Construction members and method for forming curved walls and the like

Abstract

A method of constructing curved building structures employ flexible support members formed from metal strip, having flexible elongate spines with substantially perpendicular flanges or tabs fixable to the building members, so that the building structures can be assembled flat and then curved on erection to the desired curved configuration.

Description

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] THIS INVENTION relates to curved structures in buildings, and to construction members to enable the curved structures to be constructed.

[0003] 2. Prior Art

[0004] The construction, on-site, of a curved structure such as an arch, barrel vault, column, or curved section of wall, is normally very time-consuming and expensive.

[0005] As the radius, depth and/or profile of an arch may vary considerably from one to the next, it will be apparent that such a structure must be individually planned and carefully erected. The same is true of a curved wall structure, which may be required to have regular and/or irregular curve(s) in plan view.

[0006] In U.S. Pat. No. 5,291,717 (Turner), I disclosed a method, and resulting wood frame, that could be used to construct a wall.

[0007] While the method disclosed in U.S. Pat. No. 5,291,717 was an advance on previously available methods, it had two limitations. It required two nailing strips to connect the adjacent ends of the building members (eg., wall studs) together, and the flanges or splines on the nailing strips were on the front of the studs in the wall, which interfered with the fixing of the skirting and cornices to the studs.

SUMMARY OF THE PRESENT INVENTION

[0008] It is an object of the present invention to provide a method where the erection of curved building structures is simplified.

[0009] It is a preferred object to provide a method where the side faces of the building members (eg., wall studs) are unobstructed to allow easy fixing of skirting, cornices and other building components to the building members.

[0010] It is a further preferred object to provide a method where the building structure is constructed before erection and then can be accurately erected and curved to the desired shape.

[0011] It is a still further preferred object to provide support member(s) for the method which are relatively simple and inexpensive to manufacture and which can be nested for transport.

[0012] It is a still further preferred object to provide support member(s) which can be manufactured of thinner gauge steel but used without loss of strength in the resulting building structure.

[0013] Other preferred objects will become apparent from the following description.

[0014] In one aspect, the present invention resides in a method of constructing a curved building structure, the method including the steps of:

[0015] a) forming a respective slot or kerf in end faces of a plurality of timber building members, the slots or kerfs extending between opposed faces of the building members;

[0016] b) providing at least two support members, each support member having a flexible elongate spine with a plurality of flanges or tabs extending substantially perpendicularly to at least one side of the spine;

[0017] c) placing the building members at desired spacings with their respective end faces substantially aligned;

[0018] d) inserting the spine of at least one support member into each slot or kerf of the end faces of the building members;

[0019] e) fastening the flanges or tabs to the end faces of the building members aligned therewith, to form a building structure;

[0020] f) curving the building structure to the desired curved profile(s); and

[0021] g) fastening one or more of the flanges or tabs, intermediate the building members, to supporting structure(s).

[0022] In a second aspect the present invention resides in a method of constructing a curved building structure, the method including the steps of:

[0023] a) forming a respective slot at ends of webs of a plurality of metal building members, the metal building members each having a web interconnecting respective flange members, each slot being formed by cutting or slitting the web and bending or deforming a mounting tab or flange from a portion of the web to extend substantially perpendicularly to the web;

[0024] b) providing at least two support members, each support member having an elongate flexible spine with a plurality of flanges or tabs extending perpendicularly to at least one side of the spine;

[0025] c) placing the building members at desired spacings with their respective web ends substantially aligned;

[0026] d) inserting the spine of at least one support member into each slot in the web ends of the building members;

[0027] e) fastening the spine(s) of the support member(s) to the mounting tabs or flanges aligned therewith to form a building structure;

[0028] f) curving the building structure to the desired curved profiles; and

[0029] g) fastening one or more of the flanges or tabs, intermediate the building members, to supporting structure(s).

[0030] The supporting structures may comprise floor(s), ceiling(s), adjacent wall portions or the like.

