Apparatus and Methods For Connecting Timber Flanges

Abstract

A method and apparatus for constructing a single story or multistory building using timber as a major structural material. The apparatus includes a connector plate having a series of pins extending therefrom. In a building component, each pin engages with a relatively small diameter timber flange by way of an axial bore hole formed in each flange. In this way, the flanges form a timber structural member useful in the formation of a framework of a building structure. The plate of the connector provides a fastener for fastening to other similar connectors or to other building structures. Various combinations of connectors and building flanges may be used to construct a single story building, and furthermore may be used in the construction of a multistory building.

Description

FIELD OF THE INVENTION

The present invention is directed to the field of building construction, and particularly the construction of multistorey buildings using timber as a major structural material.

BACKGROUND TO THE INVENTION

The stability of multistorey buildings is typically conferred using steel or reinforced concrete, or a combination of the two materials. A steel frame alone may be used in low rise buildings. For medium rise buildings either concrete or braced steel cores are typically used. For high rise buildings a concrete core may be used to facilitate the construction process. The core confers stability as steelwork is erected about the core. In some high rise buildings, an ‘exoskeleton’, may also be used to confer stability, this typically requiring substantial temporary works as the final stability system is only complete after a significant number of floors are erected.

The corrosion of steel as a component of reinforced concrete is a well known problem in building construction. Ideally, concrete provides adequate protection to the embedded steel by way of the protective alkaline environment provided by fresh concrete to form a protective coating on the surface of the steel, which protects it from corrosion. However, over time pH declines slowly and the alkaline conditions are lost, leading to increased probability of steel corrosion. Maintenance of an alkaline environment can be ensured by providing sufficient cement content, complete compaction and proper curing. However, these measures are firstly difficult to realize in practice fully and secondly the same are not found to be sufficient in hostile environments.

Corrosion is also a problem of structural steel beams used in building construction. Corrosion may be addressed by the use of a paint system comprising sequential coating application of paints or alternatively paints applied over metallic coatings to form a ‘duplex’ coating system. Protective paint systems usually consist of primer, intermediate/build coats and finish coats. Metallic coatings may be used such as by the processes of hot-dip galvanizing and thermal spraying. Eventually, such coating will break down and expose the underlying structural steel to the environment leading to corrosion.

Quite apart from the problems of corrosion, acceptable quality concrete or steel may not be available, or may not be available at an acceptable cost.

Taking into account environmental considerations, it is well known that the concrete industry is one of two largest producers of carbon dioxide, creating up to 5% of worldwide man-made emissions of this gas, of which 50% is from the chemical process and 40% from burning fuel. Clearly, the production of steel is a highly energy-consuming process (mainly due to the use of vast amounts of heat energy in smelting) and therefore a substantial contributor to carbon dioxide production.

As an alternative to steel and concrete, timber has been used in the construction of multistorey buildings. However, timbers having high cross-sectional areas must be used to provide the load bearing capacities and spans required. Such timbers are typically very expensive given the need to harvest the wood from the prime regions of very mature trees.

More recently, engineered timbers such as laminated veneer lumber (LVL) and glue laminated timber have been used in building construction. In producing these products, layers of wood are glued (laminated) together with heat, resin binder, and pressure to form a very strong structural member that can be produced in regular sizes and lengths. While generally effective, these wood products are expensive and therefore not useable in many applications. Furthermore, there is significant energy input required in production (mainly in heat energy) and also the use of chemicals (such as adhesive and binder).

Engineered timbers must be produced by very precise manufacturing methods, having rigorous QA and QC requirements. Accordingly, these products are not widely available and may need to be transported long distances to a building site. Where available, these products are expensive and may not be cost-effective for many applications.

It is an aspect of the present invention to overcome or ameliorate a problem of the prior art by providing materials and methods to construct a multistorey building deriving primary stability from neither steel nor concrete. It is a further aspect of the present invention to provide alternative materials and methods for building construction.

The discussion of documents, acts, materials, devices, articles and the like is included in this specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters formed part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date of each claim of this application.

SUMMARY OF THE INVENTION

In one aspect of the invention, but not necessarily the broadest aspect, the present invention provides a connector for collocating a group of timber flanges, the connector comprising a main region, the main region having extending therefrom a plurality of engaging members each of which is configured to engage with a timber flange.

In one embodiment of the first aspect, the main region comprises means for fastening the connector to a substantially similar or identical second connector.

In one embodiment of the first aspect, the main region comprises means for connecting the connector to a building structure.

In one embodiment of the first aspect, the main region comprises a first substantially planar region and a second substantially planar region, the first and second planar regions forming an angle of about 90 degrees, the first planar region comprising means for connecting the connector to a substantially similar or identical second connector, and the second planar region comprising means for connecting the connector to a building structure.

In one embodiment of the first aspect, the means for connecting the connector to a substantially similar or identical second connector or the means for connecting the connector to a building structure is an aperture configured to accept a fastener.

In one embodiment of the first aspect, the main region consists of, or comprises, a plate.

In one embodiment of the first aspect, the main region comprises a substantially planar face, and the group of engaging members extend substantially orthogonal from the planar face.

In one embodiment of the first aspect, the engaging members are disposed in an ordered array with reference to each other.

In one embodiment of the first aspect, the engaging members form a row, or a series of rows.

In one embodiment of the first aspect, the engaging members form a grid arrangement.

In one embodiment of the first aspect, the engaging members form a circle with a central engaging member at the origin, or two or more concentric circles.

In one embodiment of the first aspect, each of the plurality of the engaging members extends at least about 1 cm, 2 cm, 3 cm, 4 cm, 5 cm, 6 cm, 7 cm, 8 cm, 9 cm or 10 cm from the main region.

In one embodiment of the first aspect, each of the plurality of engaging members are substantially solid and have a cross sectional area greater than that of a 2 gauge nail.

In one embodiment of the first aspect, each of the plurality of engaging members are substantially solid and have a cross section area of at least about 0.01 cm², 0.02 cm², 0.03 cm², 0.04 cm², 0.05 cm², 0.06 cm², 0.07 cm², 0.08 cm², 0.09 cm², 0.1 cm², 0.2 cm², 0.3 cm², 0.4 cm², 0.5 cm², 0.6 cm², 0.7 cm², 0.8 cm², 0.9 cm², 1 cm², 2 cm², 3 cm², 4 cm², 5 cm², 6 cm², 7 cm², 8 cm², 9 cm² or 10 cm².

In one embodiment of the first aspect, each of the plurality of engaging members is a substantially linear member.

In one embodiment of the first aspect, each of the plurality of engaging members have substantially identical morphology.

In one embodiment of the first aspect, the connector comprises at least about 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34 or 36 engaging members.

In one embodiment of the first aspect, the main region consists of, or comprises, a plate and each of the plurality of engaging members is a dowel or pin extending from the plate.

In one embodiment of the first aspect, the connector is fabricated in whole or in part of a metal.

In one embodiment of the first aspect, the metal is corrosion resistant, or is treated so as to be corrosion resistant.

In one embodiment of the first aspect, the connector comprises a support member extending from the main region in a direction generally away from the engaging members.

In one embodiment of the first aspect, the connector is configured to end join a first group of timber flanges to a second group of timber flanges, the connector comprising a main region, the main region having extending therefrom a plurality of engaging members each of which is configured to engage with an axial bore of timber flange, the plurality of engaging members comprising a first group and a second group, wherein the first group extends in a first direction and the second group extends in a second direction.

