U.S. patent application number 10/817587 was filed with the patent office on 2005-11-17 for free-standing clear-span frame structure and components.
This patent application is currently assigned to Golden Star, Inc.. Invention is credited to Hicks, Gary B., Ritchey, Gene.
Application Number | 20050252149 10/817587 |
Document ID | / |
Family ID | 35308069 |
Filed Date | 2005-11-17 |
United States Patent
Application |
20050252149 |
Kind Code |
A1 |
Ritchey, Gene ; et
al. |
November 17, 2005 |
Free-standing clear-span frame structure and components
Abstract
Novel free-standing open-span building frames for building
construction and their use. The frames are assembled from base
plates, upright posts, post-joist-rafter connectors, and a joist.
Each base plate is a steel plate having an upper surface to which
is welded the lower end of a steel post connector. The steel plates
anchor bolt holes therethrough on each side of the post connector.
The building has a steel reinforced concrete foundation with anchor
bolts extending through the anchor bolt holes of each base plate,
each base plate being secured to the anchor bolts with nuts. Each
post has a lower end bolted to the respective steel post connector
of the first and second base plate. Each post-joist-rafter
connector comprises a post connector, a joist connector and a
rafter connector. The first post has an upper end bolted to the
post connector of the first post-joist-rafter connector, and the
second post has an upper end bolted to the post connector of the
second post-joist-rafter connector. The joist has first and second
joist ends, the first joist end being bolted to the joist connector
of the first post-joist-rafter connector, and the second joist end
being bolted to the joist connector of the second post-joist-rafter
connector. The frames are free-standing and can be spaced at
distances of from 3 to 14 meters per frame.
Inventors: |
Ritchey, Gene; (Sunnyvale,
CA) ; Hicks, Gary B.; (Mountain View, CA) |
Correspondence
Address: |
GREG O'BRADOVICH, P.C.
295 CULVER STREET
SUITE A
LAWERENCEVILLE
GA
30045
US
|
Assignee: |
Golden Star, Inc.
Reno
NV
|
Family ID: |
35308069 |
Appl. No.: |
10/817587 |
Filed: |
April 2, 2004 |
Current U.S.
Class: |
52/648.1 |
Current CPC
Class: |
E04B 2001/2415 20130101;
E04B 2001/2457 20130101; E04B 7/06 20130101; E04C 3/40 20130101;
E04B 2001/2448 20130101; E04B 7/024 20130101; E04B 2001/249
20130101; E04B 2001/2445 20130101; E04B 2001/2463 20130101; E04B
1/24 20130101; E04B 2001/2496 20130101 |
Class at
Publication: |
052/648.1 |
International
Class: |
E04H 012/00 |
Claims
The invention claimed is:
1. A free-standing open-span building frame comprising: first and
second base plates, first and second upright posts, first and
second post-joist-rafter connectors, and a joist; each base plate
comprising a steel plate having an upper surface to which is welded
the lower end of a steel post connector that is channel, round beam
or HSS with a rectangular cross-section. each post having a lower
end bolted to the respective steel post connector of the first and
second base plate; each post-joist-rafter connector comprising a
post connector, a joist connector and a rafter connector; the first
post having an upper end bolted to the post connector of the first
post-joist-rafter connector, and the second post having an upper
end bolted to the post connector of the second post-joist-rafter
connector; and the joist having first and second joist ends, the
first joist end being bolted to the joist connector of the first
post-joist-rafter connector, and the second joist end being bolted
to the joist connector of the second post-joist-rafter
connector,
2. The building frame of claim 1 including a steel reinforced
concrete foundation with an anchor bolts extending through the base
plate anchor bolt holes of each base plate, each base plate being
secured to the anchor bolts with nuts.
3. A building frame of claim 1 including a ridge connector and
first and second rafters, the ridge connector having first and
second rafter connectors; and each of the rafters having a post end
and a rafter end, the post end of the first rafter being bolted to
the rafter connector of the first post-joist-rafter connector, the
post end of the second rafter being bolted to the rafter connector
of the second post-joist-rafter connector, the ridge end of the
first rafter being bolted to the first rafter connector, and the
ridge end of the second rafter being connected to the second rafter
connector.
