Patent Application
20140305066
The present invention generally relates to overhead structures and in particular, to a corrugated metal plate and to an overhead structure incorporating the same.
As rural and urban infrastructure continues to age and develop, there is a continual demand for cost-effective technologies relating to the construction and maintenance of highways, railways and the like. Often unappreciated but vitally important to the construction of such infrastructure is the underpass system. Underpass systems are typically designed to carry not only dead loads, but also live loads. While some of the most impressive underpass systems are used in mining or forestry applications where spans can exceed twenty (20) meters, they are also very common in regular highway construction to allow passage of railway, watercourses or other vehicular/pedestrian traffic. While concrete structures have been regularly employed for these purposes, such concrete structures are very expensive to install, are cost prohibitive in remote areas, and are subject to strength weakening due to corrosion of the reinforcing metal, thereby requiring ongoing repair and limiting their use in certain environments.
In the field of overhead structures, such as for example but not limited to box culverts, circular and ovoid culverts, arch-type structures, encased concrete structures and other similar structures that make use of corrugated metal plate, there have been significant advances. For example, U.S. Pat. No. 5,118,218 to Musser et al. discloses a corrugated box culvert constructed from reinforced corrugated steel or aluminum sheets having very deep corrugations and generally having a uniform bending moment profile for the whole length of the culvert. By using significant material on the crown portions as well as on the haunch portions of the box culvert, significant loads can be carried by the box culvert. Ovoid and circular culvert structures have been generally described in U.K. Patent Application No. 2,140,848.
U.S. Pat. No. 5,326,191 to Wilson et al. discloses a reinforced metal box culvert having a standard crown, opposing sides and opposite curved haunches. The culvert is characterized in having continuous corrugated metal sheet reinforcement secured to at least the crown of the culvert, and extends the length of the culvert which is effective in supporting the load. The corrugated reinforcement has a profile which abuts the crown corrugations with the troughs of the reinforcement being secured to the crests of the corrugated crown. The corrugated reinforcement sheet has a curvature complementary to the corrugated crown to facilitate securement. The continuous reinforcement, as secured to the culvert in an uninterrupted manner, provides an optimum load carrying capacity for selected extent of reinforcement provided by the reinforcement metal sheets.
U.S. Pat. No. 5,833,394 to McCavour et al. discloses a composite concrete reinforced corrugated metal arch-type structure comprising a first set of shaped corrugated metal plates interconnected in a manner to define a base arch structure with the corrugations extending transversely of the longitudinal length of the arch, and a second series of shaped corrugated metal plates interconnected in a manner to overlay the first set of interconnected plates of the base arch. The second series of plates has at least one corrugation extending transversely of the longitudinal length of the arch, with the troughs of the corrugations of the second series of plates secured to the crests of the first set of plates. The interconnected series of second plates and the first set of plates define individual, transversely extending, enclosed continuous cavities filled with concrete to define an interface of the concrete enclosed by the metal interior surfaces of the second series of crests and first set of troughs. The interior surfaces of the cavities for each of the first and second plates have means for providing a shear bond at the concrete-metal interface to provide individual curved beams transversing the arch, whereby the structure provides positive and negative bending resistance and combined bending and axial load resistance to superimposed loads.
In some prior art overhead structures, adjacent corrugated metal plates are secured by overlapping circumferential edges of the corrugated metal plates so as to align holes therein, and then passing a fastener such as a bolt through each pair of aligned holes. As will be appreciated, this approach is cumbersome as two or more individuals are typically required to affix each bolt to the structure. Additionally, the axial strength of prior art overhead structures is generally a function of the shear strength of the bolts securing the overlapping portions of the plates.
Other approaches for securing adjacent corrugated metal plates have been described. For example, the publication entitled “Tunnel Liner Plate” by Armtec of Guelph, Ontario, Canada, discloses a steel tunnel liner plate. The liner plate forms part of a corrugated steel, two-flange sectional lining system designed for use primarily in soft-ground tunneling.
U.S. Pat. No. 4,650,369 to Thomas et al. discloses a low headroom culvert wherein a series of shallow arch-shaped flat metallic sections are overlappingly secured together. Torsion and buckle resistant reinforcing cross ribbing elements are affixed to the exterior culvert sections at selected points along the culvert to form girder-like beams. The culvert comprises crown and haunch ribs spliced or joined to each other by means of a bolt fastener and nut assembly. The bottom base flanges of the various haunch and crown rib beam segments are secured directly to the outside surfaces of the culvert sections.
