Aspects of the present disclosure relate to modular wall systems and methods of installing modular wall systems in hygienic environments. In one aspect, gap cover apparatus are disclosed. In one aspect, backplate arrangements are disclosed. In one aspect, non-progressive installation methods are disclosed. The modular wall systems can eliminate protruding ledges while maintaining structural integrity and hygienic properties.

Aspects of the present disclosure relate to modular wall systems and methods of installing modular wall systems in hygienic environments. In one aspect, gap cover apparatus are disclosed. In one aspect, backplate arrangements are disclosed. In one aspect, non-progressive installation methods are disclosed. The modular wall systems can eliminate protruding ledges while maintaining structural integrity and hygienic properties.

A structural support includes a first side-wall, a second side-wall, a first planar wall, and a second planar wall. The structural support further includes internal walls that are disposed between the first side-wall and the second side wall, and extend from a first inner surface of the first planar wall to a second inner surface of the second planar wall. The first side-wall, the second side-wall, the first planar wall, and the second planar wall define connector components. The internal walls define a plurality of channels between the connector components.

A structural support includes a first side-wall, a second side-wall, a first planar wall, and a second planar wall. The structural support further includes internal walls that are disposed between the first side-wall and the second side wall, and extend from a first inner surface of the first planar wall to a second inner surface of the second planar wall. The first side-wall, the second side-wall, the first planar wall, and the second planar wall define connector components. The internal walls define a plurality of channels between the connector components.

A truss includes a plurality of truss members, each truss member formed from a unitary folded blank of sheet metal to create a main panel, and proximal and distal flanges and a horizontal panel each extending perpendicularly from the main panel, the proximal flange of a first truss member is connected to the distal flange of a second truss member to form a truss. In one embodiment employing trusses formed of folded sheet metal, a plurality of interconnected truss modules, each truss module including a plurality of truss members, forms a plurality of oppositely extending horizontal flanges that collectively present the top and bottom surfaces of a cantilevered canopy.

A truss includes a plurality of truss members, each truss member formed from a unitary folded blank of sheet metal to create a main panel, and proximal and distal flanges and a horizontal panel each extending perpendicularly from the main panel, the proximal flange of a first truss member is connected to the distal flange of a second truss member to form a truss. In one embodiment employing trusses formed of folded sheet metal, a plurality of interconnected truss modules, each truss module including a plurality of truss members, forms a plurality of oppositely extending horizontal flanges that collectively present the top and bottom surfaces of a cantilevered canopy.

A wall section formed from sheet metal has a main panel, opposing vertical side flanges extending rearwardly from the side edges of the main panel, top and bottom horizontal flanges extending rearwardly from the panel, and stiffening flanges extending perpendicularly from the rear edges of the side, top and bottom flanges, thereby forming load bearing side beams, a header and a sill plate, the side flanges for attachment to the those of abutting wall sections to form a wall.

A wall section formed from sheet metal has a main panel, opposing vertical side flanges extending rearwardly from the side edges of the main panel, top and bottom horizontal flanges extending rearwardly from the panel, and stiffening flanges extending perpendicularly from the rear edges of the side, top and bottom flanges, thereby forming load bearing side beams, a header and a sill plate, the side flanges for attachment to the those of abutting wall sections to form a wall.

A method of bending a contoured metal sheet, the contoured metal sheet having a longitudinal axis extending along the length of the contoured metal sheet comprising: securing a first sheet section of the contoured metal sheet in a securing section between a securing surface of a securing member and an engagement surface of an engagement member; positioning at least part of a second sheet section of the contoured metal sheet in a forming section between a forming member having a pressing surface and a seating member having a seating surface; moving the forming section and the securing section relative to one another to: bend the first sheet section the selected angle relative to the second sheet section over a first bending edge; and feed the second sheet section from between the pressing surface and the seating surface, over a second bending edge, to between a forming surface and a backing surface; and positioning a following section substantially adjacent to the second bending edge to cooperate with the forming surface to engage and compress a portion of the second sheet section of the contoured metal sheet therebetween when the relative movement between the securing section and the forming section moves the backing surface to a position remote from the forming surface of the forming member.

A method of bending a contoured metal sheet, the contoured metal sheet having a longitudinal axis extending along the length of the contoured metal sheet comprising: securing a first sheet section of the contoured metal sheet in a securing section between a securing surface of a securing member and an engagement surface of an engagement member; positioning at least part of a second sheet section of the contoured metal sheet in a forming section between a forming member having a pressing surface and a seating member having a seating surface; moving the forming section and the securing section relative to one another to: bend the first sheet section the selected angle relative to the second sheet section over a first bending edge; and feed the second sheet section from between the pressing surface and the seating surface, over a second bending edge, to between a forming surface and a backing surface; and positioning a following section substantially adjacent to the second bending edge to cooperate with the forming surface to engage and compress a portion of the second sheet section of the contoured metal sheet therebetween when the relative movement between the securing section and the forming section moves the backing surface to a position remote from the forming surface of the forming member.