4. A building frame of claim 1 for a hip roof construction wherein
the rafter connector of each post-joist-rafter connector has a
connecting surface which has a hip rafter angle.
5. A building frame for a hip roof construction comprising a main
frame and a hip frame of claim 1 adjacent thereto, the main frame
including first and second main frame post-joist-rafter connectors,
first and second main frame rafters, and a ridge connector having
first and second main frame rafter connectors and first and second
hip rafter ridge connectors, the rafter connectors of the first and
second main frame post-joist-rafter connectors each having a
connecting plate aligned with the angle of its respective main
frame rafter, each of the first and second main frame rafters
having a post end and a ridge end, the post end of the first rafter
being bolted to the rafter connector of the first main frame
post-joist-rafter connector, the post end of the second rafter
being bolted to the rafter connector of the second main frame
post-joist-rafter connector, the ridge end of the first rafter
being bolted to the connecting plate of the first main frame rafter
connector, and the ridge end of the second rafter being bolted to
the connecting plate of the second main frame rafter connector, the
hip frame including first and second post-joist-hip rafter
connectors and first and second hip rafters, each of the
post-joist-hip rafter connectors having a post connector, a joist
connector and a hip connector; the hip rafter connectors each
having a connecting plate aligned with the angle of its respective
hip rafter, and said first and second hip rafter ridge connectors
each having a connecting plate aligned with the angle of its
respective hip rafter; a joist having one end bolted to the joist
connector of the first post-joist-hip connector and the other end
bolted to the joist connector of the second post-joist-hip
connector; and each of the hip rafters having a post end and a
ridge end, the post end of the first hip rafter being bolted to the
hip rafter connector of the first post-joist-hip rafter connector,
the post end of the second hip rafter being bolted to the rafter
connector of the second post-joist-hip rafter connector, the ridge
end of the first hip rafter being bolted to the first hip rafter
ridge connector, and the ridge end of the second hip rafter being
bolted to the second hip rafter ridge connector.
6. A building frame of claim 1 wherein the central axes of the
posts, joist and rafters lie in a vertical frame plane.
7. A building comprising a plurality of free-standing open-span
building frames of claim 1, at least two adjacent frame planes
being parallel and having a frame plane-to-frame plane distance of
from 3 to 14 meters.
8. A free-standing open-span building frame of claim 1 including a
third post construction spaced between the first and second base
plates, the third post construction including a third base plate,
third and fourth upright posts, a post-joist connector, and a
post-rafter connector, the third base plate comprising a steel
plate having an upper surface to which is welded the lower end of a
steel post connector in a central portion thereof, each steel plate
having at least one anchor bolt hole therethrough on each side of
the post connector; the post-joist connector comprising lower and
upper post connectors and two joist connectors, each joist
connector being bolted to a joist; the third post having a lower
end bolted to the respective steel post connector of the third base
plate and an upper end bolted to the lower post connector; the post
rafter connector having a post connector and a rafter connector;
and the fourth post having a lower end bolted to the upper post
connector and an upper end bolted to a rafter connector.
9. A building frame of claim 3 wherein the connections between the
base plates and posts; between the post-joist-rafter connectors and
the posts joists and rafters; and between the rafters and the ridge
connector are snug fits secured with bolts and nuts.
10. A building comprising a plurality of frames of claim 1
including first and second adjacent frames, in at least one pair of
adjacent first and second posts, a first reinforcing bar bolted to
the top of the first post and to the bottom of the second post, and
a second reinforcing bar bolted to the top of the second post and
to the bottom of the first post.
11. A building of claim 8 with girts secured to adjacent posts by
self-tapping screws and with purlins secured to adjacent rafters by
self-tapping screws.
12. A building of claim 8 including first and second steel clips,
each having a rafter connector and a ridge purlin connector forming
a 90.degree. angle therebetween, a first steel clip rafter
connector attached to each of two adjacent rafters and the second
steel clip rafter connector attached to other of the two adjacent
rafters, and a ridge purlin connector extending between and
attached to the ridge purlin connectors of the first and second
clips.
