The present application generally relates to light-framed wood and light-gauge steel building construction, and more particularly, to a sill plate anchorage assembly and related method for more quickly and efficiently erecting framed walls above concrete foundations for supporting pre-fabricated wall panelized construction.
Constructing buildings using pre-fabricated wall panels has become more popular both as a method of reducing construction costs and speeding construction. Such buildings often require a concrete foundation to which such pre-fabricated wall panels can be attached. In the past, there have been two primary techniques used to attach the base of such wall panels to the building foundation.
In one case, anchor bolts are set into the concrete foundation before the concrete pour; after the concrete cures, the upper ends of such anchor bolts are, at least in theory, received within pre-drilled mating mounting holes formed in the sill plates of the wall panels, and fasteners are then applied over the anchor bolts to secure the wall panels to the concrete foundation. In practice, it has been difficult, if not impractical, to ensure that the anchor bolts are positioned in the same pattern in which the receiving holes are formed in the pre-fabricated wall panels. Even if the anchor bolts are initially positioned accurately before the concrete pour begins, the process of pouring the concrete frequently displaces the anchor bolts from their initial positions. As a result, erectors of such buildings commonly find it necessary to drill out the bottom of the wall panels to match the actual spacing and position of the anchor bolts that extend upwardly from the concrete foundation. They also frequently find it necessary to remove and replace primary framing members from the wall panels in part or in entirety to match the positions of the anchor bolts. In addition, utility rough-ins such as for plumbing and electrical are often cast into the concrete in a manner that creates similar conflicts and repair necessity to the conflicting anchors. The need to perform this extra work requires extra time and slows construction.
In an alternate case, the task of setting the anchor bolts is delayed until after the concrete foundation has been cured. Holes are then drilled deep into the cured concrete footers with a hammer-drill or the like for receiving the anchor bolts. Thereafter, epoxy is applied within the drilled holes to fill the voids and secure the lower end of the anchor bolts within the concrete foundation. This process requires significant labor, is sensitive to weather conditions, and also requires extensive pull testing afterwards to confirm that the anchor bolts have been reliably set within the concrete foundation and that the epoxy has cured properly. Once again, construction is made more expensive and takes more time.
As noted above, utility rough-ins such as for plumbing and electrical are cast into the concrete before vertical wall panels are installed. These utility rough-ins are typically intended to extend into the vertical wall panels that are ultimately supported upon such concrete foundation. However, when the vertical wall panels are later attached, the locations of such utility rough-ins often interfere with framing elements already formed in a pre-fabricated vertical wall panel. By then, it is too late to move the location of the rough-ins since they are already fixed in the cured concrete. When this occurs, modifications to the pre-fabricated wall panel are required at the construction site. The need to perform this extra work likewise requires extra time and slows construction.
It is therefore an object of the present invention to provide an apparatus and method for anchoring prefabricated building walls to concrete foundations in a manner that reduces construction costs while speeding construction timeframes.
Another object of the present invention is to provide such an apparatus and method which avoids the need to align foundation anchoring bolts with the sill plates and framing members of pre-fabricated building walls.
Still another object of the present invention is to provide such an apparatus and method which avoids the need to modify the position of anchoring holes and framing members previously formed in the base portions of pre-fabricated building walls.
Yet another object of the present invention is to eliminate the need to drill holes into a cured concrete footer in order to receive anchor bolts used to secure base portions of pre-fabricated walls.
A further object of the present invention is to provide information to the various contractors, to-scale and in precise location, regarding the location of framing elements in order to enable utility rough-ins to be placed out-of-conflict with the individual elements of the pre-fabricated building walls.
A still further object of the present invention is to provide information to the various contractors to ensure that utility rough-ins are placed out-of-conflict with the individual framing elements of pre-fabricated building walls.
These and other objects of the present invention will become more apparent to those skilled in the art as the description of the present invention proceeds.
Briefly described, and in accordance with various embodiments thereof, a first aspect of the present invention relates to a sill plate anchorage assembly for supporting building walls, and including an elongated member having a number of spaced apertures formed therein. The elongated member is adapted to be releasably coupled to a concrete formwork that defines a space in which concrete will be poured for forming a foundation upon which the elongated member will be supported. A series of anchor shafts are provided, each extending between a lower end and an opposing upper end, and each such anchor shaft extends at least partially through a corresponding aperture in the elongated member. The lower end of each anchor shaft extends beyond the elongated member and is adapted to extend into the space defined by the concrete formwork. A corresponding series of fasteners are provided, each such fastener being adapted to engage the upper end of a corresponding anchor shaft. Upon pouring concrete into the concrete formwork, the lower ends of the anchor shafts become embedded within the concrete. After the concrete is cured, each such fastener is tightened over the upper end of a corresponding anchor shaft to secure the elongated member against the foundation.
In some embodiments of the invention, the aforementioned elongated member is temporarily secured to the concrete formwork before concrete is poured therein. In this manner, the elongated member is maintained at an elevation whereby the lower ends of the anchor shafts extend within the space in which concrete will be poured.
In at least some embodiments of the invention, each substantially-vertical aperture includes an enlarged recess extending below the uppermost surface of the elongated member, and wherein a fastener engages the upper end of a corresponding anchor shaft within such enlarged recess.
