BUILDING CONSTRUCTION USING BRACED FRAME SLAB ASSEMBLIES HAVING HEAVY PERIMETER RAILS

Abstract

This invention relates to the construction of a building using Braced Frame Slab Assemblies Having Heavy Perimeter Rails that comprise Floor Slab and Wall Slab Assemblies formed of heavy perimeter Rails, with Rail Frame Connectors, such as a plurality of heavy threaded screws, joining the heavy perimeter Rails to form the Floor Slabs and Wall Slabs. The Slab can then be equipped with joists for floors or studs for walls, and with structural sheathing to provide shear load carrying capacity. The Slab to Slab Connectors also secure juxtaposed Floor Slabs and Wall Slabs.

Claims

1. A method for constructing a building, comprising: constructing a plurality of Slabs, each Slab formed of a plurality of interconnected heavy perimeter Rails that enclose a predetermined space; and interconnecting each heavy perimeter Rail of the plurality of heavy perimeter Rails in a Slab with a juxtaposed heavy perimeter Rail using Rail Frame Connectors.

2. The method for constructing a building of claim 1, further comprising: joining a first Slab of the plurality of Slabs to a second Slab of the plurality of Slabs by interconnecting a heavy perimeter Rail of the first Slab to a juxtaposed heavy perimeter Rail of the second Slab using Slab to Slab Connectors.

3. The method for constructing a building of claim 2, wherein the step of joining comprises: joining the first Slab to the juxtaposed second Slab using Slab to Slab Connectors in at least one location along their juxtaposed heavy perimeter Rails.

4. The method for constructing a building of claim 1, wherein the step of constructing Slabs comprise: forming at least one of a Wall Slab and a Floor Slab by incorporating studs and joists into the Slab that extend between heavy perimeter Rails, respectively.

5. The method for constructing a building of claim 4, wherein the Wall Slabs are connected to Floor Slabs by their respective Rails and the Floor Slab is connected to the Foundation, so all structural loads on the building are transferred to the foundation.

6. The method for constructing a building of claim 5, wherein the step of constructing a Wall Slab further comprises: affixing structural sheathing to a one of an exterior face or an interior face of the structural two dimensional Slab(s) to provide in plane shear carrying capacity.

7. The method for constructing a building of claim 5, wherein the step of constructing a Floor Slab further comprises: forming a structural two dimensional Slab(s) including structural sheathing to provide shear load carrying capacity.

8. The method for constructing a building of claim 1, wherein the step of interconnecting using Rail Frame Connectors comprises: using a plurality of heavy threaded screws or other hardware with a similar function to interconnect heavy perimeter Rails.

9. The method for constructing a building of claim 1, wherein the step of interconnecting using Slab to Slab Connectors comprises: using a plurality of heavy threaded screws to interconnect the heavy perimeter Rails of juxtaposed Slabs.

10. A building, comprising: a plurality of Slabs, each Slab formed of a plurality of interconnected heavy perimeter Rails that enclose a predetermined space; and a plurality of Rail Frame Connectors which interconnect each heavy perimeter Rail of the plurality of heavy perimeter Rails in a Slab with a juxtaposed heavy perimeter Rail.

11. The building of claim 10, further comprising: a first Slab of the plurality of Slabs joined to a second Slab of the plurality of Slabs by interconnecting a heavy perimeter Rail of the first Slab to a juxtaposed heavy perimeter Rail of the second Slab using Slab to Slab Connectors in at least one location along their juxtaposed heavy perimeter Rails.

12. The building of claim 10, wherein further comprising: at least one of a Wall Slab and a Floor Slab by incorporating studs and joists into the Slab that extend between heavy perimeter Rails, respectively.

13. The building of claim 12, wherein the Wall Slabs are connected to Floor Slabs by their respective Rails, and the Floor Slab is connected to the Foundation, so all structural loads on the building are transferred to the foundation.

14. The building of claim 13, wherein the Wall Slabs further comprise: structural sheathing affixed to a one of an exterior face or an interior face of the structural two dimensional slab to provide in plane shear carrying capacity.