U.S. Pat. No. 4,958,476 to Kotter discloses an architectural cover panel system of individually adaptive panels for covering structural support members of an underlying structure such as girders. An individual adaptive panel includes a sheet of flexible material having a generally convex cross-section and is provided with corrugations oriented perpendicular to the longitudinal axis of the panel. In one preferred embodiment the convex panel is provided with edged portions attached to the lateral sides of the panel. The edge portions are similarly provided with corrugations oriented parallel to and intersecting or merging into the corrugations of the convex panel portion.
U.S. Pat. No. 7,493,729 to Semmes discloses a commercial rooftop enclosure that utilizes a roof and wall panel design incorporated with structurally bent rails connecting panel assemblies to each other and to a corrugated panel steel base. The enclosure is formed into a torsion box style building wherein the strength of the enclosure is derived from its overall “unibody” style construction. With this design the rooftop enclosure purports to offer a lower overall profile, reduced weight and increased structural strength over its conventional counterparts.
When overhead structures fabricated of corrugated metal plates are used in the presence of fluids, there may be seepage or leakage of the fluids through joints of the structures. Improvements are generally desired.
It is therefore an object at least to provide a novel corrugated metal plate and an overhead structure incorporating the same.
Accordingly, in one aspect there is provided a corrugated metal plate comprising: a plate configured to define a series of crests and troughs, the plate having longitudinal edges extending parallel to longitudinal axes of the crests and the troughs and transverse edges extending orthogonally to the longitudinal axes of the crests and the troughs; and at least one of: at least one longitudinal flange extending from each longitudinal edge, and at least one transverse flange extending from each transverse edge.
Each of the at least one transverse flange may comprise a first flange portion and a second flange portion. Each first flange portion may have an upturned orientation relative to the plate and each second flange portion may have a downturned orientation relative to the plate.
Each of the at least one longitudinal flange may be generally centered on a crest or a trough.
The crests and troughs of adjacent plates may be generally contiguous when the longitudinal flanges of the adjacent plates abut.
One or more of each of the at least one longitudinal flange and each of the at least one transverse flange may comprise a plurality of apertures for receiving fasteners.
The corrugated metal plate may be curved in at least one of a longitudinal direction and a transverse direction.
Each of the at least one transverse flange may extend non-orthogonally from the plate.
The corrugated metal plate may further comprise gussets adjoining each of the at least one transverse flange to the plate.
One or more of each of the at least one longitudinal flange and each of the at least one transverse flange may comprise a groove for accommodating a gasket or a quantity of sealant.
The at least one longitudinal flange may comprise a first longitudinal flange comprising a protrusion and a second longitudinal flange comprising a groove sized to accommodate the protrusion of an adjacent corrugated metal plate, the first longitudinal flange and the second longitudinal flange each extending from a different respective longitudinal edge. The at least one transverse flange may comprise a first transverse flange comprising a protrusion and a second transverse flange comprising a groove sized to accommodate the protrusion of an adjacent corrugated metal plate, the first transverse flange and the second transverse flange each extending from a different respective transverse edge. The groove may be sized to accommodate a gasket or a quantity of sealant.
One or more of the at least one transverse flange and the at least one longitudinal flange may comprise one or more alignment features to engage an adjacent abutting plate. The alignment features may matingly engage alignment features of the adjacent abutting plate. Each of the at least one transverse flange may comprise a plurality of alignment features. Each of the at least one longitudinal flange may comprise a plurality of alignment features.
The corrugated metal plate may further comprise one or more stiffener flanges intermediate the transverse edges of the plate.
The plate may have a pitch between about 152.4 mm and about 500 mm, and a depth between about 50.8 mm and about 237 mm.
Each of the at least one longitudinal flange may be a single longitudinal flange extending generally the length of each longitudinal edge, and each of the at least one transverse flange may be a single transverse flange extending generally the length of each transverse edge.
In another aspect, there is provided an overhead structure comprising: a corrugated structure having corrugations extending transversely of the longitudinal length of the corrugated structure, the corrugated structure comprising a plurality of corrugated metal plates, each corrugated metal plate comprising a plate configured to define a series of crests and troughs, the plate having longitudinal edges extending parallel to longitudinal axes of the crests and the troughs and transverse edges extending orthogonally to the longitudinal axes of the crests and the troughs; and at least one of: at least one longitudinal flange extending from each longitudinal edge, and at least one transverse flange extending from each transverse edge, the flanges of adjacent corrugated metal plates abutting and being secured to each other.