[0031] Preferably, the building members are wall studs or building framing members, to which may be fixed wall panels, skirting, cornices and like building components.

[0032] While the slots or kerfs may be aligned with the centre line of the building members, they may be axially offset.

[0033] Preferably, the support members are formed from metal strips, which may be galvanised, zinc-coated or otherwise corrosion-protected; or from plastics material, which may be fibre-reinforced.

[0034] In one embodiment, the support members are of substantially T-section, where the flanges or tabs alternately extend to opposite sides of the spine.

[0035] In a second embodiment, the support members are of substantially L-section.

[0036] A pair of the L-section support members may be provided with their respective spines back-to-back and their flanges or tabs directed in opposite directions.

[0037] Preferably, the flanges or tabs are provided at regular intervals along the spine and are provided with at least one hole therethrough to receive a fastener for fixing to a building member.

[0038] In third and fourth aspects, the present invention resides in a curved building structure erected by the methods of the first and second aspects, respectively.

[0039] In a fifth aspect, the present invention resides in a support member operable to interconnect a plurality of spaced building members for a curved building structure, the support member including:

[0040] a flexible elongate spine having a plurality of flanges or tabs extending to at least one side of the spine, the spine and/or spaced ones of the flanges or tabs being fastenable to the building members and intermediate ones of the flanges and tabs being fastenable to a supporting structure for the curved building structure.

[0041] Preferably, the support members are formed integrally from metal strip, and the flanges or tabs are provided at spaced intervals along the spine.

[0042] Preferably, at least one hole is provided through each flange or tab to receive a fastener to fix the flange or tab to an adjacent building member or the support structure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0043] To enable the invention to be fully understood, preferred embodiments will now be described in which:

[0044] FIG. 1 is a perspective view of a portion of a wall, where adjacent sections are to be interconnected by a curved section constructed in accordance with the present invention;

[0045] FIG. 2 is a perspective view of a plurality of timber wall studs after slots or kerfs have been formed in one end face thereof;

[0046] FIG. 3 is a perspective view of one end of the wall studs after connection by the support member(s);

[0047] FIG. 4 is a perspective view of the curved wall structure;

[0048] FIG. 5 is a perspective view of a first embodiment of the support member;

[0049] FIG. 6 is an end view showing the fixing of the support member to the wall stud;

[0050] FIG. 7 is a perspective view of a pair of support members of a second embodiment;

[0051] FIG. 8 is an end view showing the fixing of the support member to a wall stud;

[0052] FIG. 9 is a perspective view of a third embodiment of the support member;

[0053] FIG. 10 is an end view showing the fixing of the support member to a wall stud;

[0054] FIG. 11 is a perspective view of a portion of a curved building structure constructed using the second embodiment of the support member of FIGS. 7 and 8;

[0055] FIG. 12 is a similar view using a modified form of the second embodiment of the support member of FIGS. 7 and 8;

[0056] FIGS. 13 and 14 are end views showing a building structure, before and after construction, constructed by the support members of the third embodiment of FIGS. 9 and 10;

[0057] FIG. 15 is a perspective view of one end of a metal building member provided with a support member of the second embodiment of FIG. 7;

[0058] FIG. 16 is an end view of a building structure, supporting the metal stud/support member construction of FIG. 15, before curvature;

[0059] FIG. 17 is a similar view to FIG. 16, after curvature of the building structure to form a column;

[0060] FIGS. 18 and 19 are end vies of a building structure, before and after curvature respectively, to form a barrel vault or arch.

