The present invention relates to reinforcing the wood roof structures of existing houses and similar low-rise buildings against wind uplift by means of a retrofitting method and apparatus for securing roof frames to walls without having to remove roofing/sheathing.
While today's steel strap connectors excel for new construction of houses and like small buildings for securing wood roof structures to their supporting walls, they are not readily applicable to retrofitting existing structures. Such strap “ties” or “tie-downs” should have an upper portion extending over the top of a roof frame (rafter or truss) to ensure adequate tie-down strength by applying much of the restraining force onto the top of the roof frame as compression across the grain, which wood withstands quite well. If the tie-down connectors are simply nailed into the side of the roof frame—as commonly done until recent years—localized tensions are induced across the grain of the wood during nailing or especially under load, such that the rafter/truss member tends to split under hurricane-force uplifts, releasing the tie-downs' nails too easily—often much before the “design load” is reached.
The over-the-top or “wrap over” tie-down method is now widely recommended or required in the US Hurricane Belt for new construction, and even for retrofits of existing buildings. It's easily done in new construction: the roof frame and supporting wall is entirely accessible before the roof sheathing is applied. During retrofitting, however, accessing the top portion of the rafter/truss requires removal and re-installation of an area of roofing and sheathing; such a laborious and costly operation discourages such retrofit upgrading of existing housing and building stock altogether, leaving the stock needlessly vulnerable.
There have been recent efforts to devise methods for retrofit reinforcement of wood roof structures. Some steel tie-down examples simply provide more area aligned with the roof slope to allow insertion of more nails through the strap and into the side of the rafter/truss, but that can exacerbate splitting under load (and indeed the very act of crowding nails into the ultra-dry wood encountered in existing houses is seen to cause especially extensive splitting, even “shredding”).
Considerable older retrofit thinking does try to avoid such splitting. In U.S. Pat. No. 5,257,483 Netek discloses ways of installing anchor points in roof fascias and the wall surfaces below, allowing temporary placement of ties in the event of an impending storm. Winger, in U.S. Pat. No. 5,319,816, and several other inventors, disclose other temporary arrangements using multiple cables or nets over the roof which are anchored to the ground. Such temporary devices demand that the householder be at home and ready to react to storm warnings. In U.S. Pat. No. 5,311,708, Frye shows a retrofit roof tie-down method in which lag screws are installed upwardly through an angled steel plate into the bottom edge of the rafters/trusses, but costs and load transfer distortions are problematic.
Accordingly, I have devised and tested a “slant toggle” tie down (U.S. Pat. No. 7,562,494 Jul. 21, 2009), which involves drilling a hole slantingly upwards through the roof frame so that a tie can run through to emerge near the top, just under the sheathing, and be there secured to restrain the roof frame against upward movement. That, however, involves precisely angled drilling from below and awkward insertion of a clip just under the sheathing. Therefore I devised and tested a “claw” device, slope-adjustable, featuring a sharp-edged top flange hammered into the interface between frame and sheathing to apply its restraining force top-down on the roof frame (U.S. patent application Ser. No. 12/607,154, Oct. 28, 2009). That claw device proves difficult to insert in some cases, however, and is intrinsically somewhat costly. The need remained clear: devise a better retrofit over-the-top tie-down method and apparatus to upgrade existing buildings to the strength achieved by applying over-the-top strap ties in new construction.
The concept in this invention is to force the sheathing just a little off the roof frame, allowing over-the-top insertion of a tie-down strap much as practiced in new construction. It's neither an obvious nor readily practicable approach: Any kind of sledging or hammering the sheathing upward tends to puncture or smash it and/or lift it off too much, the latter itself leaving it unacceptably bulged upward and perhaps with a significantly large area poorly fastened to the roof framing. On the other hand, trying to pry or wedge the sheathing up by driving say a broad chisel between it and the top edge of the roof frame roof involves awkward and misaligned driving (the sheathing interfering with the chisel's proper stance—and sheathing and neighboring rafters/trusses interfering with a hammer's swing), and even if somehow doable can cut into the roof sheathing or roof frame or hit a roofing nail.