The corrugated metal plates may be arranged in two layers so as to form a double layer of corrugated metal plates. The corrugated metal plates forming the double layer may define at least one interior cavity configured to be filled with concrete. The overhead structure may further comprise a plurality of shear studs attached to the corrugated metal plates within at least one of the cavities for providing a shear bond at the metal-concrete interface. The corrugated metal plates forming an inner layer may be separated from the corrugated metal plates forming an outer layer by spacer plates. The corrugated metal plates forming the double layer and the spacer plates may define at least one interior cavity configured to be filled with concrete. The overhead structure may further comprise a plurality of shear studs attached to one or more of the corrugated metal plates and the spacer plates within at least one of the cavities for providing a shear bond at the metal-concrete interface.
The overhead structure may further comprise at least one reinforcement member positioned between adjacent corrugated metal plates. The at least one reinforcement member may comprise one or more of a reinforcement rib, a reinforcement beam, a hollow structural section reinforcement rib, and a boxed reinforcement rib.
The overhead structure may further comprise sealant positioned between abutting longitudinal flanges of adjacent corrugated metal plates. The sealant may comprise one or more sealant strips.
One or more of the at least one transverse flange may comprise a first flange portion and a second flange portion. Each first flange portion may have an upturned orientation relative to the plate and each second flange portion may have a downturned orientation relative to the plate.
At least some of the longitudinal flanges may be generally centered on crests or troughs. The crests and troughs of at least some adjacent plates may be generally contiguous when the longitudinal flanges of the at least some adjacent plates abut.
For at least some of the corrugated metal plates, one or more of the at least one longitudinal flange and the at least one transverse flange may comprise a plurality of apertures for receiving fasteners.
At least some of the transverse flanges may extend non-orthogonally from the plates.
At least some of the corrugated metal plates may further comprise gussets adjoining each of the at least one transverse flanges to the plate.
For at least some of the corrugated metal plates, one or more of the at least one longitudinal flange and the at least one transverse flange may comprise a groove for accommodating a gasket or a quantity of sealant.
For at least some of the corrugated metal plates, each of the at least one longitudinal flange may comprise a first longitudinal flange having a protrusion and a second longitudinal flange having a groove sized to accommodate the protrusion of an adjacent corrugated metal plate, the first longitudinal flange and the second longitudinal flange each extending from a respective longitudinal edge of the plate. For at least some of the corrugated metal plates, each of the at least one transverse flange may comprise a first transverse flange comprising a protrusion and a second transverse flange comprising a groove sized to accommodate the protrusion of an adjacent corrugated metal plate, the first transverse flange and the second transverse flange each extending from a respective transverse edge of the plate. The groove may be sized to accommodate a gasket or a quantity of sealant.
For at least some of the corrugated metal plates, each of the at least one transverse flange may comprise one or more alignment features to engage an adjacent abutting plate. The alignment features may matingly engage alignment features of the abutting plate. Each of the at least one transverse flange may comprise a plurality of alignment features. For at least some of the corrugated metal plates, each of the at least one longitudinal flange may comprise one or more alignment features to engage an adjacent abutting plate. The alignment features may matingly engage alignment features of the abutting plate. Each of the at least one longitudinal flange may comprise a plurality of alignment features.
The corrugated metal plates may further comprise one or more stiffener flanges intermediate the transverse edges of the plates.
Each of the at least one longitudinal flange may comprise a single longitudinal flange extending generally the length of each longitudinal edge, and each of the at least one transverse flange may comprise a single transverse flange extending generally the length of each transverse edge.
At least some of the corrugated metal plates may be curved in one or more of a longitudinal direction and a transverse direction.
The corrugated structure may be curved, and the longitudinal flanges of adjacent plates may align to define circumferential flanges of the corrugated structure, and wherein the transverse flanges of adjacent plates may align to define longitudinal flanges of the corrugated structure.
The corrugated metal plates may have a pitch between about 152.4 mm and about 500 mm, and a depth between about 50.8 mm and about 237 mm.
In another aspect, there is provided a corrugated metal plate comprising a first flange extending along a first edge of the corrugated metal plate, the first flange having alignment features thereon to mate with complimentary alignment features of an adjacent plate.
The corrugated metal plate may further comprise a second flange extending along a second edge of the corrugated metal plate opposite the first edge and having alignment features thereon complimentary to the alignment features on the first flange. The corrugated metal may further comprise a third flange extending along a third edge of the corrugated metal plate, the third flange having alignment features thereon to mate with complimentary alignment features of an adjacent plate. The corrugated metal plate may further comprise a fourth flange extending along a fourth edge of the corrugated metal plate opposite the third edge and having alignment features thereon complimentary to the alignment features on the third flange.