In one embodiment of the first aspect, the main region comprises opposing first and second substantially planar faces, wherein the first group of the engaging members extend substantially orthogonal to the first planar face and the second group of engaging members extend substantially orthogonal to the second planar face.

In one embodiment of the first aspect, the number of engaging members in the first group is equal to the number of engaging members in the second group.

In one embodiment of the first aspect, each of the plurality of engaging members have substantially identical morphology.

In one embodiment of the first aspect, the first and/or second group of engaging members comprises about 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34 or 36 engaging members.

In one embodiment of the first aspect, the first and second group of engaging members are arranged substantially identically, and or have substantially identical morphology.

In a second aspect the present invention provides a building component comprising the connector according to any embodiment of the first aspect and a plurality of timber flanges, each of the timber flanges having an axial bore into which is received an engaging member.

In one embodiment of the second aspect, a longitudinal surface of each of the plurality of timber flanges contacts a longitudinal surface of at least one other timber flange.

In one embodiment of the second aspect, each of the plurality of timber flanges is a pole.

In one embodiment of the second aspect, each of the plurality of timber flanges is a true round or a peeler core.

In one embodiment of the second aspect, the longitudinal surface is formed by removing a longitudinal segment of each of the contacting flanges so as to provide a substantially planar surface.

In one embodiment of the second aspect, the longitudinal surface is formed by removing a longitudinal segment of upper and/or lower timber flanges so as to provide a bearing surface and/or a mounting surface respectively.

In one embodiment of the second aspect, two contacting timber flanges are secured together with a fastener extending at an angle to the long axes of the timber flanges.

In one embodiment of the second aspect, the building component comprises a second connector according to any embodiment of the first aspect, a first group of timber flanges collocated by the first connector and a second group of time flanges collocated by the second connector, the first and group of timber flanges oriented end-to-end, the first and second connectors being fastened together so as to form a structurally integral unit.

In one embodiment of the second aspect, the building component comprises a structural column, wherein the first and second connectors are disposed on, and fixed to, the upper face of the column (or the column top plate, where present) and the first connector is fastened to the second connector.

In one embodiment of the second aspect, the building component comprises the connector of the first aspect having a support member as a third connector, the support member of the third connector interposed between the first and second connector, and the first connector is connected to the second connector (optionally by way of the support member of the third connector).

In one embodiment of the second aspect, the building component of comprises a third group of timber flanges collocated by the third connector.

In one embodiment of the second aspect, the building component comprises the connector according to any embodiment of the first aspect as a fourth connector,

In one embodiment of the second aspect, the building component comprises a fourth group of timber flanges collocated by the fourth connector.

In one embodiment of the second aspect, the fourth connector is fastened to the first and second connectors.

In one embodiment of the second aspect, the first and second group of timber flanges are configured as joists, the third group of timber flanges is configured as column of a (n+1) storey of a building, and the fourth group of timber flanges is configured as column of a (n) storey of the building.

In a third aspect, the present invention provides a method of constructing a multistorey building, the method comprising the steps of providing the building component according to any embodiment of the second aspect or a connector of the first aspect.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1A is a diagram in perspective view of paired preferred connectors of the present invention, each collocating a series of four preferred stacked timber flanges.

FIG. 1B is an end view of the paired connectors shown in FIG. 1A

FIG. 2A is a diagram in lateral view of a preferred building component of the present invention comprising an upper vertical beam, a lower vertical beam and two horizontal beams. This embodiment is useful since the space disposed above the horizontal beams allows for the pouring of a concrete floor thereon.

FIG. 2B is a plan view of the building component shown in FIG. 2A.

FIG. 3 is a diagram in lateral view of a preferred building component of the present invention comprising an upper vertical beam, a lower vertical beam and two horizontal beams. Flooring may be laid on top of the horizontal beams.

FIG. 4 is a diagram in plan view of a preferred building structure of the present invention which may be used at the corner of a building,

FIG. 5A is a preferred modular building structure of the present invention. The modular structure may be repeated as often as required according to the floor space needed.

FIG. 5B shows a similar modular building structure to that shown in FIG. 5A, although constructed as two half modules which are bolted together along the median line.

FIG. 5C shows is a diagram in later view showing the formation of a beam having a ledge, the ledge support the end of a joist. Such structures may be useful in the modular embodiments of the invention shown in FIG. 5A or 5B.

FIG. 5D is a diagram in perspective view of connector plates used to end-join two sets of collocated timber flanges. Such means may be used where the flanges must span relatively long distances.

FIG. 6 is a diagram in perspective view showing a preferred building structure of the present invention configured to join four horizontal beams, an upper column and a lower column. For clarity, not all components of the structure are shown in the diagram.

FIG. 7 is a diagram in perspective view showing a connector configured to join two of more L-shaped connectors of the type shown in FIG. 1A.

DETAILED DESCRIPTION OF THE INVENTION

Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.

Similarly it should be appreciated that the description of exemplary embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of this invention.

Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and from different embodiments, as would be understood by those in the art.

In the claims below and the description herein, any one of the terms “comprising”, “comprised of” or “which comprises” is an open term that means including at least the elements/features that follow, but not excluding others. Thus, the term comprising, when used in the claims, should not be interpreted as being limitative to the means or elements or steps listed thereafter. For example, the scope of the expression a method comprising step A and step B should not be limited to methods consisting only of methods A and B. Any one of the terms “including” or “which includes” or “that includes” as used herein is also an open term that also means including at least the elements/features that follow the term, but not excluding others. Thus, “including” is synonymous with and means “comprising”.

Furthermore, it is not represented that all embodiments display all advantages of the invention, although some may. Some embodiments may display only one or several of the advantages.

Some embodiments may display none of the advantages referred to herein.

The present invention is predicated at least in part on Applicant's proposal that relatively small diameter timbers may be collocated together to form a composite structural beam using a connector as described herein. The connector comprises a number of engaging members, each of which extends into a small diameter timber flange thereby collocating the timber flanges into a composite structural member. Accordingly, in a first aspect the present invention provides a connector for collocating a group of timber flanges, the connector comprising a main region, the main region having extending therefrom a plurality of engaging members each of which is configured to engage with a timber flange.

As will be described more fully infra, the present connectors can take many forms and may be used (in combination with timber flanges) to provide column structures, beam structure, and combination column/beam structures all of which make use of timber such as timber rounds and small diameter peeler cores. Furthermore, the present connectors allow for timber to be used in the construction of multistorey buildings. The present invention therefore represents a significant departure from prior art construction and hardware which typically rely on large cross-section sawn timber or steel members for creating the load bearing structures in a building.

The composite structural members that may be produced using the present connectors can be used as a column, a beam, a half-beam, a bearer, a joist, a brace, a truss or any other structural member of a building. As will be more fully discussed infra, the connectors may be used also to join composite structural members both as a means for end joining and for making right-angled joins between a column and a beam, for example, where the column and beam are both collocated timber flanges.

These arrangements allow for the construction of buildings of at least several storeys having a frame work predominantly of timber. In some embodiments of the invention, the building may be constructed from timber rounds, and even smaller diameter timbers such as peeler cores

The present connector is typically formed having main planar region (being a plate in one embodiment), and having engaging members extending at 90 degrees therefrom. The engaging members may be pins or bars which are generally disposed in a regular manner so as to be insertable into an axial bore of each timber flange that is collocated by the connector. The combination of plate and engaging members acts to prevent the timber flanges from acting individually in so far as one flange may not move (axially, radially or rotationally) with reference to another. The collocated timber flanges may therefore act similar to a unitary structural member with regard to the transference of load therethrough. Thus, the collocated flanges may be used to replace single large cross-section timbers, and even steel members in building construction.