13. A free-standing open-span building frame of claim 1, wherein
the steel post-joist-rafter connector comprises a post channel with
an upper end and a lower end, and a joist channel having a first
end and a second end, the post channel comprises a web and first
and second parallel post channel flanges, the joist channel
comprises a web and first and second parallel joist channel
flanges, each of the flanges forming a 90.degree. angle with its
respective web, the flanges and web of the first end of the joist
channel being welded to an outer surface of a post channel flange,
the flanges and web of the upper end of the post channel being
welded to a rafter connector plate positioned at a lower rafter
surface angle, the webs of the post channel and the joist channel
being in approximately the same plane, and the flanges of the post
channel and the joist channel extending in the same direction from
their respective webs, and a set of bolt holes in the webs adjacent
the lower end of the post channel and adjacent the second end of
the joist channel.
14. A free-standing open-span building frame of claim 3 wherein
each rafter channel having a web and first and second parallel
flanges, the first rafter channel having first and second ends and
the second rafter channel having third and fourth ends, each of the
flanges of the first and second channels forming a 90.degree. angle
with its respective web, the first end web and flanges of the first
rafter channel being welded to the third end web and flanges of the
second rafter channel, the webs forming a roof peak angle, the
second and fourth ends of the channels each having a set of bolt
holes for securing rafters to the connector.
15. A ridge connector of claim 14 wherein each of the rafter
channels is mated with the end of a rafter cee-channel and bolted
thereto, the outer dimensions of the rafter channel and the inner
dimensions of the cee-channel being selected to form a snug fit
with maximum surface to surface distances of less than 2 mm.
16. A steel post-joist-rafter connector comprising a post channel
with an upper end and a lower end, and a joist channel having a
first end and a second end, the post channel comprising a web and
first and second parallel post channel flanges, the joist channel
comprising a web and first and second parallel joist channel
flanges, each of the flanges forming a 90.degree. angle with its
respective web, the flanges and web of the first end of the joist
channel being welded to an outer surface of a post channel flange,
the flanges and web of the upper end of the post channel being
welded to a rafter connector plate positioned at a lower rafter
surface angle, the webs of the post channel and the joist channel
being in approximately the same plane, and the flanges of the post
channel and the joist channel extending in the same direction from
their respective webs, and a set of bolt holes in the webs adjacent
the lower end of the post channel and adjacent the second end of
the joist channel.
17. A post-joist-rafter connector of claim 16 wherein at least one
reinforcing plate is welded to the web and flanges of the post
channel in alignment with a flange of the joist channel.
18. A post-joist-rafter connector of claim 16 wherein the rafter is
a hip rafter and the rafter plate is positioned at a hip rafter
plate angle.
19. A ridge connector comprising first and second rafter channels,
each rafter channel having a web and first and second parallel
flanges, the first rafter channel having first and second ends and
the second rafter channel having third and fourth ends, each of the
flanges of the first and second channels forming a 90.degree. angle
with its respective web, the first end web and flanges of the first
rafter channel being welded to the third end web and flanges of the
second rafter channel, the webs forming a roof peak angle, the
second and fourth ends of the channels each having a set of bolt
holes for securing rafters to the connector.
20. A ridge connector of claim 19 wherein each of the rafter
channels is mated with the end of a rafter cee-channel and bolted
thereto, the outer dimensions of the rafter channel and the inner
dimensions of the cee-channel being selected to form a snug fit
with maximum surface to surface distances of less than 2 mm.
Description
BACKGROUND OF THE INVENTION
[0001] The small and medium sized building designs were developed
for standard wooden based building materials. Sheet metal studs
have been introduced in industrial buildings for interior and
exterior walls and increasingly into residential structures to
replace wood studs as the cost of wood increased. The same wood
structure design was retained except, in some instances, increasing
the wall stud spacing from 16 inches to from 18 and 20 inches. A
building where the wooden studs have been replaced with the light
sheet metal studs is described in U.S. Pat. No. 4,688,358. This
construction, except for the substitution of metal studs for wood
components, uses the same design concepts and labor intensive
construction methods developed for wooden structures.
