BEAM AND BOLTING CONSTRUCTION SYSTEM AND METHOD

Abstract

A beam and bolting construction method and an example dwelling (10) according to the method are provided. The method involves preliminary steps of selecting a site and determining a bolt array (19) and selection of dimensions and materials. Actual construction steps include forming a foundation slab (14) having vertical bolts (18) embedded therein in accordance with the bolt array (19). Alternating layers of beams (B), having aligned bolt bores (52) for receiving the bolts, are successively laid down over the bolts (18), with sides meeting at corners (29) with alternating sides encompassing the corner bolt. Once a desired height is achieved, washers (72) and nuts (78) are placed on the bolts and are tightened to desired pressure levels. The dwelling (10) is formed with beams (42) compressed together by threaded bolts (18) in a bolt array (19).

Description

TECHNICAL FIELD

The present invention relates generally to construction methods and system apparatus for uniform cross-section beam and bolting construction, particularly as applied to single story dwellings.

BACKGROUND ART

Like nearly all other areas of knowledge and commerce, the field of dwelling construction is subject to continual improvements in techniques, use of materials, and related structural designs. This is certainly the case in the construction of dwelling such as cabins and small houses.

Although the concept of wooden dwellings goes back into prehistory, these have always been subject to problems, both in the construction methods and in the resulting products. For example, traditional “log cabins” were difficult in finding sufficiently uniform logs and requiring caulking materials (often requiring frequent renewal) to protect the inhabitants from the elements.

Wood constructions have many advantages, particularly since natural woods, with the exceptions of some hardwoods, have at least some degree of flexibility and compressibility. This allows for better weather sealing, and for better resistance to earthquake and wind damage. Better methods of improving these aspects are highly desirable.

Accordingly, there is significant room for improvement and a need for stronger and more easily constructed walls and frames for buildings.

DISCLOSURE OF INVENTION

Accordingly, it is an object of the present invention to provide a method for constructing beam and bolting vertical walls.

Another object of the invention is to provide a method and protocol for building cabins and other buildings utilizing preformed wood beams.

A further object of the present invention is to provide for walls which are held together with adjustable pressure bots and nuts.

Yet another object of the invention is to provide secure corners in beam construction.

A further object of the present invention is to provide cabins and other buildings which are sturdy and resistant to elemental degradation.

Still another object of the invention is to provide a structure which is extremely stable in response to high winds, earthquakes, and other destructive forces.

A further object is to create a structure which utilizes a virtual lamination technique, a “Bolt-Lam” to maintain beam members in a pressure abutment structure which has synergistic advantages in weather sealing, combined strength, and durability.

Another object of the invention is that all intersecting walls are multidirectional shear walls, highly resistant to deformation of any kind.

Briefly, one preferred embodiment of the present invention is a method (M) for constructing beam and bolting walls and structures. The method involves preliminary steps of selecting a site and determining a bolting array and selection of dimensions and materials. Actual construction steps include forming a foundation slab having vertical bolts embedded therein in accordance with the bolting array. Alternating layers of beams, having aligned bolt holes for receiving the bolts, are successively laid down over the bolts, with sides meeting at corners with alternating sides encompassing the corner bolt. Once a desired height is achieved, washers and nuts are placed on the bolts and are tightened to desired pressure levels. The nuts and threaded bolt ends are situated to have an access gap such that the pressure may be adjusted as conditions change. The method and protocol may be used in forming structures such as cabins, houses, outbuildings and the like.

Other preferred embodiments are product by process structures constructed in accordance with the method (M).

An advantage of the present invention is that it provides a relatively rapid and secure protocol for raising a set of walls.

Another advantage of the invention is that it provides for constructing a building which may be made with preformed beams, having spaced-apart bolt holes for receiving vertical bolts.

An additional advantage of the invention is that embedding elongated threaded bolts in a foundation slab provides an array upon which beams may be vertically installed thereon.

A further advantage of the construction method (M) is that the “Bolt-Lam” virtual lamination by pressure has a synergistic effect superior to prior art techniques.

Yet another advantage of the present invention is that the structure is much stronger and sturdier than one created with conventional stick framing.

Still another advantage of the present invention is that the intersecting walls together form a moment frame for the entire building.