The alignment features may comprise protrusions and notches. The first flange and the second flange may each comprise at least one protrusion or at least one notch, or both. The third flange and the fourth flange may each comprise at least one protrusion or at least one notch, or both.
In another aspect, there is provided a method of assembling a corrugated structure formed of corrugated metal plates, the corrugated structure having corrugations extending transversely of the longitudinal length of the corrugated structure, at least some of the corrugated metal plates comprising a longitudinal flange extending from each longitudinal edge and a transverse flange extending from each transverse edge, at least some of the flanges comprising alignment features, the method comprising: bringing adjacent plates into abutting relationship such that alignment features on adjacent plates matingly engage; installing fasteners through aligned holes to secure abutting plates; and repeating the bringing and the installing as necessary until the corrugated structure is assembled.
The flanges may be on the exterior of the corrugated structure, and wherein the installing is performed outside the corrugated structure. The flanges may be on the interior of the corrugated structure, and wherein the installing is performed inside the corrugated structure.
Each of the transverse flanges may comprise a first flange portion and a second flange portion. Each first flange portion may have an upturned orientation relative to the plate and each second flange portion may have a downturned orientation relative to the plate.
The method may further comprise adding sealant between abutting flanges. The sealant may comprise one or more sealant strips.
At least some of the corrugated metal plates may be curved in one or more of a longitudinal direction and a transverse direction.
The corrugated structure may be curved, and wherein the longitudinal flanges of adjacent plates align to define circumferential flanges of the corrugated structure, and wherein the transverse flanges of adjacent plates align to define longitudinal flanges of the corrugated structure.
The alignment features may comprise protrusions and notches. Each of the at least some longitudinal flanges may comprise at least one protrusion or at least one notch, or both. Each of the at least some transverse flanges may comprise at least one protrusion or at least one notch, or both.
The method may further comprise positioning an intermediate plate between adjacent plates having different corrugation profile.
The method may further comprise positioning at least one reinforcement member between adjacent corrugated metal plates. The at least one reinforcement member may comprise one or more of a reinforcement rib, a reinforcement beam, a hollow structural section reinforcement rib, and a boxed reinforcement rib.
At least one of the corrugated metal plates may comprise transverse flanges that extend non-orthogonally from the plate. The method may further comprise installing the at least one corrugated metal plate having the transverse flanges that extend non-orthogonally from the plate as a keystone plate of the corrugated structure.
The corrugated metal plates may have a pitch between about 152.4 mm and about 500 mm, and a depth between about 50.8 mm and about 237 mm.
Embodiments will now be described with reference to the accompanying drawings in which:
a to 6f are sectional views of alternative embodiments of corrugated metal plates for use in the metal archway of
a is a sectional view of another embodiment of a corrugated metal plate for use in the metal archway of
b is a sectional view of the corrugated metal plate of
a is a perspective view of a portion of another embodiment of a corrugated metal plate for use in the metal archway of
b is a front view of a portion of another embodiment of a metal archway;
c is a front view of a tunnel lining;
d is a side view of another embodiment of a corrugated metal plate forming part of the tunnel lining of
e is a perspective view of a portion of another embodiment of a corrugated metal plate for use in the metal archway of
a, 9b and 9c are perspective views of portions of a reinforcement rib, a reinforcement beam and a concrete-filled hollow structural section reinforcement rib, respectively, for use in the metal archway of
d is a sectional view of a portion of another embodiment of a metal archway, constructed from the reinforcement beam of
a and 10b are perspective and sectional views, respectively, of portions of another embodiment of a metal archway;
a and 13b are perspective and front views, respectively, of a portion of another embodiment of a metal archway, showing a stand;
a and 14b are sectional views of portions of the metal archway of
a and 17b are perspective, schematic views of portions of other embodiments of metal archways, showing different spacing between corrugated metal plates;
a and 18b are perspective and sectional views, respectively, of portions of another embodiment of a metal archway;
a and 23b are sectional views of portions of another embodiment of a corrugated metal plate, showing adjacent corrugated metal plates in non-abutting and abutting positions, respectively;
a and 27b are perspective and sectional views, respectively, of a footing forming part of another embodiment of an overhead structure;
c and 27d are perspective and sectional views, respectively, of a prior art footing forming part of a prior art overhead structure;
a and 28b are perspective views of an automated assembly tool, and a gripper forming part thereof, respectively, for assembling the metal archway of
Turning now to
Turning now to
Plate 32 has longitudinal circumferential edges or opposite sides that are generally parallel to the lengths of the crests 32a and the troughs 32b. Extending generally the length of each longitudinal circumferential edge is a longitudinal circumferential flange 44 for providing a surface against which any of, for example, a longitudinal circumferential flange 44 of an adjacent plate 32, a reinforcement member, or any suitable support surface, can abut. In this embodiment, the longitudinal circumferential flanges 44 are formed by bending the plate 32 along the longitudinal circumferential edges and, as shown, the longitudinal circumferential flanges 44 are downturned relative to the plate 32. Each longitudinal circumferential flange 44 has a plurality of spaced apertures 46 formed therein, with each aperture 46 being configured to receive a respective fastener. In this embodiment, the fasteners are bolts 48, although it will be appreciated that other suitable fasteners (welds, rivets, etc.) can be used.
