. In this embodiment the width of the flat sheet panel is in the range 100mm to 500mm and the width of the flanges between 30mm and 500mm although other sizes outside these ranges are possible. The thickness of the panels and flanges are in the range 2mm to 6mm. The dimensions and positions of flanges relative to the plate panel and of secondary flanges on the flange and of the connecting lugs on the trays are determined by the requirements of the particular application. The bracket 10 of Figure 4 is for supporting elongate trays. It has two undercut channels 11 in one face for sliding engagement with the connecting lugs 3 on the elongate trays. The Figure does not show the method of attachment to the primary structure. For applications where the spacing of the discrete brackets 10 cannot be less than about 1.5 metres the elongate trays such as shown in Figures 1 to 3 are used with additional supporting members. Figure 5A shows a spine box beam 20 which is used to support elongate trays. The beam 20 comprises two parallel webs 21A, 21B, two outer flanges 22A, 22B and an inner flange 23. Each web 21A, 21B and outer flange 22A, 22B contains two undercut channels 24 for sliding engagement with the lugs 3 in the elongate trays. Any combination of the trays 4, 9A, 9B, 9C or others may be attached to the spine box beam 20 on the webs 21A, 21B and flanges 22A, 22B to suit the needs of the particular application. The trays may be used in continuous lengths or preferably, for economy of material, in discrete lengths spaced along the beam 20. Other box beam configurations shown in Figures 5B to 5F have one undercut channel 24 only in a side (web 21 and/or flange 22) of the section. As with the beam 20 of Figure 5A, these may be connected to extend between mounting brackets to form a structural spine of the system and also support continuous lengths of services support tray sections or discrete service support trays as required. Figure 13 shows an alternative beam member 40 which incorporates outstanding flanges 41A, 41B on the spine box comprising two webs 42A, 42B and two outer flange 43A, 43B and an inner flange 44. One web 42A and one flange 43A contain two undercut channels 24. Secondary flanges 45A, 45B are positioned at the extremities of the flange outstands 41A, 4IB. A beam connector 25 such as shown in Figure 6 may be used to join sections of beam 20 end to end and allow transfer of load across the joint. The connector 25 comprises a web 26 and two flanges 27A, 27B and has four connecting lugs 28. The connecting lugs 28 provide a sliding engagement to the undercut channels 24 in the box beam 20. Two connectors 25 are used at a joint either overlapping the flanges 22A, 22B of the beam 20 or the webs 21A, 2IB, the method used depending on the loading conditions on the system. In cases where loads and stresses on the beam 20 are high an alternative connector 30 shown on Figure 7 may be used. The connector 30 comprises a web 31, two flanges 32A, 32B and two secondary flanges 33A, 33B. The connector 30 has eight connecting lugs 28 for sliding engagement with the undercut channel 24 in the box beam 20. The side of the box beam 20 not fully overlapped by the connector 30 is preferably one of the webs 21A, 21B but in some instances may be one of the flanges 22A, 22B. The strength of the connection made using the connectors 25, 30 may be enhanced by using structural adhesives in the interfaces of the beam 20 and connectors 25 or 30. Referring to Figure 11, service cables or pipes may be situated inside the box beam 20 in which case the ends of the box beam 20 at joints are spaced apart, the openings 34 left between the end of the beams 20 and the extremities of the connectors 25 or 30 being used for the installation and inspection of the services. Figures 8 and 9 show two alternative support brackets 35, 36 for the box beam 20. Each bracket 35, 36 contains three connecting lugs 37 for sliding engagement with the undercut channels 24 in the box beam 20. At the locations of the brackets any continuous trays are stopped off as required. Other methods of support to the spine box 20 are possible within the scope of the invention. The Figure does not show the method of attachment to the primary structure. Figure 10 shows a complete modular system of interlocking structural members including a spine beam 20 mounted on a support bracket 35, with a number of trays attached including among others trays 4 and 9B, and shows the disposition of services 38 around the assembly. As drawn this embodiment provides six separate regions for the location of services, these regions may be used for location of different types of services and the insulation properties of the composite material ensures the separate regions are electrically insulated from each other. The system may be electrically earthed where necessary by the addition of conductive fibres into some or all of the members. The services support system of Figure 14 has ribs 50 between which extend two spine box beams 52, 54. Also carried by the ribs 50 and ranked between the upper 52 and lower 54 box beams are a number, in this case five, of elongate services support trays 56 each having an upturned free end portion 58 to confine and retain services laid thereon. Each of the box beams 52, 54 which are as shown in Figure 5E and each of the trays 56 is connected to the ribs 50 by slidably engaged connector parts in the form of elongate connecting lugs 62 on the ribs which are received within complementary undercut channels 60 extending longitudinally of the box beams and support trays. The ribs 50 may be or form part of mounting brackets attached to a wall or other supporting structure. Alternatively, wall mounting brackets (not shown) connected either to at least some of the ribs or directly to the services support members 52, 54, 56, may be used.