A further advantage of the present invention is that a completed frame is integral and very highly resistant to separation of a portion thereof by forces such as wind.

These and other objects and advantages of the present invention will become clear to those skilled in the art in view of the description of the best presently known modes for carrying out the invention and the industrial applicability of the preferred embodiments as described herein and as illustrated in the several figures of the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The purposes and advantages of the present invention will be apparent from the following detailed description in conjunction with the appended drawings in which:

FIG. 1 is a front plan view of an example dwelling constructed in accordance with the present invention;

FIG. 2 is a perspective view of a construction site at an early stage, prior to installation of any beams, showing a typical bolting array;

FIG. 3 is a plan view of the left side/end of the example dwelling;

FIG. 4 is a rear plan view of the example dwelling;

FIG. 5A is a truncated perspective view of an example beam according to the present invention;

FIG. 5B is a cross sectional view of the beam of FIG. 5A, taken along line B-B;

FIG. 6 is a plan view of the right side of the example dwelling, showing a roof mounting approach;

FIG. 7 is cutaway side view of an alternate dwelling, showing another roof mounting approach;

FIG. 8 is a fanciful cross-sectional illustration of a segment of a wall showing an interstitial bolt anchored in the foundation slab and extending upward to pass through the bolt holes in the beams;

FIG. 9 is a fanciful cross sectional view of a section of the foundation slab, an elongated bolt anchored in the slab and extending through bolt holes, and an alternate washer plate providing an external spacing and securing bracket;

FIG. 10 is a side view of a prototype partial corner section of two very short exterior walls, showing the layering and bolting techniques;

FIG. 11A shows a system for precise anchoring of an elongated threaded bolt in the foundation slab;

FIG. 11B is a top plan view of a top (or bottom) mounting bracket for the system of FIG. 11A; and

FIG. 12 shows in examples A, B, C, and D, four envisioned corner bracing configurations.

BEST MODE FOR CARRYING OUT THE INVENTION

The present invention is a method of construction (M) for dwellings and other buildings utilizing beam and bolting and of the structures resulting therefrom. An example dwelling 10, in this case a cedar or redwood beam cabin, is illustrated in a front view of FIG. 1. The structure is defined in terms of the spatial relationships (shown in phantom) including a primary vertical plane 11, a transverse vertical plane 12 perpendicular to the primary plane 11, and a horizontal plane 13 perpendicular to the vertical planes.

The preferred process (M) involves a series of steps in constructing and maintaining a beam and bolting building/dwelling. A brief summary of the steps is set forth below:

Select site and prepare layout, including bolting array positioning;

Locate corners for bolting on foundation slab;

Precisely locate bolt anchor locations for foundation slab;

Determine height of walls;

Select locations for gaps in walls (doors, windows, etc.);

Determine whether corners will have extended beam segments and sequential order of beam vertical overlap at corners;

Select materials;

Choose gauge and length of vertical bolts and choose nuts and washer plates;

Choose materials for beams (e.g. cedar, redwood, composite, etc.);

Determine cross-sectional structure of beams;

Determine default beam length;

Prepare foundation slab;

Situate and secure vertical bolts in predetermined bolt anchor locations defined by the bolting array;

Construct foundation slab to provide a flat upper surface and secure vertical bolt in precise vertical orientation;

Prepare beams;

Provide bolt bores through each beam in accordance with spacing of the predetermined vertical bolt locations;

Cut beam segments (truncated beam segments) to accommodate corners and wall gaps according to plans;

Vertically lower first beam in corner overlap sequence (cross beam) onto respective vertical bolts, including the selected corner bolt and at least one interstitial bolt, through respective bolt bores until it rests upon the foundation slab, with, if selected, extending beyond the corner bolt;

Vertically lower second beam in the corner overlap sequence (truncated transverse beam) onto respective interstitial vertical bolts such that it rests upon the foundation slab with a beam end abutting against the cross beam at the corner;

Repeating steps set forth in the two immediately preceding paragraphs, inserting bolt couplings and additional bolt segments as required, until all corners are completed;

If necessary, laying down beam segments on interstitial bolts to fill in any gaps not corresponding to doors, or the like in the layer;

Laying down additional layers until the desired wall heights are achieved, alternating the functions of the cross beam and the transverse beam in each successive layer such that the corner bolts alternatively pass through cross and transverse beams;

Upon achieving desired wall height:

Laying down washer plates (pressure distribution plates) encompassing each of the vertical bolts on top of the beams; and

Applying and tightening nuts to each of the treaded bolts to force all of the beams together to a desired pressure (creating a “Bolt-Lam”) in order to achieve a desired “seal” and a secure structure.