[0061] FIG. 20 is a perspective view of an alternative arrangement for the support members of the second embodiment;

[0062] FIG. 21 is an end view showing the fixing of the support members to a steel or timber wall stud;

[0063] FIGS. 22 and 23 are respective perspective and end views of a barrel vault formed using the support members of FIGS. 20 and 21;

[0064] FIG. 24 is an end view of a straight section formed using the support members of FIGS. 20 and 21;

[0065] FIG. 25 is a top plan view of an alternative profile for the support member, wherein two members are formed from a single metal strip; and

[0066] FIG. 26 is a perspective view of a S-profile wall section constructed using the support members of FIG. 25.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0067] Referring to FIGS. 1 to 4, a wall structure 10 has a pair of adjacent straight wall portions 11, 12 to be interconnected by a curved wall structure 20 constructed, as hereinafter described, in accordance with the present invention.

[0068] The curved wall structure 20 is to be constructed to have the curved profile defined by the lines 13, 14, eg., scribed or marked on the floor (not shown in FIG. 1). The construction of the curved wall structure 20, illustrated in FIG. 4, will now be described.

[0069] Timber wall studs 30 have slots or kerfs 31 formed (eg., by a saw) in both end faces 32, 33 of the studs 30, the slots or kerfs 31 interconnecting the opposed faces 34, 35 of the studs 30.

[0070] In the embodiment shown in FIGS. 2 to 4, the slots or kerfs 31 are aligned with the centre line of the studs 30.

[0071] The studs 30 are placed at desired spacings (eg., 200 mm/8″ centres) and support members, to be hereinafter described in more detail, have their flexible elongate spines inserted in the slots 31 so that aligned flanges or tabs abut the adjacent end faces 32, 33 of the studs 30. Fasteners (eg., nails) 17 are driven in through holes or tabs to secure the flanges or tabs to the studs 30.

[0072] The resultant assembly is then erected and curved to conform to the curvature, defined by lines 13, 14, as shown in FIG. 4.

[0073] Flanges or tabs intermediate the studs 30 can be fixed to the floor 15 and ceiling 16 by suitable fasteners (eg., nails) 17.

[0074] Referring now to FIGS. 5 and 6, a first embodiment of the support member 40 is formed from a length (eg., 3 metres) of metal strip, which as preferably corrosion-proofed by being galvanised, zinc-coated or pre-painted. The support member 40, which is of substantially T-section, has a flexible elongate spine 41, with flanges or tabs 42 alternately extending substantially perpendicularly to opposite sides of the spine 41. Holes 43, to receive the fasteners 17, are provided in the flanges or tabs 42, preferably adjacent their distal ends.

[0075] As shown in FIG. 6, the spine 41 is inserted in the slots 31 of the studs 30 and nails 17 fix the flanges or tabs 42 to the end faces 32, 33 of the studs 30.

[0076] To enable the support member to be formed from thinner gauge strip (without losing strength), and for improved nesting for transport, a pair of support members 50, each of L-section, may be used back-to-back, as shown in FIG. 8.

[0077] Each support member 50 (see FIG. 7) has a flexible elongate spine 51 with flanges or tabs 52, each provided with holes 53, extending substantially perpendicular to one side of the spine 51 at spaced intervals. By selection of the specific shape of the flanges or tabs 52, it is possible to form a pair of the support members 50 from a single metal strip, with the flanges or tabs 52 of one support member 50 being interleaved between the flanges or tabs 52 of the second support member. In use, it is preferable that the flanges or tabs 52 of the two support members 50 be offset, as shown in FIG. 7.

[0078] In certain applications, eg., where thicker studs are used, the slots or kerfs 31a may be offset from the centre line of the studs 30a, as shown in FIG. 10. For such applications, support members 60 (see FIG. 9), of L-section, but of thicker metal gauge than support members 50, can be used.

[0079] As shown in FIGS. 9 and 10, the support members 60 have a flexible elongate spine 61 with relatively longer flanges or tabs 62, each provided with three holes 63 to receive the nails 17.

[0080] FIGS. (a) 11 and 12 , and (b) 13 and 14 show building structures constructed using the support members (a) 50 and (b) 60 respectively.

[0081] As shown in FIGS. 13 and 14, the studs 30 can be of varying width and/or thickness in the building structures, without the necessity to use different support members 50.

