GB2628600A

GB2628600A - Framing system

Info

Publication number: GB2628600A
Application number: GB2304671.7A
Authority: GB
Inventors: Johnson Owen; Couldwell John
Original assignee: Voestalpine Metsec PLC
Current assignee: Voestalpine Metsec PLC
Priority date: 2023-03-29
Filing date: 2023-03-29
Publication date: 2024-10-02
Anticipated expiration: 2043-03-29
Also published as: GB2628600B; GB202304671D0

Abstract

The framing system comprises a plurality of studs 2 and at least one connectable spacer bar 5. The plurality of studs comprise at least one stud aperture 25 therein. The connectable spacer bar comprises a connector end 52 and a tail end 53, and is configured to extend between an adjacent pair of studs and through the stud aperture. The connector end of the connectable spacer bar is connectable to the tail end of a further connectable spacer bar. The framing system can be used in a method of constructing a stud wall.

Description

Framing System

Technical Field

The present invention relates to a framing system for constructing walls and buildings.

Background

Metal framing is a swift and efficient method of constructing walls for buildings, both load bearing and non-load bearing. Light gauge metal sections can be connected to form a frame onto which plasterboard, insulation and cladding can be mounted to complete the walls. The metal frame can either be provided in 'stick' form (e.g. cut and assembled on site), or prefabricated into panels which are simply connected together or to other structural elements on site.

Typical metal sections are profiled such that they are extremely efficient in terms of their use of material e.g. as C-sections, U-sections and I-sections. The reduced material within light gauge steel does, however, leave the profiles susceptible to twisting under load e.g. lateral torsional buckling. Such buckling is resisted by attaching a rigid board to the studs and/or by bracing the studs using additional metal sections.

The additional restraints are sometimes called noggins (or noggings), although this term is borrowed from traditional timber framing construction wherein the noggins are used to prevent bowing of the timber studwork.

Figure 1 shows a portion of a conventional system designed to resist lateral torsional buckling. The frame 100 comprises vertically extending studs 102, 104 which would typically be joined at their upper and lower ends by a top rail and base plate (not shown). The studs are connected by a blocking section 110 which is cut to fit tightly between the two studs 102, 104. The blocking section 110 is cut from the same profile of steel (i.e. C-section) used for the studs 102, 104. The blocking section is connected to the studs by bracing straps 106 which extend along the sides of the blocking section 110 and overlap with the studs 102, 104. Mechanical fasteners 108 are used to fix the bracing straps 106 to the studs 102, 104 and blocking section 110. Whilst this is effective, it is slow and complicated to construct, requiring a large amount of additional metal thereby increasing weight, transport costs, and embodied energy and has a higher than desired carbon footprint.

The present invention seeks to resolve or mitigate the problems of prior art metal framing systems.

Summary of Invention

According to a first aspect of the invention, there is provided a framing system. The framing system may comprise a plurality of studs. The studs may comprise at least one stud aperture therein. The framing system may comprise at least one connectable spacer bar. The spacer bar may comprise a connector end and a tail end. The connectable spacer bar may be configured to extend between an adjacent pair of studs and through the stud aperture. The connector end of the connectable spacer bar may be connectable to the tail end of a further connectable spacer bar.

The framing system is quick and easy to assemble, either on site or as a prefabrication for subsequent installation. The at least one spacer bar being connectable to a further spacer bar creates a high degree of adaptability and configurability for the framing system e.g. to produce any dimensions of wall with minimal material wastage. In use, panel materials such as plasterboard or cladding can be fixed to the framing system to complete the walls.

The connectable spacer bar may comprise a plate or profile section e.g. formed from a metal or plastics material. In some embodiments, the spacer bar comprises an angle profile. Preferably, the spacer bar is formed from a metal angle profile, such as steel. For example, the angle profile may comprise a cold-rolled steel profile or section. The angle profile may comprise two elongate surfaces which are joined by a bend running the length of the profile, as is known in the art. The angle profile may have an internal angle of 70° to 120°, from 80° to 110°, 90° to 100°, and/or approximately 95°. In some embodiments, the spacer bar is formed from a U-profile, C-profile, box section or any suitable cross-section of material. The spacer bar may have a material thickness of <1mm to 3mm, e.g. 1.0mm, 1.2mm, 1.4mm, 1.6mm, 1.8mm, 2.0mm, 2.2mm, 2.3mm, 2.4mm, 2.5mm, 2.6mm, 2.7mm, 2.8mm, or 3.0mm.

The plurality of studs may comprise a plate or profile section e.g. formed from a metal or plastics material. Preferably, the studs are formed from a C-profile, although they alternatively may be formed from a U-profile, I-profile, box section or any suitable cross-section of material. The studs may be metal e.g. steel. The studs may have a material thickness of <1mm to 3mm, e.g. 1.0mm, 1.2mm, 1.4mm, 1.5mm, 1.6mm, 1.8mm, 2.0mm, 2.2mm, 2.3mm, 2.4mm, 2.5mm, 2.6mm, 2.7mm, 2.8mm, or 3.0mm.