In various embodiments of the invention, the upper end of each anchor shaft has external threads, and the fastener is a nut for threadedly engaging the upper end of a corresponding anchor shaft. Tightening each nut over the upper end of its associated anchor shaft fastens the elongated member against the formed and cured concrete foundation in which the anchor shafts are embedded.
In some embodiments of the invention, at least one vertical wall panel has a base portion. A number of wall fasteners are provided, each such wall fastener extending through the base portion of the vertical wall panel and into the elongated member for securing the base portion of such vertical wall panel to the elongated member.
In some embodiments of the invention, the elongated member is marked with pertinent information to indicate the type and location of framing elements within a vertical wall panel that is to be secured over the elongated member after the concrete has been formed and cured. Such indicia may indicate the location and/or type of pass-through regions that extend within a vertical wall member to be supported upon the sill plate anchorage assembly.
In various embodiments of the invention, the elongated member is formed of wood, and the wall fasteners are threaded bolts.
In some embodiments, at least one vertical wall is a pre-fabricated building wall.
Another aspect of the present invention relates to a method of securing a horizontal sill plate to an underlying concrete foundation for supporting building walls. In various embodiments, such method includes forming a number of spaced apertures within an elongated member that forms the sill plate. A series of anchor shafts are extended within the plurality of apertures in a manner that allows the lower end of each such anchor shaft to extend below the elongated member. The upper end of each such anchor shaft is accessible from an upper surface of the elongated member. A concrete formwork is formed to define a space in which concrete will be poured for creating a concrete foundation upon which the elongated member will be supported. The elongated member is temporarily supported relative to the concrete formwork whereby the lower ends of the anchor shafts extend within the space in which concrete will be poured. Concrete is then poured into the concrete formwork, with the lower ends of the anchor shafts extending within the poured concrete, to form a concrete footer. After the concrete has cured, fasteners are secured to the upper ends of each anchor shaft for fastening the elongated member to the cured concrete foundation.
In various embodiments, the step of supporting the elongated member relative to the concrete formwork includes the step of temporarily securing the elongated member to a portion of the concrete formwork. The elongated member is removably coupled to the concrete formwork to facilitate removal of the formwork from the elongated member after the foundation has cured.
In various embodiments of such method, the step of forming a plurality of spaced apertures within the elongated member includes forming an enlarged recess extending below the uppermost surface of the elongated member. In some embodiments, the step of securing a fastener to the upper end of each anchor shaft includes positioning the fastener and upper end of the anchor shaft within such enlarged recess to avoid interference with the base portion of the vertical wall panel to be secured thereto.
In some embodiments of such method, the upper end of each anchor shaft is externally threaded, and the step of fastening the elongated member to the cured concrete foundation includes the steps of threadedly engaging a nut over the upper end of a corresponding anchor shaft, and tightening the nut thereover.
In various embodiments of practicing such method, at least one vertical wall panel is provided having a base portion. Wall fasteners are extended through the base portion of the vertical wall panel and into the elongated member for securing the base portion of such vertical wall to the elongated member.
In some embodiments of such method, the aforementioned vertical wall is fabricated remotely from the building site as a pre-fabricated wall.
Various embodiments of such method may also include the steps of forming markings upon the elongated member for indicating the location and/or type of an element within a building wall to be installed above the elongated member to guide contractors when locating elements that pass upwardly through the concrete foundation into a vertical wall supported above the elongated member.
The foregoing and other features and advantages of the present invention will become more apparent from the following more detailed description of particular embodiments of the invention, as illustrated in the accompanying drawings.
A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the Figures, wherein:
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In one embodiment, wooden board 102 is one and one-half inches wide when set on edge as shown in
In the embodiment illustrated in
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Those skilled in the art will appreciate that, while sill plate 110 has been described as being formed as a wooden member, other materials may be used to form sill plate 110, including steel or other metals. Likewise, while concrete formwork member 102 has been described as a wooden board, this member may be formed from other materials, including composites, steel or other metals, and may not always also be used to define the space in which the concrete is poured. Also, while wall panels 500 have been described above as pre-fabricated wall panels, it will be appreciated that such wall framing may, if desired, be constructed at the job site and secured to corresponding sill plates following the pouring and curing of the concrete footers.
It will be recognized that an apparatus and method have now been described for supporting prefabricated building walls upon concrete footers in a manner that reduces construction costs while speeding construction. The described apparatus and method eliminate any need to align foundation anchoring bolts with the base portions of pre-fabricated building walls, thereby avoiding any need to modify the position of anchoring holes previously formed in the base portions of pre-fabricated building walls to accommodate anchor shafts that shifted out of position during the concrete pour. Likewise, the described apparatus and method do away with the need to drill any holes into a cured concrete footer in order to receive anchor bolts for securing base portions of pre-fabricated walls to the concrete footer.
The embodiments specifically illustrated and/or described herein are provided merely to exemplify particular applications of the invention. These descriptions and drawings should not be considered in a limiting sense, as it is understood that the present invention is in no way limited to only the disclosed embodiments. It will be appreciated that various modifications or adaptations of the methods and or specific structures described herein may become apparent to those skilled in the art. All such modifications, adaptations, or variations are considered to be within the spirit and scope of the present invention, and within the scope of the appended claims.