[0082] As shown in dashed lines, the ends of adjacent support members 50 can be overlapped at the end of a stud 30 to enable the building structures to be made of a length greater than the, eg., 3-metre length of the individual support members 50.

[0083] Referring now to FIG. 16, the support member 50 is employed to connect a plurality of metal studs 130 together. Such stud, of C-section (or Z-section as shown in dashed lines in FIG. 16) has a web 132 interconnecting flange members 133, 134. A slot 131 is formed at each end of the web 132 by making a substantially L-shaped cut or slit in the web 132, and a mounting tab or flange 135 is bent to extend substantially perpendicular to the web 132.

[0084] A support member 50 is placed in the aligned slots 131 of the spaced metal building members 130 and the spine 51 is fixed to the mounting tab or flange 135 via a suitable fastener 136 (eg., a Tek-screw (trade mark) or rivet).

[0085] To form the column 170, illustrated in FIG. 17 to be constructed, a plurality of the metal building members 130 are interconnected at both ends by the support members 50, as shown in FIG. 16, and the resulting structure is then curved to form the column 170.

[0086] Fasteners (not shown) are driven through holes 53 in flanges 52 intermediate the metal building members 130 to fix the columns to the supporting structure(s) (not shown).

[0087] The barrel vault on arch 180 of FIGS, 18 and 19 is constructed in a similar manner.

[0088] As shown in FIGS. 20 and 21, a pair of the support members 50 may have their spines 51 fixed to the side flanges of C- or Z-metal section studs 130a by suitable fasteners 17b (eg., Tek-screws—trade mark) and nails or outer fasteners 17 (eg., concrete nails) secure at least some of the flanges or tabs 32, intermediate the studs 130a, eg., to the floor.

[0089] FIGS. 22 and 23 illustrate a barrel vault or arch 180a, where one of the support members 50 is fixed to one side of the metal studs 130a, to enable the vault 180a to be partially assembled flat, as shown in FIG. 24. The partial assembly is then curved to the desired profile, the second of the support members 50 is fixed to the other side of the metal studs 130a, and the barrel vault or arch 180a is then positioned for fixing to a support structure (eg., walls) not shown.

[0090] FIG. 25 illustrates how a pair of the support members 51a of similar configuration to the support members 50 of FIG. 7, can be produced from a single metal strip 90.

[0091] A punch or die, or other suitable metal marking device, cuts an elongate slot or slit 91 between the adjacent flanges 52a (and may simultaneously punch holes 53a with flanges). The flanges 52c are then bent at right angles to the spines 51a about bend lines 92. The support members 50a, of substantially L-shape, can then be nested together for storage) transport.

[0092] While the support member can be produced from metal strip, which is preferably corrosion-proofed, the support member can also be manufactured from suitable high-tensile plastics material (eg., polyethylene, polypropylene) which may be reinforced with eg., metal-, glass- and/or carbon-fibres.

[0093] It will be readily apparent to the skilled addressee that the ability to assemble the building structure substantially flat, and then curving it to suit the desired installation, before fixing it to the support structure (eg., floor/ceiling) is a considerable advantage.

[0094] In addition, the present invention enables the building structure to have regular and/or irregular curved profiles, over an infinite range of radii.

[0095] Various changes and modifications may be made to the embodiments described and illustrated without departing from the present invention.

Claims

1. A method of constructing a curved building structure, the method including the steps of: a) forming a respective slot or kerf in end faces of a plurality of timber building members, the slots or kerfs extending between opposed faces of the building members; b) providing at least two support members, each support member having a flexible elongate spine with a plurality of flanges or tabs extending substantially perpendicularly to at least one side of the spine; c) placing the building member at desired spacings with their respective end faces substantially aligned; d) inserting the spine of at least one support member into each slot or kerf of the end faces of the building members; e) fastening the flanges or tabs to the end faces of the building members aligned therewith, to form a building structure; f) curving the building structure to the desired curved profile(s); and g) fastening one or more of the flanges or tabs, intermediate the building members, to supporting structure(s).

