Cold formed roof and columns building structure system

• US 8,316,621 B2
• Filed: 02/27/2011
• Issued: 11/27/2012
• Est. Priority Date: 02/27/2011
• Status: Active Grant

• Current Assignee: Abolghasem Rastgoo, Haddad Miladi, Kamal Safari Kermanshahi, Kamran Safari Kermanshahi, Koroush Safari Kermanshahi
• Original Assignee: Abolghasem Rastgoo, Haddad Miladi, Kamal Safari Kermanshahi, Kamran Safari Kermanshahi, Koroush Safari Kermanshahi
• Inventors: Safari Kermanshahi, Kamal, Miladi, Haddad, Rastgoo, Abolghasem, Safari Kermanshahi, Kamran, Safari Kermanshahi, Koroush
• Primary Examiner(s): Glessner, Brian
• Assistant Examiner(s): MATTEI, BRIAN DAVID
• Application Number:
  US13/035,973
• Publication Number:
  US 20120216475A1
• Time in Patent Office: 639 Days
• Field of Search: 52836-839, 528/43, 528/48, 526/93, 526/96, 526/34, 522/89, 522/363, 522/367, 522/34
• US Class Current: 52/837
• CPC Class Codes: E04C 2003/0413 being built up from several parts
• CPC Class Codes: E04C 2003/0439 the cross-section comprising open parts and hollow parts
• CPC Class Codes: E04C 2003/0452 H- or I-shaped
• CPC Class Codes: E04C 2003/0491 the truss elements being located in one single surface or in several parallel surfaces
• CPC Class Codes: E04C 3/086 of the castellated type
• CPC Class Codes: E04C 3/09 at least partly of bent or otherwise deformed strip- or sheet-like material
• CPC Class Codes: E04D 13/1625 with means for supporting the insulating material between the purlins or rafters insulating layers disposed between two longitudinal supporting elements E04B1/7654

Abstract

An improved roof structure formed of metal sheet s. The structure comprises a plurality of cold formed columns supported by a concrete foundation, a plurality of cold formed girders supported by the plurality of columns, a plurality of cold formed beams supported by the plurality of girders, a plurality of cold formed open web joists supported by the plurality of beams, and a plurality of polystyrene roof boards supported by the plurality of joists.

Claims

1. A roof structure comprising:

(a) a plurality of cold-formed columns, each column comprising a pair of vertical posts attached to each other in juxtaposition, each post of a substantially tapered I-beam cross section comprising an elongate vertical column web interconnecting a pair of column flanges wherein the outer vertical surfaces of the column flanges are horizontal, the cross-section of each column symmetrical about central horizontal and vertical axes;

(b) a plurality of cold-formed girders supported by the plurality of columns, each girder of a substantially tapered I-beam cross section comprising an elongate girder web interconnecting a pair of upper and lower girder flanges wherein the top and bottom surfaces of the girder flanges are horizontal, the cross-section of each girder symmetrical about central horizontal and vertical axes;

(c) a plurality of cold-formed beams supported by the plurality of girders, each beam comprising a tapered I-beam comprising an elongate beam web interconnecting a pair of upper and lower beam flanges wherein the top and bottom surfaces of the beam flanges are horizontal the cross-section of each beam symmetrical about central horizontal and vertical axes;

(d) a plurality of open web joists supported by the plurality of beams, each joist comprising a cold-formed upper chord, a cold-formed lower chord, and a triangulated open web interconnecting the upper and lower chords wherein, the open web comprises a plurality of angled open web members, each open web member interconnecting the upper and lower chords by means of forging, the cross-section of each joist symmetrical about a central vertical axis; and

(e) a plurality of roof boards supported by the plurality of joists.

2. The structure of claim 1 wherein, the opposite ends of each open web member is fixedly connected to the upper and lower chords.

3. The structure of claim 1 wherein, the opposite ends of each open web member is connected to the upper and lower chords as rule joints.

4. The structure of claim 1 wherein, each open web member is formed by bending a metal rod so as to form a pair of parallel sections, each comprising upper and lower ends, an upper-chord-connecting section interconnecting the upper ends of the parallel sections such that the upper-chord-connecting section is substantially perpendicular to the pair of parallel sections, and a pair of lower-chord-connecting sections extending perpendicularly and outwardly from the pair of parallel sections;

the upper and lower chords interconnected by the open web member about upper and lower-chord-connecting sections respectively.

