This invention concerns a method and apparatus for attaching building structures together. More particularly, this invention concerns a double shear point bracket with a stabilizer extension that may be used for attaching the ledger board of a deck, patio, porch or of other add-on building structures to a rim board of an adjacent original building structure. And the invention also concerns a method of attaching the bracket between the structures.
A typical building structure may include a horizontal rim board that extends about and is supported by the foundation of the building. The floor, roof, ceiling framing, and exterior cladding of the building are referred to herein as the “original building structure”. When a deck or other add-on building structure is to be added to the exterior of the original building structure, the add-on building structure may include a ledger board that is to extend adjacent and parallel to the rim board of the original building structure. The ledger board can be mounted to and supported by the rim board of the original building structure. In this arrangement, the ledger board supports the portion of the add-on building structure that is adjacent the original building structure.
Usually both the rim board and ledger board are formed of wood and the connection of the ledger board of the add-on building structure to the rim board of the original building structure is made with brackets or dowel type connectors, typically bolts or screws. The load from the floor of the add-on building structure is transferred to its ledger board, then from the ledger board to the bolts of the bracket, then from the bolts of the bracket to the rim board of the original building structure.
The exterior cladding of a typical original building structure may include, but is not limited to brick masonry, stone masonry, stucco, exterior insulating finishing system (“EIFS”), or siding. The exterior cladding usually is removed from the original building structure at the point of mounting the ledger board of the add-on building structure to the rim board of the original building structure, so the ledger board of the deck may be located close to the rim board, making contact with the wall sheathing or rim board.
In some cases, it is desirable to space the ledger board of the add-on building structure away from the supporting original building structure to avoid removing the adjacent exterior cladding of the original building structure. This may be done for water proofing reasons or to avoid supporting the exterior cladding above the ledger board.
Usually, exterior cladding of the original building structure is not intended to be a load carrying element, and recent building codes have begun to explicitly address this. If the exterior cladding is not removed and the ledger board of the add-on building structure is separated farther from the rim board of the original building structure to leave space for the exterior cladding, the connector bracket must span farther through an unsupported gap between the two buildings. The gap may include a space or the non-structural wall cladding. This extra length of the connector bracket weakens the strength of the connections between the buildings.
A conventional “single shear” connector bracket may be used to mount the ledger board to a rim board of joined building structures. The connector bracket has two contact points, one at the rim board and the other at the ledger board. Pivoting of the connector bracket by the load of the add-on building applied to the connector bracket is resisted by a non-uniform compression stress distribution between the connector bracket and the wood of the rim and ledger boards. This potential failure mode is known as “mode II” in the National Design Specification for Wood Construction, as illustrated herein in
When the ledger board of the add-on building structure is attached to the rim board of an original building structure and the boards are in contact with one another, or very close to one another, the length of the single shear connector bracket extending between the rim and ledger boards is relatively short and a high shear load from the ledger board to the rim board can be transferred through the connector bracket.
But when the structures are separated by a wider unsupported gap, the length of the connector bracket extending between the rim and ledger boards must be greater and the maximum compression stress on the wood of the structures by the single shear connector bracket becomes higher as the connector begins to pivot. The result is the add-on building structure is not supported at an acceptable level.
Prior art U.S. patents of Jewell U.S. Pat. No. 4,953,339 and Eldeen U.S. Pat. No. 7,254,926, and Smith Patent Application Publication 2014/0215956 A1 disclose devices that span through a pre-assembled structure to a rim board with an unsupported gap there between. However, none of the known prior art could be easily installed as a retrofit in an application where the ledger board and framing of the add-on building structure are already assembled and existing. Additionally, the structural mechanics of these prior art devices are not adequately addressed or realized, including whether each contact point is designed as: “Roller”, whereby translation is resisted in one direction but rotation is not significantly resisted; “Pinned”, whereby translation is resisted in all directions but rotation is not significantly resisted (which is characteristic of most conventional screwed or bolted connection); or “Fixed”, whereby translation is resisted in all directions and rotation or moment is resisted. As a result, some prior art devices include complex features that are not necessary for structural purposes.
