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.
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.
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 comers 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 comers with alternating sides encompassing the comer 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.
The purposes and advantages of the present invention will be apparent from the following detailed description in conjunction with the appended drawings in which:
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
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 comers 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;
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;
Prepare beams;
Provide bolt bores through each beam in accordance with spacing of the predetermined vertical bolt locations;
Vertically lower first beam in comer 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 comers 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 comer 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
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
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 FIG. 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
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
For the purposes of description of a preferred embodiment (
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 comer 29. For even layers 66, the roles are reversed (see
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 comer 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
This prototype (
As other roof construction details are not strictly pertinent to the invention or method (M) these are not addressed herein.
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.
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.
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.
This is a continuation patent application, claiming priority from non-provisional application Ser. No. 15/986,605, filed May 22, 2018, claiming priority from Ser. No. 62/539,546, by the same inventor, filed Aug. 1, 2017.
Number | Name | Date | Kind |
---|---|---|---|
729408 | Pickin | May 1903 | A |
2563703 | Bonney | Aug 1951 | A |
3343328 | Rolle | Sep 1967 | A |
3449875 | Elmer | Jun 1969 | A |
4089144 | Astl | May 1978 | A |
4305238 | Harward | Dec 1981 | A |
4353191 | Schilbe | Oct 1982 | A |
4463532 | Faw | Aug 1984 | A |
4503648 | Mahaffey | Mar 1985 | A |
4510724 | Magnuson | Apr 1985 | A |
4688362 | Pedersen | Aug 1987 | A |
4745722 | Ross | May 1988 | A |
4777773 | Fry | Oct 1988 | A |
4823528 | Faw | Apr 1989 | A |
5010701 | Halsey, Jr. | Apr 1991 | A |
5115609 | Sing | May 1992 | A |
5253458 | Christian | Oct 1993 | A |
5471804 | Winter, IV | Dec 1995 | A |
5570549 | Lung | Nov 1996 | A |
5657597 | Loftus | Aug 1997 | A |
5787675 | Futagi | Aug 1998 | A |
5806249 | Helms | Sep 1998 | A |
5881515 | George | Mar 1999 | A |
5890332 | Skidmore | Apr 1999 | A |
5899040 | Cerrato | May 1999 | A |
6000177 | Davidson | Dec 1999 | A |
6023895 | Anderson | Feb 2000 | A |
6161339 | Cornett, Sr. | Dec 2000 | A |
6195949 | Schuyler | Mar 2001 | B1 |
6385929 | Englehart | May 2002 | B1 |
6588161 | Smith | Jul 2003 | B2 |
6931803 | Davis | Aug 2005 | B1 |
7117647 | Clarke | Oct 2006 | B2 |
7549263 | Porter | Jun 2009 | B1 |
7661230 | Peaco | Feb 2010 | B2 |
8387338 | Smith | Mar 2013 | B1 |
8601761 | Chadwick | Dec 2013 | B2 |
8701364 | Wrightman | Apr 2014 | B2 |
9428926 | Kramer | Aug 2016 | B2 |
20020043038 | Cerrato | Apr 2002 | A1 |
20020046519 | Houseal | Apr 2002 | A1 |
20020124524 | Lokken | Sep 2002 | A1 |
20020157334 | Smith | Oct 2002 | A1 |
20030230032 | Shahnazarian | Dec 2003 | A1 |
20040134142 | Stutts | Jul 2004 | A1 |
20040187411 | Clegg | Sep 2004 | A1 |
20050081465 | Crumley | Apr 2005 | A1 |
20050126084 | Woksa | Jun 2005 | A1 |
20060248825 | Garringer | Nov 2006 | A1 |
20080072508 | Tower | Mar 2008 | A1 |
20080083177 | Tiberi | Apr 2008 | A1 |
20090133345 | Wrightman | May 2009 | A1 |
20090199497 | Wrightman | Aug 2009 | A1 |
20090293390 | Anderson | Dec 2009 | A1 |
20100186316 | Buchanan | Jul 2010 | A1 |
20110239565 | Clarke | Oct 2011 | A1 |
20120031025 | Cox | Feb 2012 | A1 |
20130081343 | Chadwick | Apr 2013 | A1 |
20130175427 | Moyher | Jul 2013 | A1 |
20140326359 | Bennett | Nov 2014 | A1 |
20150184377 | Stein | Jul 2015 | A1 |
20160194869 | Thornton | Jul 2016 | A1 |
20170096813 | Thornton | Apr 2017 | A1 |
20190040629 | Hanson | Feb 2019 | A1 |
20190119876 | Grussenmeyer | Apr 2019 | A1 |
20210062504 | Hanson | Mar 2021 | A1 |
Number | Date | Country |
---|---|---|
9109513 | Jul 1991 | WO |
WO-9109513 | Jul 1991 | WO |
Entry |
---|
International Search Report for PCT/US2018/044528 dated Oct. 25, 2018. |
International Search Report and Written Opinion for PCT Application No. PCT/US2021/062425 dated Jan. 11, 2022, 15 pages. |
Number | Date | Country | |
---|---|---|---|
20210062504 A1 | Mar 2021 | US |
Number | Date | Country | |
---|---|---|---|
62539546 | Aug 2017 | US |
Number | Date | Country | |
---|---|---|---|
Parent | 15986605 | May 2018 | US |
Child | 17095181 | US |