Abstract
A mezzanine system includes a column extending vertically and a beam extending horizontally from the column. The beam is fixed to the column by a first bracket such that the beam is horizontally supported by a support portion of the first bracket and vertically braced by a brace portion of the first bracket. The mezzanine system also includes a joist extending horizontally from the beam and fixed to the beam by a second bracket such that the joist is horizontally supported by a support portion of the second bracket and vertically braced by a brace portion of the second bracket. A joint portion of the first bracket is welded to the column, and a joint portion of the second bracket is welded to the beam. The beam is fastened to the first bracket, and the joist is fastened to the second bracket.
Claims
1. A mezzanine system comprising: a plurality of brackets, each bracket of the plurality of brackets including a support portion, a brace portion, and a joint portion; a column extending vertically; a beam extending horizontally from the column, the beam fixed to the column by a first bracket of the plurality of brackets such that the beam is horizontally supported by the support portion of the first bracket and vertically braced by the brace portion of the first bracket; a joist extending horizontally from the beam, the joist fixed to the beam by a second bracket of the plurality of brackets such that the joist is horizontally supported by the support portion of the second bracket and vertically braced by the brace portion of the second bracket; wherein the joint portion of the first bracket is welded to the column, wherein the joint portion of the second bracket is welded to the beam, wherein the beam is fastened to the first bracket, and wherein the joist is fastened to the second bracket.
2. The mezzanine system of claim 1, wherein the joist is a first joist of a plurality of joists extending horizontally from the beam, and wherein each joist of the plurality of joists is fixed to the beam by a respective bracket of the plurality of brackets.
3. The mezzanine system of claim 2, further comprising decking extending along an upper side of the plurality of joists; and a plate disposed between the plurality of joists and the decking.
4. The mezzanine system of claim 3, wherein the decking is corrugated.
5. The mezzanine system of claim 3, further comprising a floor disposed over the decking.
6. The mezzanine system of claim 5, wherein the floor comprises poured concrete.
7. The mezzanine system of claim 2, wherein each joist of the plurality of joists is tubular.
8. The mezzanine system of claim 7, wherein each joist of the plurality of joists is sealed.
9. The mezzanine system of claim 1, wherein the beam and the joist are sealed.
10. The mezzanine system of claim 1, wherein each bracket of the plurality of brackets is U-shaped.
11. The mezzanine system of claim 10, wherein each bracket of the plurality of brackets includes a first body and a second body welded to the first body to define the U-shape of the bracket.
12. The mezzanine system of claim 11, wherein the first body and the second body are L-shaped.
13. The mezzanine system of claim 1, wherein the first bracket is welded to the column prior to the beam being fastened to the first bracket, and wherein the second bracket is welded to the beam prior to the joist being fastened to the second bracket.
14. The mezzanine system of claim 1, wherein the column is one of a plurality of columns, the beam is one of a plurality of beams, and the joist is one of a plurality of joists.
15. A method of installing a mezzanine system within a facility, the method comprising: fabricating a plurality of brackets, each bracket of the plurality of brackets including a support portion, a brace portion, and a joint portion; securing, prior to arriving at the facility, the joint portion of a first bracket of the plurality of brackets to a column; securing, prior to arriving at the facility, the joint portion of a second bracket of the plurality of brackets to a beam; erecting the column from a support surface within the facility; positioning an end of the beam within a space defined by the first bracket; fastening the beam to the first bracket; positioning an end of a joist within a space defined by the second bracket; and fastening the joist to the second bracket.
16. The method of claim 15, wherein securing the joint portion of the first bracket includes welding the joint portion of the first bracket to the first column.
17. The method of claim 15, wherein securing the joint portion of the second bracket includes welding the joint portion of the second bracket to the first beam.
18. The method of claim 15, wherein fastening the beam to the first bracket includes inserting a plurality of fasteners through corresponding holes in the brace portion of the first bracket, and wherein fastening the joist to the second bracket includes inserting a second plurality of fasteners through corresponding holes in the brace portion of the second bracket.
19. The method of claim 15, wherein fabricating the plurality of brackets includes, for each bracket, welding a first body to a second body to form a U-shape.