U.S. Pat. No. 7,254,926 to Eldeen discloses a connector composed of a rod with a sleeve at the end of a rod. The nature of the sleeve design and its use in an application with only two contact points suggests that a fixed connection at the sleeve was intended and realized. However, in an application where the rod has three contact points, fixity at the sleeve connection is redundant and unnecessary. Eldeen describes an option where the rod has a third contact point, but apparently fails to realize that fixity at this third contact point is unnecessary. Resisting moment at this connection point requires the sleeve to be of thick material, highly specialized, difficult to install, and expensive. Additionally, Eldeen exclusively locates the third contact point on the side of the supporting structure opposite the ledger board. This third contact point could be located both the side of the ledger board opposite the supporting structure and the side of the supporting structure opposite the ledger board.
U.S. Pat. No. 4,953,339 to Jewell and U.S. Patent Publication 2014/0215956 A1 to Smith disclose larger devices with two contact points. The large custom size of these devices is necessary to facilitate a fixed connection at the rim board. This moment transfer appears to cause rotation of the rim board when vertical loads are applied on the deck. Preventing rotation of the rim board is dependent on the connection at the top and bottom of the rim board, which may be existing and impossible to reasonably verify. Additionally, the large size of these devices appears to require significant removal of exterior cladding to install.
Eldeen, Jewell, and Smith disclose a vertical plate behind the ledger board as a component of the connector device. These plates serve to transfer lateral load from the ledger board through the connector, via compression, to the rim board. Without these plates, it appears that the ledger board could move freely into the gap when subjected to a lateral load towards the supporting structure. In a retrofit application, it would be difficult to install these components without rebuilding the deck.
Thus, it is an object of this invention to provide an improved connector to support a ledger board of an add-on building structure on a rim board of an adjacent original building structure that can span through an unsupported gap between the buildings. Other objects of this invention include providing a double shear connector bracket with a stabilizer extension that can transfer load about all space axes between joined buildings, can avoid fixed or moment resistant connections, can avoid or reduce significant removal of exterior cladding, can be more easily installed as a retrofit, uses readily available materials of readily available shapes, and does not require unconventional support of the joists attached to the ledger board.
A connector and method of attaching a ledger board to a supporting structure are disclosed. The connector is described as a double shear bracket with a stabilizer extension that is constructed to span through an unsupported gap between building structures and transfer loads about all three space axes from the ledger board to the supporting structure. The unsupported gap may consist of air or material not designed to support a load. Typically, the material not intended to support a load would consist of exterior cladding, including, but not limited to, siding, stucco, exterior insulating finishing system (EFS), or masonry veneer.
The double shear bracket is used for mounting through aligned openings in a rim board of an original building structure and in a ledger board of an adjacent add-on building structure, so that the facing portion of the add-on building structure is supported by the original building structure. The stabilizer extension maintains the bracket in its desired attitude, usually in a horizontal attitude.
Generally, there are three options that exist for creating a statically determinant connector that can span through an unsupported gap to support a ledger board (see
Option 1: As shown in
Option 2: As shown in
Option 3: As shown in
A conventional original building structure may include parallel floor joists 16 and flooring 18 mounted on a foundation wall 20 and studs 22 supported by the floor joists and rim board 30. A sheathing 24, such as plywood or OSB, may be applied to the stud wall and an exterior cladding 26 such as a brick veneer may be applied to the original building structure, usually with an internal air space 28 formed between the exterior cladding and the stud walls and the other exterior wall covering. Rim board 30 surrounds most of the original building structure and is supported by the foundation wall. The rim board supports parts of the building structure above the lower wall foundation in the conventional structure.
The add-on building structure 12, that may be in the form of a conventional outdoor deck, is positioned adjacent the outdoor cladding of the original building structure, such as the brick veneer 26. The add-on building structure includes a ledger board 32 that is placed parallel to the rim board of the original building structure, and parallel joists 34 mounted to the ledger board. Flooring 36 is supported by the joists 34, in the usual manner.
In order to prepare the original and add-on building structures for mounting the add-on building structure to the original building structure, the add-on building structure may be positioned adjacent the original building structure as shown in
Likewise, an opening of similar dimensions is formed through the ledger board 32 of the add-on building structure 12. The add-on building structure 12 in this embodiment of the invention is an outdoor deck that includes the ledger board 32 with parallel deck joists supported thereby. The opening through the ledger board is aligned with the opening through the rim board.
