Method and Kit for Assembly of Framed Structures

Abstract

A method for framing a structure using pre-dimensioned components comprising lower support components, framing components for assembling a series of frames, sheathing, and a template for guiding the assembly of the series of frames. The method comprises the steps of: fastening the lower support components together to produce a lower support rim; assembling the series of frames using markings on the template to guide placement of framing components; and fastening the series of frames to the lower support rim.

Claims

1. A method for framing a structure using pre-dimensioned components comprising lower support components, framing components for assembling a series of frames, sheathing, and a template for guiding the assembly of the series of frames, the method comprising: a) fastening the lower support components together to produce a lower support rim; b) assembling the series of frames using markings on the template to guide placement of framing components; and c) fastening the series of frames to the lower support rim.

2. The method of claim 1, wherein the template is marked on a part of the sheathing.

3. The method of claim 1, further comprising attaching at least a lower section of sheathing to opposing sides of the lower support rim before performing step c).

4. The method of claim 1, wherein the lower support components are rim joists or base plate members.

5. The method of claim 1, wherein each of the lower support components includes an outer ledge to facilitate placement and squaring of the sheathing prior to attachment of the sheathing to the lower support components.

6. The method of claim 1, wherein the pre-dimensioned components include a layout sheet for use in guiding the placement of corner supports for the lower support rim.

7. The method of claim 1, wherein each assembled frame of the series of frames includes an end-fastened pair of roof rafters, each with an opposite end fastened to an outer vertical beam.

8. The method of claim 7, wherein the series of frames includes a back frame with an end-fastened pair of roof rafters and at least one pair of matched intermediate vertical beams, each fastened to an equivalent intermediate position of a corresponding roof rafter of the pair of roof rafters between the center of the end-fastened pair of roof rafters and the corresponding outer vertical beam.

9. The method of claim 7, wherein the back frame further includes a center beam attached to the center of the end-fastened pair of roof rafters.

10. The method of claim 7, wherein the series of frames includes a front frame which includes at least one pair of matched intermediate vertical beams, each fastened to an equivalent intermediate position of a corresponding roof rafter of the pair of roof rafters between the center of the end-fastened pair of roof rafters and the corresponding outer vertical beam.

11. The method of claim 10, wherein the front frame further includes an upper horizontal beam fastened to and extending between the two intermediate vertical beams, wherein the combination of the pair of matched intermediate vertical beams and the horizontal beam provide support for installation of a door frame.

12. The method of claim 4, wherein the pre-dimensioned components include sections of floor sheets and floor joists, wherein the floor joists are fastened to opposed lower support rim components between step a) and step b) and wherein the floor sheets are assembled between step b) and step c) and form a continuous floor sheathing with the template marked thereon.

13. The method of claim 12 wherein the opposed lower support rim components each have an inner ledge for providing support for the floor joists prior to fastening the floor joists to the opposed lower support rim components.

14. The method of claim 13, wherein the pre-dimensioned components and the template include placement symbols to facilitate proper orientation of pre-dimensioned components prior to assembly.

15. A method for framing a structure using pre-dimensioned components comprising lower support components for forming a lower support rim, and framing components for assembling a back frame, one or more middle frames and a front frame, the method comprising: a) fastening the lower support components together to produce a lower support rim having a back rim component, a front rim component and opposing side rim components; b) assembling the back frame; c) fastening vertical beams of the back frame to the back rim component; d) assembling the middle frames and placing the middle frames against the back frame inside the lower support rim; e) assembling the front frame and fastening vertical beams of the front frame to the front of the lower support rim; and f) fastening vertical beams of the middle frames to the side rim components.

16. The method of claim 15, wherein the pre-dimensioned components include roof sheathing, wall sheathing and floor sheathing, wherein a template is marked on the roof sheathing, wall sheathing or floor sheathing, and wherein the template is used to guide the assembly of the back frame, middle frames and front frame.

17. The method of claim 15, wherein each of the lower support components includes an outer ledge to facilitate placement and squaring of the wall sheathing prior to attachment of the wall sheathing to the lower support components.

18. The method of claim 15, wherein the pre-dimensioned components include a layout sheet for use in guiding the placement of corner supports for the lower support rim.

19. The method of claim 15, wherein the back frame, the middle frames and the front frame each include an end-fastened pair of roof rafters, each with an opposite end fastened to an outer vertical beam.

20. The method of claim 19 wherein the back frame includes a center beam fastened to the center of the end-fastened pair of roof rafters and at least one pair of matched intermediate vertical beams, each fastened to an equivalent intermediate position of a corresponding roof rafter of the pair of roof rafters between the center beam and the corresponding outer vertical beam.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0092] Various objects, features and advantages of the invention will be apparent from the following description of particular embodiments of the invention, as illustrated in the accompanying drawings. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of various embodiments of the invention. An attempt has been made to use similar reference numerals to indicate similar components, wherever possible.

[0093] FIG. 1 is a plan view of a layout sheet 12 for use in certain embodiments of the invention for assembling a framed structure.

[0094] FIG. 2A is a plan view of a lower support structure according to one embodiment which is in the form of a floor frame 13 resting on corner pads 20a-d placed using the layout sheet 12 of FIG. 1. Positions where floor joists meet rim joists are indicated by rim joist markings 30b-f and 32b-f and by floor joist markings 31b-f and 33b-f.

[0095] FIG. 2B is a perspective view of a portion of the floor frame of the embodiment of FIG. 2A showing alignment of a floor joist 24d with a rim joist 22a at rim joist marking 30e and floor joist marking 31e. The floor joist 24d rests upon joist ledger 26a.

[0096] FIG. 2C is a plan view of floor sheathing 42 lying on top of the floor frame of the embodiment of FIGS. 2A and 2B (shown with dotted lines to indicate that it underlies the floor sheathing 42). In this embodiment of the invention, the floor sheathing 42 is formed from five floor sheets 38a-d and 40. The sequence of assembly is indicated by the circled numerals.

[0097] FIG. 3A is a plan view of a lower support structure according to another embodiment which is in the form of a of a support frame 115 for assembly of a framed structure without a floor. Support frame 115 is resting on corner pads 20a-d placed using the same layout sheet 12 as shown in FIG. 1. Floor joists, joist ledgers and rim joist markings for alignment of floor joists are not employed in this embodiment.

[0098] FIG. 3B is a perspective view of a portion of the floor frame of the embodiment of FIG. 3A.

[0099] FIG. 4A is a plan view of a lower support structure according to another embodiment which is in the form of a base plate 217. The base plate 217 is appropriate for placement on a large solid pad of concrete or other material. This embodiment does not require corner support pads or a layout sheet. The base plate 217 is formed from four sets of two base layers. Only the upper base layer components 223a-d are shown in this plan view. Floor joists, joist ledgers and rim joist markings for alignment of floor joists are not employed in this embodiment.

[0100] FIG. 4B is a perspective view of a portion of the floor frame of the embodiment of FIG. 4A.

[0101] FIG. 5A is a plan view of one embodiment of floor sheathing 42 which is manufactured with a template drawn thereon for assembly of frames for the framed structure. The template comprises a series of lines and/or symbols which are used to guide the placement of individual beams and roof rafters in the process of assembly of the frames.

[0102] FIG. 5B is a magnified view of the inset 5B at the upper right side of FIG. 5A showing additional detail of beam placement symbols and placement of outer beam 56 at template markings 44 and 46.

[0103] FIG. 5C is a plan view of the floor sheathing 42 as shown in FIG. 5A, but with frame beams and roof rafters placed at the template markings for assembly of the back frame 64. All template markings are covered by the beams with the exception of template marking 54 which guides placement of a horizontal beam which forms part of the front frame 70 (shown in FIG. 5E).

[0104] FIG. 5D is a plan view of the floor sheathing 42 with frame beams placed at the template markings for assembly of one of the middle frames 66 which consist of outer beams 56 and 56 and roof rafters 58 and 58. Template markings for guiding placement of all other beams remain visible.

