(19)
(11) EP 4 438 830 A1

(12) EUROPEAN PATENT APPLICATION

(43) Date of publication:
02.10.2024 Bulletin 2024/40

(21) Application number: 23165945.9

(22) Date of filing: 31.03.2023
(51) International Patent Classification (IPC): 
E04B 1/24(2006.01)
E04C 3/32(2006.01)
E04C 3/07(2006.01)
E04C 3/04(2006.01)
(52) Cooperative Patent Classification (CPC):
E04B 2001/2472; E04B 1/24; E04C 3/32; E04B 2001/2469; E04C 2003/0465; E04C 2003/0452; E04C 2003/0417; E04C 3/07
(84) Designated Contracting States:
AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC ME MK MT NL NO PL PT RO RS SE SI SK SM TR
Designated Extension States:
BA
Designated Validation States:
KH MA MD TN

(71) Applicant: Voestalpine Sadef NV
8830 Hooglede (BE)

(72) Inventor:
  • Depauw, Marc
    8610 Kortemark (BE)

(74) Representative: IP HILLS NV 
Bellevue 5/501
9050 Gent-Ledeberg
9050 Gent-Ledeberg (BE)

   


(54) CONSTRUCTION COMPRISING A LOAD-BEARING COLUMN


(57) Construction (100) comprising one or more load-bearing columns (200), any of the columns (200) comprising a first (201) and a second elongated profile (202), and each profile comprising:
- two opposing side walls (401, 402) and a base wall (403);
- a first (405) and a second edge wall (406) directed inwardly,

wherein both the opposing first edge walls (305, 405) and the opposing second edge walls (306, 406) are joined at multiple connection spots (503, 504) along the length,
wherein the joint provided at any of the connection spots (503, 504) is such that there is no play in the connection at the connection spots, and
wherein access holes (300, 400) are provided in the base wall (303, 404) or a side wall (301, 302, 401, 402) of the first and/or second elongated profile (201, 202).




Description

Field of the Invention



[0001] The present invention generally relates to the field of constructions, composed of steel profiles and comprising one or more load-bearing columns. In particular, a solution for a load-bearing column is presented, that allows for a compact profile transport and on-site assembly of the load-bearing column, without requiring any anti-corrosion aftertreatment, and while obtaining the same level of buckling resistance, torsional rigidity, and general shape stability as for a tubular column.

Background of the Invention



[0002] In a steel frame construction, steel profiles are used to provide structural members such as columns and beams. Preferably, thin-walled open profiles are used thereby limiting material costs, under the condition that still sufficient strength can be offered. In particular, columns - being vertically positioned structural members-typically carry the weight of a higher structure, the columns thus being subjected to axial and torsional loads. Therefore, an important requirement for such structural columns is their bending stiffness and torsional stiffness, thereby offering sufficient buckling resistance and torsional rigidity, and thus being stable in shape.

[0003] These requirements may be met by using tubular columns, i.e. columns each provided as a single hollow steel tube. However, such tubular columns are expensive in purchase, and are voluminous to transport, thereby increasing transport costs. Alternatively, a column may be constructed from joint steel profiles - e.g. C- or I-shaped profiles - in a manufacturing plant, using automated tools or rolling techniques, thus still implying a voluminous and costly transport.

[0004] Therefore, there is a need to assemble load-bearing columns from separate low-cost steel profiles at the construction site, after the composing profiles being transported in a compact way, while obtaining columns having the required shape stability.

[0005] In prior art solutions, assembling a column is often done by means of welding. For example, two U-shaped or C-shaped profiles are positioned with their flanges towards one another, and the corresponding edges of both profiles are connected by means of two longitudinal welds provided at the outside of the composed column. In this way, a column having the required shape stability is obtained. However, a disadvantage of welding is that it may deform the global shape. Moreover, it impacts the corrosion resistance of the galvanised metal sheets, so that an aftertreatment like painting or galvanising is required on site. Also in RU183856U1 welding is used, to connect the longitudinal edges of two C-profiles, the C-profiles being positioned web-to-web to form an I-shaped structural member. Moreover, the two side cavities of the C-profiles are filled with concrete, thereby obtaining a composite reinforced concrete beam having the required bearing capacity.

[0006] US10513849B1 presents another prior art solution, based on a mechanical connection of profiles to form a support column. In this solution, a first and second channel member, provided as two C-shaped profiles, are positioned with their flanges towards another, so as to define an interior passage extending in longitudinal direction. Inside the interior passage, an inner member, e.g. an additional C-shaped profile, is placed, the inner member being coupled to the first and second channel member via screws. The inner member provides structural support to the support column, thereby allowing to use profiles of light gauge steel and reducing weight and cost. However, as this solution requires an inner member, an additional profile, besides the two channel members, needs to be produced, transported and assembled. Moreover, the inner member is used as a coupling element, having the function of vertically coupling stacked columns, and not having the main purpose of substantially increasing the bearing capacity of the column. It is therefore doubtful that this type of solution offers the same level of buckling resistance, torsional rigidity, and general shape stability as a tubular column.

[0007] It is an objective of the present invention to disclose a construction comprising one or more load-bearing columns, and a corresponding assembly method, that resolve one or several of the above-described shortcomings of the prior art solutions. More particularly, it is an objective to present a solution for a load-bearing column that allows for a compact profile transport and on-site assembly of the load-bearing column, without requiring any anti-corrosion aftertreatment, and while obtaining the same level of buckling resistance, torsional rigidity, and general shape stability as for a tubular column.

Summary of the Invention



[0008] According to a first aspect of the present invention, the above identified objectives are realised by a construction comprising one or more load-bearing columns, defined by claim 1, the columns being structural members subjected to axial load, wherein any of the load-bearing columns comprises a first and a second elongated profile, the first and second elongated profile extending in length direction, and each comprising:
  • a channel portion, comprising two opposing side walls positioned at both sides of a base wall, the side walls and base wall together defining an open channel;
  • an edge portion, comprising a first and a second edge wall, each extending from an end of a respective side wall in a direction towards the open channel, and comprising a first respectively second edge surface facing away from said open channel,
wherein the two elongated profiles are positioned with their first edge surfaces facing each other, and their second edge surfaces facing each other, such that an internal channel is defined by the two respective channel portions, the two elongated profiles being joined together to form the load-bearing column, and wherein:
  • both the opposing first edge walls and the opposing second edge walls of the two elongated profiles are joined at multiple connection spots, located inside the internal channel and distributed along the length,
  • the joint provided at any of the connection spots is such that there is no play in the connection at the connection spots, thereby establishing a sliding-rigid connection between the respective opposing edge walls, and
  • access holes distributed along the length are provided in the base wall or a side wall of the first elongated profile and/or in the base wall or a side wall of the second elongated profile, any of the connection spots being accessible via one of the access holes during joining the two elongated profiles, and being left open or being closed afterwards.