Installing a desired roof above the walls, maintaining an access gap above all bolts and nuts to allow subsequent pressure adjustment.

Oher steps, which are not critical to the present invention, may also be performed.

Considering a product (in this case a building or dwelling) constructed in accordance with the above-described method (M) the example dwelling 10 is further explained below. For the purposes of simplified description, and since these are a matter of choice not critical to the invention, most architectural details and all interior details are omitted from the description. The preferred example dwelling (cabin) 10 illustrated in FIGS. 1-4 includes a foundation slab 14, which is carefully aligned to be parallel to the horizontal plane 13. The initial actual construction step (after site and layout and materials selection) in the method (M) is to provide the flat (level) and horizontal (perpendicular to gravitational force) foundation slab 14 with bolt anchor locations 16 in which elongated vertical threaded bolt segments (vertical bolts) 18 are countersunk and secured in precise vertical orientation (see FIGS. 2, 7-9 and 11). The foundation slab 14 is typically poured concrete but other sturdy structural approaches may be used. The vertical bolts 18 are threaded at at least the ends, are held in the bolt anchor locations 16 and are situated in a precise bolt array 19 corresponding to the dwelling design (an example array—not congruent to the example dwelling 10) is shown in FIG. 2). The array 19 includes corner bolts 20 and interstitial bolts 21 situated between corner bolts 20.

A further step in the construction method (M) relates to completing vertical walls mounted upon the vertical bolts 18. For simplicity of explanation, the example cabin 10 is rectangular, but a myriad of other configurations are possible. In the example dwelling 10 illustrated in FIGS. 1, 3, 4, and 6, a set of four exterior vertical walls 22 are provided. A front wall 23 and a rear wall 24 are aligned parallel to the primary vertical plane 11, and consequently with each other. Similarly, a left wall 26 and a right wall 28 are aligned parallel to the transverse vertical plane 12, and to each other. Each of the walls 22 will overlap at opposing ends with the respective perpendicular transverse walls at a corner 29, as described below. Each of the exterior walls 22 is constructed in accordance with the construction method (M).

A roof 30, of generally conventional construction, is mounted on and above the exterior walls 22 as described below. For at least a significant amount of the expanse, an access gap 32 separates the top of each exterior wall 22 from the roof 30 and any other overhead components, as explained below. Various other exterior details, not pertinent to the primary inventive concepts, are also shown and provided. These details include a fireplace 34 with an associated chimney 36, and doors 38 and windows 40 as desired.

The exterior walls 22 of the present invention are constructed with beams 42 as illustrated in more detail in FIGS. SA and SB. FIG. SA is a perspective view of an example beam 42 while FIG. SB is a cross sectional view taken along line B-B. The beams 42 are selected to have a beam top 44 and a beam bottom 46 which are flat and parallel to each other, and a pair of beam ends 48. The beams 42 also have beam edges 50 which may also be flat and parallel so that the beam has a rectangular cross section (square, as illustrated in FIG. SB) but may also be beveled or otherwise shaped for aesthetic purposes as these surfaces are not critical to the effectiveness of the construction. In the example dwelling 10 the beams 42 are uniform in cross sectional dimensions, but may vary in thickness as breadth as desired for particular purposes.

Each beam 42 includes series of bolt bores 52 vertically passing therethrough between the beam top 44 and beam bottom 46 surfaces. These bolt bores 52 are strategically spaced and located so as to correspond and mate with the specific bolt array 19. Each bolt bore 52 has a diameter slightly greater than the diameter of the selected vertical bolt segments 18.