[0002] In present wood constructions, metal connectors in
combination with wood studs and beams are increasingly employed to
reinforce the connections and to strengthen prefabricated portions
such as roof truss sections for their movement from trailer bed to
building. Wooden beams and sheer walls and bracings are then
applied to increase strength against dead load weight stresses and
lateral forces. Every wall in traditional construction depends for
its integrity upon adjacent walls and connecting girts, purlins,
and ridge beams. Typically, pre-assembled close-spaced walls are
raised into position and held upright with temporary struts until
they are secured to adjacent close-section walls. Although vertical
members and the base sill are secured against lateral movement by
anchor bolts and nuts, these connections and the relative weak
construction of these members does not yield free-standing
walls.
[0003] The traditional methods have exploited skills of trained
workers, and the labor costs for constructing a building have
become a major portion of the construction costs. The aging of many
skilled workers and their movement to less hazardous and strenuous
jobs has produced a serious skilled labor shortage, driving up the
costs of building construction. This is seriously impeding new home
and small industrial building construction.
[0004] For temporary and light-weight constructions such as car
ports and greenhouses, rapidly assembled light-weight frame
structures have been developed as described as in U.S. Pat. Nos.
5,966,890 and 6,276,111 B1, for example. While these structures are
light weight and easily assembled, they lack the strength and
integrity to withstand environmental stresses such as wind, and in
northern climates, snow loads required for industrial and
residential constructions; they are not suitable for permanent
structures. Their components do not include open-space or
free-standing frames.
SUMMARY OF THE INVENTION
[0005] This invention brings to small and medium sized building
construction, revolutionary new designs and methods which bring
into this construction, the industrial steel materials used in
large size open structures such as airplane hangers and
warehouses.
[0006] This invention provides novel strong steel connectors
adapted for quick assembly with steel cee-channels, HSS beams and
other components to provide free-standing clear-span frame
structures. With minimum bracing, these free-standing clear-span
frame structures will support purlins, girts, trusses, and
preassembled wall and roof components without relying on the
strength of these secondary components to provide the basic
integrity and strength of the frame structure.
[0007] This invention also provides an improved method of
construction which enables complete framing of a small to
medium-sized single or two story building with one or two minimally
skilled workman and a lift or hoist operator in a single day, and
that with assembled wall and roof components, enables closure and
interior framing of the building in a second day by the same
construction team. With suitably designed fabricated exterior wall,
interior wall, floor, ceiling and roof sections, construction of
the major portion of the building can be completed within the
second day.
[0008] This invention also provides a scalable building design and
method which provides the advances described above in buildings of
all sizes.
[0009] The frames all have a base comprising two or more posts
joined at the top with a joist with or without additional
components. The hip frame is complete with these elements. Other
frames require more. This basic construction of this invention
comprises a free-standing open-span building frame comprising first
and second base plates, first and second upright posts, first and
second post-joist-rafter connectors, and a joist. Each base plate
comprises a steel plate having an upper surface to which is welded
the lower end of a steel post connector in a central portion
thereof. Each steel plate has at least one anchor bolt hole
therethrough on each side of the post connector. Each post has a
lower end bolted to the respective steel post connector of the
first and second base plate. Each post-joist-rafter connector
comprises a post connector, a joist connector and a rafter
connector. The first post has an upper end bolted to the post
connector of the first post-joist-rafter connector, and the second
post has an upper end bolted to the post connector of the second
post-joist-rafter connector. The joist has first and second joist
ends, the first joist end being bolted to the joist connector of
the first post-joist-rafter connector, and the second joist end
being bolted to the joist connector of the second post-joist-rafter
connector.
[0010] The basic building frame can include a steel reinforced
concrete foundation with anchor bolts extending through the base
plate foundation anchor bolt holes of each base plate, each base
plate being secured to the anchor bolts with nuts.
[0011] To the basic frame can be added other components such as a
ridge connector and first and second rafters, the ridge connector
having first and second rafter connectors; and each of the rafters
having a post end and a rafter end. The post end of the first
rafter can be bolted to the rafter connector of the first
post-joist-rafter connector, the post end of the second rafter can
be bolted to the rafter connector of the second post-joist-rafter
connector, the ridge end of the first rafter can be bolted to the
first rafter connector, and the ridge end of the second rafter can
be connected to the second rafter connector. For a hip roof
construction, the rafter connector of each post-joist-rafter
connector has a connecting surface which has a hip rafter
angle.