In the embodiment shown, the alternating crests 32a and troughs 32b define a periodic pattern, and the longitudinal circumferential flanges 44 are positioned so as to be generally centered on the troughs 32b of the plate 32. In this manner, when flanges 44 of adjacent plates 32 abut, the periodic pattern of crests 32a and troughs 32b is maintained across abutting plates 32. In this embodiment, the plate 32 has a pitch, and namely a spacing between adjacent crests 32a, of about 381 mm, and a depth, and namely the distance from the bottom of a trough 32b to the top of a crest 32a, of about 140 mm.
Each plate 32 is terminated by transverse edges or opposite ends that are generally orthogonal to the lengths of the crests 32a and the troughs 32b. Extending generally the length of each transverse edge, and following the contour of the crests 32a and troughs 32b, is a transverse flange 54. In this embodiment, each transverse flange 54 is joined to the plate 32 by welding, and is sized and positioned so as to provide a first flange portion 56 having a downturned orientation relative to the plate 32 and a second flange portion 58 having an upturned orientation relative to the plate 32. The transverse flange 54 is configured to provide a surface against which any of, for example, a transverse flange 54 of an adjacent plate 32, a footing 28, a reinforcement member, or other suitable support surface, can abut. Each transverse flange 54 has a plurality of apertures 60 formed therein, with each aperture 60 being configured to receive a respective fastener. In this embodiment, the fasteners are bolts 48, although it will be appreciated that other suitable fasteners (welds, rivets, etc.) can be used.
The longitudinal circumferential flanges 44 and transverse flanges 54 advantageously allow butt joints to be formed between adjacent plates 32. As will be understood, such butt joints inherently provide an axial strength that is largely a function of the axial strength of the plate material, and which is higher than the axial strength of lap joints formed by overlapping conventional corrugated metal plates. In the latter case, the axial strength of the lap joint is largely a function of the shear strength of fasteners passing through the overlapping plate portions.
Additionally, the butt joints formed between adjacent plates 32 advantageously enable the overhead structure 22 to be assembled from a single side of the overhead structure, such as either above or below the overhead structure, as compared to an overhead structure formed by overlapping conventional plates, for which two or more individuals are typically required to affix each bolt to the structure. Those of skill in the art will appreciate that this feature enables assembly of overhead structures using robotic or automated assembly equipment, as will be further described below.
In this embodiment, the metal archway 30 further comprises sealant strips 62 positioned between abutting longitudinal circumferential flanges 44 of adjacent plates 32, as shown in
As will be appreciated, the sealant strip 62 may be used in conjunction with, or substituted with, a squeeze block (not shown) positioned between abutting longitudinal circumferential flanges 44 of adjacent plates 32, and/or between abutting transverse flanges 54 of adjacent plates 32. The squeeze block is a slab of resilient material that generally absorbs loads exerted on the metal archway 30. As will be understood, the use of plates 32 having longitudinal circumferential flanges 44 and transverse flanges 54 allows squeeze blocks to advantageously be incorporated at multiple locations within the metal archway 30, and not only between the plates and footings as in prior art metal archways formed of conventional corrugated metal plates as described in, for example, U.S. Pat. No. 4,010,617 to Armco Steel Corporation. Such incorporation of squeeze blocks at multiple locations within the metal archway 30 enables the metal archway 30 to have increased resistance to loads imposed thereon, as compared to prior art metal archways.