Unless the contrary is stated, where building structural members are recited herein (such as “column” or “beam”) it is to be taken that such structural members are formed by a number of timber flanges collocated by connection to a connector or the present invention. Typically, two connectors will be used: one at each end of the flanges. The number of flanges collocated together to form a structural member will depend on the load expected in use. Broadly speaking, an increased load will require an increased number of flanges, or flanges having an increased cross-sectional area. The flanges may be disposed linearly (i.e. one atop the other, comprising 2, 3, 4, 5, 6, 7, 8, 9 or 10 flanges), or in a grid formation (for example having 2, 3, 4, or 5 rows; with 2, 3, 4 or 5 columns). In some embodiments the grid formation is a square (such as 2 rows×2 columns), however other formations are contemplated (such as 4 rows×1 column, or 3 rows by two columns).

Whilst it is the primary role of the engaging members to locate a fix the positions of the flange ends and prevent each flange from acting individually, a secondary role may be to prevent crushing of the wood fibres in the flange ends. The engaging members may transfer at lead some of any downward load imparted on the connector to regions deeper in the flange.

In one embodiment, the engaging member may be configured to extend at least about 1 cm, 2 cm, 3 cm, 4 cm, 5 cm, 6 cm, 7 cm, 8 cm, 9 cm or 10 cm into the flange. To resist deformation forces occasioned on the engaging member (for example, by compression due to overlying structures or lateral forces) the engaging member may be configured to have a minimal cross-sectional area having regard to the expected level of deformation force that may be applied in a given application. A member having a cross sectional area greater than that of a 2 gauge nail is useful in many applications, with preferred forms being similar to a rebar (high yield rebar, high tensile rebar or mild steel rebar) having diameters of at least about 5 mm, 6 mm, 8 mm, 10 mm, 12 mm, 16 mm, 20 mm, 24 mm, 25 mm, 28 mm, 32 mm, 40 mm or 50 mm.

The engaging members are generally elongate and linear and configured to insert into a borehole made centrally and axially into the end of the flange. The dimensions of the engaging member and flange may be configured such that a pressure fit is provided. Alternatively some space may be left between the two components to allow for the use of an adhesive. In any event, the growth rings of the flange (which may be concentric with the engaging member) may act to resist deformation of the engaging member and to spread load evenly throughout the flanges and connector. Generally the engaging members are identical, however this feature is not considered essential to all forms of the invention.

In some embodiments, the engaging member may have profiles which are not strictly pin-shaped or bar-shaped. A member may be wedge-shaped, conical or pyramidal for example.

The main region of the connector and the engaging members is typically fabricated from a deformation-resistant material such as steel, or a high strength polymer. In many embodiments, the main portion of the connector (typically being a plate) and the engaging members (typically in the form of pins) are both fabricated from steel. The plate may be separately fabricated and the pins attached by welding (or equivalent means of fixation), or the entire connector may be formed or moulded as a unitary product. In other embodiments, holes are formed in a plate and the engaging members are threaded and screwed through the plate to as to extend outwardly from the other side. Given the benefit of the present specification, the skilled person is amply enabled to conceive of other suitable methods for forming an engaging member on the main region of the connector. In one embodiment, the main region is a plate and the engaging members extend from the plate. It is not necessary for the main region to be a continuous structure, with some embodiments having cut-outs or other discontinuities therein.

The main region of the connector may or may not be configured to extend beyond the periphery of the collocated flanges in any or all directions. In some applications (and often for fire safety reasons) the main region is smaller in cross-sectional area than the region described by the periphery of the collocated flanges. This allows for horizontal sheeting to be recessed into and above the end timber area equally around the main region to abut the sides thereof. The concrete floor or sheeting on the next (upper) storey can be recessed into any under any timber end grain area thereby concealing or rebating the connector man region and protecting both connector and timber ends from direct heat or flame. A potential disadvantage of this embodiment is that the amount of load that can be assumed by the plate is reduced, however this may be overcome by the use of more or larger cross-sectional area flanges.

A composite column comprising a connector of the present invention, as connected to may act in the a building application as a component of a secondary directed load sharing system which depends at least to some extent on the flat end bearing capacity of the end fibres of the plurality of timber flanges collocated together (at the top and bottom), and in particular to the fibres ability to bear loads in compression from a present connector which is already bearing a load from a similarly collocated group of flanges above.

The connector may have engaging members extending in two directions from the main region. In one embodiment, the engaging members extend from opposed sides of the main region. Such embodiments are useful in end joining a first group of flanges to a second group of flanges.

In another embodiment, the connector is configured to fasten to another identical or similarly functioning connector. In this way, a first connector may be used to collocate a first set of timber flanges, a second connector may be used to collocate a second set of timber flanges, and the first connector is fastened to the second connector so as to form an indirect structural connection between the first and second groups of flanges.

Alternatively, the connector may be configured to fasten to a building, or a part of building during construction thereof. For example, the connector may be configured to connect to a prior art building component such as a column, a beam, a bearer, a joist, a truss or any other frame member of a building. Configuration may also be provided to connect to non-timber building components such as a steel frame component, a concrete component, or a masonry component. As a further alternative, configuration may be provided to connect to building hardware such as a bracket, a brace, a plate a cap or similar contrivance. As a further option, the connector may be configured to fasten to a structural member formed by the collocation of a number of timber flanges with a connector of the present invention.

In a form configured so as to facilitate fastening, the connector may comprise one or more apertures dimensioned to receive a bolt or similar fastener. A bolt may extend through the apertures of two connectors with a nut being used to make the fastening semi-permanent. As an alternative, a clamping mechanism may be used to fasten a first connector to a second connector or other building component. In another version, threaded pins may be used to fasten the present connector to another connector or other building component. Given the benefit of the present specification, the skilled person is enabled to conceive of other fastening means and configure the connector accordingly.

The engaging members may be configured to be driven directly into the flanges in a manner similar to a nail such that the act of driving in the engagement member forms a borehole in the flange. In some circumstances, this may lead to splitting of the flanges in which case alternative means are used. Preferably, each of the engaging members is configured as a pin configured to be inserted into a pre-formed bore of the flange. An adhesive may be injected into the bore before insertion of the engaging member so as to provide for a more dependable union.

Typically, the flanges are of equal length, and a connector is applied to both ends of the flanges. Thus, the flanges are bound together at both ends and the flanges are substantially incapable of radial movement relative to each other or axial movement relative to each other.

As discussed supra, the present connector has advantage in so far as multiple wood flanges of relatively small diameter may be collocated to form a unified composite structural member. Suitable flanges include timber rounds. Timber rounds are described in Section 6 of Australian Standard 1720, and are typically produced from softwood trees grown commercially as renewable forest plantation timber. These timbers are typically fast growing, easily harvested, and have a low natural defect rate.

Various species of timber are suitable to form the true rounds, particularly those types of species that tend to have a relatively constant diameter for a considerable portion of their length to minimise waste during the trimming and circularising processes. Plantation pine materials, such as slashpine or Carribaea hybrids, tend to form suitable true rounds. Other materials that might be considered include Douglas fir, and various eucalypt species.