15. The building of claim 11, wherein the Floor Slab comprises: a structural two dimensional slab including joists that extend between heavy perimeter Rails.

16. The building of claim 15, wherein the Floor Slab further comprises: a structural two dimensional slab including structural sheathing to provide shear load carrying capacity.

17. The building of claim 10, wherein the Rail Frame Connectors comprise: a plurality of heavy threaded screws that present a structurally secure Rail in the first Slab to the juxtaposed Rail in the second Slab by interconnecting the Rails that form the perimeter of these Slabs.

18. The building of claim 10, wherein the step of interconnecting using Rail Frame Connectors comprises: a plurality of heavy threaded screws to interconnect heavy perimeter rails.

19. The building of claim 10, wherein the step of interconnecting using Slab to Slab Connectors comprises: a plurality of heavy threaded screws to interconnect the heavy perimeter rails of juxtaposed Slabs.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] FIG. 1 illustrates a perspective view of a Wall Slab which is a pre-fabricated, framed wall component of wall studs and the cavity space between them, deriving shear strength from sheathing applied to at least one vertical surface of the Wall Slab, which includes heavy Rails as its perimeter, used as a framing assembly construction element in the construction of a dwelling;

[0027] FIG. 2 illustrates a perspective view of the interconnection of a Head Rail and an Wall End Rail to form a Wall Slab used as a construction element in the construction of a dwelling;

[0028] FIG. 3 illustrates a perspective view of the interconnection of two Wall Slabs used in the construction of a dwelling;

[0029] FIG. 4 illustrates a perspective view of additional details in the interconnection of two Wall Slabs used in the construction of a dwelling;

[0030] FIG. 5 illustrates a perspective view of additional details in the interconnection of two Wall Slabs used in the construction of a dwelling as shown in FIG. 4;

[0031] FIG. 6 illustrates a side view of additional details in the interconnection of two Wall Slabs used in the construction of a dwelling as shown in FIG. 4;

[0032] FIG. 7 illustrates a perspective view of a Wall Slab with the inclusion of a plurality of framing elements;

[0033] FIG. 8 illustrates a perspective view of a Wall Slab with the inclusion of a plurality of framing elements as well as sheathing and inside drywall;

[0034] FIG. 9 illustrates a perspective view of the Wall Slab of FIG. 8 once the sheathing and drywall are affixed to the framing elements;

[0035] FIG. 10 illustrates a perspective view of a Wall Slab with the inclusion of a plurality of framing elements that provide openings for a window and a doorway, with the use of a Heavy Head Rail;

[0036] FIG. 11 illustrates a perspective view of a Wall Slab with the inclusion of a plurality of framing elements as well as sheathing and inside drywall;

[0037] FIG. 12 illustrates a perspective view of the Wall Slab of FIG. 11 once the sheathing and drywall are affixed to the framing elements; FIG. 13 illustrates a perspective view of a Floor Slab used as a construction element in the construction of a dwelling;

[0038] FIG. 14 illustrates a perspective view of the interconnection of two Floor Edge Rails to form a Floor Slab used as a construction element in the construction of a dwelling;

[0039] FIG. 15 illustrates a plan view of the interconnection of two Floor Slabs used in the construction of a dwelling;

[0040] FIG. 16 illustrates a perspective view of additional details in the interconnection of two Floor Slabs used in the construction of a dwelling as shown in FIG. 15;

[0041] FIG. 17 illustrates a perspective view of additional details in the interconnection of two Floor Slabs used in the construction of a dwelling as shown in FIG. 15;

[0042] FIG. 18 illustrates a perspective view of a Floor Slab with the addition of a plurality of joists therein;

[0043] FIG. 19 illustrates a perspective view of the Floor Slab of FIG. 18 with the application of floor sheathing to the top surface thereof; and

[0044] FIG. 20 illustrates a perspective view of the joining of a Wall Slab with Floor Slabs.