As will be understood, when the overhead structure 22 is assembled, the corrugated metal plates 32 are connected end to end and side by side with the transverse flanges 54 and the longitudinal flanges 44 of adjacent corrugated metal plates 32 being in abutment.
When the overhead structure 22 is assembled, the transverse flanges align to define longitudinal flanges that extend parallel to the longitudinal length of the metal archway 30, and the longitudinal circumferential flanges align to define circumferential flanges that extend in a circumferential direction of the metal archway 30. Accordingly, for ease of description of some embodiments described below, the transverse flanges of the corrugated metal plates are referred to as longitudinal flanges, and the longitudinal circumferential flanges of the corrugated metal plates are referred to as circumferential flanges.
The flange configuration of the corrugated metal plate is not limited to that of the embodiment described above and in other embodiments, the corrugated metal plate may have other flange configurations. For example,
Still other configurations are possible.
c shows still another embodiment of a corrugated metal plate for use in the metal archway 30, and which is generally indicated by reference numeral 332. Plate 332 is generally similar to plate 32 described above and with reference to
d shows still another embodiment of a corrugated metal plate for use in the metal archway 30, and which is generally indicated by reference numeral 432. Plate 432 is generally similar to plate 132 described above and with reference to
e shows still another embodiment of a corrugated metal plate for use in the metal archway 30, and which is generally indicated by reference numeral 532. Plate 532 is generally similar to plate 132 described above and with reference to
The corrugated metal plates may alternatively comprise both upturned and downturned circumferential flanges. For example,
It will be appreciated that the corrugated metal plates described above and with reference to
The corrugated metal plates shown in
a and 7b show another embodiment of a corrugated metal plate for use in the metal archway 30, and which is generally indicated by reference numeral 732. Plate 732 is generally similar to plate 32 described above and with reference to
In other embodiments, the flanges may alternatively extend from the plate non-orthogonally. For example,
It will be understood that that two (2) adjacent and abutting plates 832 may be oriented non-horizontally so as to advantageously define a generally vertical butt joint. Plate 832 is therefore well-suited for use in curved structures, such as for example a metal archway or a tunnel lining, where vertical butt joints may be desired for providing support points for suspending an apparatus within the interior of the curved structure. For example,
It will be appreciated that a corrugated metal plate having non-orthogonal longitudinal flanges is well-suited for use in curved structures, such as for example in a metal archway or a tunnel lining, and where the non-orthogonal longitudinal flanges allow the plate to be easily inserted as the final or “keystone” piece of the curved structure during assembly. For example,
e shows a portion of another embodiment of a corrugated metal plate for use in the metal archway 30, and which is generally indicated by reference numeral 1032. Plate 1032 is generally similar to plate 832 described above and with reference to
To provide additional support and to increase the load carrying capabilities of the overhead structure 22, one or more reinforcement members can be secured to the overhead structure 22. For example, an embodiment of a reinforcement member in the form of a reinforcement rib for use in the metal archway 30, and which is generally indicated by reference numeral 1174 is shown in
Other forms of reinforcement members may be used. For example,
It will be understood that the reinforcement beam is not limited to an I-beam configuration, and may be in the form of a beam of different cross-sectional shape, such as for example a C-beam, a T-beam, a box beam, a hollow structural section (HSS), or a beam of other suitable cross-sectional shape.
Still other forms of reinforcement members may be used. For example,
Although the portions of the reinforcement rib 1174, the reinforcement beam 1274 and the HSS reinforcement rib 1374 are shown in
Still other forms of reinforcement members may be used. For example
a and 10b show portions of another embodiment of a metal archway, and which is generally indicated using reference numeral 1530. Metal archway 1530 is constructed from a plurality of interconnected structural corrugated metal plates 32 that are arranged in two similarly-oriented layers, so as to define a double layer having a first layer of plates 1533a and a second layer of plates 1533b. The plates 32 of the first layer 1533a are separated from the plates 32 of the second layer 1533b by a plurality of spacer plates 1583 positioned between the circumferential flanges 44 of adjacent plates 32. Each of the spacer plates 1583 has a plurality of apertures 1584 formed therein arranged in two rows, and which are positioned so as to align with apertures 46 of the circumferential flanges 44, enabling the spacer plates 1583 to be secured to the plates 32 using suitable fasteners. In this embodiment, the fasteners are bolts 48, although it will be appreciated that other suitable fasteners (welds, rivets, etc.) meeting the specific structural and load requirements can be used.
