GB2464760A

GB2464760A - Sheet metal fence post with gussets and anchoring formations

Info

Publication number: GB2464760A
Application number: GB0819797A
Authority: GB
Inventors: David O'grady; James Kenneth Broadhurst
Original assignee: Individual
Current assignee: Individual
Priority date: 2008-10-29
Filing date: 2008-10-29
Publication date: 2010-05-05
Also published as: GB0819797D0

Abstract

The fence post 100 has a cross-sectional profile wherein at least part of the profile is formed by more than one layer of sheet metal. The post may be formed by cold rolling steel and have an I-shaped cross-section forming channels 118 comprising a web 106 and side elements 102, 104 that include flanges overlapping the web. The flanges may be secured to the web by continuous or spot welding and one or more strengthening gussets may be secured in the channels. Anchoring formations such as tags may be provided to secure the post to the ground. A method of manufacturing the post and a fence system is also disclosed.

Description

FENCING

This invention concerns fencing systems. More particularly it relates to the form and methods of manufacture of metal fence posts.

It is well known to produce metal fence posts particularly for use in supporting fence panels consisting of metal palisades. One method used to produce metal fence posts employs hot rolling from a metal billet. This has the disadvantage that the metal must be heated to high temperatures in order that it is workable and heavy machinery (expensive both to purchase and to run) is required to perform the hot rolling. Typically, hot rolled metal fence posts weigh around 7.5 kg/metre An additional problem to which most fence posts are susceptible is whip and/or flex in the fence post which may be caused by for example wind or other impacts. If fence posts whip or flex then over time the fence structure may be weakened as joints are stressed by relative movement.

Another potential weakness in a fencing system is a low resistance of fence posts to being pulled out of the ground. If fences are not secured in the ground sufficiently resiliently the fence may be prone to collapse, especially in heavy winds or following impacts by for example falling trees or by accidental or intentional vehicle impacts.

The present invention has been made from a consideration of the problems discussed above.

In its broadest aspect, the invention provides a fence post and a method of manufacturing a fence post from sheet metal.

Thus, according to one aspect of the invention, there is provided a metal fence post made of sheet metal wherein, in cross-section, the post has a profile which at least in part is formed by more than one layer of sheet metal.

Preferably, the post is formed by cold rolling a strip of sheet metal. Cold rolling may reduce manufacturing costs compared to hot rolling since the metal sheet does not have to be heated to an elevated temperature prior to forming. Preferably, the sheet metal is steel although other sheet metal materials may be employed.

In a preferred embodiment, the post has a substantially I' shaped cross section with two parallel side elements joined by a connecting web which extends substantially normal to the side elements. In this way, the side elements and connecting web define longitudinally extending channels on opposite sides of the connecting web.

Preferably, one and more preferably both side elements comprise at least in part two adjacent layers of sheet metal. The connecting web may comprise a single layer of sheet metal. Alternatively, the connecting web may comprise at least in part more than one layer of sheet metal.

In a preferred embodiment, side edges of the metal sheet terminate in flanges that overlap the connecting web. The flanges may reinforce and strengthen the post. The flanges may be secured to the connecting web, for example by welding. A continuous weld may be provided along the length of the post. Alternatively a series of spot welds may be provided spaced apart along the length of the post.

Preferably, the post is provided with one or more gussets in either or both of the channels. Where provided, the or each gusset may reinforce and strengthen the post. The gussets may be of any suitable shape and configuration and may be secured to the side elements and/or the connecting web, for example by welding.

Preferably, the post is provided with one/or more anchor formations on the connecting and/or the side elements at or near that end of the post that, in use, is buried when the post is installed. The or each formation assist retention of the post in position, especially where concrete is used to surround the base of the post.

In a preferred embodiment, the or each formation comprises a tag formed out of the sheet metal of the post, for example by stamping the sheet metal in a selected location. Where provided, the tag may extend in a direction that increases the anchoring effect. Forming the tag from the sheet metal of the post is preferred to attaching separately formed tags to the post which may increase manufacturing costs and may be less reliable if the tags are not secured adequately.

The other end of the post which, in use, is uppermost may be cut and/or shaped so as to Suit its intended purpose. This may be advantageous where, for example, the post is used with railings that are spiked or pointed to deter an attempt to climb over the fence post.