[0105] FIG. 5E is a plan view of the floor sheathing 42 with frame beams placed at the template markings for assembly of the front frame 70. All template markings are covered by the beams with the exception of template marking 52 which guides placement of a center beam which forms part of the back frame 64 (see FIG. 5C).

[0106] FIG. 6A is a plan view of the floor sheathing 142 according to another embodiment, wherein the frames are configured to provide support for a framed structure having a wider door frame. All template markings are identical to those shown in FIG. 5A (and therefore have identical reference numerals), with the exception of template markings 148, 148, 150, 150 and 154 which provide a front frame 164 (see FIG. 6D) and a back frame 170 (see FIG. 6B) configured to support a wider door frame.

[0107] FIG. 6B is a plan view of the floor sheathing 142 as shown in FIG. 6A, but with frame beams placed at the template markings for assembly of the back frame 164. All template markings are covered by the beams with the exception of template marking 154 which guides placement of a horizontal beam which forms part of the front frame 170 (see FIG. 6D). Template marking 154 is longer than template marking 54 of FIG. 5A which guides placement of a shorter horizontal beam in the previous embodiment shown in FIGS. 5A to 5E.

[0108] FIG. 6C is a plan view of the floor sheathing 142 with frame beams placed at the template markings for assembly of the middle frame 66 which consists of outer beams 56 and 56 and roof rafters 58 and 58. The middle frame 66 assembled in this embodiment is identical to those of the previous embodiment shown in FIGS. 5A to 5E and therefore identical reference numerals are employed. Template markings for guiding placement of all other beams remain visible.

[0109] FIG. 6D is a plan view of the floor sheathing 142 with frame beams placed at the template markings for assembly of the front frame 170. All template markings are covered by the beams with the exception of template marking 52 which guides placement of a center beam which forms part of the back frame 164 (see FIG. 6B).

[0110] FIG. 7A is a front perspective view of a partially assembled framed structure showing an installed back frame 64 assembled using the indicated template of floor sheathing 42 whose template markings are shown. Opposed sections of lower side wall sheathing 72 and 72 are also shown.

[0111] FIG. 7B is the same front perspective view of a partially assembled framed structure of the same embodiment as FIG. 7A with installed back frame 64 as shown in FIG. 7A but with the back wall sheathing upper, middle and lower sections 74, 75 and 77 installed and fastened to the back frame 64.

[0112] FIG. 7C is a front perspective view of a partially assembled framed structure of the same embodiment as FIGS. 7A-B, with frames assembled using the indicated template on the floor sheathing 42. The frames are assembled and stacked against the back wall frame 64 prior to installation in their final vertical positions. The template markings on the floor sheathing are visible, as is the complete set of stacked upright frames including back frame 64, three middle frames 66, 66, 66 and front frame 70. Also shown are opposed sections of lower side wall sheathing 72 and 72.

[0113] FIG. 7D is a front perspective view of a partially assembled framed structure of the same embodiment as FIGS. 7A-C at a point in the assembly process subsequent to that of FIG. 7C. The front frame 70 is now fixed in its final vertical position at the front of the structure. The remaining middle frames 66, 66 and 66 remain stacked against the back frame 64 at the back of the structure.

[0114] FIG. 7E is a front perspective view of a partially assembled framed structure of the same embodiment as FIGS. 7A-D at point in the assembly process subsequent to the point shown in FIG. 7D. All of the frames are now installed at their final vertical positions.

[0115] FIG. 7F is a front perspective view of a partially assembled framed structure of the same embodiment as FIGS. 7A-E at point in the assembly process subsequent to the point shown in FIG. 7E. Section of upper sidewall sheathing 73 73 have been installed and fastened to the frames.

[0116] FIG. 7G is a front perspective view of a partially assembled framed structure of the same embodiment as FIGS. 7A-F at point in the assembly process subsequent to the point shown in FIG. 7F. The upper and lower front sheathing sections 81, 81 and 79, 79 have been installed and fastened to the front frame which is now hidden from view.

[0117] FIG. 7H is a front perspective view of a partially assembled framed structure of the same embodiment as FIGS. 7A-G at point in the assembly process subsequent to the point shown in FIG. 7G. Side wall trim 84, 84 has been installed at the top of the upper side wall sheathing 73 and 73.

[0118] FIG. 7I is a front perspective view of a partially assembled framed structure of the same embodiment as FIGS. 7A-H at point in the assembly process subsequent to the point shown in FIG. 7H. Front and back sections of roof sheathing, 85, 85 and 86, 86 have been installed and fastened to the roof rafters (now hidden from view) and to the side wall trim 84, and 84.

[0119] FIG. 8A is a partial front view of the front left corner of the structure corresponding to the inset square of FIG. 7I. It is seen that the front section of roof sheathing 86 is placed in proper alignment with the upper surface of the side wall trim 84. The positions of the front frame roof rafter 58 and the front frame outer beam 56 are indicated with dotted lines behind the front wall sheathing sections 79 and 81.

[0120] FIG. 8B is a partial perspective view of a portion of sidewall trim 84 as in FIG. 8A which has a horizontal upper surface.

[0121] FIG. 8C is a partial perspective view of another embodiment of sidewall trim 384 which has a chamfered upper surface to provide effective alignment of the roof sheathing (not shown).

DETAILED DESCRIPTION OF THE INVENTION

Rationale

[0122] Typical construction practices require a high degree of skill, knowledge of practical as well as safety procedures for operation of tools, and the ability to read blueprints or detailed plans and apply the instructions given to the construction practices required.

[0123] Basic small pre-fabricated buildings requiring little skill to assemble have been marketed using plastic panels that snap or bolt together, but they tend to be limited in their use and practicality. More complex pre-fabricated buildings have been marketed in various forms, including concrete panels, wood wall panels, and steel structures, all requiring a significant degree of technical skill on the part of the individuals assembling the building due to the complex nature of the pre-fabrication process and the blueprints and/or detailed instructions provided.

[0124] It would be advantageous to provide methods and kits with careful attention to assembly sequence and including visual features to simplify the process of assembly of framed structures, thereby allowing more complex buildings to be self-squaring during the framing process and assembled with minimal hand tools by unskilled assemblers, which may include individuals who are not proficient in English or other major global languages.

Definitions

[0125] As used herein, the term pre-dimensioned means manufactured to have specific dimensions. The specific dimensions of components allow the components to fit with other components of the framed structure during the assembly process. The skilled person will recognize that pre-dimensioning of components is commonplace in the art of development of kits for assembly of structures or devices.

[0126] As used herein, the term joist refers to a horizontal supporting member for support of walls. In certain embodiments of the invention, joists include rim joists for support of walls and floor joists for support of a floor.

[0127] As used herein, the term template refers to a series of markings on a surface which are provided for direct guidance of assembly of components. Scaling is not used in template markings because the components guided by the template are lined up directly against the template markings. As such a template is different from a blueprint which typically includes scaling.

[0128] As used herein, the term sheathing is used to refer to flat sheet-like material for forming the various flat surfaces of the inside and the outside of the framed structure (including front, side and back walls, the roof and the floor, if applicable). Alternatively, the sheathing can represent an intermediate surface upon which an additional outer covering surface is fastened.

[0129] As used herein, the terms rafter and roof rafter refer to internal beams extending to the peak of a roof and constituting part of one of the frames of the framed structure.

[0130] As used herein, the term beam refers to a frame member spanning, or providing support to, other frame members.

[0131] As used herein, the term self-squaring refers to a result of a process for assembling a framed structure wherein the construction process results in each corner of the structure being ninety degrees within acceptable error, as determined with a conventional carpenter's square tool.

[0132] As used herein, the term squaring components refers to pre-dimensioned parts which are used in the process of squaring various corners of a structure. The squaring components may be used temporarily or they may become a part of the finished structure. The squaring components may be formed of wood, plastic or other materials. A carpenter's level or a carpenter's square are not to be considered as squaring components in context of this description.

[0133] As used herein, the term level means horizontal within acceptable error, as indicated by a carpenter's level tool.

[0134] As used herein, the term plumb means vertical within acceptable error, as determined by a carpenter's level or a plumb bob.