Although all of the beams 42 in the example dwelling 10 are substantially similar for the purposes of construction method (M) it is convenient to refer to them separately for the purposes of description. Thus, some beams, which are aligned with the primary vertical plane 11 (e.g. front wall 23 and rear wall 24) are referred to as cross beams 54 while those aligned with the transverse vertical plane 12 (e.g. left wall 26 and right wall 28) are designated as transverse beams 56. An unmodified beam 42 such as is illustrated in FIG. 5A is referred to as a full beam 58, while a beam that is cut short so as to abut against a full beam 58 at a corner 29 is designated as a truncated beam 60. A beam segment 62 is defined as a section of a beam used to fill in gaps in the structure.

As described above in respect to the steps of the preferred method (M) the exterior walls 22 are constructed in a vertically ascending series of layers, as the beams are fitted onto the respective vertical bolts 18. The layers are designated as an odd layer 64 (the lowest of which abuts against the foundation slab 14) and an even layer 66 which rests on top of an odd layer 64 to create a vertical overlap 68 of beams in adjacent layers at each corner 29. The discussion below with regard to FIG. 12 shows four envisioned corner overlap schemes for suitable stable corners 29.

For the purposes of description of a preferred embodiment (FIG. 12, depiction D), and referring to the left end of the front wall 23 (and the rear wall 24), the cross beam 54 in an odd layer 64, will be mounted to include a corner bolt 20, as illustrated in FIGS. 3 and 4. In the preferred corner 29 in the example dwelling 10 (as shown in FIG. 10), the cross beam 54 includes an integral extended segment 70 which extends outward beyond the corner 29.

For the odd layers 64 the transverse beams 56 are truncated beams 60 which are mounted only on interstitial bolts 22 and have one beam end 48 which abuts against a cross beam 54 at each corner 29. For even layers 66, the roles are reversed (see FIGS. 4, 5, and 10) and the transverse beams 56 include extended segments 70 and are mounted to include a corner bolt 20, while the cross beams are truncated beams 60, and are mounted only on interstitial bolts 21.

In order to facilitate construction it is ordinarily necessary to insert bolt couplings 71 at a convenient working height above the foundation slab 14. Workers can usually only effectively lift and position beams 42 on and over the vertical bolt segments 18 to a certain height which is usually consistent with the height of the bolt segment above the foundation slab 14. As the typical threaded bolt segment 18 is about six feet long in US constructions, and since bottom of the lowermost bolt segments is typically embedded about one foot into the foundation slab 14, the most common location to insert a coupling 71, with another bolt segment 18′ in the same vertical alignment, will be at a height of about five feet above the foundation slab 14. The upper bolt segment 18′ will then extend to slightly above the typical ten foot height of each wall 22, and placement of the beams 14 will then be accomplished with the aid of scaffolding or mechanical lifts,

The alternating layers continue until the desired wall height is reached. At this stage rigid washer plates 72 are placed over the elongated bolt 18′ and against the top layer of the beams 42. Right angle corner plates 74 are situated on corner bolts 20 to lay against both abutting beams while elongated plates 76 are placed over interstitial bolts 21, preferably extending between two or more interstitial bolts. Nuts 78 are then threaded onto the respective elongated bolts 18′ and tightened to the desired pressure levels, forcing the beams against the foundation slab 14 and each other to form a “Bolt-Lam”.

A prototype shortened corner segment of intersecting walls is shown in FIG. 10. This shows the alternating levels, with extended segments 70 at appropriate levels of the cross beam 54 and transverse beam 56, as well as the corresponding abutment of a truncated beam 60 of the respective beam type for each level. Although shown without an elongated vertical bolt 18 anchored in a foundation slab 14 this also shows the washer plate 72 and nut 78 attached to be tightened to force the beams in adjacent layers together.

This prototype (FIG. 10) has been wind-tunnel tested and was shown to successfully withstand gale and hurricane force winds (from many angles and with winds of 50 to 150 mph) without any compromise of integrity.

FIGS. 8 and 9 illustrate, in fanciful cross sectional views, the anchoring of elongated bolts 18 in the foundation slab 14 and extending upward through the bolt holes 52 of each beam in the layer. In FIG. 8 an alternate washer plate 72′, adapted to connect to an element above the wall, is shown being held in place by a nut 78. In FIG. 9 a spacing/securing bracket 80 is illustrated providing spacing between the foundation slab 14 and the bottom beam 42′ and also engaging the bottom beam 42′ to hold it securely in position.