A method and apparatus is provided for reinforcing the connection of an existing roof frame to a wall or like structure below it, which comprises a) lifting just a small area of the roof sheathing off the roof frame just sufficiently to allow b) inserting a head end of a tie-down strap (the strap) into the gap on one side of the roof frame and completely inward over the frame's top edge, and with the lifting means and amount reliably set to avoid damage to sheathing or frame or the hold of one to the other; then c) pushing the head end of the strap further to protrude beyond the top far edge of the roof frame sufficiently to allow d) bending the protruding portion of the strap tightly down over the far edge and onto the far side of the roof frame far enough to accept sound fastening there; and finally e) driving fasteners such as nails or screws through that bent-down portion of the strap and into the far side of the roof frame, so that the strap itself (when its tail is fastened in prior-art manner on the near side of the roof frame too, and secured to the wall below) must apply much of its restraining force downward into the top of the roof frame, so that wood splitting forces are minimized and any such splitting during installation or under uplift load will have minimal weakening effect on the strap's restraining strength.
It will be clear that the strap itself should differ from prior art straps, in that its head end should be angled flatwise outward from the main axis of the rest of the strap so that when protruding beyond the top far edge of the roof frame and bent downward it is oriented outward, despite the usual slope of the top of the roof frame, and so remains outboard of any potentially interfering framing (such as common “blocking” between roof frames) and is accessible for fastening operations such as nailing or screwing into the far side of the roof frame.
It will be clear that the strap itself should differ from prior art straps, in that its head end should be angled flatwise outward from the main axis of the rest of the strap so that when protruding beyond the top far edge of the roof frame and bent downward it is oriented outward, despite the usual slope of the top of the roof frame, and so remains outboard of any potentially interfering framing (such as common “blocking” between roof frames) and is accessible for fastening operations such as nailing or screwing into the far side of the roof frame.
In accordance with one embodiment of the present invention, the lifting of the roof sheathing off the roof frame is accomplished by driving a sharp-pointed wedge squarely into the interface between the top of the roof frame and the underside of the roof sheathing and then across much of said top, preferably using a worm gear or ratchet type of drive, the wedge and drive being mounted in a horizontally oriented bar (hereinafter the device being named the “bar wedge”), which bar is adjustably fitted between that roof frame and the next with its opposing end restrained by the near side of the next roof frame; whereby the driving of the wedge of a certain thickness lifts the roof sheathing to provide just a sufficient gap off the roof frame's top alongside the wedge to allow full insertion and thence deployment of the over-the-top tie-down strap.
There being many sheathing nails and some roofing nails intruding through the roof sheathing into the top of the roof frame, with perhaps a 1:8 chance of one happening to intrude into the path of the advancing wedge across the top of the roof frame, a means of evading such an obstruction is provided according to the invention by having the point and head end portion of the wedge divided into at least two prongs, each prong being pointed so that even if one hits the nail the wedge need only sidestep slightly as it proceeds across the top of the roof frame, the nail being accommodated between prongs or alongside the wedge.
In a second embodiment of the present invention, called the U-wedge, the lifting of the roof sheathing off the roof frame is accomplished by positioning a first wedge squarely against the first side and a second wedge squarely against the opposite side of the roof frame, the two wedges being directed toward each other into the interface between the top of the roof frame and the underside of the roof sheathing, each wedge being equipped with a worm gear or ratchet type of drive and each such assembly being integrally mounted on a vertical arm of a U frame which fits up over the sides of the roof frame from below to provide exact positioning and restraint for the wedges; thence driving both wedges into that interface toward each other with each being capable of advancing across much of the top of the roof frame, so that if an obstructing sheathing or roofing nail brings one wedge to a premature stop the other wedge can continue being driven toward the stopped wedge across the remaining top of the roof frame until that other wedge is also stopped by the nail, the wedges then intruding across almost all of the top of the roof frame and just sufficiently lifting the roof sheathing therefrom.