20. The method of claim 15, further comprising supporting the end of the beam with the support portion of the first bracket while fastening the beam to the first bracket; and supporting the end of the joist with the support portion of the second bracket while fastening the beam to the second bracket.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a perspective view of a mezzanine system, according to an embodiment, illustrating flooring of the system in various stages of installation.
[0029] FIG. 2 is a partial perspective view of an underside of the mezzanine system of FIG. 1.
[0030] FIG. 3 is a front view of a portion of the mezzanine system of FIG. 1.
[0031] FIG. 4 is a side view of the portion of FIG. 3.
[0032] FIG. 5 is another partial perspective view of an underside of the mezzanine system of FIG. 1, illustrating brackets useable with the mezzanine system.
[0033] FIG. 6 is a front view of two brackets from FIG. 5.
[0034] FIG. 7 is a side view of one or more brackets from FIG. 5.
[0035] FIG. 8 is a perspective view of a portion of the mezzanine system of FIG. 1.
[0036] FIG. 9 is an isometric view of a portion of the mezzanine system of FIG. 1.
[0037] FIG. 10 illustrates an exemplary installation including the mezzanine system of FIG. 1, with brackets of different heights.
[0038] FIG. 11 illustrates an exemplary installation of flooring of the mezzanine system of FIG. 1.
[0039] Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
DETAILED DESCRIPTION
[0040] FIG. 1 illustrates a structure, such as a mezzanine system 10, according to one embodiment. The mezzanine system 10 includes columns 14, beams 18, and joists 22 (e.g., joist tubes) assembled together to support intermediate flooring 26 above a ground floor 30 of a facility (e.g., factory, industrial space, theater, lobby, etc.). In some embodiments, the columns 14 extend vertically, the beams 18 are secured to the columns 14 adjacent upper ends of the columns 14 and extend horizontally (i.e. perpendicular to the columns 14), and the joists 22 are coupled to the beams 18 and extend horizontally (i.e. perpendicular to the columns 14) and also perpendicular to the beams 18. A plurality of joists 22 may be coupled to each beam 18 and span between two adjacent beams 18. The mezzanine system 10 may include additional structures assembled on the intermediate flooring 26, such as framing 34 for a room or manufacturing system. Further, the columns 14, beams 18, and/or joists 22 may be sealed, closed, or the like. In the illustrated embodiment, the columns 14, beams 18, and/or joists 22 are welded shut to prevent mold, bacteria, or other unwanted growth, particularly within inner portions of the columns 14, beams 18, and/or joists 22.
[0041] Referring still to FIG. 1, the intermediate flooring 26 may include plates 38 supported on the joists 22, decking 42 extending across the plates 38, and a flooring material 46 installed on the decking 42 and the plates 38. In some embodiments, the decking 42 may be corrugated (i.e., the decking 42 may include undulations). Once installed, the intermediate flooring 26 may increase the useable floor space within the facility.
[0042] With reference to FIGS. 2-4, the columns 14 may be sunken into and secured within the ground floor 30. In another embodiment, the columns 14 may additionally or alternatively be fastened (e.g., bolted, nailed, spiked, etc.) directly to the ground floor 30, or to hardware (e.g., brackets, bolts, or the like) secured to the ground floor 30. The columns 14 may then be erected throughout the facility in a network or arrangement that allows beams 18 to be extended between adjacent columns 14. The beams 18 may then support a network of joists 22 that extend between opposing beams 18. Once the joists 22 are arranged in a deck-like (e.g., floor joist) arrangement, the decking 42 may be placed over an upper side 50 of the joists 22.
[0043] The mezzanine system 10 further includes brackets 54 that may be secured to the columns 14, the beams 18, and/or, in some embodiments, the joists 22. As will be described in greater detail below, the brackets 54 may be secured accordingly to support the various elements of the mezzanine system 10 (e.g., columns 14, beams 18, joists 22, etc.) and create a structure supporting the intermediate flooring 26. In some embodiments, the brackets 54 may alternatively or additionally be secured to a wall surface 58. In some embodiments, the mezzanine system 10 may include a plurality of identical brackets 54 used to secure each of the joists 22 to one or more beams 18, and/or each of the beams 18 to one or more columns 14. In other embodiments, the brackets 54 used to secure the beams 18 to the columns 14 may differ from the brackets 54 used to secure the joists 22 to the beams 18. In some embodiments, various different brackets 54 may be used (e.g., to account for different angles and configurations of the installation site for the mezzanine system 10).