FIGS. 6 and 7 illustrate potential methods/arrangements for mounting a roof 30 onto a dwelling. It is emphasized in method (M) that any roof or ceiling structure requires that an access gap 82 is provided such that each nut 78 may be accessed from inside the structure in order to adjust the pressure level and compensate for the slight material deformations over time. It is also necessary that the roof 30 be secured to the wall structures. In order to typically accomplish this a series of roof spacer blocks 84 (beam segments including bolt bores 52) are placed on top of the wall 22 intermediate the access gaps 82. These roof spacer blocks 84 and rafters 86 and other connective portions of the roof 30 are then secured to the top and potentially lower beams. The securing method includes roof bolting 88 having involving threaded bolt segments 18″ with an additional coupling 71 to extend through the upper beams 42 to beyond and through and above the spacer blocks 84 and rafters 86 and provided with washer plates 72 and nuts 78 to tighten the wall and roof elements together in a stable and secure fashion. Depending on the nature of the roof 30, the rafter bolting 88 and roof spacer blocks 84 may only be needed on some of the exterior walls 22.

As other roof construction details are not strictly pertinent to the invention or method (M) these are not addressed herein.

FIGS. 11 (A & B) and 12 (A, B, C, and D) show examples of helpful construction details and alternate corner bolting configuration in accordance with the present invention.

FIG. 11 illustrates, both in cut away view (11A) and top view (11B), an alignment system 90 for placing and aligning each bottom vertical bolt 18 in the desired bolt anchor location 16 in the foundation slab 14. Prior to pouring the foundation slab 14, a foundation frame 92 is placed around the desired border. This is typically in the form of a wooden border, in the illustration a 4x8 board. The foundation frame rests outside a foundation cavity 94, into which the concrete or other solid filler will be poured once the bolt array 19 is prepared. A nut 78 is threaded onto the vertical bolt segment above the level of the foundation frame 92, while a further nut 78 and washer plate 72 are situated well below, near the nether end of the bolt segment 18.

A top bracket 96 and a bottom bracket 98 are adapted to fit about the upper and lower surfaces of the foundation frame 92 and extend into the foundation cavity 94. The top bracket 96 and lower bracket 98 each include a right angle flange 100 to abut against the outside of the foundation frame to form a horizontal plate 102, with a centering notch 104 at its interior end in order to receive the bolt segment 18. When the brackets 96 and 98 are properly placed and aligned, the bolt segment 18 is placed to vertically fit into the centering notches 104 of both brackets, with the exterior nut 78 tightened to secure the bolt segment 18 into position and alignment. When all necessary alignment systems 90 are set up around the perimeter (and in portions of the interior when interior walls or the like are included in the plan), the foundation slab 14 may be poured to set each bolt segment into the bolt anchor locations 16 of the array 19. The top bracket 96 and bottom bracket 98 may either be left in place or laterally slid out as the foundation slab hardens.

FIG. 12 shows (in sub-Figures A, B, C, and D) four possible desirable corner 29 structures, each including one or more “L” brackets 106 situated on the interior or exterior angle, or both. In three of the example corners 29 (B, C, and D), the corner bolt 20 extends through the actual corner location and through the alternating layers 64 and 66 of the beams. In the upper right example (FIG. 12A) there are two offset corner bolts 20′ passing through respective cross beams 54 and transverse beams 56, each of which is trimmed at a forty-five degree angle so as to abut each other at the apex of the corner 29. The lower left example (FIG. 12D) is the top view of a corner 29 as described above for the example dwelling 10.

The materials selected for the components of the building constructed according to the Method (M) are structurally strong. The preferred foundation slab 14 is poured concrete, but other materials may also suffice. The preferred elongated threaded bolts 18 are formed of construction steel and have dimensions as described above. The preferred beams 42 are selected from stable, yet slightly deformable woods, such as cedar or redwood, while other types of slightly compressible materials, such as synthetic and composite materials, all having compatible upper and lower surfaces, may also be suitable, The beams 42 are most simply elongated and have square cross sections. Uniform thickness of alternating layers is preferred but differing height (thickness) of the layers may be feasible, so long as each layer has a uniform thickness. Bolt hole 52 separation and locations in the beams 42 may be standardized and prefabricated beams 42′ may be provided such that onsite drilling is avoided and time is saved.

