End Caps for Structural Members

Abstract

The invention provides a method of constructing a multi-storey building from modular panel components. Each panel component comprises a framework of cold-formed C-profile structural steel members including vertical members, horizontal members and optional diagonal cross-brace members. The vertical members include some load-bearing structural uprights of the finished building, each of which is provided with an end cap on each of its top and bottom ends, connected to the corresponding load-bearing structural upright by welding or by brazing. Each end cap comprises a back plate portion secured across the open side of the C-profile of the associated structural upright, to side plate portions secured to opposite sides of the associated structural upright and an end plate portion which lies across the otherwise open end of the associated structural upright. The end plate portion is in continuous metal-to-metal contact with the associated load-bearing structural upright, so that in the finished building the end caps at the top ends of the load-bearing structural uprights of one storey are in contact, either directly or via one or more metal shim plates, with the interior faces of a C-profile horizontal structural member spanning two or more structural uprights or with the end caps at the bottom ends of the load-bearing structural uprights to the next higher storey. This construction, relying as it does on continuous metal-to-metal contact, enables the building of higher structures than would otherwise be possible using cold-formed C-profile structural steel members.

1 : A method of constructing a multi-storey building from modular panel components wherein:
 each panel component comprises a framework of cold-formed C-profile or U-profile structural steel members including vertical members and horizontal members of which at least some of the vertical members are C-profile members forming load-bearing structural uprights of the finished building;   each of the said load-bearing structural uprights is provided at each of its top and bottom ends with an end cap which is connected to the load-bearing structural upright by welding or by brazing, and which comprises a back plate portion secured across the open side of the C-profile of the associated structural upright, two side plate portions secured to opposite sides of the associated structural upright, and an end plate portion which lies across the otherwise open end of the associated structural upright, the end plate portion being in continuous metal-to-metal contact with the associated end of the load-bearing structural upright; and   in the finished building the end cap at the top of each of the load-bearing structural uprights of one storey is in contact, either directly or via one or more metal shim plates, with the internal walls of a U-profile horizontal member spanning two or more of the structural uprights or with an end cap at the bottom end of one of the load-bearing structural uprights of the next higher storey so as to transmit the vertical load of the building directly through the end caps down through the associated load-bearing structural uprights.   
   
   
       2 : A method according to  claim 1 , wherein the end caps are formed by cold-bending a steel sheet so that two wing portions are bent over by 90° from the back plate portion to create the side plate portions and an upstanding portion is bent over by 90° from the back plate portion to create the end plate portion, and edges of the side plate portions are secured to edges of the end plate portion by welding or by brazing. 
   
   
       3 : A method according to  claim 2 , wherein the end caps are made to establish face-to-face contact with all three internal walls of an associated U-profile horizontal member spanning two or more of the structural uprights, by forming the outer side edges of the end plate portion of the end cap to abut but not completely to overlie the associated edges of the side plate portion thereof and by connecting together the abutting edges by a seam weld or braze so as to define therebetween a recess or chamfer to accommodate an internal form radius of the associated U-profile member. 
   
   
       4 : A method according to  claim 1 , wherein one of the pair of end caps secured to each of the load-bearing structural uprights is provided with one or more spigots projecting longitudinally from the end cap and the other of the pair of end caps secured to the same structural upright is provided with one or more apertures in its end plate portion, so that in the finished building each of the spigots projecting from the structural uprights of one storey is located in a corresponding one of the apertures to locate the structural uprights of adjacent storeys in longitudinal alignment one with another. 
   
   
       5 : A method according to  claim 4 , wherein the spigots are secured to their associated end caps by passing each one through an aperture in the end plate portion of the end cap and securing it in position by swaging. 
   
   
       6 : A method according to  claim 5 , wherein the spigots are internally threaded. 
   
   
       7 : A method according to  claim 1 , wherein the back plate portion of the end cap is welded or brazed to each of the mutually aligned edge portions of the open end of the associated C-profile structural upright so as to create, at the said top or bottom end of the C-section structural upright a complete box section profile. 
   
   
       8 : A method according to  claim 7 , wherein each weld or braze between the back plate portion of the end cap and the mutually aligned edge portions of the open end of the associated C-profile structural uprights is a spot weld or a plug weld or plug braze. 
   
   
       9 . A method according to  claim 7 , wherein the side plate portions of each end cap are secured to the opposite sides of the associated C-profile structural uprights by screws or by welding or brazing. 
   
   
       10 : A method according to  claim 1 , wherein the framework of each panel includes at least one diagonal cross-brace member which is also a cold-formed C-profile structural steel member.