[0009] Thus, the invention concerns a construction wherein structural profiles, typically steel profiles, are mutually connected to form a frame or skeleton. For example, the frame construction is used as a structure for a solar carport or as a high-bay storage rack, or it forms the skeleton of a building. The construction comprises one or more load-bearing columns. A column is a structural member, used vertically and supporting elements of the superstructure. The columns in the construction are thus subjected to axial load, thereby acting as a vertical compression member. Each of the vertically loaded columns contributes to carrying the weight of another structure, e.g. a roof structure, floor structure or storage platform. In an embodiment the load of the supported structure is completely carried by the one or more load-bearing columns according to the invention. In another embodiments, other structural members may contribute to carry this load, besides the invented load-bearing columns. Apart from the vertical or axial load, the load-bearing columns may be subjected to other types of load, e.g. a torsional load or bending moment. Typically, the construction is designed such that the axial stresses due to axial force and bending moment are close to the allowable tensile strength of the applied steel sheet. For carport applications, the column length is typically between 3 and 5 meter, and the column's cross section is typically between 350 mm × 200 mm and 450 mm × 240 mm. For a high-bay storage rack application, the columns are typically up to 15 m in length, and having a cross section of typically between 140 mm × 200 mm and 160 mm × 350 mm.

[0010] Each of the load-bearing columns comprises a first and a second elongated profile, extending according to a longitudinal direction or length direction. A profile refers to a structural profile or building profile, typically a structural steel profile. A profile typically has an elongated shape and a specific cross section repeated along the length. Various production techniques may be used to make a profile, e.g. roll forming, or extrusion. For example, the profiles may be made of galvanised steel, in view of obtaining a good corrosion resistance. Typically, the profiles are made from plates having a thickness between 3 and 5 mm.

[0011] Both the first and the second elongated profile comprise a channel portion and an edge portion. The channel portion comprises two opposing side walls positioned at both sides of a base wall, the side walls and base wall together defining an open channel. The base wall may also be referred to as the web of the profile, and the side walls as the flanges. The edge portion comprises a first and a second edge wall, each extending from an end of a respective side wall in a direction towards the open channel, The edge walls, sometimes also referred to as flanges, are thus directed inwardly, both edge walls pointing to one another. For example, the first and second elongated profile are C-profiles or sigma-profiles. In these cases, the channel portion is U-shaped, comprising two substantially parallel side walls or legs, positioned at both sides of a base wall. In case of the C-profile, the base wall has a flat top surface extending in a direction substantially perpendicular to the direction of the side walls. In case of the sigma-profile, the base wall has a longitudinal slit in its top surface.

[0012] In an embodiment, the edge walls are flat plates extending in a single direction. For example, both side walls are substantially parallel, and both edge walls extend in a direction substantially perpendicular to the direction of the side walls. In another embodiment, the edge walls comprise more than one flat plate, each of the flat plates extending in another direction. For example, the edge wall may be hook-shaped, comprising a flat plate substantially perpendicular to the direction of the parallel side walls, and another flat plate substantially parallel to the direction of the parallel side walls.

[0013] In an embodiment, the first and the second elongated profile have the same cross section, e.g. both being a C-shaped profile or both being a sigma-shaped profile. In another embodiment, the first and second elongated profile each have a different cross section, e.g. one of them is C-shaped and the other one is sigma-shaped, or both are C-shaped but with other dimensions. Typically, the edge walls are continuous elements in length direction. In an embodiment, however, an edge wall may consist of multiple separated plates according to the length direction.

[0014] The first edge wall comprises a first edge surface, and the second edge wall comprises a second edge surface. Both edge surfaces are directed outwardly, thus facing away from the open channel defined by the channel portion. The two elongated profiles are positioned with their first edge surfaces facing each other, and their second edge surfaces facing each other, thereby forming a hollow column. In this, the channel portion of the first elongated profile and the channel portion of the second elongated profile together define an internal channel, the latter being a cavity enclosed by both channel portions. Typically, the first edge surfaces of both elongated profiles are in direct contact with each other, and the second edge surfaces of both elongated profiles are in direct contact with each other. It is also possible, however, that an additional element is positioned between the opposing first edge surfaces and/or between the opposing second edge surfaces.

[0015] The two elongated profiles are joined together to form the load-bearing column. The load-bearing column extends in a longitudinal direction or length direction, corresponding to the axial direction or height direction of the column. For joining the profiles together, the opposing first edge walls - of the first and second elongated profile - are joined at multiple connection spots along the length, and the opposing second edge walls - of the first and second elongated profile - are joined at multiple connection spots along the length. The two profiles are thus connected spotwise, at multiple separated connection spots provided at the opposing first edge walls, and at multiple separated connection spots provided at the opposing first edge walls, the connection spots being located inside the internal channel of the column and being distributed along the length of the column.

[0016] The joint provided at any of the connection spots is such that there is no play in the connection at the connection spots. A play-free connection is thus provided at any of the connection spots, for connecting the opposing first edge walls and connecting the opposing second edge walls. Thus, the type of joint is such that no small movements are possible of the opposing edge walls with respect to each other at the spot where they are connected. Such a play-free connection may e.g. be obtained due to plastically deforming material of the opposing edge walls in the region where they are connected. For example, a fastener such as a thread-forming self-tapping screw or a self-piercing rivet may be used to form the joint, thereby obtaining plastically deformed regions in the opposing edge walls that perfectly fit with the fastener's outer surface. As no clearances or gaps are present between the plastically deformed edge wall materials and the fastener's outer surface, the play-free connection is established. In another embodiment, the play-free connection may be obtained due to plastically forming an interlock between the opposing edge walls, without using a fastener, like in a clinching type of connection. In this case, no clearances or gaps are present between the plastically deformed material of the first edge wall and the plastically deformed material of the second edge wall, thereby establishing the play-free connection.

[0017] In any of the embodiments, the play-free connections at the respective connection spots results in establishing a sliding-rigid connection between the respective opposing edge walls. A sliding-rigid connection means that the opposing edge walls do not slide with respect to each other, or over each other, when being used in the columns of the construction. The established connection may also be referred to as sliding-free, slip-free, slip-resistant or shear-rigid. In a preferred embodiment, the two elongated profiles are joined by relying only on the aforementioned play-free joints at the internally located connection spots, without relying on any other connection means.

[0018] The composed column further comprises access holes, provided in the first and/or second elongated profile, and distributed over the length of the first and/or second profile. The access holes are placed such that any of the connection spots is accessible via at least one of the access holes during joining the two elongated profiles. This means that during assembly of the column, an access hole is used to enter the internal cavity of the column, e.g. with a tool, thereby reaching the spot at the opposing edge walls where the joint is to be formed. For example, a self-tapping fastener, attached to the front end of a tool, e.g. an impact screw gun or socket wrench, may be inserted via the access hole for installing the fastener at the corresponding connection spot. Thus, there is a first group of access holes, distributed along the length of the column, giving access to the connection spots at the opposing first edge walls, and a second group of access holes, distributed along the length of the column, giving access to the connection spots at the opposing second edge walls. Preferably, the access holes are limited in size, in order not to adversely affect the buckling resistance and bending strength of the column.

[0019] Access holes may be present in the base wall of the first and/or second profile, or in one of the side walls of the first and/or second profile, or in both side walls of the first and/or second profile, or in any combination of the base and side walls of the first and/or second profile. Typically, one of the profiles or both profiles comprise a series of access holes distributed along the length of the profile, wherein e.g. every access hole is placed at the same length or height position as a particular connection spot, thereby giving access to the particular connection spot. In an embodiment, there is one access hole per connection spot, e.g. when the type of joint allows for a one-sided installation. In this case, the number of access holes equals the number of connection spots. In another embodiment, there are two access holes per connection spot, such that the amount of access holes is twice the number of connection spots.