Preferably, the sheet metal is steel. Steel is particularly suitable for forming a strong post due to its suitability for rolling to form the post.

Thus, properties such as hardness, ductility and tensile strength of steel may be varied (for example by varying the quantity of the alloying material) to provide steel that can be rolled to form the post while providing the necessary strength and rigidity for the intended application.

According to another aspect of the invention a method for the manufacture of a metal fence post is provided comprising rolling sheet metal to form, in cross-section, a profile that at least in part is formed by more than one layer of sheet metal.

The method may include providing the post with one or more strengthening gussets following the cold rolling process. Where provided, the or each gusset may be formed separately and secured by any suitable means such as welding.

The method may include providing the post with one or more anchoring formations following the cold rolling process. Preferably, the or each formation is located at or near one end of the post which in use is buried in the ground. Where provided, the or each formation may be formed out of the material of the post or formed separately and secured to the post by any suitable means such as welding.

In the preferred embodiment, the post has an I-section comprising side elements joined by a central connecting web to define longitudinal channels on both sides of the web and one or both side elements comprises two adjacent layers of sheet metal. Preferably, the sheet metal is steel although other sheet metal materials may be employed Embodiments of the invention will now be described in more detail by way of example only with reference to the accompanying drawings in which: Figure 1 is an end view of one embodiment of a fence post according to the invention; Figure 2 is a perspective view of the fence post shown in Figure 1; Figure 3 is a perspective view of the fence post shown in Figure 1 incorporating a gusset; Figure 4 is a perspective view of the fence post shown in Figure 1 with a shaped top; Figure 5 is a perspective view of the fence post shown in Figure 1 incorporating a pressed tag; Figure 6 is a top view of another embodiment of a fence post according to the invention; and Figure 7 is a perspective view of the fence post shown in Figure 6.

Referring first to Figures 1 and 2, a first embodiment of a fence post according to the invention is shown generally at 100. The post 100 has been cold rolled from one continuous strip of rectangular sheet metal so as to have an I' shaped cross-section when viewed from either end. The sheet metal is typically steel and may be provided with a surface treatment such as galvanising before or after the forming process. Where the surface treatment is applied before forming, a further treatment may be required after forming to cover any exposed surfaces. The post 100 comprises two side elements 102,104 joined by a connecting web 106 extending perpendicular to the two side elements 102,104. During the cold rolling process the sheet metal is folded such that the side elements 102,104 are substantially double thickness with two adjacent layers of sheet metal forming the majority of each of the side elements 102,104. Additionally the sheet metal 102 has been folded so that the longitudinal side edges form flanges 108,110 that overlap the connecting web 106 adjacent to the side edges 102,104 providing the web 106 with two areas of double thickness each one proximate to one of the side elements 102,104. The flanges 108,110 are secured to the connecting web by a series of spot welds 112,114 spaced apart along the length of the post 100. In this embodiment, the post 100 is symmetrical about the line AA in Figure 1 and the areas of double thickness and welding make the post particularly strong.

Referring now to Figure 3 a fence post 100 is shown similar to that shown in Figures 1 and 2 provided with a strengthening gusset 116. The gusset 116 is positioned in one of the channels 118 created on opposite sides of the connecting web 106 by the side members 102,104. The gusset 116 is configured to be a close fit within the channel 118 and has cut out regions 120 to accommodate the areas of double thickness in the connecting web 106. The gusset 116 is secured to the side elements 102,104 and the connecting web 106 by welding. The provision of the gusset 116 in this embodiment may increase the strength of the post and reduce any tendency to whip and/or flex. More than one gusset may be provided in the channel 118 spaced apart along the length of the post.

One or more gussets may be provided in the channels on both sides of the connecting web 106. Where gussets are provided in both channels, the gussets may be aligned or offset in the direction of the length of the post.

The number and/or arrangement of the gussets may be varied according to the length of the post and/or the strength requirements for a given application.

Referring now to Figure 4 a fence post 100 is shown similar to that shown in Figures 1 to 3 where the top 122 of the post has been shaped to a point after the post 100 has been formed. This is an illustration of one of many ways the fence post 100 may be shaped following its formation so as to make it practically or aesthetically better suited for many different possible types of use.