[0135] Acceptable error in respect of each of the criteria described above is determined according to the judgement and knowledge of a carpenter with ordinary skill in carpentry.

[0136] As used herein, the term lower support rim in its broadest sense refers to the basic lower structure upon which frames are supported. In examples described herein, rim joists or base members are used to construct the lower support rim of different embodiments. While the examples described herein pertain to a square lower support rim, it is to be understood that a lower support rim may be assembled in other geometric shapes.

[0137] As used herein, the term floor plate to the assembled combination of the lower support rim and the floor sheathing installed thereon.

INTRODUCTION

[0138] Various aspects of the invention will now be described with reference to the figures. For the purposes of illustration, components depicted in the figures are not necessarily drawn to scale. Instead, emphasis is placed on highlighting the various contributions of the components to the functionality of various aspects of the invention. A number of possible alternative features are introduced during the course of this description. It is to be understood that, according to the knowledge and judgment of persons skilled in the art, such alternative features may be substituted in various combinations to arrive at different embodiments of the present invention. For example, the ensuing description illustrates embodiments using a layout sheet and a floor template. Alternatives such as the use of a floor template without a layout sheet and the use of a template marked on wall sheathing prior to installation of the wall sheathing at its final vertical position are possible. Other alternatives may include the use of a template marked on a separate sheet which does not form part of the finished structure. In such alternative embodiments, the separate template may be attached to a section of sheathing before it is used to guide the assembly of frames, or it may be placed on a relatively level section of ground or other surface prior to its use for assembly of frames. Modifications of the embodiments described herein which would be required to arrive at such alternative embodiments can be effected by the skilled person without undue experimentation and are within the scope of the invention as defined by the claims.

[0139] Any terms which have not been explicitly defined herein, are to be considered as having meanings as they would be understood by persons skilled in the art. Such terms may also be reasonably inferable from the drawings and description and the combination thereof with the knowledge of the skilled person.

[0140] The individual components used in the method and kit for assembly of framed structures will first be described with reference to FIGS. 1-8 together with a description of their uses in an example of assembly process. Additional concise example embodiments will then be described to highlight the advantages provided by the invention which are provided by the order of assembly.

Layout Sheet

[0141] Certain embodiments of the invention include the use of a layout sheet to assist in positioning corner supports or pads. The framed structure sits upon these supports or pads (hereinafter referred to simply as pads or alternatively corner supports. In some embodiments the layout sheet has the pad locations identified by a symbol to locate the center of the pad where placement is not dimensionally critical, in other embodiments the provision of outlines indicating the proper positioning of the pads is advantageous because it allows proper positioning of the pads without requiring measurements to be performed by unskilled individuals.

[0142] One example of a layout sheet appropriate for use with the embodiments of the invention described herein is shown in FIG. 1. This particular embodiment of the layout sheet 12 has a center-line crease 14 which allows the layout sheet 12 to be conveniently folded for transport and/or packaging. A line may be marked at the center-line crease 14 to guide an assembler who may wish to make a fold along the center-line crease 14. Additional folds or creases may be provided, depending upon packaging requirements of kits of various embodiments. The primary purpose of the center-line crease is to provide a reference to the center of the layout sheet without requiring measurement, so that if the structure is to be erected in an area that is not level or requires digging to remove non load bearing materials and set suitable bearing materials in place for the pad to rest on, a simple process whereby pins are driven through each end of the centerline crease, once the building location has been confirmed, thus holding the layout sheet in a fixed location. Either one or both edges of the center-line sheet can then be folded back into the center of the sheet, and any excavation, in-fill or other related work can be done without losing the general layout location. To check on progress, the workers simply fold the layout sheet 12 back over the area, check progress, and fold it back to the center to continue with their work. Once completed, the layout sheet 12 can be laid back over the entire area and the markings on the layout sheet will either indicate the center of, or outline of, the corner pads in their originally selected location. The embodiment of the layout sheet 12 of FIG. 1 is provided with 4 corner pad markings 16a-d corresponding to pre-measured positions of corner pads which, in this particular embodiment, provide a foundation for the assembly of a storage shed with a 1212 square floor. Other framed structures with different dimensions may be assembled by alternative embodiments of the method and kit of the invention.

[0143] The layout sheet 12 of FIG. 1 is provided with mid-span pad markings 18a and 18b which may be used to position mid-span pads (not shown) if needed. The skilled person will recognize this as an optional feature, particularly for a relative small framed structure which will typically have sufficient support provided by its four corner pads 16a-d. It should be noted that the mid-span markings 18a and 18b are omitted from the layout sheet of FIGS. 2A and 3A in an effort to preserve clarity.

[0144] In addition to facilitating the positioning of corner pads without measurement, an advantage to the use of a layout sheet, such as layout sheet 12 is that it helps the assembler to visualize an appropriate position for the framed structure before it is assembled. This is particularly useful if other obstacles and/or equipment are present and/or if sections of the area are not level. The assembler may move the layout sheet to different positions and then select the optimal position for the framed structure. Subsequent components described herein are presented in the remaining figures in an effort to preserve consistency such that the layout sheet 12 is compatible with the floor frame, the floor sheathing, the floor template and the frames.

[0145] The layout sheet is advantageously constructed of flexible plastic which allows it to be conveniently folded and moved.

Floor Plate Formed from Floor Frame and Floor Sheathing

[0146] An embodiment of a lower support rim which forms part of a floor frame 13 assembled using the layout sheet 12 of FIG. 1 is shown in FIG. 2A. It is seen that the layout sheet 12 (shaded area) remains in place and that corner pads 20a-d have been placed at the corners of the layout sheet as indicated by the corner pad markings 16a-d in FIG. 1. Mid-span markings 18a and 18b are omitted from the layout sheet of FIG. 2A as noted above.

[0147] The left side rim joist 22a sits on top of corner pads 20a and 20c and the right side rim joist 22b sits on top of corner pads 20b and 20d. The back side rim joist 22c (at the top of FIG. 2) sits on top of corner pads 20a and 20b. In a similar manner, the front side rim joist 22d (at the bottom of FIG. 2) sits on top of corner pads 20c and 20d. When connected at the corners, the rim joists 22a-d form a general support structure designated herein as the lower support rim (additional embodiments of lower support rims are described hereinbelow). In FIG. 2A the side rim joists 22a and 22b of the lower support rim each have a corresponding joist ledger 26a and 26b provided by a ledge formed in or attached to the inner sides of the rim joists 22a and 22b. The joist ledgers 26a and 26b provide a support surface for the five floor joists 24a-e, and are set at a pre-determined depth in accordance with the depth dimension of the particular floor joist, so that no measuring is required for the installation of the floor joists. This support function is illustrated in greater detail in FIG. 2B which shows a side perspective of floor joist 24d supported by joist ledger 26a.

[0148] The skilled person will recognize that while the embodiment of FIGS. 2A and 2B uses five floor joists, alternative embodiments are possible which use more or fewer floor joists which may vary in thickness from the relative dimensions illustrated in FIG. 2. In other embodiments, where floor sheathing is sufficiently strong, or the applications intended for the framed structure permit, it may be possible to omit the floor joists altogether. Other embodiments do not include a floor structure. Such embodiments will be described hereinbelow.

[0149] Returning now to FIG. 2A, the positioning of the ends of the floor joists 24a-e at the side rim joists 22a and 22b is facilitated by rim joist markings 30b-f and 32b-f which, in this particular embodiment, take the form of a combination of dotted lines and symbols. Identical symbols 31b-f and 33b-f on the ends of floor joists 24b-f are provided to indicate that symbol F of the floor joists should be lined up with symbol F of the rim joists.

[0150] The outer sides of each one of the rim joists 22a-d is provided with a wall sheathing stop 28a-d which is in the form of a ledge that wall sheathing can rest upon while it is positioned and fastened to the rim joists 22a-d. When the wall sheathing is installed in such a manner and sequence, and set down upon the wall sheathing stop, the wall sheathing stop serves to self-square the wall sheathing with the floor plate. The wall sheathing stop 28a-d provides a means for an unskilled individual to properly align the wall sheathing with the rim joists 22a-d, and the entire floor plate which, in this particular embodiment, is represented by the assembled combination of the rim joists 22a-d, the floor joists 24a-e and floor sheathing 42 (see FIG. 2C). It should be noted that failure to provide proper alignment of wall sheathing according to the method described herein, could lead to construction of an improperly framed and sheathed structure.