The framing system may comprise a plurality of connectable spacer bars. The plurality of connectable spacer bars may be configured to extend between adjacent pairs of studs and to be connected to one another to form an elongate strut. In some embodiments, the or each connectable spacer bar may extend through a single stud aperture only.

The connector end of the connectable spacer bar may comprise at least one connector aperture for receiving a mechanical fastener therethrough. The mechanical fastener may comprise a screw or bolt, such as a self-tapping screw or a self-drilling screw. In some embodiments, the connector end comprises a pair of connector apertures. In embodiments comprising an angle profile, the connector end may comprise a connector aperture per face of the connectable spacer bar.

The connector end may be configured to engage the stud aperture of one of the plurality of studs. The connector end may thus resist twisting of the stud. The studs may comprise a plurality of stud apertures.

The connector end may comprise at least one slot for receiving the wall of the stud adjacent the stud aperture therein. In some embodiments, the connector end comprises a pair of slots. Additionally or alternatively, the connector end may comprise at least one shoulder configured to bear against the stud adjacent to the stud aperture. For example, the shoulder may comprise one side of a slot. In some embodiments, the slot and/or shoulder may be spaced approximately 600mm, or alternatively 400mm or 450mm, from the terminal end of the tail. By approximately, it is intended that the studs to which the spacer bar is fitted would be positioned on 600 or 450mm centres. Thus the position of the slot and/or shoulder may be a few millimetres off 600mm or 450mm in order to accommodate varying material thicknesses, slot sizes, and or to ease installation or prevent excessive friction. In one series of embodiments, the slot and/or shoulder may be spaced between 590mm-600mm or 595mm-599mm, or between 440mm-450mm 445mm -449mm from the terminal end of the tail.

In some embodiments, the slot and/or shoulder may be located less than 100mm from the terminal end of the connection end. i.e. the connection end may have a length of less than 100mm. Alternatively, the connection end may have a length of less than 80mm, 60mm, 50mm, 40mm, 30mm, or 20mm.

The framing system may further comprise at least one bracket. The bracket may be for connecting the tail of one of the connectable spacer bars to one of the studs. The bracket may comprise one or more connection apertures e.g. for receiving a mechanical fastener therethrough. The bracket may comprise one or more flanges for connecting to a stud. The bracket may comprise a connection portion configured to conform to the surface of the spacer bar.

The framing system may further comprise at least one top rail and/or base track connectable to the upper and/or lower ends of the plurality of studs respectively. The top rail may be a slotted rail.

In a second aspect of the invention, there is provided a connectable spacer bar configured for use in the framing system described herein.

In a third aspect of the invention, there is provided a method for constructing a stud wall comprising a framing system described herein. The method may comprise inserting the connector end of a first connectable spacer bar through the stud aperture of a first stud. The method may comprise connecting the connector end to the tail end of a second connectable spacer bar.

The first and second connectable spacer bars may be connected with at least one mechanical fastener. The method may comprise aligning the connector end of the first spacer bar over the tail end of the second spacer bar.

The method may comprise repeating the process with a plurality of connectable spacer bars to form an elongate stud.

The method may comprise connecting the connector end to the stud. For example, the connector end may comprise at least one slot, and connecting the connector end to the stud may comprise moving or rotating the spacer bar such that the slot locates over the walls of the stud aperture.

The method may comprise connecting the tail end of at least one of the connectable spacer bars to a stud using a bracket. The bracket may be connectable to the stud and the connectable spacer bar using mechanical fasteners. The method may comprise cutting a spacer bar to reduce its length prior to connecting to a stud.

Brief Description of the Figures

The invention will now be described with reference to the following Figures, wherein Figure 1 is a perspective view of a portion of a prior art framing system; Figure 2 is a perspective view of a framing system; Figure 3 is a zoomed in view of the highlighted region of Figure 2; Figures 4a and 4b are a perspective and top view of a component for a metal framing system; and Figure 5 is a perspective view of a component for a metal framing system.

Specific Description

Turning now to Figure 2 and 3, there is shown a framing system 1 for use in constructing a wall.

The framing system 1 comprises a series of regularly spaced studs 2 connected at their lower end by a base plate 3 and at their upper end by a top rail 4. Between each pair of adjacent studs 2 is a connectable spacer bar 5. The base plate 3 and the top rail 4 are formed from metal U-sections, for example, steel channel. The width of the base plate 3 and top rail 4 is slightly greater than the width of the studs 2, such that they can easily receive the studs 2 within the channel. The base plate 3 and top rail 4 are connected to the studs by mechanical fasteners (such as self-drilling screws) which extend through the base plate and top rail and into the studs 2.