[0020] In an embodiment, each of the access holes is provided in a base wall, of the first or the second elongated profile. In this case, a connection spot may be reached by entering the cavity in a direction substantially perpendicular to the base wall, thereby reaching the opposing edge walls being flat plates parallel to the direction of the base walls. Per connection spot, only one access hole may be present, in one of the base walls, or two access holes may be present, in each of the base walls. In an embodiment, any of the access holes comprised in the first group, thus giving access to connection spots located at the opposing first edge walls, are provided in the base wall of the first elongated profile, and any of the access holes comprised in the second group, thus giving access to connection spots located at the opposing second edge walls are provided in the base wall of the second elongated profile. In another embodiment, the access holes comprised in the first group, thus giving access to connection spots located at the opposing first edge walls, are distributed between the base wall of the first profile and the base wall of the second profile, e.g. in an alternating way. Similarly, the access holes comprised in the second group, thus giving access to connection spots located at the opposing first edge walls, may be distributed between the base wall of the first profile and the base wall of the second profile, e.g. in an alternating way.

[0021] In another embodiment, each of the access holes is provided in a side wall, of the first or the second elongated profile. For example, the first and second edge walls of both elongated profiles may be hook-shaped, each of the edge walls comprising a plate in a direction substantially perpendicular to the side wall and a plate in a direction substantially parallel to the side wall. In mounted condition, the hooks of the opposing edge walls may be in contact with one another. The access holes may be provided at the first and second side wall of one of the elongated profiles, or they may be provided at the first side wall of the first profile and the second side wall of the second profile. Thus, a connection spot at the opposing first or second edge walls may be reached by entering the cavity through an access hole in a side wall of the first or second profile, thus entering in a direction substantially perpendicular to the side wall, thereby reaching the portion of the edge walls which is parallel to the direction of the side walls.

[0022] After forming the joints during assembly of the column, the access holes may be left open, i.e. perforations along the length are present in the column when being used in the construction. In another embodiment, the access holes may be closed after having formed the joints, for example by means of caps a or a filling material.

[0023] By virtue of the provided access holes, the elongated profiles can be joined in a very easy and fast way, only requiring simple tools that can be operated by construction workers at the construction site. It suffices, for example, to screw self-tapping fasteners into the edge walls by means of a manually operated tool such as a an impact screw gun or socket wrench. As such, columns may easily be assembled on site, without requiring automated machines or installations that are only usable in a production environment. Moreover, despite the simple joint technique, yet a column with excellent strength characteristics is obtained. Indeed, surprisingly it was found that the play-free connections at the connection spots along the length, result in a column having the same level of buckling resistance, bending stiffness in all planes, torsional rigidity or torsional stiffness, and general shape stability, as for a tubular column. Such strength characteristics would not be obtainable if another type of simple joint like classical screws would be used, the latter entailing some play in the connection, however limited that play may be. Thus, the invention brings the advantage that a stiff and shape-stable column is obtained, without increasing the profile weight, and without requiring expensive tubular columns or requiring complex installations to assemble columns in a production plant. Accordingly, the individual profiles, e.g. C- or sigma-shaped, may be compactly stacked during transport, thus allowing for a reduced transport cost.

[0024] Furthermore, due to the presence of access holes, the joints may be applied at the inside of the hollow column, without having to enter the internal cavity via the open ends of the column, the latter being infeasible with the tools available at a construction site. The internally located joints have the advantage that they are less prone to corrosion and damage. Moreover, the outer borders of the edge walls - often being more corrosion sensitive as they correspond to the saw cuts when cutting the profile plate from a galvanised strip of material - are located at the inside of the column, so that any occurring corrosion will have no technical or visual effect. Finally, as no weld seams are applied at the outside of the elongated profiles, the galvanized coating of the profiles is not affected, thereby optimally retaining corrosion resistance without requiring an aftertreatment on site like painting or galvanising.

[0025] Optionally, according to claim 2, material of the opposing first edge walls and material of the opposing second edge walls is plastically deformed at the connection spots due to formation of the joints, such that the plastically deformed materials of the opposing first respectively second edge walls fit with one another and/or each fit with a fastener's outer surface, without leaving any intermediate clearances. This implies that by forming the joint, the opposing edge walls are locally deformed, involving a local plastic deformation. In an embodiment, a fastener is used to form the joint, and the plastic deformation results from installing the fastener, the fastener e.g. being a self-tapping fastener like a self-tapping screw or a flow-drilling screw. In this way, the plastically deformed regions of the opposing edge walls perfectly fit with the fastener's outer surface, e.g. the screw's outer surface. As no clearances or gaps are present between the plastically deformed edge wall materials and the fastener's outer surface, a play-free connection is established. In another embodiment, the fastener is also plastically deformed during installation, the fastener e.g. being a self-piercing rivet. In this case, no clearances are present between the plastically deformed regions of the two opposing edge walls, and no clearances are present between the plastically deformed edge walls and the fastener's outer surface, thereby obtaining the play-free connection. In yet another embodiment, no fastener is used, but an interlock is created between the plastically deformed materials, e.g. by means of a clinching technique. In this case, no clearances are present between the plastically deformed material of the first edge wall and the plastically deformed material of the second edge wall, thereby establishing the play-free connection. Relying on a plastic deformation to establish a play-free connection has the advantage that a reliable joint is created, not being dependent on creating sufficient friction between both opposing surfaces, the latter being difficult to obtain when galvanised plates are used. Moreover, an inexpensive type of fasteners can be used, that also allow for a fast assembly.

[0026] Optionally, the joint at any of the connection spots is established by means of a fastener, the fastener being placed through a hole in the opposing first or second edge walls. The final holes in the edge walls, wherein the fastener is found, may be formed during installing the fastener. When fasteners are used to form the joints at the connection spots, an access hole gives access for installing the fastener, i.e. the fastener can be inserted through an access hole for reaching the connection spot. In a preferred embodiment, after installing the fastener, it is completely located inside the column's internal channel, and no portions or elements of the fastener are located at the outside of the column.

[0027] Optionally, according to claim 3, the joint at any of the connection spots is established by means of a fastener, the fastener being placed through a hole in the opposing first or second edge walls, and the shape of the hole results from plastically deforming the opposing first respectively second edge walls while forming the joint, such that the plastically deformed edge wall materials fit with the outer surface of the fastener without leaving any intermediate clearances. For example, before applying the fastener not any hole may be present in the edge walls, or a pilot hole may be present adapted to receive the fastener's front end.

[0028] Optionally, according to claim 4, the joint provided at any of the connection spots allows for a one-side installation. This means that access to the connection spot from a single side suffices to apply the joint. This has the advantage that one access hole per connection spot is sufficient, thereby limiting the amount of material that is taken away from the profile's wall to provide the access holes. In this way, the buckling resistance and bending strength of the column are not adversely affected, or only to a minimal extent. Moreover, the one-side installation allows for a fast application of the fasteners, and thus a reduced assembly time. In an embodiment, a blind fastener is used to form the joint from one side, like a self-tapping screw or a blind rivet.