[0151] FIG. 2B illustrates a perspective view of side rim joist 22a and the positioning of floor joist 24d by lining up the F symbol of the rim joist marking 30e with the F symbol 31e of the floor joist 24d. It is seen that the floor joist 24d rests upon the joist ledger 26a. For added convenience in assisting non-skilled individuals in the assembly process, orientation markings may be provided such as orientation marking arrow 34 on the rim joist 22a and orientation marking arrow 36 shown on the floor joist 24d.

[0152] Although the rim joist 22a of FIG. 2B is shown as being formed as a 3-ply structure (see the end face of the left side of the rim joist 22a), the skilled person will understand that alternative rim joists may also be constructed of fewer or more layers according to the support requirements of different structures and that such alternatives are within the scope of the invention.

Floor Sheathing

[0153] Shown in FIG. 2C is a plan view of a series of floor sheets 38a-d and 40 which collectively form the floor sheathing 42. Floor sheathing 42 sits on top of the floor frame which is depicted as a floor frame outline 37 in dotted lines showing the positions of the rim joists and the floor joists (reference numerals of these individual components are omitted from FIG. 4 to preserve clarity). Floor sheets 38a-d are each 48 rectangles and floor sheet 40 is a 44 square. Thus, the entire 144 square foot area of the 1212 floor is covered with floor sheathing sections with a minimal requirement for sections of different dimensions. This is an advantage for the process of manufacturing kits for assembly of framed structures as described in detail hereinbelow. As noted above, the rim joists, floor joists and floor sheathing collectively form the floor plate.

[0154] The floor sheets 38a-d and 40 are installed and fastened to the rim joists and floor joists. As indicated by the circled sequence numbers in FIG. 2C, floor sheet 38c is installed first, followed by floor sheet 38b, floor sheet 38a, floor sheet 38d and lastly, the square floor sheet 40. Floor sheathing is installed in a manner and sequence such that installation enables the floor plate to be self-squared. The floor plate is thus self-squaring without a requirement for it to rest on a level surface during the assembly process.

[0155] In this particular embodiment, the assembled floor sheathing 42 includes a template, installed on the individual floor sheets at the time of manufacture such that when the floor sheathing is installed in a manner and sequence forms a series of template markings for assembling the frames of the framed structure. The template markings are omitted from FIG. 2C to preserve clarity in efforts to describe the assembly of floor sheets 38a-d and 40 in forming the floor sheathing 42. The skilled person will recognize from the ensuing description of template markings that failure to assemble the floor sheathing 42 properly will lead to an incorrect assembly of template markings.

[0156] The floor sheathing, when installed correctly, serves to self-square the floor plate assembly on a horizontal plane. The floor plate assembly may not be flat (as opposed to level) at the time the floor sheathing is installed, but when the roof sheathing is fastened to the side wall trim in accordance with the method of assembly described below, the fastening of the roof sheathing acts to self-square the vertical structure. By bringing the floor plate into a flat plane, it becomes square with the building as a whole because all components are tied together in an inter-related manner designed to accomplish this same self-squaring aspect. As a consequence of the approach provided by the present invention, the floor plate does not have to be level, nor the walls plumb, for the building to become squared properly as it is assembled. More details regarding the squaring of portions of the structure are described in Example 3.

Assembly of a Lower Support Frame for a Framed Structure without a Floor

[0157] Another embodiment of a lower support rim will now be described. The features of this embodiment will now be described with reference to FIGS. 3A and 3B which describe features using reference numerals in the 100 series (except for the corner pads and layout sheet, which are identical to the corner pads and layout sheet of FIG. 2A). FIG. 3A is a plan view of a support frame 115 (an embodiment of a lower support rim) which has a number of features similar to the floor frame shown in FIG. 2A, such as rim joists 122a-d with corresponding wall sheathing stops 128a-d. The corner pads 20a-d are placed using layout sheet 12, which is also visible. However, the absence of a floor negates the requirement for floor joists and corresponding placement markings on the rim joists 122a-d. Joist ledgers are also absent from FIGS. 3A and 3B. FIG. 3B is a perspective view of rim joist 122a which has rim joist markings 130a and 130g, wall sheathing stop 128a and orientation marking 134. Additional rim joist markings A 135abc (on rim joist 122a) and 137abc (on rim joist 122b) indicate the positions of the outer beams of the middle frames and additional rim joist markings B 138ab, 139ab on and X 141ab and 143ab (on rim joists 122c and 122d) indicate the positions of the intermediate beams on the front and back frames. These markings are not shown in FIGS. 2A and 4A in order to preserve clarity. The skilled person will understand that alternative symbols may be used and placement of the symbols on the rim joist will depend upon the support requirements and features of the structure being framed.

[0158] FIG. 3B is a perspective view of rim joist 122a resting on corner pads 20a and 20c. Although the rim joist 122a of FIG. 3B is shown as being formed as a 3-ply structure (see the end face of the left side of the rim joist 122a), the skilled person will understand that alternative rim joists may also be constructed of fewer or more layers according to the support requirements of different structures. The wall sheathing stop 128a and rim joist markings 130a, 130g and 135a-c are also indicated.

Assembly of a Base Plate on an Existing Foundation Pad for Assembly of a Framed Structure without a Floor

[0159] Another embodiment of a lower support structure and a portion thereof is shown in FIGS. 4A and 4B which describe features using reference numerals in the 200 series. The lower support structure of this embodiment is herein designated a base plate 217 and is intended for use when the framed structure is to be assembled on a pre-existing foundation pad 211 which is formed from concrete or other permanent foundation material, which may be a pre-existing foundation such as the concrete floor of a garage or hangar, for example, in an embodiment where a smaller enclosed structure is assembled within a garage or hangar. Instead of the joists shown in FIGS. 2 and 3, base layer members are used to construct the base plate 217. In the plan view of FIG. 4A, only the upper base layer members 223a-d are visible. The lower base layer members 225a and 225c are shown as underlying base layer members 223a and 223c in FIG. 4B. The wall sheathing stops 228a-d are attached to the lower base layer member, as shown in the partial perspective view of FIG. 4B, where wall sheathing stop 228a is attached to lower base layer member 225a.

[0160] The base plate may have multiple layers of base material, and will include a wall sheathing stop attached to at least one base layer member, as illustrated in FIG. 4B, where wall sheathing stop 228a is attached to lower base layer 225a. The skilled person will understand that although only two base layers are shown in FIG. 4B, additional base layers may be provided as needed. Also shown in FIG. 4B are markings 230a and 230g of upper base layer 223a. There would be no need to provide similar markings on lower base layers. The wall frames which will be described in detail below, are set upon and fastened to the upper layers 223a-d of the base plate 217. After fastening of wall sheathing to the wall frames and base plate, the base plate can be shimmed and fastened down to the foundation pad 211 to compensate for any irregularities in the level of the foundation pad 211. A similar process would be used for providing second story wall framing on a multiple-story structure.

[0161] The base plate 217 of the present embodiment and the combination of the rim joists of the embodiments described above may be considered as variations of a structure designated herein as the lower support rim. For greater clarity, in the embodiment shown in FIGS. 2A-C, the lower support rim is formed by the rim joists 22a-d. Likewise, in the embodiment shown in FIGS. 3A-B, the lower support rim is formed by the rim joists 122a-d and in FIGS. 4A-B, the lower support rim is formed by the lower and upper base layers 233a-d and 225a-d which are also collectively described as the base plate 217. The lower support rim is not to be confused with the floor plate of the embodiment of FIGS. 2A-C. The floor plate includes the rim joists 22a-d, floor joists 24a-e and floor sheathing 42.