True rounds are particularly strong since the natural strength of the timber fibres is not disrupted by sawing or other treatment. The integrity of the round is maintained, and the trimming process required to circularise the round does not greatly affect the overall strength of the round. The natural characteristics of timber are that the central core or pith of the round is relatively soft and has low structural strength. The periphery of the timber, on the other hand, is much harder and the timber fibres are able to carry a high tensile load. Also, this hard outer layer is more resistant to water absorption and attack by insects, and thus by keeping the outer circumference of the timber largely intact in the process of preparing a true round, the structural integrity of the timber is maintained

The rounds in some forms of the invention do not strictly conform to Australian Standard 1720, and may be of a smaller diameter such that the Standard is not satisfied. However, by the fastening of at least three rounds together a required load bearing capacity may be nevertheless attained.

In some embodiments, the timber flanges are “peeler cores”. As is understood by the skilled person, a peeler core is a round pressure treated post. A peeler core has been turned in a milling machine to the point that substantially all the soft wood has been removed (for plywood manufacturing), leaving the hardwood core which is typically dense and inflexible. The milling process peels off the bark, cambium layer, sapwood, and even some of the heartwood to make veneer panels. This leaves no sapwood on the post.

The hardwood core of a peeler core does not absorb the pressure treatment and preservatives as well as the softwood resulting in an inferior post that will typically not last as long as a post with treated softwood on the exterior.

Applicant has discovered an economically and technically viable use for peeler cores in that the cores may be used in a composite timber product such as that disclosed herein. The use of multiple peeler cores (and even those with a diameter down to about 70, 60, 50 or 40 mm) can produce a member which is useful in construction and yet is highly cost-effective. Peeler cores are often considered a waste product of forestry, having little value in the market. In one embodiment, the present invention is directed to timber structural members that are comprised of peeler cores only in combination with a present connector.

Given the low diameters of peeler cores, it will be appreciated that a greater number of rounds may be required to achieve any desired structural property. For example, while a structural member composed only of larger diameter rounds may only require 2 or 3 rounds, the use of peeler cores may require 4, 5, 6, 7 or 8 cores to achieve a useful result.

Typically, the flanges and connector are configured so as to ensure that the surface of each flanges makes contact with all neighbouring flanges. Thus, the diameter of the flanges and the spacing of the engaging members may be configured so as to ensure flange-to-flange contact. As will be appreciated, the diameters of timber rounds can be variable and the spacing of engaging members is generally fixed. Accordingly, some embodiments of the invention provide for opposing longitudinal segments to be removed (by a chamfering process) from each flange so as to provide opposing substantially planar surfaces which can act as a contact interface between flanges.

The amount of wood removed from a flange may be varied from flange to flange so as to provide a fixed distance between the flange centre and substantially planar surface. Thus, when two so-formed flanges are stacked on their long axes, the centre-to-centre distance is fixed. The fixed distance is concordant with the distance between the engaging members of the connector and the so-formed composite structural member is therefore assembled easily and with the avoidance of unforeseen forces acting on any of the flanges or engaging members that may be caused by poorly fitting components.

In some embodiments, the flanges are laminated together by an adhesive disposed between the regions of contact between two flanges. In addition or alternatively, the flanges have fasteners extending therethrough, and generally across the long axis. For example, the fasteners may be steel rods inserted into bore holes made at alternating acute and obtuse angles to form a repeating V-pattern along the length of the flanges. This arrangement of fasteners provides a trussing effect to afford greater resistance of the composite timber member to bending, and is therefore particularly useful where the flanges are used to form a composite floor joist or similar. The flanges may be laminated together according to any of the various means disclosed in any of the following international patent specifications, the contents of which are herein incorporated by reference: WO/2015/176125, WO/2015/031957, and WO/2010/057243, WO/2009/094696, WO/2016/086275, Australian provisional patent application 2016902472 (filed 23 Jun. 2016).

In one embodiment, the main region of the connector has a support member extending therefrom and generally in the direction opposite to that of the engaging members. Preferably, the main region is a plate disposed horizontally, the engaging members extending upwardly and vertically from the main region plate, the support member being a plate extending generally downwardly from the centre of the main region plate. This modified version of the connector allows for the collation of group of flanges into an upwardly extending column, with the column being supported above a surface by the vertical plate support member.

In another embodiment, the connector is configured such that the main region is a plate that forms an angle (typically an angle of about 90 degrees) such that a horizontal portion of the plate is (in use) disposed upon an underlying structure, the surface acting to support and/or stabilise the vertically extending portion of the main region, the vertically extending portion having the engaging members extending horizontally therefrom. The horizontal portion may be configured to fasten to the underlying structure, and may have for example apertures allowing for a fastener (such as a bolt or a screw) to pass through and extend into the underlying structure.

This combination of connectors having (i) right-angled main regions and (ii) support regions can be used to unify an upwardly extending column, a downwardly extending column, a beam extending horizontally to the left and a beam extending horizontally to the right. By way of construction, the downwardly extending column is installed in place firstly with the main region plate collating the flanges which comprise the downwardly extending column being set horizontally. The beams extending left and right horizontally are then mounted on the horizontal plate of the upwardly extending beam with the horizontally extending portions of the plates of each connector of each beam being mounted on and bolted to the underlying plate. A space is left between the vertically extending portions of the plates of each connector of each beam. The function of this space is to snugly accept the vertical plate support member of the connector of the upwardly extending column. Bolts extend through (i) the vertical plates of the connectors of the beams and (ii) the vertical plate support member sandwiched between the aforementioned vertical plates. By this arrangement, a rigid unification of all components is provided.

The present invention may comprise the combination of a number of flanges with a connector to form a structural column capable of resisting compressive forces expected in building construction. In some embodiments, a connector is present on one of both ends of the flanges. In any event, where a downwardly acting force bears on an upwardly presented face of the connector, the connect acts to transfer the force downwardly and into the underlying collocated flanges.

In other embodiments one or more connectors are used to join two groups of flanges end-to-end so as to provide an extended length column. Without wishing to be limited by theory in any way, it is believed that where the connector forms end-grain connections between an upper group of collocated flanges and a lower group of collocated flanges so as to form an extended height column, the ends of the upper flanges transfers the vertical load component through the connector and onto the ends of the lower flanges. The engagement pins engage the flanges (both upper and lower) and provide composite action in the nodal zone. For any given building application, and according to any relevant building code with reference to the final load to be assumed by the column, it will be possible to determine the number of flanges and the cross-sectional area of each flange so as to satisfy the application.

A present connector may be used in the construction of a multistorey building. For example, a connector may be disposed at the interface between two floors of the building such that the lower group of collocated flanges together define a beam traversing the floor to ceiling of the first storey, and the lower group of collocated flanges together define a beam traversing the floor to ceiling of the second storey. This arrangement can be repeated such so as to provide a third storey, fourth storey, fifth storey etc. In applications for multistorey buildings, it may be necessary to use flanges having a higher cross-sectional area (or more flanges in total) as columns on the lower storeys of the building so as to support the vertical load imparted by multiple upper storeys of the building.

Typically, in use the flanges are of equivalent length and are collocated at both ends with a connector of the present invention. The collocation of flanges at both ends with connectors of the present invention prevents independent behaviour of flanges across the entire length of the collocated flanges. This prevents buckling or warping of the flanges when placed under load by minimizing any moment bias in any given lateral direction perpendicular to the collocated flanges.