[0029] Optionally, the joint at any of the connection spots is established by means of a self-tapping fastener. A self-tapping fastener is a fastener that can tap its own thread as it is driven into the material, for example it is a self-tapping screw. In a preferred embodiment, the used self-tapping screw is not self-drilling, wherein a self-drilling type of screw refers to screws having a tip shaped like a drill head and thus being able to drill a hole into the material without requiring a pilot hole. Accordingly, self-tapping screws that are not self-drilling typically require a pilot hole to allow insertion of the screw. Using self-tapping screws that are not self-drilling has the advantage that they are typically strong enough to pierce through relatively thick plates, e.g. 3 to 5 mm thickness, in high-strength steel. Moreover, typically they have a larger diameter than self-drilling screws, thereby being able to withstand substantial forces occurring in the connections between large profiles. Finally, in case of a self-drilling screw, steel fibres are removed and end up on the profiles, thereby entailing a risk for corrosion.

[0030] Optionally, according to claim 5, the self-tapping fastener is a thread-forming self-tapping screw. A thread-forming self-tapper is a fastener that displaces material without removing it. It distinguishes from a thread-cutting self-tapping screw, wherein thread-cutting refers to that fact that material is removed as the screw is inserted. When a thread-forming self-tapping screw is driven into the material, the material is pushed away by the screw, the material thus being plastically deformed. The thread-forming self-tapping screw must be of a type such that both opposing edge walls are plastically deformed, and in installed condition no clearances or gaps are present between the screw's outer surface and the plastically deformed region of the edge wall of the first profile, and between the screw's outer surface and the plastically deformed region of the edge wall of the second profile. Using thread-forming self-tapping screws has the advantage that a connection without play can be guaranteed, as they result in precisely fitted threads. Moreover, a cheap type of fasteners can be used, and the access holes may be small, the latter avoiding that taking away a substantial amount of material form the profile's walls would affect the strength properties of the column. Finally, the thread-forming self-tapping screws allow for a fast assembly, and for a reliable and durable joint.

[0031] Optionally, according to claim 6, the joint at any of the connection spots is established by means of a self-tapping screw, the self-tapping screw being tapered, across at least a portion of its length. In an embodiment, the threaded part of the fastener comprises a first portion which is not tapered, and a second portion which is tapered, the first portion being located near the head of the fastener, and the second portion being located near the tip of the fastener. The tapered second portion is such that it becomes narrower, in a direction from head to tip. In another embodiment, the threaded part of the fastener is tapered along its whole length, wherein it becomes narrower in a direction from head to tip. Using self-tapping screws with a tapered section has the advantage that while applying the fastener, the material of the edge walls is gradually deformed, thereby gradually pushing away the material and forming the play-free connection. Moreover, due to the tapered shape of the screws, the two profiles, which may have a slight bend longitudinally, become aligned with respect to each other while screwing the fastener. In this way, both profiles are perfectly positioned relatively to one another, such that the outer border of the obtained column is nicely rectangular, without one of the profiles extending laterally from the other profile.

[0032] Optionally, according to claim 7, one access hole is provided per connection spot. This has the advantage that less material is taken away from the profile's walls, thereby minimally affecting the strength characteristics of the column.

[0033] Optionally, according to claim 8, any of the access holes is placed at the same length position as one of the connection spots, thereby giving access to that connection spot. The length position refers to the position at the column according to the length direction; it may also be referred to as the height position with respect to the mounted column. In an embodiment, the joint at any of the connection spots is established by means of a fastener, and for any of the connection spots, the fastener is at the same length position as an access hole. This means that the central axis of the fastener is in line with the central axis of the access hole.

[0034] Optionally, according to claim 9, a first series of access holes, giving access to the connection spots located at the opposing first edge walls, is provided in the base wall of the first elongated profile, and a second series of access holes, giving access to the connection spots located at the opposing second edge walls, is provided in the base wall of the second elongated profile. Thus, one row of access holes, distributed along the length, is present in the base wall of the first profile, and another row of access holes, distributed along the length, is present in the base wall of the second profile. Such a pattern of access holes has the advantage that the first and second elongated profile may be identical parts, contributing to ease of manufacturing and assembly.

[0035] Optionally, according to claim 10, any of the access holes has a circular shape, with a diameter between 20 mm and 35 mm. This implies that the access holes are provided as small perforations, thereby not taking away more material than is needed just for giving access to the connection spots, and thus minimally affecting the strength characteristics of the column. In particular, an advantage of using access holes being sufficiently small in size, is that the buckling resistance and bending strength of the column is not adversely affected.

[0036] Optionally, according to claim 11, the opposing first edge walls are joined by a first series of joints along the length, and the opposing second edge walls are joined by a second series of joints along the length, wherein the distance, measured along the length, between two consecutive joints of the first series, and the distance, measured along the length, between two consecutive joints of the second series, is maximum 80 cm, preferably maximum 60 cm, more preferably maximum 50 cm. Thus, the interval distance between two consecutive joints is at most 80 cm.

[0037] Optionally, according to claim 12, the construction comprising a structure of which the load is completely carried by the one or more load-bearing columns. For example, the structure, being supported by the columns, is a roof structure, a floor structure or a storage platform. This implies that in the construction no other elements than the invented columns are used for carrying the structure's weight. In an embodiment, the construction is a carport or solar carport. In other possible embodiment, the construction is a high-bay storage rack or the skeleton of a building.

[0038] According to a second aspect of the present invention, the above identified objectives are realized by a method for assembling a construction comprising one or more load-bearing columns, defined by claim 13, the method comprising:
  • assembling the one or more columns by, for each of the columns:

    ∘ providing a first and a second elongated profile, the first and second elongated profile extending in length direction, and each comprising:

    ▪ a channel portion, comprising two opposing side walls positioned at both sides of a base wall, the side walls and base wall together defining an open channel;

    ▪ an edge portion, comprising a first and a second edge wall, each extending from an end of a respective side wall, and comprising a first respectively second edge surface facing away from said open channel,

    wherein access holes distributed along the length are provided in the base wall or a side wall of the first elongated profile and/or in the base wall or a side wall of the second elongated profile;

    ∘ positioning the two elongated profiles with their first edge surfaces facing each other, and their second edge surfaces facing each other, such that an internal cavity is defined by the two respective channel portions;

    ∘ joining the two elongated profiles together to form the load-bearing column, by joining both the opposing first edge walls and opposing second edge walls of the two elongated profiles at multiple connection spots distributed along the length, wherein:

    ▪ the connection spots are located inside the internal channel, any of the connection spots being accessible via one of the access holes during joining the two elongated profiles, and

    ▪ the joint provided at any of the connection spots is such that there is no play in the connection at the connection spots, thereby establishing a sliding-rigid connection between the respective opposing edge walls;

  • mounting the one or more columns and mounting a structure, such that structure is carried by the one or more load-bearing columns, the columns thereby at least being subjected to axial load.


[0039] The construction, load-bearing columns, elongated profiles and structure, and their features, are defined as with respect to the first aspect of the invention. Apart to axial load, the columns may be subjected to other types of load, e.g. a bending moment.

[0040] Optionally, according to claim 14, for each of the columns, pilot holes are present in the first and second edge walls of the first and second elongated profile, and joining the opposing first edge walls and joining the opposing second edge walls is done by means of fasteners, wherein a fastener is inserted through overlapping pilot holes in the first respectively second edge walls at any of the connection spots. In this way, during inserting the fastener, material of the first respectively second edge walls is plastically deformed, thereby obtaining a hole in the respective edge wall being larger than the original pilot hole. Providing pilot holes has the advantage that the fasteners, e.g. self-tapping fasteners, may be accurately positioned and easily driven into the material.