5. The structure of claim 4 wherein, the upper chord comprises an elongate, vertical upper-chord-connecting wall comprising a plurality of equidistant holes disposed thereon wherein, each hole receives the upper-chord-connecting section therewithin, and an elongate member attached to the top edge of the upper-chord-connecting wall;

the elongate member comprising a substantially planar top surface.

6. The structure of claim 5 wherein, the elongate member comprises a hollow member of uniform rectangular cross section comprising an elongate top wall, an elongate bottom wall, and a pair of elongate opposing sidewalls connecting the longitudinal edges of the top and bottom walls, the pair of side walls disposed parallel to the upper-chord-connecting wall.

7. The structure of claim 4 wherein, the lower chord comprises:

(a) a pair of opposing, vertical, lower-chord-connecting walls each comprising a plurality of equidistant holes disposed thereon such that the holes on either lower-chord-connecting walls are aligned, each pair of opposing holes for receiving the pair of lower-chord-connecting sections therethrough, and

(b) an elongate horizontal, rectangular lower panel longitudinally attached to the bottom edges of the pair of lower-chord-connecting walls;

the lower panel extending laterally beyond the connecting point of the pair of lower-chord-connecting walls.

8. The structure of claim 7 wherein, the lower chord further comprises a pair of elongate metal strips of substantially L-shaped cross section, wherein the longitudinal edges of each strip connects the longitudinal top edge of a lower-chord-connecting wall and the longitudinal edge of the lower panel thereby forming a hollow metal tube of uniform rectangular cross section;

the lower chord formed by longitudinal bending a metal sheet.

9. The structure of claim 4 wherein, the lower chord comprises a pair of opposing, elongate, horizontal, lower-chord-abutting rectangular metal strips wherein, each lower-chord-abutting strip fixedly rests over the plurality of lower-chord-connecting sections, an elongate, horizontal, rectangular lower panel disposed parallel to the pair of lower-chord-abutting strips, and a pair of opposing, elongate, vertical, rectangular side strips, each interconnecting the lower-chord-abutting strips and the lower panel;

the lower chord formed by longitudinal bending a metal sheet.

10. The structure of claim 4 wherein, the upper chord comprises a plurality upper-chord segment members, each comprising a vertical upper-chord-connecting wall segment comprising a hole disposed thereon, each hole for receiving the upper-chord-connecting section therewithin, and a horizontal, rectangular upper panel segment attached to the top edge of each upper-chord-connecting wall segment, and an elongate, hollow bar attached on top of the plurality of upper-chord segment members;

each upper-chord segment member cold-formed by longitudinally bending a metal sheet.

11. The structure of claim 4 wherein, the upper chord comprises a plurality upper-chord segment members wherein each segment member comprises a vertical upper-chord-connecting wall segment comprising a hole disposed thereon, each hole for receiving the upper-chord-connecting section therewithin, and a metal tube segment upwardly extending from the top edge of each wall, and an elongate hollow member received within the plurality of tube segments;

the outer surface of the hollow member conforming to the inner surface of the plurality of tube segments;

each upper-chord segment member and the upper-chord hollow member cold-formed by longitudinally bending a plurality metal sheets.

12. The structure of claim 4 wherein, the lower chord comprises a plurality of lower-chord segment members, each comprising a pair of opposing vertical lower-chord-connecting wall segments, each comprising a hole disposed thereon, the pair holes for receiving the pair of lower-chord-connecting sections therethrough, a horizontal rectangular bottom panel interconnecting the bottom edges of the vertical wall segments, and a pair of horizontal rectangular flanges, each extending outwardly from the top edge of a lower-chord-connecting wall segment, and an elongate platform comprising a longitudinal groove within which the plurality of lower-chord segment members are fixedly received such that the bottom surfaces of the plurality of rectangular bottom panels abut the surface of the groove.

13. The structure of claim 1 wherein, the girder is formed by:

(a) longitudinally bending each of a pair of metal sheets at right angles at first and second points so as to form a vertical girder web section and a pair of opposing upper and lower horizontal girder flange sections, the first and second points located at an equal distance from first and second longitudinal edges of the metal sheet respectively;

(b) longitudinally bending the pair of upper and lower girder flange sections at third and fourth points respectively, the upper and lower girder flanges bent inwardly towards the girder web section at an acute angle so as to form a pair of opposing elongate horizontal sides and a pair of opposing elongate angled panels, each extending from the longitudinal edge of the elongate horizontal side, the third and fourth points located at an equal distance from the first and second longitudinal edges respectively;

(c) longitudinally bending the pair of upper and lower angled panels at fifth and sixth points respectively, the pair of upper and lower angled panels bent outwardly away from the girder web section so as to form a pair of opposing elongate angled sides and a pair of opposing elongate vertical collars, each extending from the longitudinal edge of the angled side and fixedly abutting the girder web section, the fifth and sixth points located at a equal distance from the first and second longitudinal edges respectively; and

(d) attaching the planar side of bent sheets on either planar sides of an elongate rectangular girder web so as to form a tapered substantially I-shaped beam;

the girder web is of hollow rectangular cross-section.