Assembly of Wall Frames Using Two Different Embodiments of Floor-Based Templates

[0162] Two different embodiments of templates provided on floor sheathing of the 1212 storage shed will now be described with reference to FIGS. 5 and 6. The skilled person will recognize that the features described with respect to these two embodiments are applicable to other embodiments of structures with different dimensions and which may have floor plan areas which are square, rectangular or other geometries.

[0163] Additionally, in alternative embodiments which do not include a floor, the template may be provided on sheathing for one of the walls or roof. Such a template may be marked on such sheathing by the skilled person in accordance with the principles of the invention, and would be employed to construct the wall frames prior to attachment of the sheathing that contains the template.

[0164] The first template embodiment is shown in FIGS. 5A to 5E and the second template embodiment is shown in FIGS. 6A to 6D. Both floor sheathing embodiments are compatible with all other features illustrated in FIGS. 1 and 2. The template of the embodiment of FIGS. 5A to 5E is employed to produce a 1212 storage shed with a narrow door frame and the embodiment of FIGS. 6A to 6D is employed to produce a 1212 storage shed with a wider door frame. In FIGS. 5A to 5E and FIGS. 6A to 6D, identical reference numerals indicate identical parts. In FIGS. 6A to 6D, reference numerals of the 100 series indicate parts and assemblies that differ in dimensions from those of FIGS. 5A to 5E. Both embodiments use the same placement symbols for indicating placement of beams and rafters. The symbol A is a placement symbol for outer beams. The symbol R is a placement symbol for roof rafters. The symbol B is a placement symbol for a first intermediate beam. The symbol X is a placement symbol for a second intermediate beam. The symbol D is a symbol for placement of a center beam. The symbol H is a symbol for placement of a horizontal beam. The skilled person will recognize that other symbols may be used instead of the symbols described above. In certain embodiments, the symbols are also color-coded to facilitate proper placement by a non-skilled assembler.

[0165] Turning now to FIG. 5A, there is shown a plan view of floor sheathing 42 with a template provided by a series of template markings provided to indicate proper positioning of frame beams for assembly of individual wall frames (hereinafter referred to simply as frames of the framed structure. Paired template markings 44 and 44 indicate the positions of the outer beams 56 and 56 (as shown in FIGS. 5C to 5E) which are used in all of the frames. Paired template markings 46 and 46 indicate the positions of the roof rafters 58 and 58, which also are used in all of the frames. Paired template markings 48, 48, 50 and 50 indicate the positions of intermediate beams 60, 60, 62 and 62 which are used in the back frame 64 (FIG. 5C) and in the front frame 70 (FIG. 5E). Template marking 52 indicates the position of the center beam 57 which forms part of the back frame 64. Template marking 54 indicates the position of the horizontal beam 68 which forms part of the front frame 70 (FIG. 5E).

[0166] FIG. 5B is a magnified view of inset 5B of FIG. 5A and shows additional detail of the floor sheathing 42 at the position where template marking 44 meets template marking 46. Placement symbols A and R are also shown. The A symbol 76 is an identification symbol used to identify outer beam 56. The A symbol 80 is a placement symbol and indicates that outer beam 56 is to be placed next to template marking 44 and below template marking 46. Placement symbol R 78 indicates that roof rafter 58 is to be placed next to template marking 46. Various embodiments can include colored symbols to identify placement of corresponding components as well. Lastly, placement symbol A 82 indicates the vertical (upright) placement position of outer beam 56 for middle frame 66 (this latter symbol and other similar symbols are omitted from FIGS. 5 and 6 in an effort to preserve clarity, but should be understood to be included to indicate vertical placement of the outer beams for attachment to floor plates or base plates of various embodiments of the invention). The skilled person will recognize that similar placement symbols may be provided at all other locations of the floor sheathing 42 in a similar manner to guide placement of beams and roof rafters when the template markings are used to assemble the individual frames and when the individual frames are placed vertically at their final locations.

[0167] FIG. 5C shows the assembled back frame 64 lying on the floor sheathing 42 against the template markings, which are obscured by the outer beams 56, 56, the center beam 57, the roof rafters 58, 58 and the intermediate beams 60, 60, 62, and 62. All template markings are used for assembly of the back frame 64 with the exception of template marking 54. With proper placement of all of the beams, they can be fastened together by known fastening means such as screws, with or without pre-drilled screw holes, or similar fastening arrangements known to the skilled person. When the back frame 64 is completely assembled, it is raised to a vertical orientation and installed on the floor plate at its final location as described below with reference to FIG. 7A.

[0168] In a manner similar to that shown in FIG. 5C, in FIG. 5D an example of a middle frame 66 is shown lying on the floor sheathing 42 against the template markings 44, 44, 46 and 46 which are obscured. The visible template markings 48, 48, 50, 50, 52 and 54 are not used in assembling the middle frame because only the outer beams 56 and 56 and the roof rafters 58 and 58 are used. The skilled person will recognize that alternative embodiments may include the use of collar ties, horizontal ceiling rafters, second story floor joists and the like. Such alternative embodiments are within the scope of the invention.

[0169] In a manner similar to that shown in FIGS. 5C and 5D, in FIG. 5E an example of a front frame 70 is shown lying on the floor sheathing 42 against the template markings, all of which are obscured with the exception of template marking 52 which is used to guide the placement of the center beam 57 (not used in the front frame 70). The front frame includes intermediate beams 60, 60, 62, and 62 and horizontal beam 68. The intermediate beams 60 and 60 and horizontal beam 68 provide support for installation of a door frame (not shown). Such a door frame installation is performed according to known methods after installation of front wall sheathing.

[0170] Turning now to FIGS. 6A to 6D, the second template embodiment and the characteristics of the frames assembled therefrom will now be described. As noted above, reference numerals of the 100 series indicate parts and assemblies that differ in dimensions from those of FIGS. 5A to 5E. All other parts and assemblies are identical to those of FIGS. 5A to 5E. The skilled person will recognize that such an arrangement allows similar components to be used in more than one kit for assembly of a framed structure, as will be described in more detail below. As such, processes for manufacturing the components of a series of building kits are minimized.

[0171] FIG. 6A shows a different floor sheathing 142 which has a series of template markings provided thereon, some of which differ from those of FIG. 5A. The template of floor sheathing 142 is designed to guide the assembly of front and back frames which differ from those of the embodiments shown in FIGS. 5C and 5E by having different intermediate beam lengths and positions as well as a longer horizontal beam that provides support for a wider door (not shown).

[0172] It is thus seen in FIG. 6A that template markings 148, 148, 150 and 150 which guide the placement of intermediate beams 160, 160, 162 and 162 are located closer to their respective outer template markings 44 and 44 than the counterpart template markings 48, 48, 50 and 50 of the embodiment of FIGS. 5A to 5E which guide the placement of intermediate beams 60, 60, 62 and 62. This arrangement requires that the lengths of the intermediate beams 160, 160, 162 and 162 are shorter than their counterparts in the previously described embodiment.

[0173] Another difference is that template marking 154 which guides the placement of horizontal beam 168 (see FIG. 6D), is longer than its counterpart template marking 54 of the previous embodiment (FIG. 5A).

[0174] FIG. 6B shows how the back frame 164 is assembled on the floor sheathing 142. The back frame 164 is different from its counterpart of the previous embodiment. The outer beams 56 and 56 the center beam 57 and the roof rafters 58 and 58 are the same as those of the previous embodiment but the lengths of the intermediate beams 160, 160, 162 and 162 are shorter as noted above.

[0175] FIG. 6C shows how the middle frame 66 is assembled. In this embodiment, the middle frame 66 is identical to that of the previous embodiment and consists of outer beams 56 and 56 and the roof rafters 58 and 58. The non-used template markings 52, 148, 148, 150, 150 and 154 are visible.

[0176] FIG. 6D shows how the front frame 170 is assembled. The front frame 170 is different from its counterpart of the previous embodiment. The outer beams 56 and 56 and the roof rafters 58 and 58 are the same as those of the previous embodiment but the lengths of the intermediate beams 160, 160, 162 and 162 are shorter as noted above. Also, the horizontal beam 168 is longer than its counterpart in the previous embodiment, in order to provide support for a wider door frame.