[0041] Optionally, according to claim 15, at least some of the pilot holes are provided as an elongated slot, having straight opposing borders. In a preferred embodiment, any of the pilot holes is provided as an elongated slot. The straight opposing borders are substantially parallel. Moreover, the slots are oriented such that, when positioning the two elongated profiles with their first and second edge surfaces facing each other, the slots of the first elongated profile are rotated over 90 degrees with respect to the slots of the second elongated profile, resulting in a square-shaped overlap between two opposing slots, for receiving the fastener. The elongated slots, serving as pilot holes, may e.g. being rectangular or stadium-shaped. A slot comprised in the first profile is rotated over 90 degrees with respect to the corresponding slot comprised in the second profile. For example, any of the slots extends in a direction which is angled with respect to the longitudinal direction, e.g. at an angle of 45 degrees, but the slots of the first profile are rotated over 90 degrees compared to the slots of the second profile. Using such elongated slots as pilot holes has the advantage that overlapping slots always result in the same square overlapping hole, even when the two elongated profiles are not perfectly aligned. More freedom is thus obtained in aligning the two profiles with respect to each other.

[0042] In a preferred embodiment, the fasteners have a shape that is adapted to the dimensions of the square overlapping hole. For example, a fastener has a tapered threaded portion, of which the diameter at the tip end is smaller than the diameter of the inscribed circle of the square overlap, while the diameter at the head end is larger than the diameter of the inscribed circle of the square overlap. In this way, the fastener will tap itself in the overlapping hole, and will deform the borders of the elongated slots during insertion. Thus, after having installed a fastener, the opposing borders of an elongated slot are not parallel anymore, but are partially deformed at the position where the fastener is in contact with the border. Accordingly, in mounted condition of the columns, any of the columns comprises the aforementioned elongated slots, the slots being deformed during forming the joints.

[0043] According to a further independent aspect of the invention, a method is described for anchoring the load-bearing column in a ground surface, the method comprising:
  • providing a column, the column being assembled according to the second aspect of the invention;
  • providing a concrete casting, comprising a central recess adapted for receiving the bottom part of the column;
  • positioning the concrete casting into a pit in the ground surface;
  • positioning the column in the central recess, such that it is supported by the concrete casting;
  • filling the remaining space between the bottom part of the column and the concrete casting with concrete.


[0044] Optionally, the space between the outer surface of the concrete casting and the walls of the pit is filled with screed, for fixing the concrete casting. Further optionally, one or more apertures are provided in the surface of the bottom part of the column, such that concrete may run into the internal channel of the column. Further optionally, a portion of the of the internal channel of the column may be filled with concrete, the concrete being inserted from the top end of the hollow column.

Brief Description of the Drawings



[0045] 

Fig. 1 illustrates a construction, namely a structure for a solar carport, according to an embodiment of the invention.

Fig. 2 gives a 3D view of an assembled column, according to an embodiment of the invention.

Fig. 3 and Fig. 4 give a 3D view of a first respectively second elongated profile, according to an embodiment of the invention.

Fig. 5 gives a transverse cross section of an assembled column, according to an embodiment of the invention.

Fig. 6 illustrates a self-tapping screw, according to an embodiment of the invention.

Fig. 7 and Fig. 8 each give a transverse cross section of an assembled column, according to other possible embodiments of the invention.

Fig. 9 illustrates the presence of elongated slots in the edge walls, serving as pilot holes, according to an embodiment of the invention.

Fig. 10 and Fig. 11 each give a 3D view of a column, to which two beams are attached, according to an embodiment of the invention.

Fig. 12 illustrates the anchoring of a column in the ground, according to an embodiment of the invention.


Detailed Description of Embodiment(s)



[0046] Fig. 1 shows a construction 100, according to a possible embodiment of the invention. The shown construction 100 serves as a carport, placed at a large parking space, and adapted to mount solar panels on top. The construction 100 comprises columns 200 and a roof structure 101, the latter being carried by the columns 200. The roof structure 101 comprises beams 801, 802 and purlins 102. In the construction 100, the weight of the roof structure 101 is carried by the columns 200, the latter serving as load-bearing columns 200. The columns 200 are subjected to axial load and bending moments.

[0047] Fig. 2 gives a closer view on a load-bearing column 200, the latter being in assembled condition. The column 200 extends in X-direction 204, also referred to as the vertical direction, length direction, or height direction. The assembled column 200, comprise a first elongated profile 201 and a second elongated profile 202. In the shown embodiment the elongated profiles 201, 202 are structural steel profiles, made of galvanised steel. The two elongated profiles 201, 202 are joined together, at multiple connection spots distributed along the length, thereby forming the load-bearing column 200. The column 200 is hollow, having an internal cavity or internal channel 203.

[0048] Fig. 3 shows the first elongated profile 201, and Fig. 4 shows the second elongated profile 202. In the shown embodiment both elongated profiles 201, 201 are identical parts. In Fig. 3 and Fig. 4, the elongated profiles 201, 202 are shown in the condition before assembly, i.e. before being joined together.

[0049] In the embodiment shown in Fig. 3, the first elongated profile 201 is a C-profile. It comprises a channel portion, the channel portion comprising a base wall 303 and two opposing side walls 301, 302. The first side wall 301 and the second side wall 302 are substantially parallel, both being substantially perpendicular to the base wall 303. The channel portion is thus U-shaped, wherein the base wall 303 and side walls 301, 302 together define an open channel 304. The first elongated profile 201 further comprises an edge portion, the edge portion comprising a first edge wall 305 and a second edge wall 306. The first edge wall 305 extends from the first side wall 301, i.e. it is connected to the side wall's 301 end but protrudes from the plane in which the first side wall 301 is situated. Similarly, the second edge wall 306 extends from the second side wall 302. Both edge walls 305, 306 are provided as flat plates lying in the same plane. They are directed inwardly, towards the open channel 304, i.e. both edge walls 305 and 306 are directed such that they are pointing towards one another. The first edge wall 305 comprises a first edge surface 309, and the second edge wall 306 comprises a second edge surface 310, both edge surfaces 309, 310 facing away from the open channel 304 and being directed downwards in Fig. 3.

[0050] Fig. 3 further shows that the base wall 303 comprises a first series of access holes 300, provided as circular perforations distributed along the length of the profile 201. The access holes 300 are arranged in a longitudinal row, this row being placed in the portion of the base wall 303 opposing the first edge wall 305. Finally, Fig. 3 shows that the first edge wall comprises elongated slots 307, serving as pilot holes, which will be described in more detail below.

[0051] In the embodiment shown in Fig. 4, the second elongated profile 202 is a C-profile. It comprises a channel portion, the channel portion comprising a base wall 403 and two opposing side walls 401, 402. The first side wall 401 and the second side wall 402 are substantially parallel, both being substantially perpendicular to the base wall 403. The channel portion is thus U-shaped, wherein the base wall 403 and side walls 401, 402 together define an open channel 404. The second elongated profile 202 further comprises an edge portion, the edge portion comprising a first edge wall 405 and a second edge wall 406. The first edge wall 405 extends from the first side wall 401, i.e. it is connected to the side wall's 401 end but protrudes from the plane in which the first side wall 401 is situated. Similarly, the second edge wall 406 extends from the second side wall 402. Both edge walls 405, 406 are provided as flat plates lying in the same plane. They are directed inwardly, towards the open channel 404, i.e. both edge walls 405 and 406 are directed such that they are pointing towards one another. The first edge wall 405 comprises a first edge surface 409, and the second edge wall 406 comprises a second edge surface 410, both edge surfaces 409, 410 facing away from the open channel 404 and being directed upwards in Fig. 4.