Referring now to Figure 5 a fence post 100 is shown similar to that shown in Figures 1 to 4 provided with a tag 124 proximate to the bottom 124 of the post 100 pressed or otherwise formed out of the sheet metal of the connecting web 106. The tag 122 is of rectangular shape formed to extend outwards and upwards towards the top of the post. In use the bottom of the post 100 is buried (possibly in concrete) during installation along with the tag 124 which acts as an anchor increasing the resistance of the post to vertical movement. It will be appreciated that any number of tags 124 may be provided and that the or each tag may be of rectangular shape or any other shape.

Referring now to Figures 6 and 7 a second embodiment of a fence post according to the invention is shown generally at 300. This embodiment is similar to the previous embodiment and like reference numerals in the series 300 are used to indicate similar parts. In this embodiment, the post 300 has again been cold rolled from one continuous strip of rectangular metal sheet so as to have an I' shaped cross-section when viewed from either end. In this embodiment, during the cold rolling process, the metal sheet has been folded such that the longitudinal side edges of the sheet metal terminate in the side elements 302,304 adjacent to the connecting web 306 which comprises a single layer of sheet metal.

In other words, the flanges 108,110 of the previously described embodiment are omitted in this embodiment. The side edges of the sheet metal may be secured, for example by welding at the junction with the connecting web 306 or to the other layer of the side element. In this embodiment the post 300 is substantially symmetric about the lines AA and BB in Figure 6. In other respects the construction of the post 300 is similar to that of the previous embodiment and the post 300 may be provided with one or more strengthening gussets, anchoring tags or shaped top end as shown in Figures 3 to 5.

As will now be understood from the description of preferred embodiments, the invention provides a design and method of manufacture of a metal fence post that is strong and so as to resist flexing or whipping when used to construct a fence. The post is preferably cold rolled from one continuous piece of sheet metal. This may increase the efficiency of the manufacturing process as fewer components need to be assembled and/or there may be less waste material, as one or more posts may be formed from a single metal sheet with size and shape manufactured to the required specifications. We have found that a post of acceptable strength can be constructed using sheet metal with a thickness of 2.5mm producing a fence post weighing in the region of 5 kg/metre that represents a considerable reducing in weight and material costs compared with existing hot rolled steel fence posts that typically weigh in the region of 7.5 kg/metre. Additionally materials that have been cold rolled are hardened, which may be advantageous where fence posts need to be particularly resistant to denting, bending and the like. A further advantage is that it may be possible to surface treat the sheet metal, for example by galvanising steel to improve corrosion resistance, before it is cold rolled such that any surface treatment after forming the post may be reduced or avoided. In contrast, where the post is formed by hot rolling and a surface treatment is required, for example galvanising to improve corrosion resistance, such treatment must be carried out on the formed post after the hot rolling process.

It will be understood that the invention is not limited to the embodiment above-described and various modifications and improvements can be made without departing from the various concepts described herein. For example, in the first embodiment, the sheet metal may be folded so that side edges forming the flanges are arranged on opposite sides of the connecting web. In the first embodiment, one or both of the flanges may extend the full width of the connecting web so that the post comprises two layers of sheet metal for substantially the whole profile. In the second embodiment, the sheet metal may be folded so that the side edges terminate in the side elements on opposite sides of the connecting web.

In either embodiment, only part of one or both side elements may be provided with two layers of the sheet metal. Posts having other cross- sectional shapes are envisaged, for example a U-section, T-section, L-section, where some or all of the profile comprises at least two layers of sheet metal may be provided. Various cross-sections and profiles with part or all of the profile having more than layer of sheet metal are envisaged and within the scope of the invention.

It will also be appreciated that any of the features described herein may be employed separately or in combination with any other features and the invention extends to and includes all combinations and sub-combinations of one or more features described herein in any form of metal fence post.

Claims

CLAIMS1. A fence post made of sheet metal wherein, in cross-section, the post has a profile which at least in part is formed by more than one layer of sheet metal.
2, A fence post according to claim 1 wherein, the post is formed by cold rolling a strip of sheet metal.
3. A fence post according to claim 1 or claim 2 wherein, the sheet metal is steel.
4. A fence post according to. any preceding claim wherein, the post has a substantially I' shaped cross section with two parallel side elements joined by a connecting web which extends substantially normal to the side elements.
5. A fence post according to claim 4 wherein, the side elements and connecting web define longitudinally extending channels on opposite sides of the connecting web.
6. A fence post according to claim 4 or claim 5 wherein, one or both side elements comprise at least in part two adjacent layers of sheet metal.