In a further embodiment of the invention the lifting of the roof sheathing off the roof frame is accomplished by positioning a lever assembly near one side of the roof frame where it crosses the supporting wall, and preferably a second lever assembly near the other side of the roof frame, each such lever assembly having a fulcrum seated solidly on the supporting wall near its exterior surface or on the blocking often present atop that wall, a short load arm projecting inward from that fulcrum to a lifting end set against the underside of the roof sheathing, and a long effort arm extending outward, whereby pushing down on the lever's effort arm exerts a multiplied force upwards at the lifting end against the underside of the roof sheathing to force the roof sheathing off the roof frame just the amount needed for passage of the tie-down strap. Excessive lifting is prevented by the downswing arc of the lever's effort arm being limited by the wall's exterior surface below, the short length of the lever's load arm and the shape of the lever's load tip being such that said limited downswing can only lift the load tip a desired amount.
These and other features and advantages of the present invention, my “Strapeze™” invention, will be better understood with reference to preferred embodiments described hereinafter.
Reference will now be made to the accompanying drawings showing by way of illustration preferred embodiments of the present invention, each being a method/device for lifting a small area of roof sheathing slightly off the top of a roof frame in a controlled, practicable manner.
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Preferably two such lever setups are used for each such sheathing lift, with a fulcrum assembly 13 set alongside each side of an R/T and with a pair of lever bars lifting the sheathing at both points simultaneously, as noted below.
The lever device lifts the roof sheathing just enough to allow passage of a tie down strap over the top of the roof frame, as follows: The fulcrum assembly 13 is adjusted so that the actual fulcrum (the top of the plate 13a) is a certain distance below the underside of the roof sheathing S (a distance preferably set by “horns” 13d, as shown below); the geometry is such that the lever's load tip 12b can lift the pad 12d just a certain amount, no more, as the lever's effort arm is pushed down through the available arc which is limited by the wall below; further, when the lever bar is tilted down past a certain angle it will simply slide downward across the fulcrum, friction being overcome. It can be shown that such controlled lifting is obtained, creating the correct gap 14, with a range of roof slopes from flat to say 7:12 slope. Almost all roofs in “hurricane country” are sloped within this range. Moreover, where steeper slopes are encountered the typical side-nailed straps generally suffice even for retrofit purposes, the force on their nails or screws being more aligned with the grain of the wood and much less likely to cause splitting under load—so lifting for over-the-top tie straps is not needed.
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Testing has shown that both the wedge and lever devices work well to lift roof sheathing off a roof frame, whether the roof sheathing is formed of wood boards as in older houses or of modern plywood. The recent OSB forms (Oriented Strand Board) have not been tested but they're generally found in the “hurricane belt” only in newer houses already using “wrap over” tie down straps.
The two distinct “Strapeze™” devices, the wedge and the lever, should be discussed further at this point.
The wedge can be placed between two adjacent R/Ts close to the wall line, but also 1) farther outboard where appropriate for certain types of tie-down straps. Not so with the lever. Conversely, the wedge is usable where roof frames are normally spaced apart (from 16″ o.c. to 24″ o.c., generally) but not where close together (e.g. where three in a group offer no space of at least 16″ o.c. on either side of the middle one requiring retrofit tie-down). Many houses have at least one such condition. There, the lever would be needed. (Skipping retrofitting of just one of such close-together R/Ts would often be acceptable engineering-wise, real-world-wise . . . but not likely to the eyes of an inspector or the letter of a building code, where acceptability and simple physics may not be related.) Further, the wedge might be somewhat awkward to handle and use on a scaffold, and perhaps a little slow in operation.
Where the wedge uses narrow prongs to allow it to move past a sheathing nail—requiring some sidewise movement—the U Wedge need not: An advancing wedge hitting a nail (the left one in this sketch) simply stops, the extra resistance being sensed by the installer, while the opposing wedge is driven further across until hitting the same nail from the other side or simply until completing the lifting of the roof sheathing. (Nails may be encountered often enough, as noted earlier, but never more than one in any one wedge path.)
Whereas the bar wedge can be placed to fit against any normal roof slope, the U Wedge must itself be positioned more or less vertically, so its wedges must rotate to fit into the interface between roof sheathing and sloping roof frames. Accordingly, the guide 15 is mounted on the U-piece 4′ by means of the drive 2b′ through the holes 17, thus being freely hinged to rotate when pressed against the underside of the roof sheathing (not shown here). The rotation is here limited by the end protusion 18 and similar shelf 18′.
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Finally, in any such retrofitting, the strap's tail cannot readily be anchored to the wall's framing (as often so easily done in new construction, as seen in