[0052] Fig. 4 further shows that the base wall 403 comprises a second series of access holes 400, provided as circular perforations distributed along the length of the profile 202. The access holes 400 are arranged in a longitudinal row, this row being placed in the portion of the base wall 403 opposing the second edge wall 406. Finally, Fig. 4 shows that the first edge wall 405 comprises elongated slots 407, and that the second edge wall 406 comprises elongated slots 408. The slots 407, 408, serving as pilot holes, will be described in more detail below.

[0053] Fig. 5 gives a cross section of the column 200, in assembled condition, i.e. after joining the first and second elongated profile 201, 202 together. In the assembled condition, the two elongated profiles 201, 202 are positioned such that their first edge surfaces 309, 409 are facing each other and their second edge surfaces 310, 410 are facing each other. In the shown embodiment the edge surfaces 309, 409 are in direct contact and the edge surfaces 301, 410 are in direct contact with one another. In joined condition, the channel portion of the first elongated profile 201 and the channel portion of the second elongated profile together define an internal channel 203, corresponding to the internal cavity of the hollow column 200.

[0054] The opposing first edge walls 305, 405, of the first 201 and second elongated profile 202 respectively, are joined at multiple connection spots 503. The connection spots 503 are located inside the internal channel 203 and are distributed over the length of the column 200. The first edge walls 305, 405 are thus joined spotwise, via a first series of mutually separated connection spots along the length, of which one connection spot 503 is illustrated in Fig. 5. Similarly, the opposing second edge walls 306, 406, of the first 201 and second elongated profile 202 respectively, are joined via a second series of mutually separated connection spots along the length, of which one connection spot 504 is illustrated in Fig. 5.

[0055] As is clear from Fig. 2 and Fig. 5, the access holes 300 in the first elongated profile 201 give access to the first series of connection spots 503, and the access holes 400 in the second elongated profile 202 give access to the second series of connection spots 504. In this embodiment, there is a single access hole 300, 400 per connection spot 503, 504, wherein any connection spot 503 of the first series has a corresponding access hole 300 in the first elongated profile 201, and any connection spot 504 of the second series has a corresponding access hole 400 in the second elongated profile 201. In the shown embodiment, a typical column length is between 3 and 5 meter, and the mutual distance between two consecutive connection spots, or between two consecutive access holes 300, is between 50 and 60 cm. The access holes 300, 400 are provided as small circular perforations, with a diameter between 20 mm and 35 mm.

[0056] In the embodiment show in Fig. 5, the joint at any of the connection spots is provided by means of fasteners 501, 502. The fastener 501 is placed through the opposing first edge walls 305, 405, and the fastener 502 is placed through the opposing second edge walls 306, 406. In the shown embodiment, the fasteners 501, 502 are thread-forming self-tapping screws, e.g. NONUT screws commercialized by SFS. When joining the elongated profiles 201, 202, screws 501 are inserted through the corresponding access holes 300, and driven into the opposing first edge walls 305, 405. For this purpose, a tool may be used, e.g. an impact screw gun. Similarly, screws 502 are inserted through the corresponding access holes 400, and driven into the opposing second edge walls 306, 406.

[0057] Fig. 5 shows that the central axis 507 of fastener 501 is in line with the central axis 505 of the corresponding access hole 300, and the central axis 508 of fastener 502 is in line with the central axis 506 of the corresponding access hole 400. In other words, every connection spot 503 resp. 504 or fastener 501 resp. 502 is at the same length or height position as the corresponding access hole 300 resp. 400.

[0058] Fig. 6 shows the self-tapping fastener 501, 502, extending between a head end 601 and a tip end 602. The fastener 501 comprises a head part 600 and an elongated part 603. The elongated part 603 comprises a threaded portion 604. The threaded portion 604 is tapered across a portion of its length, see 605, with an increasing diameter in a direction from the tip end 602 to the head end 601. When the fastener 501 is driven into a material, it taps its own thread, by pushing away the material, thereby plastically deforming the material without removing it. The fastener 501 is a blind fastener, thus allowing for a one-side installation and therefore a fast assembly.

[0059] Fig. 2 to Fig. 5 illustrate one specific embodiment of the invention. It is clear that other embodiments are possible, using a different type of elongated profiles, or having a different distribution or pattern of access holes. For example, in an embodiment, the column may be similar as in Fig. 2, but wherein the first group of access holes, giving access to the first series of connection spots 503, is partially provided in the base wall 303 of the first profile 201, and partially provided in the base wall 403 of the second profile 202, and similar for the second group of access holes. For example, within the first group of access holes, according to the length direction, an access hole in base wall 303 is alternated with an access hole in base wall 403, and similar for the second group of access holes.

[0060] Fig. 7 illustrates yet another embodiment. In the shown embodiment, the elongated profiles 7001, 7002 are sigma-profiles. The side walls 301, 302, 401, 402 and the edge walls 305, 306, 405, 406 have the same shape as in the embodiment of Fig. 2 to 5. However, the base wall 7003 of the first elongated profile 7001 and the base wall 7004 of the second elongated profile 7002 have a different shape than in the embodiment of Fig. 2-5. Indeed, both base walls 7003, 7004 are not provided as flat plates lying in one plane, but each comprise a longitudinal slit 7000 resp. 7005. In the shown embodiment, two profiles 7001, 7003 are connected in a similar way as in Fig. 2-5, by means of self-tapping fasteners 501, 502 through opposing edge walls.

[0061] Fig. 8 illustrates yet another embodiment, wherein the access holes are not provided in the base walls, but are provided in side walls. In this embodiment, the first elongated profile 8001 comprises a hook-shaped first edge wall, and a hook-shaped second edge wall. The first edge wall comprises a plate 8003 extending in a plane substantially parallel to the base wall 303, and a plate 8004 extending in a plane substantially parallel to the side wall 301. The second edge wall comprises a plate 8008 extending in a plane substantially parallel to the base wall 303, and a plate 8009 extending in a plane substantially parallel to the side wall 302. Similarly, the second elongated profile 8002 comprises a hook-shaped first edge wall, and a hook-shaped second edge wall. The first edge wall comprises a plate 8005 extending in a plane substantially parallel to the base wall 403, and a plate 8006 extending in a plane substantially parallel to the side wall 401. The second edge wall comprises a plate 8010 extending in a plane substantially parallel to the base wall 403, and a plate 8011 extending in a plane substantially parallel to the side wall 402. In assembled condition the hook-shaped opposing first edge walls are in contact with one another, and the hook-shaped opposing second edge walls are in contact with one another.