Much of the load may be orientated along the centroid of the column, thereby minimising or lessening the tendency of the flanges to buckle by virtue of either unstable moment bias due to inherent eccentricity of loading to the centroid, imperfections in timber cross-section, non-uniformity of timber material and the like. To minimise the prospect for buckling, flanges having a symmetrical shape are preferred, and moreover the regular disposition of flanges into a defined group or matrix is preferred. Furthermore, flanges should preferably make contact with other flanges as far as possible along their lengths so as to provide a more highly stabilised structural member.

In order to further minimise column failure by buckling the flanges may be optionally connected at one or more points such as by extending a retaining band about the circumference of the collocated flanges, and/or by an adhesive disposed at point of contact between two flanges, and/or by insertions of fasteners (such as steel dowels, optionally inserted al alternative angles along the flanges) through two or more flanges. In addition or alternatively to these measures, the flanges may be modified to increase the flange-to-flange contact area. For example, round flanges may be chamfered along their length such that each flange has a large contact surface suitable for contacting a similarly formed chamfer on an adjacent flange. Methods of chamfering and laminating flanges are discussed in Applicant prior published patent document WO/2015/176125, WO/2015/031957, and WO/2010/057243, WO/2009/094696, WO/2016/086275, Australian provisional patent application 2016902472 (filed 23 Jun. 2016), the contents of which are incorporated herein by reference.

The present connectors may be used as a means for connection of collocated flanges, each group of collocated flanges extending outwardly in 2, 3, 4 or 4 directions. Typically, an angle of substantially 90 degrees or 180 degrees exists between any two flange collocations. Where two flange collocations are concerned the connector and flange collocations may form a linear shape (the connector being disposed between the two groups of flanges which are coaxial). Alternatively, the two collocated flanges may form an L-shape with the connector disposed at the angle of the L. Where three flange collocations are concerned, the flanges may form a T-shape with the connector disposed at the intersection of the T. Where four flange collocations are concerned, a cruciform structure may result with the connector being located at the centre of the cross.

Such combinations of connector and flange collocations is that an inter-storey cavity space between floor levels for housing can be created. Collocated flanges which function as beams can be connected before or at the same time that the next level of columns are installed for an overlying storey such that a complete storey can be completed before commencing construction of the next. The zone provided can be used as a cavity into which services (such as air conditioning conduit, water, electrical cabling and the like) can be disposed. It is further proposed that this method of construction is more cost-effective ad requires shorter periods of time for which workers must operate at heights.

In another embodiment of combination connector/flange collocations, there is provided the combination of an upper connector plate (having engaging pins extending upwardly therefrom) which bolts directly to an opposing mirror image lower connector plate (having engaging pins extending downwardly therefrom) with the plates having means for laterally joining one or more horizontal beams (each of the beams being collocated flanges). Such means may comprise a plate having laterally extending engaging members. The plate may be bolted vertically downwardly to the lower connecting plate.

The present invention may provide for rapid methods for constructing pre-formed panels on the ground of the building site or in a dedicated factory environment. The panels may be comprised of joists consisting of two half-beam bearers with a plurality of cross-joists are 450 to 600 mm centres. The panels are lowered onto the top corners of 4 columns with only the connector plates (previously engaged therewith) and the corner connections secured. When another panel is lowered the two side-by-side half-beams are simply bolted together to form a whole beam. The resultant grids can be quickly sheeted with timber flooring, for example, or prepared for a slab as described infra.

Such panels or grids may comprise at least two joists acting a half-beam bearers (say, 5 members high) cross joined by a plurality of similar joists (say, 4 members high) at suitable spacing of between say 45 0 mm to 600 mm to form a 4.8 m×6 m grid or a 6 m×6 m grid for example. The joists may joined in the same plane and the joists ends may be collocated by a present connector, I which case the engaging members may be wither Y bar or threaded bar. In addition the ends may be radially cut so as to engage the rounded sides of the joists and be end bolted through the bearer joists in a non-moment bolted connection or be laminated on site in the case of a Y bar end connection.

A further advantage of the present connectors and collocated flanges is that a composite concrete-to-timber slab may be poured without the need the screw in numerous shear connectors into the tops of the joists and bearers. This is achieved in-factory be extending the rebar engaging members up above the joists and bearers. The bottom formwork or ply layer is designed to be recessed into the joists and bearers such that the tops of both are level. This can be safely achieved with sheets that are fitted between joists from below, say of 400 mm to remain level with the joist tops at 450 mm spacings. When the slab is poured with its multiple opposite-facing shear connectors the concrete slab becomes essentially composite with the timber and therefore unlikely to separate.

Before the slab is poured, pods or anchors may be strategically positioned around the column or grid edges and running down to the third or fourth bearer or joist member to create further shear resistance for the slab. This arrangement may be used at the corners of a building.

In some embodiments, the rapid installation methods of the present invention involve the use of any one or more of the following.

(i) Joists, which are in many embodiments collocated flanges. The flanges are collocated by each of the flanges having an axial bore hole into which inserts an engaging member (which may be a Y bar or a threaded bar). The ends of the joists may have ends which are radially cut so as to engage the rounded sides of adjacent rounded structures such beams formed from timber rounds which act as bearers. In some embodiments, the beams to which the joists are configured to attach take the form of half beam bearers as further described.
(ii) Half beam bearers have the engaging members of the connector glued into the joist ends to form a half-beam bearer. The connectors are further attached to column collector plates by bolting down onto top connector plates on site.
(iii) Full beams are two half-beam bearers cross bolted or laminated together to form a full beam. These can be used as cross beams between columns where required.
(iv) Top connector plates which are configured to be embedded (via the engaging members) and laminated into the tops of columns, so as to collocate the individual flanges to form a column. The top connector plate may be welded with two vertical plates in the centre configured to receive and sandwich therebetween the downward facing flange of a column above which is through bolted together as well as to receive and support a connector plate from up to four directions by bolting down through the plate. To avoid nuts or boltheads on the bottom, these may just be bolt threads extending upwardly from the top of the connector plates to screw the nuts down onto.
(v) Bottom connector plates having a welded flange vertical to the connector plate on the opposite side of the engaging members. A columns in embedded onto the engaging members. The connector plate and column can be lowered into position onsite for through-bolting to other connector plates.
(vi) Corner connector plates for corners of a building. These may have a flange plate running the same as for a normal connection or with the vertical flange plate at 45 degrees in either orientation or the vertical flange plate in the shape of a cross or just as a half-cross as a box section.

A preferred method of building is as follows. Four columns are lowered into place firstly. Each column is a set of flanges collocated with a connector plate. Grid-like building modules (each comprised of intersecting joists and beams) are lowered down onto the connector plate and between the corners of the four column tops. From an under-platform or scaffold, workers secure connector plates with nuts and washers. All other half-beam bearers and full beams are secured in this way.

The grids are then sheeted by passing appropriately-sized (say 400 mm×2400 mm) ply sheet up through the spaces between joists and allowing them to rest in preformed rebates. From above, concrete is poured onto the ply to form a slab floor.

New columns are then lowered into the connection zone such that the vertical portion of the connector plate is sandwiched between the connector plates at the top of the underlying column and bolt through to fix.

This basic method may be repeated so as to form a multistorey building framework.

