Structural system and method using monolithic beams having improved strength

A structural system for replacing a standard beam having a weight per unit length, a depth in a load direction, a characteristic cross-sectional shape and a width in a cross direction substantially perpendicular to the load direction, the structural system comprising:

• a monolithic beam having the characteristic cross-sectional shape, the depth in the load direction and the weight per unit length, the monolithic beam including
• a first flange extending in the cross direction and having a first thickness in the load direction, the first flange being not wider than the width in the cross direction;
• a second flange extending in the cross direction and having a second thickness in the load direction, the second flange being not wider than the width in the cross direction, at least one of the first flange and the second flange having the width in the cross direction, the second thickness being different from the first thickness;
• and
• a transverse section connecting the first flange and the second flange, the first flange, the second flange, and the transverse section being an integrated structure forming the monolithic beam;
• wherein the standard beam has a first standard flange, a second standard flange and a standard transverse section connecting the first standard flange and the second standard flange, the first standard flange extending in the cross direction and having a first standard thickness in the load direction, the first standard flange being not wider than the width in the cross direction, the second standard flange extending in the cross direction and having a second standard thickness in the load direction, the second standard flange being not wider than the width in the cross direction, at least one of the first standard flange and the second standard flange having the width in the cross direction, the first thickness plus the second thickness being equal to the first standard thickness plus the second standard thickness.

A method for providing a structural system for replacing a standard beam having a weight per unit length, a depth in a load direction, a characteristic cross-sectional shape and a width in a cross direction substantially perpendicular to the load direction, the method comprising:

• providing a monolithic beam having the characteristic cross-sectional shape, the depth in the load direction and the weight per unit length, the step of providing the monolithic beam including
• forming a first flange, a second flange and a transverse section, the first flange extending in the cross direction and having a first thickness in the load direction, the first flange being not wider than the width in the cross direction, the second flange extending in the cross direction and having a second thickness in the load direction, the second flange being not wider than the width in the cross direction, at least one of the first flange and the second flange having the width in the cross direction, the second thickness being different from the first thickness, the transverse section connecting the first flange and the second flange, the first flange, the second flange, and the transverse section being an integrated structure forming the monolithic beam;
• wherein the standard beam has a first standard flange, a second standard flange and a standard transverse section connecting the first standard flange and the second standard flange, the first standard flange extending in the cross direction and having a first standard thickness in the load direction, the first standard flange being not wider than the width in the cross direction, the second standard flange extending in the cross direction and having a second standard thickness in the load direction, the second standard flange being not wider than the width in the cross direction, at least one of the first standard flange and the second standard flange having the width in the cross direction, the first thickness plus the second thickness being equal to the first standard thickness plus the second standard thickness.