The connector bracket 14 includes a rectilinear connector rod 40 that may be formed with external or internal spiral threads extending along its length or positioned at certain contact points along the rod. The connector rod that may be comprised of, but not limited to, steel, aluminum, or fiber reinforced polymer is extended through the aligned openings formed in the rim board of the original building structure and extending through the ledger board of the adjacent add-on building structure. The connector rod is of a length to include a stabilizer extension that extends beyond the connection between the building structures to a supportive structure displaced from the rim board and ledger board. Preferably, the connector rod is of a length sufficient to extend over six inches from the ledger board. However, the connector rod may be shortened if desired, thereby increasing rod shear forces, increasing rod bearing forces, and decreasing rod deflection, or lengthened if desired, thereby decreasing rod shear forces, decreasing rod bearing forces, and increasing rod deflection.
The stabilizer end 48 of the connector rod extends through a supportive structure 50 that is displaced from the rim board and ledger board, out between adjacent joists of the add-on building structure 12. The supportive structure can be blocking mounted at its ends to adjacent joists with an opening through the blocking with the connector rod extending through or up to the opening and attached thereto with a suitable nut, etc.
The supportive structure 50 at the stabilizer end of the connector rod maintains the connector rod 40 at a fixed height and attitude extending away from the rim board 30 and ledger board 32, and holds the ledger board 32 at a position where its opening is aligned with the opening of the rim board 30. This tends to avoid any pivoting movement of the rectilinear connector rod 40. The supportive structure prevents the stabilizer end 52 from tilting vertically or horizontally (or translating axially depending on the type of fastener used—described further below), thereby maintaining the ledger board in proper alignment with the rim board of the original building structure.
If resistance to axial translation was required in both directions then a secondary nut and washer could be installed on the opposing face of the rim board, ledger, or supportive structure.
In some cases it may not be possible to install this secondary nut and washer, for example if an existing ledger is held tight against existing exterior cladding. Alternatively, the washer 61 could include small holes 64 around the perimeter edge and could be adhered to the nut. Small screws would be driven through the holes 64 in the washer 61 into the ledger. In this case, as the ledger pulls away from the washer, the screws would be loaded in withdrawal and would engage the washer, nut, and rod.
In order to avoid load being transferred from the rod 40 to the exterior cladding 26 (when loads are applied to the add-on building structure 12 and the rod 40 deflects) the hole in the exterior cladding would ideally be made of larger breadth than the breadth of the connector rod. However, if the add-on building and original building are already existing, it would be difficult to only over-drill the hole in the exterior cladding 26, without also over-drilling the holes in the ledger board 32 or rim board 30. The cylindrical sleeve 63 provides a means to over-drill the hole through the ledger board, exterior cladding, and rim board, while making contacting at only the desired locations. Over-drilling the hole in the exterior cladding 26 also provides a space to apply an impermeable material, such as caulk or silicon, between the rod 14 and exterior cladding 26 to prevent leakage of air or water into the interior of the original building structure.
Another embodiment would include a connector rod 40 that is installed at an angle, or is curved, so that it can be directly attached to the side of a floor joist with screws or bolts. This would eliminate the need for the blocking 50 shown in
The rectilinear connector rod is described as including external or internal spiral threads and the fasteners are described as including matching internal or external threads for mounting the fasteners at the desired positions along the length of the connector rod. It is also possible to form other shapes of the connector rod and fasteners, such as, but not limited to, a bayonet connection, ribs, or openings in the connector rod and fasteners formed to match the ribs or openings.
While the expressions “rim board” and “ledger board” have been used to describe the structural features of the connection points of the add-on building structures and original building structures, these expressions are to include other supporting structures that are suitable for connection together by the inventions disclosed herein.
Although preferred embodiments of the invention have been disclosed in detail herein, it will be obvious to those skilled in the art that variations and modifications of the disclosed embodiments can be made without departing from the spirit and scope of the invention as set forth in the following claims.
Applicants claim priority to U.S. Provisional Patent Application Ser. No. 61/995,770, filed in the U, S. Patent & Trademark Office on Apr. 21, 2014.
Number | Date | Country | |
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61995770 | Apr 2014 | US |