[0012] A suitable hip roof construction includes a main frame and a
hip frame adjacent thereto. The main frame includes first and
second main frame post-joist-rafter connectors, first and second
main frame rafters, and a ridge connector having first and second
main frame rafter connectors and first and second hip rafter ridge
connectors. The rafter connectors of the first and second main
frame post-joist-rafter connectors each have a connecting plate
aligned with the angle of its respective main frame rafter. Each of
the first and second main frame rafters have a post end and a ridge
end, the post end of the first rafter being bolted to the rafter
connector of the first main frame post-joist-rafter connector, the
post end of the second rafter being bolted to the rafter connector
of the second main frame post-joist-rafter connector, the ridge end
of the first rafter being bolted to the connecting plate of the
first main frame rafter connector, and the ridge end of the second
rafter being bolted to the connecting plate of the second main
frame rafter connector. The hip frame includes first and second
post-joist-hip rafter connectors and first and second hip rafters,
each of the post-joist-hip rafter connectors having a post
connector, a joist connector and a hip connectors. The hip rafter
connectors each have a connecting plate aligned with the angle of
its respective hip rafter, and said first and second hip rafter
ridge connectors each having a connecting plate aligned with the
angle of its respective hip rafter. The structure includes a joist
having one end bolted to the joist connector of the first
post-joist-hip connector and the other end bolted to the joist
connector of the second post-joist-hip connector. Each of the hip
rafters has a post end and a ridge end, the post end of the first
hip rafter being bolted to the hip rafter connector of the first
post-joist-hip rafter connector, the post end of the second hip
rafter being bolted to the rafter connector of the second
post-joist-hip rafter connector, the ridge end of the first hip
rafter being bolted to the first hip rafter ridge connector, and
the ridge end of the second hip rafter being bolted to the second
hip rafter ridge connector.
[0013] The posts, joist and rafters of each frame lie in a vertical
frame plane. A building frame can comprises a plurality of
free-standing open-span building frames, at least two adjacent
frame planes being parallel and having a frame plane-to-frame plane
distance of from 3 to 14 meters.
[0014] The building frame can include a third post construction
spaced between the first and second base plates, the third post
construction including a third base plate, third and fourth upright
posts, a post-joist connector, and a post-rafter connector. The
third base plate comprises a steel plate having an upper surface to
which is welded the lower end of a steel post connector in a
central portion thereof, each steel plate having at least anchor
bolt hole therethrough on each side of the post connector. The
post-joist connector comprises lower and upper post connectors and
two joist connectors, each joist connector being bolted to a joist.
The third post has a lower end bolted to the respective steel post
connector of the third base plate and an upper end bolted to the
lower post connector. The post rafter connector has a post
connector and a rafter connector; and the fourth post having a
lower end bolted to the upper post connector and an upper end
bolted to a rafter connector.
[0015] The building can be stiffened and strengthened against
lateral and other forces with reinforcing bars. For adjacent first
and second posts in first and second adjacent frames, a first
reinforcing bar can be bolted to the top of the first post and to
the bottom of the second post, and a second reinforcing bar can be
bolted to the top of the second post and to the bottom of the first
post. This construction can be repeated symmetrically throughout
the building for buildings exposed to severe conditions.
[0016] In preparation for completion of the building, girts can be
secured to adjacent posts by self-tapping screws, and purlins can
be secured to adjacent rafters by self-tapping screws.
[0017] The roof construction can use first and second steel clips,
each having a rafter connector and a ridge purlin connector forming
a 90.degree. angle therebetween with a first steel clip rafter
connector attached to each of two adjacent rafters and a second
steel clip rafter connector attached to other of the two adjacent
rafters. A ridge purlin connector can extend between and attached
to the ridge purlin connectors of the first and second clips.
[0018] The individual connectors used in the building frame are a
part of this invention.