*::::
7. A fence post according to any of claims 4 to 6 wherein, the connecting web comprises a single layer of sheet metal. **** S..
8. A fence post according to any of claims 4 to 6 wherein, the connecting web comprises at least in part more than one layer of sheet *:::: metal. * 30SS S *s
9. A fence post according to any of claims 4 to 6 wherein, side edges of the metal sheet terminate in flanges that overlap the connecting web.
10. A fence post according to claim 9 wherein, the flanges reinforce and strengthen the post.
11. A fence post according to claim 9 or claim 10 wherein the flanges are secured to the connecting web.
12. A fence post according to claim 11 wherein, the flanges are secured by a continuous weld along the length of the post.
13. A fence post according to claim 11 wherein, the flanges are secured by a series of spot welds spaced apart along the length of the post.
14. A fence post according to any of claims 5 to 13 wherein, one or more gussets is provided in either or both of the channels.
15. A fence post according to claim 14 wherein, the or each gusset reinforces and strengthens the post.
16. A fence post according to claim 14 or claim 15 wherein, the or each gusset is secured to the side elements and/or the connecting web.
17. A fence post according to any of claims 4 to 16 wherein, one/or ** S....' more anchor formations is provided on the connecting and/or the side elements at or near that end of the post that, in use, is buried when the *:::: post is installed. S **
18. A fence post according to claim 17 wherein, the or each formation assists retention of the post in position.
19. A fence post according to claim 18 wherein, the or each formation comprises a tag formed out of the sheet metal of the post.
20. A fence post according to claim 19 wherein, the tag extends in a direction that increases the anchoring effect.
21. A metal fence post is formed by cold rolling sheet steel to form an I-section with side elements connected by a web, the side elements are formed by two layers of sheet steel to have a double thickness by folding the sheet steel back on itself.
22. A fence post substantially as hereinbefore described with reference to Figures 1 to 4 of the drawings.
23. A fence post substantially as hereinbefore described with reference to Figures 1 to 4 of the drawings as modified by Figure 5 of the drawings.
24. A fence post substantially as hereinbefore described with reference to Figures 6 and 7 of the drawings. *i* * * * ** *
25. A method for the manufacture of a fence post is provided **** comprising rolling sheet metal to form, in cross-section, a profile that at least in part is formed by more than one layer of sheet metal.**S.*. * S
26. A method according to claim 25 including providing the post with one or more strengthening gussets following the cold rolling process.
27. A method according to claim 26 wherein, the or each gusset is formed separately and secured to the post.
28. A method according to any of claims 25 to 27 including providing the post with one or more anchoring formations following the cold rolling process.
29. A method according to claim 28 wherein, the or each formation is located at or near one end of the post which in use is buried in the ground.
30. A method according to claim 28 or claim 29 wherein, the or each formation is formed out of the material of the post.
31. A method according to claim 28 or claim 29 wherein, the or each formation is formed separately and secured to the post.
32. A method according to any of claims 25 to 31 wherein, the post has an I-section comprising side elements joined by a central connecting web to define longitudinal channels on both sides of the web and one or both side elements comprises two adjacent layers of sheet metal.

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33. A method according to any of claims 25 to 32 wherein, the sheet metal is steel. ***S
34. A method for the manufacture of a fence post substantially as *Sq*4d * hereinbefore described with reference to Figures 1 to 4 of the drawings. *4 * . * ** * S. 0S S *U
35. A method for the manufacture of a fence post substantially as hereinbefore described with reference to Figures 1 to 4 of the drawings as modified by Figure 5 of the drawings.
36. A method for the manufacture of a fence post substantially as hereinbefore described with reference to Figures 6 and 7 of the drawings.
37. A fence post made by the method according to any of claims 25 to 36.
38. A fence system comprising at least one fence post according to any of claims 1 to 24 or claim 37. e. * * * ** * * I** *. S..S S...S *eSS. * S * SS S. S SS * * S.Q