[0062] The first side wall 301 of the first elongated profile 8001 comprises access holes 8007, distributed along the length. The access holes 8007 allow a fastener 501 to be inserted into the internal cavity of the column, thereby giving access to a connection spot located at the portion of the opposing first edge walls that is parallel to the side walls. Indeed, in the shown embodiment, the fastener 501 is placed through the plates 8004 and 8006, wherein the central axis of the fastener 501 is in line with the central axis of the access hole 8007. Similarly, the second side wall 402 of the second elongated profile 8002 comprises access holes 8012, distributed along the length. The fastener 502 is placed through the opposing plates 8009 and 8011, wherein the central axis of the fastener 502 is in line with the central axis of the access hole 8012.

[0063] Pilot holes may be provided in the first and second edge walls of both profiles, serving as a starting point for the holes being tapped by the self-tapping fasteners. In the embodiment shown in Fig. 2 to 5, the pilot holes are provided as elongated slots 307, 407 in the first edge walls 305, 405, and elongated slots 308, 408 in the second edge walls 306, 406. Fig. 9 illustrates the opposing slots 308 and 408, in the condition wherein the second edge wall 306 of the first profile 201 is positioned against the second edge wall 406 of the second profile 202. The same concept applies to the opposing slots 307, 407 of the opposing first edge walls 305, 405. The shape of the slots shown in Fig. 9 is their unaffected shape, i.e. before the fastener 502 was inserted.

[0064] Before joining the profiles, any of the elongated slots 307, 407, 308, 408 is stadium-shaped, having two parallel opposing borders. Moreover, any of the slots 307, 407, 308, 408 extends in a direction which is at an angle of 45 degrees with respect to the length direction. In the condition of Fig. 9, the opposing slots 308, 408 are rotated over 90 degrees with respect to each other. Similarly, the opposing slots 307, 407 are rotated over 90 degrees with respect to each other. Fig. 9 shows that the overlapping slots 308 and 408 result in a square-shaped overlap hole 700. Fig. 9 further illustrates how the dimensions of the fastener 501, 502 relate to the dimensions of the square-shaped overlap 700. The figure shows the maximum diameter 702 of the fastener's tapered portion 605 and the minimum diameter 701 of the tapered portion. The minimum diameter 701 is smaller than the inscribed circle of the square overlap 700, while the maximum diameter 702 is larger than the inscribed circle of the square overlap 700.

[0065] When inserting the fastener 501, 502, it will tap itself in the overlapping hole 700, and will gradually deform the borders of the elongated slots 308, 408 during insertion. Due to the tapered shape of the fasteners 501, 502, the two elongated profiles are gradually aligned with respect to each other when inserting the fastener. After having installed a fastener 501, 502, the parallel borders of an elongated slot 308, 408 are not straight anymore, but are partially deformed at the position where the fastener 501, 502 is in contact with the border. In particular, the edge walls materials are plastically deformed locally, wherein the plastically deformed borders of the slots 308, 408 perfectly fit with the outer surface of the threaded portion 604. In this way, a joint is formed wherein no clearances remain between the outer surface of the threaded portion 604 and the plastically deformed edge wall materials, thereby establishing a connection without play at the connection spot. It is clear however, that in the region where the slot borders are not deformed due to insertion of the fastener, a gap remains between the slot border and the fastener's outer surface. These gaps, however, do not cause play in the connection being formed between the opposing edge walls at the connection spots.

[0066] Due to the multiple play-free connections along the length, a sliding-rigid connection is established between the opposing edge walls. Simulation results show that assembling a column 200 in this way, results in a column having the same level of buckling resistance, torsional rigidity, and general shape stability as for a tubular column. The simulations were done for two C-profiles, made of S450 steel, with 4 mm plate thickness and having a cross section with the following dimensions: 400 mm (base wall dimension), 100 mm (side wall dimension), 35 mm (edge wall dimension). When the two C-profiles are connected according to an embodiment of the invention, using self-tapping NONUT screws, an effective moment of inertia Iz around the weak axis, representing the degree of bending stiffness and buckling resistance, is obtained of 2402 cm4, and an effective torsional moment of inertia It, also referred to as torsional constant It, representing the torsional rigidity and resistance against second order deformations, of 8070 cm4. These It and Iz values are substantially larger compared to a solution wherein the two C-profiles are connected, either back-to-back or belly-to-belly, by means of classical bolts and nuts (Iz = 574 cm4; It = 2.60 cm4), and compared to a solution wherein the two C-profiles are welded with their base walls against one another (Iz = 942 cm4; It = 2.60 cm4).

[0067] Fig. 10 and Fig. 11 further illustrate how the column 200 is used in the construction 100. Two beams 801, 802, provided as C-profiles are attached to the opposing base walls of the column 200. The beams 801, 802 may be connected to the column 200 by means of fasteners 800, e.g. self-tapping screws or classical bolts and nuts. During assembly of the construction 100, the beam 801 may be connected to the first elongated profile 201, and the beam 802 connected to the second elongated profile 202, before the two elongated profiles 201, 202 are joined to form the column 200. Using blind fasteners is thus not required for connection the beams 801, 802 to the column 200, such that classical bolts and nuts may suffice.

[0068] Fig. 12 illustrates how the column 200 is anchored in the ground surface 1000. A pit is made in which a prefabricated concrete casting 1002 is inserted and fixed by means of screed 1001. The concrete casting 1002 has a U-shaped cross section, with a central recess for receiving the column's bottom end. The column 200 is positioned such that it is supported by the concrete casting 1002, and the remaining space 1003 between the column's bottom part 200 and the concrete casting 1002 is filled with concrete. The column 200 is provided with apertures 1004 to allow the concrete to run into the internal cavity of the column 200. Furthermore, a portion of the internal cavity may be filled with concrete 1005, the concrete being inserted from the top end of the hollow column 200.

[0069] Although the present invention has been illustrated by reference to specific embodiments, it will be apparent to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied with various changes and modifications without departing from the scope thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. In other words, it is contemplated to cover any and all modifications, variations or equivalents that fall within the scope of the basic underlying principles and whose essential attributes are claimed in this patent application. It will furthermore be understood by the reader of this patent application that the words "comprising" or "comprise" do not exclude other elements or steps, that the words "a" or "an" do not exclude a plurality, and that a single element, such as a computer system, a processor, or another integrated unit may fulfil the functions of several means recited in the claims. Any reference signs in the claims shall not be construed as limiting the respective claims concerned. The terms "first", "second", third", "a", "b", "c", and the like, when used in the description or in the claims are introduced to distinguish between similar elements or steps and are not necessarily describing a sequential or chronological order. Similarly, the terms "top", "bottom", "over", "under", and the like are introduced for descriptive purposes and not necessarily to denote relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances and embodiments of the invention are capable of operating according to the present invention in other sequences, or in orientations different from the one(s) described or illustrated above.