[0019] The invention includes a base plate comprising a steel plate
having an upper surface and a steel post connector having a
rectilinear cross-section and a lower end, the lower end of the
post connector being welded to a central portion of the upper
surface with at least one anchor bolt hole therethrough on each
side of the post connector. The post can be channel or HSS with a
rectangular cross-section.
[0020] The steel post-joist-rafter connector of this invention
comprises a post channel with an upper end and a lower end, and a
joist channel having a first end and a second end. The post channel
comprises a web and first and second parallel post channel flanges,
and a joist channel comprises a web and first and second parallel
joist channel flanges. The flanges and web of the first end of the
joist channel are welded to an outer surface of a post channel
flange and the flanges and web of the upper end of the post channel
are welded to a rafter connector plate positioned at a lower rafter
surface angle. The webs of the post channel and the joist channel
being in approximately the same plane, and the flanges of the post
channel and the joist channel extend in the same direction from
their respective webs. Sets of bolt holes in the webs are adjacent
to the lower end of the post channel and adjacent to the second end
of the joist channel. In one embodiment, at least one reinforcing
plate is welded to the web and flanges of the post channel in
alignment with a flange of the joist channel. For post-joist-rafter
connectors wherein the rafter is a hip rafter, the rafter plate is
positioned at a hip rafter plate angle.
[0021] The ridge connector of this invention comprises first and
second rafter channels, each rafter channel having a web and first
and second parallel flanges. The first rafter channel has first and
second ends, and the second rafter channel having third and fourth
ends. The first end web and flanges of the first rafter channel are
welded to the third end web and flanges of the second rafter
channel, the webs forming a roof peak angle. The second and fourth
ends of the channels each have a set of bolt holes for securing
rafters to the connector. When assembled, each of the rafter
channels is mated with the end of a rafter cee-channel and bolted
thereto, the outer dimensions of the rafter channel and the inner
dimensions of the cee-channel being selected to form a snug fit,
which can optionally have maximum surface to surface distances of
less than 2 mm.
[0022] The splice connector of this invention comprises first and
second channels, the first channel having a first and second end
and the second channel having a third and fourth end. The first end
web and flanges of the first splice channel are aligned with and
welded to the third end web and flanges of the second splice
channel. The second and fourth ends of the splice channels each
have a set of bolt holes for securing cee-channel to the connector.
When assembled, each of the splice channels is mated with the end
of a cee-channel and bolted thereto, the outer dimensions of the
channels and the inner dimensions of the cee-channels being
selected to form a snug fit with maximum surface to surface
distances of less than 2 mm.
[0023] The ridge butt connector of this invention comprises a first
main rafter channel having a first and second end, a second main
rafter channel having a third and fourth end, a first hip channel
having a fifth and sixth end, and a second hip channel having a
seventh and eighth end. The first end web and flanges of the first
main rafter channel are welded to the third end web and flanges of
the second main rafter channel, the main channel webs forming a
roof peak angle. The fifth end web and flanges of the third hip
rafter channel are welded to the seventh end web and flanges of the
fourth hip channel and the fifth and seventh ends are welded the
inner surfaces of the first and third end web and flanges, the
upper flanges of the third and fourth hip channels forming a hip
peak angle with the webs of the first and second main rafter
channels. A set of bolt holes are provided adjacent the second,
fourth, sixth and eighth ends for securing rafters to the
channels.
[0024] The slope change connector comprises a main rafter channel
having a web and parallel flanges, and a slope changed rafter
channel having a web and parallel flanges. An end of the web and
flanges of the main rafter channel are welded to an end of web and
flanges of the slope changed rafter channel. The webs of the main
rafter channel and the slope changed rafter channel each have a set
of bolt holes, and the webs of the main rafter channel and the
slope changed rafter channel have a common plane.
[0025] The slope-butt connector of this invention comprises a slope
rafter connector channel with a web and parallel flanges, and a
post connector channel having upper and lower ends and first and
second parallel post connector channel flanges. One end of the
flanges and web of the slope rafter connector are welded to the
first post connector channel flange, the angle between the flanges
of the slope rafter connector and the first post connector channel
flanges constituting the slope angle.