Claims: CLAIMS ; 1. A modular services support system of fibre-reinforced composite structural members connected or for connection together by slidably engageable connector parts in the form of an undercut channel on one member and a complementary head or lug on the other, the system comprising at least one elongate services support member connected to extend between wall mounting brackets or other mounting members for attachment to a supporting structure. 2. A system according to claim 1 wherein the said at least one elongate services support member comprises a plurality of separate sections disposed and interconnected end to end by a connector member adapted to receive end portions of adjacent sections and having a connector part in or for sliding engagement with a connector part on each of said adjacent sections. 3. A system according to claim 1 or claim 2 wherein the said at least one services support member comprises a box beam member for receiving and supporting services therein. 4. A system according to claim 3 wherein the box beam member comprises a rectangular beam having at least two parallel flanges and two spaced parallel webs lying in planes transverse to the planes of the flanges and with a connector part, on one or more of the outer flanges and webs. 5. A system according to claim 3 or claim 4 wherein the box beam member comprises a plurality of beam sections interconnected end to end by a beam connector member comprising a web with two spaced flanges in planes transverse to the plane of the web for receiving therebetween end portions of adjacent box beam sections, and a connector part on the inner face of at least one web and/or flange in or for slidable engagement with a connector part on a web and/or flange of the box beam sections. 6. A system according to any preceding claim having at intervals along the said at least one elongate service support member discrete services support members, each in the form of a panel with flanges extending transversely thereof to define a tray for receiving services to be supported. 7. A system according to claim 6 wherein an array of discrete services support members is connected to the said elongate services support member at intervals therealong. 8. A system according to any preceding claim and having an elongate services support member comprising a tray having upstanding flanges between which the services are received and confined. 9. A system according to any preceding claim wherein the connector part or parts on each mounting member, comprises a lug having head and neck-like features for sliding engagement in undercut channels in the said at least one elongate services support member. 10. A system according to any one of claims 1 to 7 comprising separate connector members that intervene to form a slidably interlocking connection between the mounting members and the services support members and/or between services support members. 11. A system according to any preceding claim wherein the said elongate services support member has on at least one face thereof two or more of said connector parts. 12. A system according to any preceding claim wherein the said elongate services support member has at least one connector part on each of two or more faces thereof. 13. A system according to any preceding claim wherein the composite members each comprise fibre, preferably glass fibre, reinforcement embedded in a plastics or ceramics material matrix.

Inventors: CHURCMAN ALLAN ERNEST, HEAD PETER RICHARD, CHURCMAN, ALLAN, ERNEST, HEAD, PETER, RICHARD
Applicants: MAUNSELL STRUCTURAL PLASTICS, MAUNSELL STRUCTURAL PLASTICS LIMITED
Application year: 1990
Main classification: E21F17
IPC codes: E21F17, F16L3, H02G3