14. The structure of claim 13 wherein, the girder further includes a pair of elongate, cold-formed, girder flange reinforcing members comprising an outer surface and an inner surface wherein, the inner surface of each reinforcing member fixedly abuts the outer surface of a girder flange, and the surface of each collar;

the reinforcing members built by bending metal sheets.

15. The structure of claim 1 wherein, each cold-formed beam flange is built by longitudinally bending a metal sheet at an acute angle at first and second points so as to form an elongate horizontal side and a pair of elongate angled panels, the first and second points located at an equal distance from first and second longitudinal edges of the metal sheet respectively, and longitudinally bending the metal sheet outwardly at third and fourth points, each point located on an angled panel so as to form a pair of vertical strips and a pair of angled sides, the third and fourth points located at an equal distance from the first and second longitudinal edges respectively wherein, the inner surfaces of the pair of vertical strips of each beam flange fixedly abut the outer opposing surfaces of the beam web comprising a vertical, rectangular metal strip wherein, the top and bottom edges of the metal strip abut the inner surfaces of the top and bottom beam flanges respectively.

16. The structure of claim 15 wherein, the longitudinal edge of each vertical strip comprises a series of web-connecting edges, a series of non-web-connecting edges wherein, each non-web-connecting edge disposed between a pair of web-connecting edges, and a plurality of angled edges joining the successive web-connecting and non-connecting edges;

the inner surfaces extending from each pair of opposing web-connecting edges of the pair of vertical strips of each girder flange fixedly abut the outer opposing surface of a vertical, rectangular beam web panel, the plurality of beam panels make up the girder web.

17. The structure of claim 1 wherein, each column flange is built by:

(a) longitudinally bending a metal sheet at an acute angle at first and second points so as to form an elongate rectangular main side and a pair of elongate rectangular angled panels extending from the elongate edges of the main side, the first and second points located at an equal distance from first and second elongate edges of the metal sheet respectively, and

(b) longitudinally bending the metal sheet outwardly at third and fourth points, each point located on an angled panel so as to form a pair of angled sides and a pair of elongate strips, each disposed substantially perpendicular to the main side, the third and fourth points located at an equal distance from the first and second elongate edges respectively;

wherein, the inner surfaces of the pair of vertical strips of each column flange fixedly abut the outer opposing surfaces of the column web and wherein, the pair of vertical posts fixedly abut about the first points of column flanges so that the column webs of the pair of vertical posts are disposed in a parallel relationship;

the column web of each post extending upward beyond the length of the column flanges;

the column web comprising a vertical, rectangular metal strip wherein, the top and bottom edges of the metal strip abut the inner surfaces of the top and bottom column flanges respectively.

18. The structure of claim 1 wherein, each roof board comprises:

(a) a main solid block comprising a rectangular bottom surface, a rectangular planar top surface, a pair of vertical lateral sides, each interconnecting the lateral edges of the top and bottom surfaces, a pair of vertical longitudinal sides, each extending upwardly from a longitudinal edge of the bottom surface, and a pair of longitudinal slant sides, each interconnecting the top edge of a vertical longitudinal side and a longitudinal edge of the top surface;

(b) a plurality of solid, rectangular bottom blocks abutting the bottom surface of the main block, the bottom blocks are regularly spaced so as to form a plurality of lateral recesses of uniform cross section therebetween, the plurality of bottom blocks laterally lie within the bottom surface so as to expose end lateral portions of the bottom surface, the end lateral portions to rest on the lower chords of opposing, successive joists as the roof board is supported between the joists; and

(c) a plurality of metal pipes, each to be tightly received within a recess, the metal pipes for improving the load bearing capacity of the roof board;

the roof boards made of polystyrene.

19. The structure of claim 1 wherein, the metal sheets employed forming each of the columns, girders, beams, joists, or parts thereof comprise ST32 sheets.

20. The structure of claim 1 wherein, the metal sheets employed forming each of the columns, girders, beams, joists, or parts thereof comprise ST57 sheets.