The plates 32 and spacer plates 1583 of the metal archway 1530 define a plurality of interior cavities C. One or more of the cavities may be filled with concrete so as to provide internal reinforcement of the metal archway 1530. Shear studs (not shown) may be attached to interior surfaces of the plates 32 for providing a shear bond at the metal-concrete interface.
As will be appreciated, the spacing of the opposing plates 32 is defined by the height of the spacer plates 1583. The height of the spacer plates 1583 may therefore be selected to provide a desired total volume of the interior cavities C, and in turn a desired amount of internal reinforcement of the metal archway 1530.
Each hollow structural section 1683 defines an interior cavity C1, and interior surfaces of the plates 32 and exterior surfaces of the hollow structural sections 1683 define a plurality of interior cavities C2 within the metal archway 1630. One or more of the cavities C1 and C2 may be filled with concrete so as to provide internal reinforcement of the metal archway 1630, and shear studs (not shown) may be attached to the interior surfaces of the plates 32 and/or to the interior and/or exterior surfaces of the hollow structural sections 1683 for providing a shear bond at the metal-concrete interface.
As will be appreciated, the spacing of the opposing plates 32 is defined by the height of the hollow structural sections 1683. The height of the hollow structural sections 1683 may therefore be selected to provide a desired total volume of the interior cavities C1 and C2, and in turn a desired amount of internal reinforcement of the metal archway 1630.
Other structures may be used to separate plates arranged within double layers. For example,
Still other structures may be used to separate plates arranged within double layers. For example,
In this embodiment, the metal archway 2030 further comprises cavities C formed between opposing pairs of troughs. In the embodiment shown, one of the cavities C is filled with concrete so as to provide an internal reinforcement rib 2085. Shear studs 2084 are attached to interior surfaces of the plates 32 defining the cavities C for providing a shear bond at the metal-concrete interface.
The opposing plates 32 and plates 2181 of the metal archway 2130 define a plurality of interior cavities C, with one or more of the cavities being filled with concrete so as to provide internal reinforcement of the metal archway. Shear studs 2184 are attached to interior surfaces of the plates 32 and the spacer plates 2183 for providing a shear bond at the metal-concrete interface. In this embodiment, tubular ducts 2186 are also provided within the cavity filled with concrete.
The structural corrugated metal plates arranged in double layers within the metal archways are not limited to the configurations shown above, and in other embodiments, the metal archway may alternatively have a different configuration. For example,
As will be appreciated, the circumferential and longitudinal flanges of the corrugated metal plates advantageously allow adjacent corrugated metal plates of different profile, such as different corrugation pitch and/or different corrugation depth, to be secured to each other in a facile manner, and without the need to form lap joints by partially overlapping neighbouring plates. For example,
In the embodiment shown, adjacent plates 2332a and 2332b are secured using an intermediate plate 2384. The intermediate plate 2384 has two (2) rows of apertures formed therein, with the apertures of each row having the same positioning as apertures 2346a and 2346b of the plates 2332a and 2332b. The two rows of apertures of the intermediate plate 2384 are spaced by an offset distance. As will be appreciated, the intermediate plate 2384 effectively serves as an adapter for allowing adjacent plates 2332a and 2332b to be secured to each other.
To facilitate assembly of the metal archway, the flanges of the corrugated metal plate may comprise alignment features. For example,
Although alignment features comprising pins and notches have been described, mating formations of alignment features having other configurations may be used. For example, in other embodiments, each plate may alternatively comprise one longitudinal flange comprising one (1) or more pins only, and no notches, and one longitudinal flange comprising a corresponding one (1) or more notches only, and no pins. As will be understood, in addition to ensuring that adjacent plates are correctly aligned relative to each other prior to being secured with fasteners, such a configuration would also ensure that adjacent plates are arranged in a correct order relative to each other prior to being secured with fasteners.