[0044] With specific reference to FIGS. 3 and 4, the plates 38 may be arranged between the upper side 50 of the joists 22 and an underside 62 of the decking 42. This arrangement provides a smooth surface below the decking 42 and prevents creation of undesirable ledges, which can accumulate dust, debris, bacteria, or the like. In the illustrated embodiment, the joists 22 and the decking 42 are arranged along a first direction, and the plates 38 extend along a second direction orthogonal to the first direction. In other embodiments, the directional-arrangement may be different. For example, the joists 22 may extend in the first direction, while the plates 38 and the decking 42 extend in the second direction.
[0045] As illustrated in FIG. 3, the plates 38 may extend across the upper side 50 of multiple sequential joists 22, which are each supported in a bracket 54 secured to a beam (not shown in FIG. 3) or column (not shown in FIG. 3). The decking 42 may be arranged in a series across multiple plates 38 that separate the decking 42 from an area below the joists 22 (see also FIG. 11). Once the decking 42 is laid, the flooring material 46, such as concrete, may be provided over the decking 42. In the illustrated embodiment, the flooring material 46 may have a thickness between approximately 3 inches and 7 inches (e.g., 5 inches).
[0046] Referring to FIG. 4, the plates 38 may be lined up and laid next to each other across the joists 22. In the illustrated embodiment, the plates 38 may then be secured (e.g., welded, fastened, etc.) together to create a single smooth surface below the decking 42. In some instances, the plates 38 may be pre-welded to the decking 42 before being laid across the joists 22, thus reducing steps and adding ease to installation. The smooth surface below the decking 42, in either instance, reduces unwanted pockets, ledges, surfaces, and/or the like that may be present in similar systems that use other components, such as I-beams, which typically cannot be used in clean manufacturing spaces (e.g., food and beverage production or packaging facilities, pharmaceutical plants, etc.). In other words, the smooth surface formed by the generally continuous plates 38 provides an intermediate flooring solution that may be useable in such clean manufacturing spaces.
[0047] Moving on to FIGS. 5-7, each bracket 54 may include a support portion 66, a brace portion 70, a joint portion 74, and a fastener receiving portion 78. The joint portion 74 may be secured (e.g., welded) directly to the side of a column 14 or beam 18 to join the bracket 54 with the column 14 or beam 18. This operation may be completed outside of the facility, such as at a remote location (e.g., off-site work shop, third-part manufacturer, etc.). Securing the brackets 54 to the columns 14 or beams 18 outside of the facility reduces the amount of time needed to assemble the mezzanine system 10 because beams 18 or joists 22 may be dropped directly into the brackets 54 rather than needing to be welded separately.
[0048] For example, a current mezzanine system may require a lift and/or crane to align a horizontal beam with a vertical column. Once aligned, an on-site welder must weld the two components together. This process is costly and requires more involved labor relative to the installation of the mezzanine system 10. In the illustrated embodiment, a bracket 54 may be welded to a column 14 off-site, and the same column 14 may be brought on-site to the facility. Rather than needing to weld the brackets 54 after the column 14 is erected, a beam 18 may be simply dropped into the brackets 54 that were pre-welded to the column 14.
[0049] With reference to FIGS. 6 and 7, in the illustrated embodiment, each bracket 54 includes a first body 82 and a second body 86. In the illustrated embodiment, each of the first body 82 and the second body 86 is generally L-shaped. A vertical or longer portion of the L-shape defines the brace portion 70, and the horizonal or shorter portion of the L-shape defines the support portion 66. During installation, the first body 82 and the second body 86 of a bracket 54 may be pre-welded to a column 14 to form a U-shape. In some embodiments, the first body 82 and the second body 86 of the bracket 54 may be pre-welded into the U-shape and then attached to the column 14. In yet other embodiments, the first body 82 and the second body 86 may be integrally formed together as a single body.