Sequence of Assembly and Installation of Wall Sheathing, Frames and Roof Sheathing

[0177] The sequence of assembly and installation of wall sheathing, frames and roof sheathing will now be described with reference to FIGS. 7A to 7I. The front and back frames 64 and 70 used in this description correspond to the first frame set embodiment with the front frame 64 shown against its template in FIG. 5C and the back frame 70 shown against its template in FIG. 5E. The features of the floor plate correspond to the embodiments illustrated by FIGS. 2A-C and the description above associated therewith.

[0178] The sequence of assembly and installation of wall sheathing and frames begins at a point when the assembly of the floor sheathing 42 has been completed and the template is visible on the floor sheathing 42. The template on the floor sheathing 42 is the same template shown in FIG. 5A. The lower side wall sheathing sections 72 and 72 (shaded) are placed with their bottom edges on corresponding wall sheathing stops 28a and 28b (the latter is not seen in FIG. 7A due to the perspective view) to self-square the side wall sheathing 72 and 72 to the horizontal plane of the floor plate. The side wall sheathing sections 72 and 72 are then fastened in place against the floor plate. Then the back frame 64, assembled as shown in FIG. 5C, is placed at the back of the floor sheathing 42 and the outer vertical faces of the outer beams 56 and 56 are attached to the edge of the side wall sheathing to square the back frame 64 to the sidewall sheathing sections 72 and 72. This squares the back frame on a plane vertical to the floor plate. The beams are fastened through the floor sheathing 42 to the back rim joist 22c (see FIG. 3). The structure resulting from this process is shown in FIG. 7A. In some embodiments, the proper positioning of the back frame 64 is facilitated by rectangular placement markings (similar to the example outer beam vertical placement symbol 82 shown in FIG. 5B) on the floor sheathing 42 which indicate the outline positions of the outer beams 56 and 56, the intermediate beams 60, 60, 62 and 62 and the center beam 57.

[0179] Installation of the back frame 64 now allows the back wall sheathing sections 74, 75 and 77 to be installed as shown in FIG. 7B. The lower back wall sheathing section 77 is set on the wall sheathing stop 28c (not seen in FIG. 7B due to the perspective) to square the lower section of the back wall sheathing 77 with the floor plate. The vertical corner end faces of the lower section back wall sheathing 77 are aligned with the square ends of the side wall sheathing 72 and 72 at the corners to self-square the vertical plane side to side and then the lower section of back wall sheathing 77 is fastened to the vertical beams 56 and 56 of the back wall frame 64. The middle section of back wall sheathing 75 is then aligned with the lower section 77 and fastened to the vertical beams 56 and 56 of the back wall frame 64. This step is repeated with the upper back wall sheathing section 74 and the sloped upper edges of this back wall sheathing section 74 are aligned with the edges of the rafters 58 and 58 of the back frame 64. After fastening of all outer edges of the back wall sheathing sections 74, 75, 77, to the rafters 58 and 58 and the outer beams 56 and 56 the back wall sheathing sections 74, 75, 77 are fastened to the remaining vertical beams of the back frame 64.

[0180] Next, three middle frames 66, 66 and 66 are sequentially assembled as indicated in FIG. 5D and placed sequentially against the back frame 64. Lastly, the front frame 70 is assembled as shown in FIG. 5E and placed against middle frame 66. This arrangement is shown in FIG. 7C. Alternatively, after assembly of the front frame 70 as described above, it can be moved directly to its final position at the front of the structure and fastened thereto. The arrangement shown in FIG. 7C allows for convenient sequential positioning and installation of front frame 70, followed by middle frame 66, then middle frame 66 and, lastly, middle frame 66. As indicated for the back frame 64, in certain embodiments, the positions of the outer beams 56 and 56 for each of these remaining frames is facilitated by rectangular placement markings (similar to the example outer beam vertical placement symbol 82 shown in FIG. 5B) on the floor sheathing 42. Certain embodiments have layout markings at the top edge of the lower section of side wall sheathing 72 and 72, corresponding with the rectangular placement markings on the floor plate, to align the vertical frame beam as a function of the self-squaring attributes of the assembly. FIG. 7D shows the final placement of the front frame 70 and FIG. 7E shows the final framing arrangement with each of the three middle frames 66, 66 and 66 placed at their final positions.

[0181] With the completion of the frames as described above, the remaining tasks of finishing the side walls, front wall roof with sheathing may be performed. These final steps also contribute to the self-squaring function of the assembly order. As for all components previously described, the remaining upper sidewall, front wall and roof sheathing sections are pre-dimensioned to facilitate proper placement and may also include orientation and placement markings.

[0182] In the process of installation of the upper side wall sheathing sections 73 and 73, the lower edge of each of the upper side wall sheathing sections 73 and 73 is aligned with corresponding lower side wall sheathing sections 72 and 72 and with the outer edges of the upper side wall sheathing sections 73 and 73 are aligned with the outer edges of the front and back frames 64 and 70. The upper side wall sheathing sections 73 and 73 are then fastened to the vertical beams of the middle frames 66, 66 and 66. The resulting structure is shown in FIG. 7F.

[0183] As shown in FIG. 7G, the sheathing of the front frame 70 advantageously is provided in a series of sections which do not cover the central open space of the frame to allow for installation of a door frame and door according to known methods. As the process produces a completed structure which has been self-squared, the supports for the door frame, which are provided by vertical beams 62, and 62 and horizontal beam 68 will be square at their corners and the vertical beams 62, and 62 will be square with respect to the floor plate.

[0184] The next step in the process is the installation of the front wall sheathing, which, in the present embodiment is shown in FIG. 7G in four sections represented by lower front wall sheathing sections 79 and 79 and by upper front wall sheathing sections 81 and 81. In the process of installation of the lower front wall sheathing sections 79 and 79, the lower edges of the front wall sheathing sections 79 and 79 are set down upon the wall sheathing stop 28d of rim joist 22d, to square the lower front wall sheathing sections 79 and 79 with the floor plate. The outer edges of the front wall sheathing sections 79 and 79 are aligned with the outer edges of the front frame 70 and fastened thereto. The inner edges of the lower front wall sheathing sections 79 and 79 are aligned with the inner edges of the innermost intermediate beams (beams 62 and 62 as shown in FIG. 5E; hidden from view in FIG. 7G) and fastened thereto. Further fastening to the other pair of intermediate beams is then completed.

[0185] The upper sections of the front wall sheathing 81 and 81 are aligned against the upper edges of the lower front wall sheathing sections 79 and 79 and the edges of the bottom and top sloped upper edges of the upper sections of the front wall sheathing 81 and 81 are aligned with the upper edges of the corresponding rafters 58 and 58 and the horizontal beam 68 of the front frame 70 (see FIG. 5E; not visible in FIG. 7G). Then the upper sections of the front wall sheathing 81 and 81 are further fastened to the intermediate beams 60, 60 62, 62 (see FIG. 5E; not visible in FIG. 7G).

[0186] In the next step, shown in FIG. 7H, a squaring component designated herein as the side wall trim 84, 84, is installed at or adjacent to the upper edge of the upper side wall sheathing 73 and 73. In this embodiment, each length of sidewall trim 84, 84 is arranged to provide a ledge having at least a point or, alternatively an entire upper surface in line with the slope to be formed by a section of roof sheathing extending from the peak of the roof to the upper outer edge of the sidewall trim 84, 84. As shown in FIG. 7H, the side wall trim 84, 84 is installed at or adjacent to the top edge of the upper side wall sheathing 73, 73.

[0187] A view of the front face of sidewall trim 84 is shown in FIG. 8A which represents a magnified view of the upper left corner of the structure of FIG. 7I (which will be described in more detail below). It is seen in FIG. 8A that the roof sheathing section 85d ends flush with the outer face of the side wall trim 84. The underside of the roof sheathing 85d rests upon the upper surface of rafter 58 of the front frame 70 and makes contact with the upper outer corner of the side wall trim 84. This side wall trim 84 acts as a squaring component. The side wall trim may be provided as a rectangular member as indicated in FIG. 8B or a member with a chamfered upper surface that matches the slope of the roof rafter 58 as shown in FIG. 8C.