DETAILED DESCRIPTION

[0045] The standard framing paradigm used in conventional construction is a “braced frame” structure where the bracing is provided via the OSB sheathing that covers the floors and walls once they are secured in place. Standard framing utilizes a uniform sheathing on both floors and walls (except at door and window openings) to create a braced frame (a.k.a. a diaphragm). The emphasis in this type of construction is the continuity of the OSB sheathing across the full extent of the wall and floor elements. For example, each of the parts in a wall frame is dedicated to a specific purpose—bottom plate, full studs, trimmer studs, headers, top plate, etc. There are no pieces in this structure that support another purpose—i.e. for the primary structural attachment of adjoining independent panelized components.

[0046] In contrast, the present Braced Frame Slab Assemblies Having Heavy Perimeter Rails incorporates heavy perimeter Rails for this purpose, which is a fundamental distinction over the standard framing described above. In the present Braced Frame Slab Assemblies Having Heavy Perimeter Rails, there is no need for surface continuity of the OSB panels, either in floors or walls. In fact, all of the Wall Slabs and Floor Slabs are interrupted with joints between adjacent Slab Assemblies. So shear continuity is achieved by the structural connection between independent Slab Assemblies via the interconnection of the perimeter “heavy” Rail frames of this framing system, because customary shear continuity to the edges of full floor and wall elements with continuous OSB is impossible. This is a non-obvious and novel means to create “braced frame” integrity in a whole structure. The Slab Structure does this by interconnecting completely independent Floor Slabs and Wall Slabs by joining their perimeter Rails to achieve the same end to end shear element functionality for the full walls and floors that is required.

[0047] Conventional, sequenced, individual trade based conventional frame construction “teaches away” from the present Building Construction Using Braced Frame Slab Assemblies Having Heavy Perimeter Rails. The goal of conventional framing is to minimize the cost of this individual aspect of the whole house—i.e. just the framing part alone. This is why there are no individual pieces that do not have relevance in the required elements for the whole, completed home. If there were such pieces, they would by definition be wasteful if one looked at the frame without consideration of the entirety of the construction more broadly.

[0048] In the present Building Construction Using Braced Frame Slab Assemblies Having Heavy Perimeter Rails, the frame not only provides the structural integrity for the finished structure, but it also is a primary means of streamlining many (otherwise) independent aspects of construction. Completed, closed-Wall Slabs can be made with the present Braced Frame Slab Assemblies Having Heavy Perimeter Rails, off foundation in a more efficient plant setting or on-site assembly area, so now incremental efficiency is gained in overall time as well as time, material and logistics related costs to install: electrical, insulation, drywall, siding, windows and doors, plumbing, etc.

Braced Frame Slab Assemblies having Heavy Perimeter Rails

[0049] FIG. 1 illustrates a perspective view of a Wall Slab which is a pre-fabricated, framed wall component that derives shear strength from the sheathing that will cover it including the heavy Rails forming its perimeter that enclose a predetermined space, which is referred to as 2-Dimensional because of its slab-like configuration, used as a framing assembly construction element in the construction of a dwelling, and FIG. 2 illustrates of the interconnection of a Head Rail and an Wall End Rail to form a Wall Slab used as a construction element in the construction of a dwelling. This technology is based on Slab Assemblies, primarily 2D (they can also be 3D for planned bathrooms and/or kitchens), of both Wall Slabs and Floor Slabs. All of them have a “heavy” perimeter of Rails so that they can be structurally attached together to enclose a predetermined space. Braced frame Floor Slabs can be affixed to adjoining braced frame Floor Slabs, braced frame Floor Slabs can be affixed to braced frame Wall Slabs, braced frame Wall Slabs can be affixed to adjacent braced frame Wall Slabs, all by attaching the heavy perimeter Rail frame of each via Slab to Slab Connectors, such as long, structural screws. These Slab to Slab Connector screws can be put into Slab Assemblies independent of whether they are open panels (with no drywall or other covering), and also if the Slab Assemblies are fully covered up with finish materials. If the Slab Assemblies are covered up (ex.: drywall), then you just screw right through the drywall into the heavy perimeter Rails of two adjacent Slab Assemblies, and later patch up the small hole left from the fastening. The use of heavy Rails, reinforced by wall studs or floor joists and the sheathing, allows structural Slab to Slab Connector placement freely at any location along the Rail. This is completely unique and represents the full completion of the Rail apparatus, namely, that the Rail enables adjacent Slab Assemblies to be structurally connected to adjacent Slab Assemblies with Slab to Slab Connector placement freely located on these Rails. Normally, in framing the heavy connection hardware must be placed at studs and/or posts and/or solid blocking in a floor to achieve the strength that we get with our continuous heavy perimeter Rails.