The studs 2 are metal C-sections, having a central web 21 flanked by flange 22, each having a lip 23 thereon. The central web 21 has a stud aperture 25 therein located approximately halfway along the height of the studs 2. The stud aperture 25 has a rounded rectangular shape, although circular, oval and stadium shaped apertures may also be provided.

With additional reference to Figures 4a and 4b, the connectable spacer bars 5 are formed from an elongate length of angle steel i.e. a long plate which has been bent longitudinally so as to provide a pair of faces 51 at an angle to each other. The connectable spacer bars 5 have a connector end 52 at a first end and a tail end 53 at a second, opposite end thereof. The connector end 52 is provided with a pair of connector apertures 54, one in each surface 51, and a pair of slots 55, also provided with one in each surface 51. Each slot 55 forms a pair of shoulders 56 in the spacer bar. The slots 55 are provided a first length, L1, from the terminal end of the tail end 53 and a second length, L2, from the terminal end of the connector end 52. L1 is approximately 600mm, and L2 is approximately 40mm. The slots 55 are configured to fit tightly around the central web 21 of the stud 2 around the stud aperture 25. The slots 55 thus have a width approximately equal to the thickness of the material used for the studs 2 e.g. approximately 2mm.

The term 'approximately' above is intended to include a small variation to allow easy fitting of the spacer bar between studs. For example, the length L1 is configured to allow the studs 2 to be placed at 600mm centres, and thus may be a few millimetres shorter than 600mm. Furthermore, the length L1 needs to account for the width of the slots 55, which may vary depending on the thickness of the material being used for the studs. For example, for studs produced from 2mm steel, the slots 55 may have a width of 2 to 2.2mm. The length L2 of the connector end can be varied by the manufacturer as long as it is great enough to provide a secure connection to the tail of the adjacent spacer bar 2.

Turning now to Figure 5, there is shown a bracket 6 for use within the framing system 1. The bracket 6 comprises a pair of angled faces 61 configured to conform to the angle of the spacer bar 2, and a pair of bracket flanges 63 configured to abut a stud 2 in use. Each angled face 61 has a length L3 which is provided with a bracket aperture 62 through which a mechanical fastener (not shown) can be inserted.

A method of assembly will now be described with reference to all of Figures 2 to 5. The base plate 3 and top rail 4 are positioned and fixed in their desired location with mechanical fasteners or similar. A stud 2 is positioned between the base plate 3 and top rail 4 and rotated such that it extends vertically and into the channels of the base plate 3 and the top rail 4. The stud 2 can be secured to the base plate 3 and top rail 4 using mechanical fasteners, such as self-drilling screws.

An installer then inserts the connector end 52 of a connectable spacer bar 2 through the stud aperture 25 and rotates the connectable spacer bar 2 such that the slots 55 receive the walls of the stud aperture 25 therein. As shown in Figure 3, typically this would leave the 'open' face of the connectable spacer bar 2 facing downwards. The connectable spacer bar 2 can be pushed downwards to fully secure the slots 55 within the stud aperture, or alternatively, it may be held in position by the friction of the shoulders 56 against the central web 21 of the stud 2.

A second stud 2 can then be positioned adjacent to the first stud 2 and between the base plate and top rail without being secured in position. A second connectable spacer bar 5 is connected to the second stud 2 as described above, and positioned such that the tail end 53 of the second spacer bar 5 extends underneath the connector portion 52 of the first connectable spacer bar 5. Since the length L1 of the spacer bars 2 is approximately 600mm, the tail end 53 of the second spacer bar 5 should be tight against the first stud 2. Mechanical fasteners, such as self-drilling screws 57, can then be inserted through the connector apertures 54 of the first spacer bar 5 and into the tail end 53 of the second spacer bar 5 to form a single elongate strut. Mechanical fasteners 31, 41 can be used to secure the second stud 5 to the base plate 3 and top rail 4. This process can be repeated, installing studs 2 and connectable spacer bars 5 together until the desired length of wall is achieved. In most installations, this will leave at least one spacer bar 5 with an unconnected tail end 53. Accordingly, the free tail end 53 can be connected to the final stud 2 using a bracket 6. The bracket 6 is positioned such that the angled faces 61 locate over the tail end 53 and the bracket flanges 63 abut the central web 21 of the stud 2 to which the bracket 6 will be attached. Mechanical fasteners can then be inserted through the bracket apertures 62 into the tail end 53, and through the central web 21 and bracket flanges 63.