[0050] The fastener receiving portion 78, as illustrated best in FIG. 7, may include recesses 90 configured to receive one or more fasteners 94 (FIG. 3). Next, a beam 18 may be dropped (e.g., positioned) within the U-shape between the bodies 82, 86 to bear against the brace portion 70 and the support portion 66. As such, the brace portion 70 of each bracket 54 may vertically brace the beam 18 or joist 22 against horizontal movement, and the support portion 66 of each bracket 54 may horizontally support the beam 18 or joist 22 against vertical movement. Once in position, fasteners 94 may be inserted into the recesses 90, which align with complementary recesses pre-formed (e.g., drilled) in the beam 18 or joist 22, to ultimately couple the beam 18 or joist 22 to the column 14. This operation may be repeated any number of times depending on a desired size and/or shape of the mezzanine system 10. This same method may be used to couple any number of joists 22 to the beams 18.
[0051] In addition to the fasteners 94 being used to couple the beams 18 and joists 22 to the brackets 54, the joint portion 74 of each bracket 54 provides a surface for welding the bracket 54 to the associated column 14 or beam 18. Further, as best illustrated in FIGS. 6 and 9, the joint portion 74 of each of the first body 82 and the second body 86 may be L-shaped to form a joint 98 (e.g., welding beam, seam, etc.) between each bracket 54 and the column 14/beam 18. In the illustrated embodiment, the joint 98 may also be L-shaped. In other embodiments, the joint 98 may be another shape (e.g., I-shaped, l-shaped, etc.).
[0052] As shown in FIG. 6, the brace portion 70 and support portion 66 are generally positioned on an inner side of each bracket 54. It should be understood that the joint portion 74 is provided on an entire face of the bracket 54, such that the joint 98 may be formed along an inner side and outer side of the bracket 54 (e.g., along four or more edges of the bracket 54). In other embodiments, the joint 98 may be formed along a singe side, edge, or the like of each bracket 54.
[0053] With reference to FIG. 10, in some embodiments, the mezzanine system 10 may include joists 22a, 22b having different heights. The heights of the joists 22a, 22b may vary depending on particular strength requirements and/or clearance requirements. For example, the mezzanine system 10 illustrated in FIG. 10 includes a first plurality of joists 22a and a second plurality of joists 22b having a height shorter than the height of the first plurality of joists 22a. The illustrated mezzanine system 10 also includes brackets 54a having a first height H1 corresponding to the height of the first joists 22a, and brackets 54b having a second height H2 corresponding to a height of the second joists 22b. In some embodiments, brackets of multiple different sizes (e.g., brackets 54a, 54b) may be attached to the same beam 18 or column 14. Due to the modular nature of the mezzanine system 10, brackets (e.g., brackets 54a, 54b) can be provided in various different combinations and sizes to suit the needs of a particular installation.
[0054] Moving briefly to FIG. 8, the mezzanine system 10 may further include a foot 100 for fastening the columns 14 to the ground floor 30. Like the brackets 54 being pre-welded to the columns 14/beams 18, the foot 100 may also be pre-welded or otherwise attached to the columns 14 before the columns 14 are sent to the facility. This further allows for more pre-fabrication, which reduces the amount of on-site labor, cost, and inefficiency. As further shown in FIG. 8, some of the brackets 54 may vary in dimensions based on the dimensions of the member the bracket 54 will receive. For example, the bracket 54 that is secured to the column 14 and receives the beams 18 may be larger than the bracket 54 that is secured to the beams 18 and receives the joists 22. In other embodiments, all of the brackets 54 have uniform dimensions.
[0055] Referring now to FIG. 9, the columns 14, beams 18, and joists 22 may all have polygonal cross-sections. The columns 14 of the illustrated embodiment may have a square cross-section, while the cross-section of the beams 18 and/or joists 22 may be rectangular. In some embodiments, each of the columns 14, beams 18, and joists 22 have a square cross-section, while in other embodiments, each of the columns 14, beams 18, and joists 22 have a non-square cross-section. In general, the brackets 54 may be sized and pre-welded based on the member which they are meant to receive and support. This not only increases speed and cost-savings, but further creates a roadmap for a more simplified installation.
[0056] Various features and aspects of the disclosure invention are set forth in the following claims.