Claims

1. Construction (100) comprising one or more load-bearing columns (200), the columns (200) being structural members subjected to axial load,

wherein any of the load-bearing columns (200) comprises a first (201) and a second elongated profile (202), the first (201) and second elongated profile (202) extending in length direction (204), and each comprising:

- a channel portion, comprising two opposing side walls (401, 402) positioned at both sides of a base wall (403), the side walls (401, 402) and base wall (403) together defining an open channel (404);

- an edge portion, comprising a first (405) and a second edge wall (406), each extending from an end of a respective side wall (401, 402) in a direction towards the open channel (404), and comprising a first (409) respectively second edge surface (410) facing away from said open channel (404),

wherein the two elongated profiles (201, 202) are positioned with their first edge surfaces (309, 409) facing each other, and their second edge surfaces (310, 410) facing each other, such that an internal channel (203) is defined by the two respective channel portions, the two elongated profiles (201, 202) being joined together to form the load-bearing column (200),

CHARACTERIZED IN THAT:

both the opposing first edge walls (305, 405) and the opposing second edge walls (306, 406) of the two elongated profiles (201, 202) are joined at multiple connection spots (503, 504), located inside the internal channel (203) and distributed along the length,

wherein the joint provided at any of the connection spots (503, 504) is such that there is no play in the connection at the connection spots, thereby establishing a sliding-rigid connection between the respective opposing edge walls, and

wherein access holes (300, 400) distributed along the length are provided in the base wall (303, 404) or a side wall (301, 302, 401, 402) of the first elongated profile (201) and/or in the base wall or a side wall of the second elongated profile (202), any of the connection spots (503, 504) being accessible via one of the access holes (300, 400) during joining the two elongated profiles, and being left open or being closed afterwards.


 
2. Construction (100) according to any of the preceding claims,

wherein material of the opposing first edge walls (305, 405) and material of the opposing second edge walls (306, 406) is plastically deformed at the connection spots (503, 504) due to formation of the joints,

such that the plastically deformed materials of the opposing first (305, 405) respectively second edge walls (306, 406) fit with one another and/or each fit with a fastener's (501, 502) outer surface, without leaving any intermediate clearances.


 
3. Construction (100) according to any of the preceding claims,

wherein the joint at any of the connection spots (503, 504) is established by means of a fastener (501, 502), the fastener (501, 502) being placed through a hole in the opposing first (305, 405) or second edge walls (306, 406), and

wherein the shape of the hole results from plastically deforming the opposing first respectively second edge walls while forming the joint, such that the plastically deformed edge wall materials fit with the outer surface of the fastener (501, 502) without leaving any intermediate clearances.


 
4. Construction (100) according to any of the preceding claims,
wherein the joint provided at any of the connection spots (503, 504) allows for a one-side installation.
 
5. Construction (100) according to any of the preceding claims,
wherein the joint at any of the connection spots (503, 504) is established by means of a self-tapping fastener (501, 502), the self-tapping fastener being a thread-forming self-tapping screw.
 
6. Construction (100) according to any of the preceding claims,
wherein the joint at any of the connection spots (503, 504) is established by means of a self-tapping screw (501, 502), the self-tapping screw being tapered, across at least a portion (605) of its length.
 
7. Construction (100) according to any of the preceding claims,
wherein one access hole (300, 400) is provided per connection spot (503, 504).
 
8. Construction (100) according to any of the preceding claims,
wherein any of the access holes (300, 400) is placed at the same length position as one of the connection spots (503, 504), thereby giving access to that connection spot.
 
9. Construction (100) according to any of the preceding claims,
wherein a first series of access holes (300), giving access to the connection spots (503) located at the opposing first edge walls (305, 405), is provided in the base wall (303) of the first elongated profile (201), and a second series of access holes (400), giving access to the connection spots (504) located at the opposing second edge walls (306, 406), is provided in the base wall (403) of the second elongated profile (202).
 
10. Construction (100) according to any of the preceding claims,
wherein any of the access holes (300, 400) has a circular shape, with a diameter between 20 mm and 35 mm.
 
11. Construction (100) according to any of the preceding claims,

wherein the opposing first edge walls (305, 405) are joined by a first series of joints along the length, and the opposing second edge walls (306, 406) are joined by a second series of joints along the length,

and wherein the distance, measured along the length, between two consecutive joints of the first series, and the distance, measured along the length, between two consecutive joints of the second series, is maximum 80 cm, preferably maximum 60 cm, more preferably maximum 50 cm.


 
12. Construction (100) according to any of the preceding claims,
the construction (100) comprising a structure (101) of which the load is completely carried by the one or more load-bearing columns (200), the structure (101) being a roof structure, a floor structure or a storage platform.
 
13. Method for assembling a construction (100) comprising one or more load-bearing columns (200), the method comprising:

- assembling the one or more columns (200) by, for each of the columns (200):

∘ providing a first (201) and a second elongated profile (202), the first (201) and second elongated profile (202) extending in length direction, and each comprising:

▪ a channel portion, comprising two opposing side walls (401, 402) positioned at both sides of a base wall (403), the side walls (401, 402) and base wall (403) together defining an open channel (404);

▪ an edge portion, comprising a first (405) and a second edge wall (406), each extending from an end of a respective side wall (401, 402), and comprising a first (409) respectively second edge surface (410) facing away from said open channel (404),

wherein access holes (300, 400) distributed along the length are provided in the base wall (303, 403) or a side wall (301, 302, 401, 402) of the first elongated profile (201) and/or in the base wall or a side wall of the second elongated profile (202);

∘ positioning the two elongated profiles (201, 202) with their first edge surfaces (309, 409) facing each other, and their second edge surfaces (310, 410) facing each other, such that an internal channel (203) is defined by the two respective channel portions;

∘ joining the two elongated profiles (201, 202) together to form the load-bearing column (200), by joining both the opposing first edge walls (305, 405) and opposing second edge walls (306, 406) of the two elongated profiles (201, 202) at multiple connection spots (503, 504) distributed along the length, wherein

▪ the connection spots (503, 504) are located inside the internal channel (203), any of the connection spots (503, 504) being accessible via one of the access holes (300, 400) during joining the two elongated profiles (201, 202), and

▪ the joint provided at any of the connection spots (503, 504) is such that there is no play in the connection at the connection spots, thereby establishing a sliding-rigid connection between the respective opposing edge walls;

- mounting the one or more columns (200) and mounting a structure (101), such that structure (101) is carried by the one or more load-bearing columns (200), the columns (200) thereby at least being subjected to axial load.


 
14. Method according to claim 13,

wherein, for each of the columns (200), pilot holes (307, 308, 407, 408) are present in the first (305, 405) and second edge walls (306, 406) of the first and second elongated profile (201, 202),

and wherein joining the opposing first edge walls (305, 405) and joining the opposing second edge walls (306, 406) is done by means of fasteners (501, 502), wherein a fastener is inserted through overlapping pilot holes (308, 408) in the first respectively second edge walls at any of the connection spots, such that during inserting the fastener (501, 502), material of the first (305, 405) respectively second edge walls (306, 406) is plastically deformed, thereby obtaining a hole in the respective edge wall being larger than the original pilot hole.


 
15. Method according to claim 14,

wherein at least some of the pilot holes are provided as an elongated slot (307, 308, 407, 408), having straight opposing borders,

and wherein the slots (307, 308, 407, 408) are oriented such that, when positioning the two elongated profiles (201, 202) with their first (309, 409) and second edge surfaces (310, 410) facing each other, the slots (307, 308) of the first elongated profile (201) are rotated over 90 degrees with respect to the slots (407, 408) of the second elongated profile (202), resulting in a square-shaped overlap (700) between two opposing slots (308, 408), for receiving the fastener (501, 502).


 




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Cited references

REFERENCES CITED IN THE DESCRIPTION



This list of references cited by the applicant is for the reader's convenience only. It does not form part of the European patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be excluded and the EPO disclaims all liability in this regard.

Patent documents cited in the description