The present invention will be more fully described by reference to the following non-limiting preferred embodiments.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Reference is made to FIG. 1 which shows a perspective view of paired connectors (each connector marked as 10) of the present invention having a main region, being a vertical plate 12 in this embodiment, the plate 12 having extending at a right angles thereform a series of cylindrical pins 14 each of which is an engaging member configured to be received by an axial bore (not shown) made in each of a series of chamfered timber flanges 16. In this embodiment each connector 10 has a stacked series of four flanges 16. It will be noted that each of the flanges 16 abut each other at the interface between the chamfered surfaces 17 so as to prevent any free play or rotation. Minor chamfering is applied also to the inside surfaces 19 of the flanges 16 for the same reason. The chamfered inside surfaces of the flanges are more clearly shown at FIG. 6.

The plate 12 has a first series of bolt holes (not shown) into which of each a bolt 18 inserts to allow for fastening of the connector 10 to a second identical connector set behind (not shown in this drawing), such that the plates of the two connectors are parallel and the pins for the first connecter extend in the opposite direction to those of the first connector. In other embodiments, the bolt ends may insert into another type of connector or any other building structure.

The plate 12 has a lower horizontal extension 20 extending at right angles therefrom to form an L-shaped bracket. This lower extension 20 functions so as to support the bottom flange 16A, but also to provide means to fasten the connector 10 to an underlying connector (not shown in this drawing) or to an underlying building structure (not shown in this drawing). In particular the lower extension 20 comprises a second series of bolt holes (not shown) through which a second series of bolts 22 which facilitate such fastening to another connector or structure. It will be understood that it is not necessary for the connector to have bolt holes passing through both the vertical plate and the horizontal plate, although in this embodiment both are provided. It is to be further understood that it is not necessary for the connectors to be paired as shown in this drawing. In some embodiments a single connector may be used, optionally with bolt holes disposed lateral to both sides of the flanges 16.

The flanges 16 in the foreground are collocated by the connector in the foreground, with the flanges 16 in the background being collocated by the connector in the background.

The connectors 10 are shown in end-on view in FIG. 2, whereby the minor chamfering on the inside abutting surfaces 19 of the flanges is more clearly shown. In some applications, it will be preferable for the portions of the plate 20 that sit immediately below the flanges 16A to be removed such that the flanges 16A are able to directly contact an underlying support surface. In this way, the overall height profile of the combination of the connector 10 with flanges 16 is lowered.

Typically, the areas of plate 20 lateral to the flanges 16A remains as a means for accepting the bolts 22.

Use of the paired connectors 10 in a first application is shown in FIG. 2A (lateral view) and FIG. 2B (top view). In FIG. 2A the second of the paired connectors 10 is disposed immediately behind the first (forward most, as drawn) connector and is therefore obscured.

As shown most clearly in FIG. 2A, there is shown a cruciform building structure providing a vertical column and horizontal beam arrangement. This arrangement structurally connects an upper column 100, a lower column 200, a left lateral beam 300 and a right lateral beam 400. Each of the columns 100, 200 and beams 300, 400 are comprised of chamfered timber flanges 16 as those shown in FIG. 1. The cruciform building structure comprises L-shaped connectors 500, 510 which are disposed back-to-back in a mirror-image arrangement.

Each connector 500, 510 comprises a series of pins 14 each of which engages with a flange 14 by way of an axial borehole (not shown) in the flange end. Each connector has a series of vertical bolt holes and horizontal bolt holes to accept a series of bolts. The vertical bolt holes of each connector 500, 510 are aligned so as to be fastenable together by horizontal bolts 18.

Together the flanges 16 collocated by the connector 500 form the left hand laterally extending beam 300, and the flanges 16 collocated by the connector 510 form the right hand laterally extending beam 400.

As is shown clearly in the plan view of FIG. 2B, the connector 500 has a paired connector 502 set adjacently thereto. In addition, the connector 510 has a paired connector 512 set adjacently thereto.

A third connector 520 comprises a horizontal plate 522 from which a series of pins 14 each of which extend so as to engage an axial bore (not shown) in each of the upper column 100 flanges 16. Together the flanges 16 collocated by the connector 510 form the upper column 100. Extending downwardly from the horizontal plate 522 is a vertical plate 524 configured to snugly fit between the vertical plates of the connectors 500, 510. The vertical plate 524 comprises bolt holes (not shown) positioned to accept the horizontal bolts 18.

A fourth connector 530 comprises a horizontal plate from which a series of pins 14 extend vertically and downwardly therefrom. Each of the pins 14 engage with an axial borehole (not shown) in each flange 16. Together the flanges 16 collocated by the connector 530 form the lower column 200. The horizontal plate 532 comprises a series of bolt holes positioned so as to align with the bolt holes of the horizontal plate of connector 500 and connector 510.

The flanges 16 which form the columns 100 and 200 are chamfered in a similar manner to the flanges shown in FIGS. 1A and 2B

In the embodiment of FIG. 2A, the vertical flanges 16 of column 100 form a column of an upper storey of a building, while the column 200 forms the column of an immediately lower storey of the building. The flanges 16 are disposed in a 4×4 matrix, and accordingly the pins 14 extending from the horizontal plates 522 and 532 are disposed in a 4×4 matrix such that each pin engages with an axial borehole of its corresponding flange 16.

In the course of construction, the connectors 500, 510 and 530 (each with its respective column or beam already engaged) are bolted together. The third connector (with its column attached) is lowered into the space between the horizontal plates of connectors 500 and 510. The connectors 500 and 510 are then bolted together.

Ply may be laid on top of the upper flanges 16 of beams 300, 400 and concrete poured thereon.

FIG. 2B shows a plan view of the cruciform building structure of FIG. 2A.

Reference is now made to FIG. 3 which shows an alternative cruciform building structure which is similar to that of FIGS. 2A and 2B, the main difference being that the upper vertical column 100 is disposed between the connectors 500 and 510 with there being no requirement for a vertical plate (524 of FIG. 2A) to extend between connectors 500 and 510. In the structure of FIG. 3, two L-shaped connectors 600, 610 are provided having horizontally extending pins 14. The horizontal plates of each connector 600, 610 have a series of horizontal bolt holes (not shown) configured to accept the vertical bolts 612. There are no bolt holes on the vertical plates of connectors 600, 610 in this embodiment.

A third connector 700 comprises a horizontal plate with upwardly and vertically extending pins 14 each of which engages with a corresponding flange 16 of the upper column 100. Bolt holes are disposed so as for the fourth connector of FIG. 2A, the position of bolt holes shown as for FIG. 2B.

A fourth connector 800 comprises a horizontal plate from which pins 14 extend vertically and downwardly, each of which engages a flange of the lower column. The fourth connector has bolt holes positioned so as to align with the bolt holes of the first 600, second 610 and third connector 700. In this embodiment, the lower column (with connector) is placed firstly, and the upper column 100 (with connectors 600 and 610 attached) then lowered downwardly thereon. The two L-shaped connectors 600, 610 (each with a collocated beam 300, 400 attached) are then positioned so as to sit on the connectors 700, 800 with the horizontal plates of all four connectors being bolted together.

The plan view of the structure of FIG. 3 will be the same as for FIG. 2B.

In this arrangement, each of the horizontal beams 300, 400 may be considered a half-beam upon which flooring (not shown) may be laid.