Once assembled, as shown in Figure 2, the connectable spacer bars 5 form an elongate strut which spans all of the studs 2 in the framing system 1. The spacer bars 5 perform two functions -accurate positioning of the studs 2, and high resistance to lateral torsional loading. Lateral torsional stresses on the framing system 1 can cause an axial twist in the studs 2, and eventually, failure of the stud. This twisting motion is resisted by the shoulders 56 and/or the slots 55 which are positioned tightly against the central web 21 of the stud 2. Twisting stresses are thus transferred to the spacer bars as compression and extension stresses through the shoulders, and since the spacer bars 5 have high strength in this axis, the twist of the stud is effectively resisted.

Furthermore, the spacer bars 5 use much less material than the prior art solution of cutting lengths of stud to act as blocking sections as shown in Figure 1, and may also lead to reductions in the material thickness of the studs 5 themselves. Since most commercial steel production methods are high carbon emitters, reducing the material required reduces both the embodied carbon in the construction as well as the reducing the energy and carbon emissions involved in transporting the framing system.

In some embodiments (not shown), the shoulders 56 may be provided by a large cut out or recess, rather than a narrow slot. In such embodiments, the shoulder 56 would still be fitted against the central web 21 and resist lateral torsional stress. Since the tail end 53 of the next spacer bar 5 would be located tight to the central web 21 on the opposite side to the shoulder 56, the tail end can also act as the opposing shoulder (i.e. on the connector end of the spacer bar).

In further embodiments (not shown), the studs may each comprise a plurality of stud apertures therein. The plurality of stud apertures may be located adjacent to each other e.g. to provide the installer with options for the height at which the spacer bars are to be installed. Additionally or alternatively, the stud apertures may be spaced apart along the length of the stud e.g. for receiving two parallel spacer bars at different heights. The stud apertures (including any additional studs apertures) may also be used for routing cabling, fibre optics and/or pipework through the walls.

Since the connectable spacer bars 5 are a predetermined length, the studs can be positioned with a very high degree of precision. As described above, the length L1 of the spacer bars 5 is approximately 600mm, thereby allowing studs to be positioned on 600mm centres accurately. Alternatively, depending on the material being fixed to the studs 2, connectable spacer bars 5 with a length L1 of approximately 400mm or 450mm or any other suitable length may be used.

It would also be understood that due to the limitations and dimensions of the building being constructed, the framing system may require additional studs to be placed at an alternative distance apart e.g. to accommodate doors or windows, cladding movement joints, or for support for cavity barriers. In such cases, regular placement of the studs is interrupted, but the connectable spacer bars can be easily cut to the desired length and still connected to the studs 2 and further spacer bars 5 as described above and/or with further brackets 6. Advantageously, the framing system thus provides a very high degree of adaptability whilst only requiring a minimal number of cuts to be made on site, and while minimising the material used to do so.

Claims

CLAIMS: 1. A framing system comprising: a plurality of studs, comprising at least one stud aperture therein, and at least one connectable spacer bar comprising a connector end and a tail end, wherein the connectable spacer bar is configured to extend between an adjacent pair of studs and through the stud aperture, and wherein the connector end of the connectable spacer bar is connectable to the tail end of a further connectable spacer bar.
2. The framing system of claim 1, comprising a plurality of connectable spacer bars configured to extend between adjacent pairs of studs and to be connected to one another to form an elongate strut.
3. The framing system of either preceding claim, wherein the connector end of the connectable spacer bar comprises at least one connector aperture for receiving a mechanical fastener therethrough.
4. The framing system according to any one of the preceding claims, wherein the connector end is configured to engage the stud aperture of one of the plurality of studs.
5. The framing system according to claim 3, wherein the connector end comprises at least one slot for receiving the wall of the stud adjacent the stud aperture therein.
6. The framing system according to either claim 4 or 5, wherein the connector end comprises at least one shoulder configured to bear against the stud adjacent to the stud aperture.
7. The framing system according to either claim 5 or 6, wherein the slot and/or shoulder is spaced approximately 600mm from the terminal end of the tail.
8. The framing system according to any one of the preceding claims, wherein the spacer bar comprises an angle profile.
9. The framing system according to any one of the preceding claims, further comprising at least one bracket for connecting the tail of one of the connectable spacer bars to one of the studs.
10. The framing system according to any one of the preceding claims, further comprising at least one top rail and/or base track connectable to the upper and/or lower ends of the plurality of studs respectively.
11. A connectable spacer bar configured for use in the framing system of any one of the preceding claims.
12. A method for constructing a stud wall comprising a framing system according to any one of claims 1 to 10, the method comprising: inserting the connector end of a first connectable spacer bar through the stud aperture of first stud, and connecting the connector end to the tail end of a second connectable spacer bar.
13. The method according to claim 12, wherein the first and second connectable spacer bars are connected with at least one mechanical fastener.
14. The method according to claim 12 or 13, comprising connecting the tail end of at least one of the connectable spacer bars to a stud using a bracket, and wherein the bracket is connectable to the stud and the connectable spacer bar using mechanical fasteners.