[0050] The perimeter Rails are different and bigger than traditional framing elements, and serve a unique function that is not present in standard framing. They are also similar to one another, i.e. the Heavy Perimeter Rails in a Floor Slab serve the same purpose and are configured in the same perimeter arrangement as the Heavy Perimeter Rails in a Wall Slab, so the names that identify each unique piece carry a commonality with regard to the balance of related pieces.

[0051] The word “Rail” connotes a member of size and significance that is different than customary framing pieces in houses. A “Rail” is strong, and an identity element different than the pieces around it that enclose a predetermined space. It can be horizontal (in floors or in the top or bottom of a wall), or vertical (at the terminus of walls). All Wall Slab Assemblies have: a “Head Rail” or “Heavy Head Rail” at the top, depending on whether it was a Wall Slab without windows or one with windows; a “Toe Rail” at the bottom; “Wall End Rails” at the side of all Wall Slab. On Floor Slabs there are “Floor Edge Rails” on all four sides of all Floor Slab. In all instances of Wall Slab and Floor Slab creation there are Rails at the perimeter. In all instances of connection—of any two Slab Assemblies together—a Rail in one Slab is affixed to a Rail in an adjoining Slab. In traditional construction, framing typically uses dimensional lumber, such as 2″×4″ or 2″×6″ members to create the wall frames. In contrast, the present Braced Frame Slab Assembly Having Heavy Perimeter Rails makes use of Rail members that are heavy to provide a source of stability in the joining of the Wall Slabs and Floor Slabs. These Rail elements can be sawn lumber of greater dimensions than traditional framing members, or manufactured elements, for example, such as Glulam or VersaLam members manufactured by Boise Cascade, or even steel members. These “heavy Rails” provide the sound structure that allows the joining of Slab Assemblies in a secure, solid manner noted above. The Rails also enable the Wall Slabs and Floor Slabs to be capable of hoisting and handling without damage to the Wall Slabs and Floor Slabs and their installed components.

[0052] FIG. 1 illustrates a basic Wall Slab 100 which consists of a Head Rail 101 which spans the space between Wall End Rails 103, 104 which are affixed to Toe Rail 102. The smallest dimension of all of these Rails is greater than used in conventional framing construction and/or of a material that is stronger than untreated lumber. The Head Rail 101 spans the distance between Wall End Rails 103, 104 and functions to rigidly interconnect these elements as well as provide a load bearing capability for the Wall Slab 100. FIG. 2 illustrates a perspective view of the interconnection of a Head Rail 101 and a Wall End Rail 103 to form a braced frame Wall Slab 100 used as a construction element in the construction of a dwelling. The interconnection of Head Rail 101 and Wall End Rail 103 is accomplished by the use of Rail Frame Connectors, such as countersunk long screws 103-1 and 103-2 which penetrate deeply into Wall End Rail 103 to secure these two Rail elements together. A similar interconnection between Wall End Rails 103, 104 and Toe Rail 102 is accomplished via Rail Frame Connectors, such as the use of countersunk screws (not shown) as described with respect to Head Rail 101 and an Wall End Rails 103, 104.