2. A method of constructing a curved building structure, the method including the steps of: a) forming a respective slot at ends of webs of a plurality of metal building members, the metal building members each having a web interconnecting respective flange members, each slot being formed by cutting or slitting the and bending or deforming a mounting tab or flange from a portion of the web to extend substantially perpendicular to the web; b) providing at least two support members, each support member having an elongate flexible spine with a plurality of flanges or tabs extending perpendicularly to at least one side of the spine; c) placing the building members at desired spacings with their respective web ends substantially aligned; d) inserting the spine of at least one support member into each slot in the web ends of the building members; e) fastening the spine(s) of the support member(s) to the mounting tabs or flanges aligned therewith to form a building structure; f) curving the building structure to the desired curved profile(s); and g) fastening one or more of the flanges or tabs, intermediate the building members, to supporting structure(s).

3. A method as claimed in claim 1 wherein: the supporting structures comprise floor(s), ceiling(s), or adjacent wall portions or the like; and the building members are wall studs or building framing members, to which are fixed wall panels, skirting, cornices and the like building components.

4. A method as claimed in claim 1 wherein: the slots or kerfs are aligned with, or axially offset relative to, the center line of the building members.

5. A method as claimed in claim 1 wherein: the support members are formed from metal strips, which may be galvanized, zinc-coated or otherwise corrosion-protected.

6. A method as claimed in claim 1 wherein: the support members are of substantially T-section, where the flanges or tabs alternately extend to opposite sides of the spine.

7. A method as claimed in claim 1 wherein: the support members are of substantially L-section.

8. A method as claimed in claim 7 wherein: a pair of the L-section support members are provided with their respective spines back-to-back and their flanges or tabs directed in opposite directions.

9. A method as claimed in claim 1 wherein: the flanges or tabs are provided at regular intervals along the spine and are provided with at least one hole therethrough to receive a fastener for fixing to a building member.

10. A curved building structure erected by the method as claimed in claim 1.

11. A support member operable to interconnect a plurality of spaced building members for a curved building structure, the support member including: a flexible elongate spine having a plurality of flanges or tabs extending to at least one side of the spine, the spine and/or spaced ones of the flanges or tabs being fastenable to the building members and intermediate ones of the flanges and tabs being fastenable to a supporting structure for the curved building structure.

12. A support member as claimed in claim 11 wherein: the support members are formed integrally from metal or plastic strip; and the flanges or tabs are provided at spaced intervals along the spine.

13. A support member as claimed in claim 12 wherein: at least one hole is provided through each flange or tab to receive a fastener to fix the flange or tab to an adjacent building member or the support structure.

14. A method as claimed in claim 2 wherein: the supporting structures comprise floor(s), ceiling(s), or adjacent wall portions or the like; and the building members are wall studs or building framing members, to which are fixed wall panels, skirting, cornices and the like building components.

15. A method as claimed in claim 2 wherein: the slots or kerfs are aligned with, or axially offset relative to, the center line of the building members.

16. A method as claimed in claim 2 wherein: the support members are formed from metal strips, which may be galvanized, zinc-coated or otherwise corrosion-protected.

17. A method as claimed in claim 2 wherein: the support members are of substantially T-section, where the flanges or tabs alternately extend to opposite sides of the spine.

18. A method as claimed in claim 2 wherein: the support members are of substantially L-section.

19. A method as claimed in claim 18 wherein: a pair of the L-section support members are provided with their respective spines back-to-back and their flanges or tabs directed in opposite directions.

20. A method as claimed in claim 2 wherein: the flanges or tabs are provided at regular intervals along the spine and are provided with at least one hole therethrough to receive a fastener for fixing to a building member.

21. A curved building structure erected by the method as claimed in claim 2.