FIG. 4 shows an alternative embodiment useful at a corner of a building. Show in plan view is the upper surface of a first connector plate 900 having a central region 905 extending from which is a first extended region 910 and a second extended region 920. The extended regions 910 and 920 support first L-shaped connector 930 and a second L-shaped connector 940 which are disposed on top of the first connector 900. The extended region 910 and L-shaped connector 930 have aligned bolt holes to facilitate fastening to each other with vertical bolts 905. The extended region 920 and L-shaped connector 940 have aligned bolt holes to facilitate fastening to each other with vertical bolts 905

Extending downwardly and vertically from the central region 905 is a series of pins (not shown) each of which engages with a borehole in a flange, each flange being a component of a column.

Each L-shaped connector 930 and 940 has a series of pins 14 extending from its vertical component, each of the pins engaging with a flange 16, the flanges being collocated into beams 950 and 960.

Extending upwardly and vertically from the central region 905 of the first connector 900 is an L-shaped plate 970 which is welded to the upper surface of first connector 900. Bolts 908 are provided to fasten together the horizontal components of the L-shaped plate 970 with L-shaped connectors 930 and 940.

The arrangement of connectors 930, 940 and plate 970 leaves an L-shaped space allowing for the lowering of a box-shaped vertical flange 980 downwardly and onto the central region 905 of the connector 900. The box-shaped flange 980 originates from a column disposed above (not shown) and extends from a connector plate having pins extending upwardly so as to collocate a number of flanges to form the column.

The box-shaped vertical flange 980 has bolt holes which align with bolt holes of the vertical components of the L-shaped connectors 930, 940 and the L-shaped plate 970. Bolts are inserted through these bolt holes as a final step so as to secure the corner structure.

Thus, it will be apparent that by this arrangement the beams 950 and 960 form a right angle at to the column at a corner of a building.

Reference is made to FIG. 5A showing the use of the corner structures shown in FIG. 4 in the context of an entire building floor. Each of the corner structures 1000, 1100, 1200, 1300 has extending therefrom two beams 1400 at right angles. The beams have inside ledges 1410 allowing for the disposition of a series of flooring joists 1500 thereon. In this embodiment, the beams 1400 are constructed from true rounds, chamfered and stacked four flanges high, and then abutting the four-stacked flanges are two-stacked flanges as is shown in FIG. 5C. The ledge 1410 is shown more clearly in FIG. 5C. It is not necessary for the ledge 1410 to be continuous as shown in the drawings. Instead, for example, a simple block-like support may be affixed to the beam 1400 only where necessary to support a joist 1500. Neither beam 1400D nor 1400B has any ledge in this embodiment.

Each joist 1500 is comprised of a stack of three, four or five chamfered timber flanges, which may be laminated together by any method deemed suitable by the skilled person. In addition or alternatively, the flanges may be collocated using a connector of the present invention, being generally a plate having outwardly extending pins inserting into a borehole of each flange. The joists may be comprised of peeler cores which are collocated with a connector comprising a plate having pins extending therefrom and into an axial borehole in each flange as generally taught herein.

In the building structure of FIG. 5A the beams 1400D and 1400B are pre-fitted to their respective supporting corner columns. On site, the beams 1400A and 1400C are assembled with joists 1500. Each joist 1500 (being timber flanges collocated by a connector of the present invention) may be bracketed or cleated or otherwise attached to the beam 1400A and 1400C. Once assembled, the combination of beams and joists (forming a grid-like building module) is lowered onto and secured to the columns upon which each beam rests. Building structures that can be assembled on site at least to some extent, are advantageous in that transport of the unassembled components is typically easier and less expensive than for assembled modules. Alternatively, structures comprising all four beams 1400A, 1400B, 1400C, 1400D and all joists 1500 may be fabricated on site as a module and lowered onto the columns at the corners 1000, 1100, 1200, 1300. As an alternative to on-site fabrication, such building modules may be fabricated in an off-site factory and transported fully assemble to the building site.

Further advantage is provided where a building structure does not require any gluing to be performed on site. In some embodiments, flanges are collocated without the need for gluing, in which case a pressure fit is typically formed between a pin of a connector and an axial bore hole of a timber flange. The avoidance of glue saves a considerable amount of time in construction given there is no need to (i) apply glue and (ii) allow sufficient time for the glue to cure before moving assembled modules.

Reference is now made to FIG. 5B which is directed to an alternative building structure to that shown in FIG. 5A. It will be noted that the joists 1500 are about one-half the length of those shown in FIG. 5A and accordingly requires a median beam 1510 disposed one-half way between the beams 1400A and 1400C.

The median beam 1510 rests on the ledges 1410B and 1410D and spans across beams 1400B and 1400D. Median beam 1510 functions so as to support and transfer load from the joists 1500, and then to beams 1400D and 1400B. In turn, load force is transferred from 1400D and 1400B to the columns at each corner 1000, 1100, 1200, 1300. The median beam 1510 may be comprised of chamfered timer flanges collocated using a connector of the present invention. In the embodiment shown in FIG. 5B two sets (1510A and 1510B) of stacked flanges are cross-bolted together with bolts 1515.

Thus, in the construction of the 6000 mm×4800 mm module shown in FIG. 5B, two half-modules each of 6000 mm×2400 mm may be fabricated on-site or prefabricated in a factory. The first half-module comprises beams 1400A and 1510A with half-joists 1500 extending therebetween, and the second half-module comprises beams 1400C and 1510B with half-joists 1500 extending therebetween. The half-joists 1500 may be end grain pinned into the median beam 1510.

The two half-modules may be fastened together with bolts 1515 either before or after being lowered into position on beams at corners 1000, 1100, 1200, 1300. A supplementary beam (not shown) may be sandwiched between 1510A and 1510B so as to provide increased strength if required.

With regard to the embodiment of FIG. 5B it will be noted that a ledge 1410B is provided along beam 1400B, and a further ledge 1410D provided along beam 1400D, these ledges providing support for the median beam 1510.

Reference is made to FIG. 5C which shows an exemplary arrangement of a joist 1500 resting on a ledge 1410. A cross-pin 1530 is inserted into a bore hole drilled through the stacked flanges.

As will be appreciated, this arrangement is exemplary only, with many other variations being utile.

Where it is required to end join any beam or joist in order to span a required distance across a building, an arrangement as shown in FIG. 5C may be used whereby two connector plates 1560, 1570 having pins extending therefrom to collocate the individual chamfered flanges 16 are end fastened with bolts 1575 so as to form a structurally integral joist or beam. The plates 1560, 1570 may be configured so as to sit on or attach to other building components as required. This is a relatively simple form of the connector of the present invention, being a single plate with a series of pins extending therefrom.

The building modules shown in FIGS. 5A and 5B can be fabricated onsite or offsite as required and lifted into position, with sequential floors being placed on top of the other so as to create a multistorey building.

Any of the beams or joists in a building structure of the present invention may be fabricated according to WO/2015/176125, WO/2015/031957, WO/2010/057243 WO/2009/094696, WO/2016/086275, Australian provisional patent application 2016902472 (filed 23 Jun. 2016), the contents of which are herein incorporated into the specification by reference.

The structure of FIG. 5A or 5B may be considered modular in nature, and therefore amenable to be substantially repeated and extended in all directions (x, y) as required according to the area of the building footprint. For example, beam 1400A may have an identical beam bolted to its rear face (i.e. the face opposed to the ledged face), with the identical beam having a ledge extending in the opposite direction to the ledge 1410A. This arrangement provides a beam having an inverted T-shaped cross-section. The ledge on the identical beam in turn supports one end of a further series of joists identical to those marked 1500. Typically, the beam 1400A and its abutting identical beam will be bolted together at a number or points along their lengths.