It is noted that the bolt array 19 defines an exterior frame 108 for the dwelling 10 and the exterior frame 108 defines an interior 110 for the dwelling 10.

Many modifications to the above embodiment may be made without altering the nature of the invention. The dimensions and shapes of the components and the construction materials may be modified for particular circumstances.

While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not as limitations.

INDUSTRIAL APPLICABILITY

The Beam and Bolting Construction Method (M) and the walls and buildings constructed according to the method (M), such as example dwelling 10, according to the present invention are adapted to be constructed precisely and quickly with potentially prefabricated material components, thus greatly enhances the effectiveness of building construction.

Greater effectiveness in cabin and other simple building constructions results in significant economic advantages. In addition, the ability to adjust vertical pressure on the vertical layers in a wall to compensate for deterioration and environmental variations is a significant advantage in minimizing the need to any caulking or other sealing remedies, and is especially effective with redwood materials.

For the above, and other, reasons, it is expected method (M) and products by process 10 according to the present invention will have widespread industrial and construction applicability. Therefore, it is expected that the commercial utility of the present invention will be extensive and long lasting.

Claims

29. A method for constructing a bolt and beam wall structure, comprising: i) preparatory steps, which may be performed simultaneously or in any order, including a) selecting a site;b) designing a specific predetermined bolt array system for supporting and aligning one or more walls in the wall structure;c) selecting materials and dimensions; andii) construction steps to be performed, including a) preparing a foundation plate forming a base for said wall structure;b) mounting a plurality of top brackets and bottom bracket in pairs, each pair comprising one of said plurality of top brackets and one of said plurality of bottom brackets, each of said top and bottom brackets in said pairs having an alignment slot, on said foundation plate to form an alignment system corresponding to said predetermined bolt array;c) placing and securing a bolt segment in said alignment slot of each corresponding pair of said top and bottom brackets such that each said bolt segment extends vertically upward and is aligned with a particular bolt anchor location in said bolt array;d) said foundation plate receives and secures said bolt segments in said bolt array so as to fix in place each of said bolt segments;e) placing a series of layers of beam segments serially upward upon said bolt segments, extending said bolt segments when the desired vertical extent of said walls exceeds the length of one vertical bolt by inserting bolt couplings and additional bolt segments, until a desired height of a said wall structure including an uppermost beam segment having at least one vertically-oriented side is achieved; each said beam segment having a flat top surface parallel to a flat bottom surface, both surfaces extending lengthwise between opposite beam ends; andf) tightening each said nut of said bolt segments on the uppermost beam segment so as to compress adjoining layers of beam segments in said series together, forming a wall comprising a multiplicity of beam segments—which functions as a single unit wall segment; the multiplicity of beam segments comprising a subset designated as cross beam segments and a subset designated as transverse beam segments;g) as part of step (ii) e), constructing multiple ones of said wall segments including cross beam segments and transverse beam segments, at least some of which cross beam segments and transverse beam segments intersect at least one respective corner to form a corner having an apex, andh) at least one corner bolt in said bolt array extends only through either a cross beam segment or a transverse beam segment in alternating adjacent layers at said corner; andi) wherein in alternating layers at each said corner, one of said cross beam segments extends across said corner and one of said transverse beam segments has an end which abuts flush against said cross beam segment, while on vertically adjacent layers, one of said transverse beam segments extends across said corner and one of said corresponding cross beam segments has an end which abuts flush against said transverse beam segment.

30. The method of constructing a bolt and beam structure of claim 29, wherein: an access gap is provided above each said tightening nut, which said access gap is accessible from outside the beam segment such that said tightening nut may be adjusted after construction from a side of the uppermost beam segment.

31. The method for constructing a bolt and beam wall structure of claim 29 wherein: each beam segment of said wall segment which extends across said corner in each layer of the series of layers further extends beyond said corner.

32. The method for constructing a bolt and beam wall structure of claim 29, wherein: three said corner bolts are preset at each corner, including one apex bolt centered in the apex of said corner and two offset corner bolts displaced from said apex bolt in each beam;each of said two offset corner bolts respectively extends through the end portion of each abutting beam segment.

33. The method for constructing a bolt and beam wall structure of claim 29, wherein: at least a portion of said bolt array defines an exterior boundary of a horizontally enclosed structure including multiple corners.