[0188] With reference to FIG. 7I, the process of installing roof sheathing continues with the installation of the roof sheathing in sections. For the most part, the rafters and frames are not visible in FIG. 7I but, when referred to in this description, the reference numerals used in FIGS. 5A to 5E are used to clarify the process.

[0189] In the present embodiment, there are two roof sheathing sections on each side of the peaked roof formed by the rafters. Roof sheathing sections 85a and 85b are on the left side and roof sheathing sections 86a and 86b are on the right side. Each of these roof sheathing sections are pre-dimensioned to extend back across the roof rafters 58 of the back frame 64, middle frames 66, 66 and 66 and the front frame 70. In this particular embodiment. The back edge of roof sheathing section 85a is first aligned with the outer edge of the back frame 64. Then roof sheathing section 85a is aligned with the side wall trim 84. To achieve this alignment, it is effective to first fasten the back edge of the roof sheathing section 85a to the roof rafter 58 of the back frame 64. Then the section of roof sheathing can be used as a lever to pull the back frame 64 to square it with the side wall trim 84 (because the upper part of the back frame 64 will be slanted forward or backward at this stage i.e. not square with the side walls at this stage). This is effectively achieved by grasping the front-facing edge of roof sheet and pulling it side to side to induce the lower edge of the section of roof sheathing to align with the outer top edge of the side wall trim 84. After the left side of the roof sheathing section 85a is aligned with the side wall trim 84, the left side of the roof sheathing section 85a is fastened to the side wall trim 84 and the front side of the roof sheathing section 85a is fastened to the top surface of roof rafter 58 of the front frame 70. This process also contributes to squaring of the middle frame 66 with respect to the left side wall.

[0190] Next, the back edge of roof sheathing section 85b is first aligned with the outer edge of the back frame 64 and aligned with the right edge of roof sheathing section 85a. The back edge of roof sheathing section 85b is fastened to the top surface of the roof rafter 58 of the back frame 64 and then to roof rafters 85 of the middle and front frames. The process is repeated with the right side roof sheathing sections 86a and 86b to complete the roof sheathing.

[0191] The skilled person will recognize that alternative embodiments are possible wherein the roof sheathing is assembled in sections which span the distance between the side wall trim 84 and the roof line 89. Pre-dimensioned sections of roof sheathing for such an embodiment can be designed and prepared without undue experimentation by the skilled person and used by unskilled workers.

[0192] This manner and sequence of installing the roof sheathing represents a process which results in self-squaring of the entire structure. During this specific sequence, as the roof sheathing is aligned with and fastened to the side wall trim 84, the plane formed by the outer corners of the vertical beams 56 of the frames is squared with the plane of the floor plate.

[0193] In certain embodiments, a protective covering is added to the roof sheathing according to known methods. In certain embodiments protective siding is provided against all of the sheathing. Then, door frame members (not shown) are installed on the horizontal beam 68 and intermediate beams 62 and 62 of the front frame 70 to provide a door frame according to known methods and a door (not shown) is connected to the door frame according to known methods.

[0194] In certain embodiments the wall sheathing stop also enables the simple installation of the door, setting the height and square of the door in the opening and only requiring fastening of the hinges to the frame to set the door.

A Kit for Assembly of Framed Structures

[0195] One aspect of the present invention is a kit for assembly of framed structures, such as the example 1212 storage shed described herein. Advantageously, all of the structural components of the kit are pre-dimensioned to the exact required lengths to avoid damage that might otherwise be caused by unskilled assemblers. Thus, the lower support components (rim joists or base layers), floor joists and floor sheathing (if applicable), beams, roof rafters, wall sheathing and roof sheathing need only be placed appropriately using the provided placement markings and fastened together using fastening means adapted for convenient use by unskilled assemblers such as screws and pre-drilled screw holes and/or bolt and nut combinations, heavy duty staples, or essentially any fastening system deemed by the skilled person to be most appropriate for a non-skilled assembler to use correctly.

[0196] In certain embodiments, the placement markings used to indicate the proper positions of components prior to fastening may be color-coded and may use any kind of symbol which may be easily recognizable to a non-skilled assembler, even an assembler who is not proficient in English or other common languages. In certain embodiments, a selection of letters from the 26-letter Roman alphabet is used as the combination of symbols used as placement markings. In certain embodiments, the placement markings are accompanied by outline marks to show the exact positioning of a particular component.

[0197] In certain embodiments, the kit is for assembly of a framed structure with a floor and includes a layout sheet, four rim joists, each provided with a wall sheathing stop, wherein two of the rim joists include an inner floor joist ledger, a series of floor joists, side wall, end wall and front wall sheathing pre-dimensioned to cover exposed frames, and a series of pre-dimensioned beams and roof rafters. In some embodiments, the side wall, back wall and end wall sheathing is provided with markings to indicate positions for engagement of fastening means such as pre-dimensioned screw or bolt holes that correctly line up with the outer beams of the frames which serve the function of wall studs.

[0198] In certain embodiments, the kit includes a door with hinges and associated hardware and the parts required to assemble a door frame.

[0199] In certain embodiments, the kit includes pre-dimensioned squaring components which may be designed to form part of the finished framed structure or may be designed to use temporarily to square one aspect of the structure prior to fastening the aspect in the squared orientation. Such temporary squaring components may be represented by pre-dimensioned triangular sheets for squaring of the corners of lower support rim members or by pairs of pre-dimensioned lengths of wood or plastic which span the interior area of the lower support rim. The skilled person has the ability to square a structure using such squaring components.

[0200] In certain embodiments, the kit includes roofing material for covering roof sheathing. Advantageously the roofing material is provided in sections that cover the areas between the roof rafters. Thus, in FIG. 7I example, each half of the peaked roof of the structure is covered by two sections of sheathing. These sections may be further covered by additional roofing material. In certain embodiments, all sheathing is pre-dimensioned pressed wood prepared according to known methods.

[0201] In certain embodiments, the kit includes written and/or illustrated instructions describing the sequence of assembly steps.

Materials and Fasteners

[0202] While wood is a preferred material for the methods and kits described herein, the skilled person will recognize that other materials such as relatively lightweight metal or relatively rigid plastic may also be used. Conventional means are employed to connect various components and may include simple fastening means such as bolts/bolt receivers, screws, nails or heavy duty staples, and the like. Pre-drilled holes may be provided to facilitate the process of connecting components, according to known methods. Features of various components referred to in this outline will be described in more detail hereinbelow.

Alternative Embodiments

[0203] The skilled person will recognize that, relative to the three examples outlined above, certain features can be provided in a number of alternative combinations. These alternative combinations are also within the scope of the invention. For example, the layout sheet introduced in the second aspect may be included with the first aspect to provide a new combination. The skilled person will recognize appropriate alternative embodiments and has the skills to prepare kits and develop methods corresponding to these alternative embodiments without undue experimentation.

[0204] The example embodiments described above illustrate the use of a template provided on floor sheathing. The skilled person will recognize that alternative embodiments are possible wherein certain framed structures are designed to not include a floor. In such embodiments, the framing template may be provided on wall sheathing or roof sheathing which is used to assemble frames, before the template-marked wall or roof sheathing is installed on the wall or the roof. In such embodiments, the wall or roof sheathing which includes the template markings is laid flat on the ground or other surface so that the components (beams and roof rafters) of the frames can be placed thereon in correct orientation to facilitate fastening of the frame components together.

[0205] It is to be further noted that the principles illustrated herein can be applied to assemble buildings and/or framed structures with any dimensions deemed to be applicable for convenient handling by non-skilled assemblers. Thus, alternative embodiments of the assembly methods and kits can be used to assemble a wide range of wall configurations of framed structures with any type of roof configuration including gable, gambrel, flat, shed, hip, Dutch hip, and offset slope among others.