In this description of FIGS. 5A and 5B, all columns, beams and joists are comprised of collocated timber flanges. In some embodiments, prior art timbers (such as square sawn lumber, any laminated timber or otherwise engineered timber) may be used for at least some of the columns, beams or joists. In some circumstances, the expense of prior art timbers may be justified for reasons of strength, ease of use or local building regulations.

In some building applications, it may be necessary to form a join between four beams, with upper and lower beams being disposed at the intersection of the beams. A suitable arrangement of connectors is shown in FIG. 6. The arrangement comprises a cruciform plate 2000, each of the four arms of the plate 2000 being to support a beam formed from collocated chamfered timber flanges, of the type marked 2010. Two upwardly extending parallel plates 2020, 2030 are welded onto the centre portion of the plate 2000. The space between the plates 2020, 2030 is dimensioned so as to accept the vertical plate 524. The plates 2020 and 2030 are used so as to afford greater overall strength as compared with the arrangement shown in FIG. 2A whereby the connector plates 500 and 510 are bolted directly to the vertical plate 524. As such the plates 2020 and 2030 are optional.

The vertical plate 524 is joined to a horizontal plate (not shown) and collocated upper column flanges (not shown) as drawn in FIG. 2A (see components 524, 520, 522, 100).

In this arrangement, there are four beams (only one of which is shown as 2010 for clarity) each of which extend outwardly from the centre at the 12 o'clock, 3 o'clock, 6 o'clock and 9 o'clock position. The beam shown as 2010 is formed from flanges collocated using the L-shaped connector 2040. The connector 2040 contacts the plate 2030 upon assembly. A mirror image of the connector 2040 and beam 2010 contacts the plate 2020 upon assembly. The two beam which extend at 90 degrees to beam 2010 are similarly collocated with an L-shaped connector, with the vertical components of the connectors abutting the edges of plates 2020 and 2030, with the horizontal components of the L-shaped connectors bolting downwardly to the plate 2000 (bolt holes not shown). A lower beam (not shown) is formed of flanges collocated by a connector similar to that marked 530 in FIG. 2A.

As will be appreciated, an arrangement suitable for joining three beams in a T-formation may be provided by modifying the cruciform plate 2000 to exhibit a T-shape.

Reference is now made to FIG. 7 which shows an H-shaped connector 2100 having two parallel plates 2110 and 2120. The bottom edge of each plate 2110 and/or 2120 may be welded to a lower connector plate. Each of plates 2110 and 2120 has a series of bolt holes 2130 allowing bolting of L-shapes connector plates (such as that shown as 10 in FIG. 1A) to the outwardly directed faces of plates 2110 and 2120. Bolts holes are also formed in the cross-plate 2140 allow for the attachment of further connector plates. The cross-plate 2140 may be not be required in some embodiments, in which case the connector comprises simply one of plates 2110 and 2120.

In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.

In the following claims, any of the claimed embodiments can be used in any combination.

Claims

1. A connector for collocating a group of timber flanges, the connector comprising a main region, the main region having extending therefrom a plurality of engaging members each of which is configured to engage with a timber flange.

2. The connector of claim 1 wherein the main region comprises means for fastening the connector to a substantially similar or identical second connector, or to a building structure.

3. (canceled)

4. The connector of claim 1 wherein the main region comprises a first substantially planar region and a second substantially planar region, the first and second planar regions forming an angle of about 90 degrees, the first planar region comprising means for connecting the connector to a substantially similar or identical second connector, and the second planar region comprising means for connecting the connector to a building structure.

5. The connector of claim 4 wherein the means for connecting the connector to a substantially similar or identical second connector or the means for connecting the connector to a building structure is an aperture configured to accept a fastener.

6. The connector of claim 1 wherein the plurality of engaging members are disposed in an ordered array with reference to each other.

7. The connector of claim 1 wherein the main region consists of, or comprises, a plate and each of the plurality of engaging members is a dowel or pin extending from the plate.

8. The connector of claim 1 configured to end join a first group of timber flanges to a second group of timber flanges, the connector comprising a main region, the main region having extending therefrom a plurality of engaging members each of which is configured to engage with an axial bore of timber flange, the plurality of engaging members comprising a first group and a second group, wherein the first group extends in a first direction and the second group extends in a second direction.

9. The connector of claim 8 wherein the main region comprises opposing first and second substantially planar faces, wherein the first group of the engaging members extend substantially orthogonal to the first planar face and the second group of engaging members extend substantially orthogonal to the second planar face.

10. A building component comprising:

(i) a first connector comprising a main region, the main region having extending therefrom a plurality of engaging members each of which is configured to engage with a timber flange, and

(ii) a plurality of timber flanges, each of the timber flanges having an axial bore into which is received one of the engaging members.

11. (canceled)

12. (canceled)

13. The building component of claim 10 wherein each of the plurality of timber flanges is a true round or a peeler core.

14. The building component of claim 10 wherein a longitudinal surface is formed by removing a longitudinal segment of each of the timber flanges so as to provide a substantially planar surface, and wherein a substantially planar surface of each of the plurality of timber flanges contacts a substantially planar surface of at least one other timber flange.

15. (canceled)

16. The building component of claim 14 wherein two contacting timber flanges are secured together with a fastener extending at an angle to the long axes of the timber flanges.

17. The building component of claim 10, further comprising:

(iii) a second connector comprising a main region, the main region having extending therefrom a plurality of engaging members each of which is configured to engage with a timber flange, and

wherein the plurality of timber flanges comprises a first group of timber flanges collocated by the first connector and a second group of timber flanges collocated by the second connector, the first and second groups of timber flanges oriented end-to-end, the first and second connectors being fastened together so as to form a structurally integral unit.

18. The building component of claim 17 comprising a structural column, wherein the first and second connectors are disposed on, and fixed to, the upper face of the column, or a plate engaged with the top of the column, and the first connector is fastened to the second connector.

19. The building component of claim 17 comprising a third connector comprising a main region, the main region having extending therefrom a plurality of engaging members each of which is configured to engage with a timber flange, the third member further comprising a support member extending from the main region in a direction generally away from the engaging members, the support member of the third connector interposed between the first and second connector, and the first connector is connected to the second connector.

20. The building component of claim 19 comprising a third group of timber flanges collocated by the third connector.

21. The building component of claim 19 comprising a fourth connector comprising a main region, the main region having extending therefrom a plurality of engaging members each of which is configured to engage with a timber flange.

22. The building component of claim 21 comprising a fourth group of timber flanges collocated by the fourth connector and the fourth connector is fastened to the first and second connectors.

23. (canceled)

24. The building component of claim 22 wherein the first and second group of timber flanges are configured as joists, the third group of timber flanges is configured as column of a (n+1) storey of a building, and the fourth group of timber flanges is configured as column of a (n) storey of the building.

25. A method of constructing a building component, the method comprising use of a building component comprising: wherein the method comprises engaging one of the plurality of axial bores with one of the plurality of engaging members.

(i) a connector comprising a main region having extending therefrom a plurality of engaging members and

(ii) a plurality of timber flanges each of which comprises an axial bore configured to receive one of the engaging members,