[0053] FIG. 3 illustrates a perspective view of the interconnection of two Wall Slabs used in the construction of a dwelling; FIG. 4 illustrates a perspective view of additional details in the interconnection of two Wall Slabs used in the construction of a dwelling; FIG. 5 illustrates a perspective view of additional details in the interconnection of two Wall Slabs used in the construction of a dwelling as shown in FIG. 4; and FIG. 6 illustrates a side view of additional details in the interconnection of two Wall Slabs used in the construction of a dwelling as shown in FIG. 4.

[0054] In FIG. 3, two braced frame Wall Slabs 100, 110 are illustrated, interconnected at respective juxtaposed ends in an orthogonal orientation. Braced frame Wall Slab 100 consists of Head Rail 101, Toe Rail 102 and Wall End Rails 103, 104, while braced frame Wall Slab 110 consists of Head Rail 111, Toe Rail 112 and Wall End Rails 113, 114. As with braced frame Wall Slab 100, Rail Frame Connectors, such as countersunk screws 113-1 and 113-2 are used to secure Head Rail 111 with Wall End Rail 113. This connection of Wall End Rails 103, 113 is illustrated in additional detail in FIGS. 4-6, where the braced frame Wall Slab 100 is connected to the braced frame Wall Slab 110 via the use of Slab to Slab Connectors, such as a plurality of countersunk screws, of which 113-5 is shown in FIGS. 4-6, which penetrate Wall End Rail 113 and into Wall End Rail 103.

[0055] The interconnection of Wall End Rails 113 and 103 is preferably accomplished by the use of two screws in one location, at different angles from each other (90 degree offset is strongest), to lock that location in place at a high load capacity (as shown in FIG. 17). Also, the screws go in at an angle, so a screw going into a “heavy” perimeter Rail that is 2 ⅝″ thick actually intersects that “heavy” perimeter for 3″-5″, depending on the angle of the screw. So even a “heavy” Rail perimeter that is only 2 ⅝″ thick (i.e. not a huge piece) becomes a very strong embedment for the structural screws because they contact that member for 3″-5″ (i.e. plenty of contact length for high capacity connection). These pairs of screws can be used near the distal ends of the two Wall End Rails for best interconnection or can be freely placed at any location along the common Rail boundary between Slabs. In addition, the long structural screws can be, for example, the “Ledger Lock” variety, where the shank next to the screw head has no threads, and the half of the shank near the tip of the screw has heavy threads, so when it is driven into a Rail, it climbs itself into the material in a “self-tapping” manner and soundly sucks the two members together as the threads bite into the “far” piece and pull it tightly against the “near” piece between the wide screw head on the “near” piece and the secure bite into the far piece. They lock together with considerable force resulting in a high capacity structural connection—especially with two screws in one location at different angles to each other.

[0056] FIGS. 7-9 illustrate a perspective view of a braced frame Wall Slab Assembly 100 with the inclusion of a plurality of framing elements 100-1 to 100-8, as well as drywall 121, structural sheathing 122 and insulation 123 and once the sheathing is affixed to the framing elements to form a wall module W1.

Braced Frame Wall Panel having Window and Door Openings using Rails

[0057] FIGS. 10-12 illustrates a perspective view of a braced frame Wall Slab Assembly used as a Wall Slab 200 construction element in the construction of a dwelling with the inclusion of a plurality of framing elements 205-1 to 205-3 that provide openings for a door frame 205 and framing elements 206-1 to 206-4 that provide openings for a window 206, as well as wall studs 200-1 to 200-5 and drywall 221, structural sheathing 222 and insulation 223 and once the sheathing is affixed to the framing elements to form a wall module W2.

[0058] In the manner described above with respect to braced frame Wall Slab 100, braced frame Wall Slab 200 consists of a Heavy Head Rail 201 which spans the space between Wall End Rails 203, 204 which are affixed to Toe Rail 202. All of these Rails are members of size (dimensions) that are greater than used in conventional framing construction and/or of a material that is stronger than untreated lumber. The Heavy Head Rail 201 spans the distance between Wall End Rails 203, 204 and functions to rigidly interconnect these elements with the Heavy Head Rail 201 optionally being heavier than the Head Rail 101 noted above due the voids created by the presence of a window 206 and a door frame 205 to thereby provide additional rigidity to the Wall Slab 200. As noted above, the interconnection of Heavy Head Rail 201, Toe Rail 202 and Wall End Rails 203, 204 is accomplished by the use of countersunk long screws (not shown) which penetrate deeply into Wall End Rails 203, 204 to secure these elements together.