EXAMPLES

Example 1: Assembling a Framed Structure Using a Sheathing-Based Template

[0206] In this example, a series of pre-dimensioned components are used to assemble a framed structure. The pre-dimensioned components include lower support rim components, framing components for assembling a series of frames, sheathing, and a template marked on a section of the sheathing. The method includes the steps of: [0207] a) fastening the lower support rim together to produce a lower support rim; [0208] b) assembling the series of frames using markings on the template to guide placement of framing components; and [0209] c) fastening the series of frames to the lower support rim.

[0210] The lower support components may be represented by rim joists or by base layers. The template may be marked on floor sheathing in embodiments where the framed structure includes a floor. Alternatively, the template may be marked on wall sheathing or roof sheathing and used to guide the assembly of the frames prior to installation of the wall sheathing or roof sheathing.

Example 2: Assembling a Framed Structure Including a Floor Using a Layout Sheet

[0211] In this example, a framed structure with a floor is assembled using a kit of pre-dimensioned components. The pre-dimensioned components include a layout sheet for indicating positions of support pads, the support pads themselves, rim joists for forming a lower support rim, floor joists for supporting a floor, and floor sheets for forming floor sheathing. The floor sheathing when assembled from the floor sheets, includes template markings for assembling frames. The method includes the steps of: [0212] (a) positioning the layout sheet at the desired location for assembly of the framed structure; [0213] (b) installing the corner support pads at the indicated locations on the layout sheet; [0214] (c) positioning the rim joists on the corner support pads and connecting the rim joists to each other at the corners, using rim joist markings as guides; [0215] (d) positioning a plurality of floor joists on the inner joist ledges which form the support for installation of the side walls of the framed structure using rim joist markings and floor joist markings as guides, and connecting the floor joists to the rim joists to form a complete floor frame; [0216] (e) installing the sheets of the floor sheathing on top of the floor frame; [0217] (f) installing at least lower sections of side wall sheathing to both of the side rim joists; [0218] (g) using a template marked on the floor of the completed floor sheathing to guide the assembly of a back frame; [0219] (h) fastening back wall sheathing to the outside of the back frame; [0220] (i) fastening the back frame to the back rim joist; [0221] (j) using the template marked on the floor to guide assembly of the middle and front frames; [0222] (k) stacking the middle and front frames against the back frame in order with the front frame at the front of the stack, and the middle frames stacked between the back frame and the front frame; [0223] (l) installing the front and middle frames vertically against the side wall sheathing at locations indicated by marked symbols, in order with the front frame installed first, and the middle frames installed next; and [0224] (m) installing the remaining side and front wall sheathing and roof sheathing against the frames and performing all remaining steps for finishing the structure according to known methods.

Example 3: A Self-Squaring Process of Assembly of a Building with a Roof

[0225] This example describes a sequence for assembly of a framed structure with a square or rectangular floor. As described above, pre-dimensioned components are employed to facilitate the construction without any measuring and cutting of the components. The pre-dimensioned components include lower support rim members with outer ledges, framing components, and sheathing for walls and a roof. Sheathing is provided in sections to facilitate placement and alignment with the lower support rim and with the outer edges of the frames. The frames are assembled generally according to procedures described hereinabove using a template marked on a section of sheathing. Placement of vertical beams of the frames is guided by placement markings provided on the lower support rim or the floor. The steps of the method are performed in sequence to produce a structure which becomes squared as it is assembled (i.e. all corners have sides which are 90 with respect to each other). The method includes the steps of: [0226] a) assembling the lower support rim and squaring each of its corners using pre-dimensioned squaring components; [0227] b) placing side wall sheathing on the outer ledges of opposed lower support rim members, aligning the front and back edges of the side wall sheathing with the front and back edges of the lower support rim, and fastening the side wall sheathing to the lower support rim; [0228] c) placing the back wall frame on the lower support rim at the back, aligning the side edges of the back wall frame with the corresponding outer edges of the side wall sheathing and fastening the side wall sheathing to the back wall frame; [0229] d) placing back wall sheathing on the outer ledge of the back support rim, aligning the outer edges of the back wall sheathing with the outer edges of the back wall frame and fastening the back wall sheathing to the back wall frame; [0230] e) placing the front wall frame on the lower support rim at the front, aligning the side edges of the front wall frame with the corresponding outer edges of the side wall sheathing and fastening the side wall sheathing to the front wall frame; [0231] f) placing each middle frame at its pre-determined position on the lower support rim and fastening each middle frame to the side wall sheathing; [0232] g) placing front wall sheathing on the outer ledge of the front support rim, aligning the outer edges of the front wall sheathing with the outer edges of the front wall frame and fastening the front wall sheathing to the front wall frame; [0233] h) installing an upper side wall squaring component to the front, middle and back frames across the length of each of the opposed sides of upper side wall sheathing adjacent to the top edge of the upper side wall sheathing; and [0234] i) placing the roof sheathing on roof rafters of the back, front and middle frames and fastening the roof sheathing to the roof rafters and to the upper side wall squaring component.

[0235] Each of the steps outlined above produces an effect of squaring specific corners of the structure in sequence, or preparing an aspect of the building prior to squaring of specific corners. In embodiments where a floor is installed, the floor sheets act as the pre-dimensioned squaring components and the process of installing the sheets of the floor sheathing on top of the floor frame have the effect of squaring the floor plate (i.e. squaring all corners of the floor plate). In embodiments which do not include a floor, the pre-dimensioned squaring components are separate components which do not form part of the finished structure. For example, sheeting in the shape of a right-triangle can be used to square the corners of the lower support rim. These triangle-shaped sheets can then be removed after the structure is completely assembled.

[0236] In a similar manner, the process of installing side wall sheathing to opposing sides of the lower support rim joists on the ledge (wall sheathing stops) has the effect of squaring the side wall sheathing to the lower support rim. In this particular example, the side wall sheathing is provided in a lower section extending across the entire length of each side of the structure and an upper section with the same length dimension and with sufficient height to extend to align with the top surface of each vertical beam of each frame. Advantageously, in this particular example, the lower sections of side wall sheathing are installed first, followed by installation of the back frame, back frame sheathing, front frame, middle frames and front wall sheathing, followed by the upper sections of the side wall sheathing. Advantageously in this particular example, placement markings for the vertical beams of the middle frames are be marked near the top edge of the lower side wall sheathing to facilitate proper alignment of the vertical beams of the middle frames. The lower side wall sheathing is then fastened to the vertical beams of the middle frames.

[0237] The process of aligning and fastening the back frame to the side wall sheathing has the effect of squaring the back wall frame to the lower support rim.

[0238] The process of aligning and fastening the back wall sheathing to the back frame has the effect of adding further support or strength to the squaring of the back wall frame to the lower support rim.

[0239] The process of aligning and fastening the front frame has the effect of squaring the front wall frame to the lower support rim.

[0240] The process of aligning and fastening the middle frames has the effect of squaring the middle frames to the lower support rim;

[0241] The process of aligning and fastening the front wall sheathing to the front frame has the effect of adding further support or strength to the squaring of the front wall frame to the lower support rim.

[0242] The process of fastening the upper side wall squaring component to the front, middle and back frames contributes to the squaring of the upper corners of the structure.

[0243] The process of fastening the roof sheathing to the frames and to the upper side wall squaring component squares the plane formed by the upper surfaces of the vertical beams of the frames (hereinafter referred to as the top plane) with the front, back and side walls. The top plane is then parallel with the plane formed by the squared lower support rim.

EQUIVALENTS AND SCOPE

[0244] Other than described herein, or unless otherwise expressly specified, all of the numerical ranges, amounts, values and percentages, such as those for amounts of materials, elemental contents, times and temperatures, ratios of amounts, and others, in the following portion of the specification and attached claims may be read as if prefaced by the word about even though the term about may not expressly appear with the value, amount, or range. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0245] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains error necessarily resulting from the standard deviation found in its underlying respective testing measurements. Furthermore, when numerical ranges are set forth herein, these ranges are inclusive of the recited range end points (i.e., end points may be used).

[0246] Also, it should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of 1 to 10 is intended to include all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10. The terms one, a, or an as used herein are intended to include at least one or one or more, unless otherwise indicated.

[0247] Any patent, publication, internet site, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.

[0248] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.

[0249] While this invention has been particularly shown and described with references to embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.