Still other configurations are possible. For example,
Still other configurations are possible. For example,
In other embodiments, the flanges of the corrugated metal plates may comprise features for accommodating other forms of sealant strip. For example,
The flanges of the corrugated metal plates may comprise still other features for accommodating other forms of sealant strip. For example,
Other configurations are possible. For example,
Although in embodiments described above, the longitudinal flanges follow the contour of the crests and troughs, in other embodiments, the longitudinal flanges may alternatively not follow the contour of the crests and troughs and therefore may alternatively be rectangularly shaped, or otherwise. For example,
To provide additional support and to increase the load carrying capabilities of the overhead structure, one or more longitudinal reinforcement members can be secured to the metal archway. For example,
As will be appreciated, the longitudinal flanges of the corrugated metal plates enable the plates to be fastened directly to the concrete footing of the overhead structure, and without requiring use of an intermediate footing channel. For example,
In contrast, conventional overhead structures constructed from conventional corrugated metal plates typically require a footing channel for securing the plates to the concrete footing. For example,
As mentioned above, the flanges of the corrugated metal plates enable metal archways or other structures to be readily assembled using robotic or automated assembly equipment. For example,
Other automated assembly equipment, such as an automated fastening unit (not shown) capable of securing individual corrugated metal plates to a partially-constructed metal archway or other structure, may be used in conjunction with the automated assembler 3370. As will be appreciated, such automated assembly equipment may advantageously be used for assembly of structures in hazardous environments that may otherwise pose a safety risk to laborers.
The flanges of the corrugated metal plates also advantageously provide convenient connection surfaces for items inside the curved structure when the plates are oriented such that the flanges are inside the structure. For example,
In embodiments described above, the corrugated metal plates are shown as being circumferentially curved, whereby the crests and troughs are curved along their lengths and thereby define a circumferential radius of curvature of the plate. However, as mentioned above, those skilled in the art will understand that the corrugated metal plate may alternatively be generally flat, whereby the lengths of the crests and troughs define generally parallel planes that extend the length of the plate. As will be appreciated, such generally flat plates are well-suited for use in structures comprising generally planar portions, such as bridges. For example,
As will be appreciated, the corrugated metal plates described above are not limited to use in overhead structures, and in other embodiments, the corrugated metal plates may be used in other structures or for other applications. For example, the corrugated metal plates may be used to form walls of shipping containers, or may be used to form walls or other components of buildings.
As will be understood, the positioning of the apertures of the circumferential flanges and longitudinal flanges is not limited to those shown in the embodiments described above, and in other embodiments, the apertures may alternatively be positioned differently along one or more of the circumferential flanges and longitudinal flanges.
Although embodiments described above are directed to corrugated metal plates, it will be understood by those of skill in the art that the corrugated metal plates may be of a range of thicknesses, and therefore may alternatively be corrugated metal sheets or otherwise.
Although in embodiments described above, the longitudinal flanges follow the contour of the crests and troughs, in other embodiments, the longitudinal flanges may alternatively not follow the contour of the crests and troughs and may alternatively be rectangularly shaped, or otherwise.
Although in embodiments described above, each longitudinal flange is formed by welding the longitudinal flange to the plate, in other embodiments, each longitudinal flange may alternatively be joined to the plate by other suitable joining methods.
Although in embodiments described above, the circumferential flanges are formed by bending the plate along the circumferential edges, in other embodiments, the circumferential flanges may alternatively be formed by joining the circumferential flange to the plate, such as by welding or other suitable joining methods.
Although in embodiments described above, the transverse flanges of the corrugated metal plate comprise alignment features, in other embodiments, the longitudinal flanges of the corrugated metal plate may also, or alternatively, comprise alignment features.
Although in embodiments described above, the corrugated metal plate has a pitch, and namely a spacing between adjacent crests, of about 381 mm, and a depth of about 140 mm, it will be understood that the pitch and the depth are not limited to these values and, in other embodiments, the plate may alternatively have a different pitch and/or a different depth. For example, in other embodiments, the plate may alternatively have a pitch of about 500 mm, a depth of about 237 mm. As another example, in other embodiments, the plate may alternatively have a pitch of about 152.4 mm, a depth of about 50.8 mm.
Although in embodiments described above, the corrugated metal plate comprises longitudinal flanges and transverse flanges, in other embodiments, the corrugated metal plate may alternatively comprise only longitudinal flanges or only transverse flanges.
Although in embodiments described above, each transverse flange extends continuously along the length of the transverse edge, in other embodiments, there may alternatively be two or more transverse flanges that extend along the length of the transverse edge and are separated by one or more gaps. Analogously, although in embodiments described above, each longitudinal flange extends continuously along the length of the longitudinal edge, in other embodiments, there may alternatively be two or more longitudinal flanges that extend along the length of the circumferential edge and are separated by one or more gaps.
Although embodiments have been described, it will be appreciated by those skilled in the art that variations and modifications may be made without departing from the scope thereof as defined by the appended claims.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/CA2012/000752 | 8/10/2012 | WO | 00 | 6/26/2014 |
| Number | Date | Country | |
|---|---|---|---|
| 61594367 | Feb 2012 | US | |
| 61523026 | Aug 2011 | US |