Braced Frame Floor Slab using Rails

[0059] FIG. 13 illustrates a perspective view of a braced frame Floor Slab Assembly 300 used as a Braced Frame Slab Assembly Having Heavy Perimeter Rails for a construction element in the construction of a dwelling and FIG. 14 illustrates a perspective view of the interconnection of Floor Edge Rails 301, 302, 303, and 304 to form a braced frame Floor Slab 300 used as a construction element in the construction of a dwelling. In particular, Floor Edge Rails 301, 302 are interconnected with Floor Edge Rails 303, 304 using Rail Fame Connectors, such as deeply seating countersunk screws 302-1 to 302-3 as described above with respect to FIGS. 1-6.

[0060] It should be noted that for large spans, typically, builders use an intermediate beam (not shown) in the middle of the floor structure, framing one side of Floor Slabs into it on both sides. In this way we create a largely column free space in the building and provide the necessary support for the floor.

[0061] FIGS. 15-17 illustrate plan and perspective views of additional details in the interconnection of two coplanar braced frame Floor Slab 300, 310 used in the construction of a dwelling. Braced frame Floor Slab 300 consists of Floor Edge Rails 301, 302,303, and 304, while braced frame Floor Slab 310 consists of Floor Edge Rails 311, 312, 313, and 314. These interconnections use Slab to Slab Connectors, such as deeply seating countersunk screws 302-5, 311-5 as described above with respect to FIGS. 1-6. As noted, such an interconnection is best effected using at least two sets of screws, located at or near the distal end of the Floor Edge Rails. FIG. 17 illustrates in shadow view the deeply seating countersunk screws 302-5, 311-5.

[0062] FIG. 18 illustrates a perspective view of a braced frame Floor Slab 300 with the addition of a plurality of joists 305-307 therein and FIG. 19 illustrates a perspective view of the braced frame Floor Slab 300 of FIG. 18 with the application of floor sheathing 308 to the top surface thereof.

[0063] FIG. 20 illustrates a perspective view of the joining of a braced frame Wall Slab Assembly 100 with the braced frame Floor Slabs 300 and 310. This interconnection can be implemented in the context of “balloon framing”, where the exterior braced frame Wall Slab 100 are connected to the end of braced frame Floor Slab 300, 310 to form a continuous wall from the foundation to the roof of the building, and are not interrupted by the floor platforms in customary “western platform framing”, which is the universal standard for almost all framing. So tall wall sections 10 feet by 21 feet tall can be implemented. In this configuration the second floor of a building must affix to the inside of the tall wall section half way up. The reason that you would utilize “balloon framing” is that all exterior finish on these walls can be applied in the factory, installed with the component erection program, and field application of exterior finish could be avoided. If you tried this in “western platform framing” the first and second floor platforms, each about 18 inches thick, would interrupt the finish continuity above and below them, so it really is not practical.

SUMMARY

[0064] The heavy perimeter Rail framing elements in the braced frame Wall Slab Assemblies are different and bigger than traditional framing elements, and serve a unique function that is not present in standard framing. They are similar to the Rails in the Floor Slab, i.e. the heavy perimeter members in a Floor Slab serve the same purpose and are configured in the same perimeter arrangement as the heavy perimeter members in a Wall Slab. The heavy perimeter is the connection element used to secure all Assemblies to one another, with the interconnection being effected by the use of specialty Slab to Slab Connectors that inherently create concentrated loads requiring the Heavy Perimeter Rails. The Slab to Slab Connectors are heavy threaded screws, freely placed at any location along the common Rail boundary between Slabs.