[0026] The T-connector of this invention comprises a post channel
having a web and first and second parallel post channel flanges and
a joist channel with a web and first and second parallel joist
channel flanges. The webs of the post channel and the joist channel
are in the same plane, and each of the flanges forming a 90.degree.
angle with its respective web. Both ends of the post channel have
at least one set of post bolt holes for securing the post channel
to posts. The joist channel has first and second ends, the first
end having at least one set of joist bolt holes for securing the
joist channel to a joist. The flanges and web of the second end of
the joist channel are welded to a flange of the post channel
between the sets of post bolt holes. In one embodiment, at least
one reinforcing plate is welded to the web and flanges of the post
channel in alignment with a flange of the joist channel.
[0027] The X-connector of this invention comprises a post channel
having a web and first and second parallel post channel flanges,
and first and second joist channels having a web and first and
second parallel joist channel flanges. The webs of the post channel
and the joist channels are in the same plane. Each of the flanges
forms a 90.degree. angle with its respective web, and both ends of
the post channel having at least one set of post bolt holes for
securing the post channel to posts. The first joist channel has
first and second ends, and the second joist channel has third and
fourth ends. The first and third ends each have at least one set of
joist bolt holes for securing the respective joist channel to a
joist. The flanges and web of the second end of the joist channel
are welded to the first flange of the post channel between the post
bolt holes, and the flanges and web of the fourth end of the joist
channel are welded to the second flange of the post channel in
alignment with the flanges of first joist channel.
[0028] The post-rafter connector of this invention a post channel
having a web and first and second parallel post channel flanges,
and having an upper end and a lower end with a set of bolt holes
for securing the post channel to a post. A rafter connector has a
web and upper and lower flanges and has a first and second end,
each of the flanges forming a 90.degree. angle with its respective
web. The first and second ends each have a set of bolt holes for
bolting the rafter connector to the ends of rafters, the ends of
the web and flanges of the upper end of the post channel being
welded to the lower flange of the rafter connector to form with the
rafter channel flange an angle which maintains the slope of the
upper flange at a roof slope angle. In one embodiment, at least one
reinforcing plate is welded to the web and flanges of the post
channel adjacent to the upper end thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is a schematic view of a free-standing clear-span
frame structure of this invention.
[0030] FIG. 2 is a schematic view of the free-standing clear-span
frame structure of FIG. 1 with added ridge beam, hip beams, and
cross-bars.
[0031] FIG. 3 is a schematic view of a free-standing clear-span
frame structure according to this invention supporting purlins and
girts.
[0032] FIG. 4 is a top cross-sectional view of channel post base of
this invention.
[0033] FIG. 5 is a cross-sectional view of the channel post base of
FIG. 4 taken along the Line 5-5.
[0034] FIG. 6 is a top cross-sectional view of a HSS post base of
this invention.
[0035] FIG. 7 is a cross-sectional view of the HSS post base of
FIG. 6 taken along the line 7-7.
[0036] FIG. 8 is a front view of a post-joist-rafter connector of
this invention FIG. 9 is a rear view of the post-joist-rafter
connector of FIG. 8.
[0037] FIG. 10 is a top view of a ridge connector according to this
invention.
[0038] FIG. 11 is a cross-sectional view of the ridge connector of
FIG. 10 taken along the line 11-11.
[0039] FIG. 12 is a cross-sectional view of the ridge connector of
FIG. 10 taken along the line 12-12.
[0040] FIG. 13 is a top view of a splice connector according to
this invention.
[0041] FIG. 14 is a cross-sectional view of the splice connector of
FIG. 13 taken along the line 14-14.
[0042] FIG. 15 is a cross-sectional view of the splice connector of
FIG. 14 taken along the line 15-15.
[0043] FIG. 16 is a top view of a ridge-butt connector according to
this invention.
[0044] FIG. 17 is a front view of the ridge-butt connector of FIG.
17.
[0045] FIG. 18 is a back view of the ridge-butt connector of FIGS.
16 and 17.
[0046] FIG. 19 is a top view of a hip frame according to this
invention.
[0047] FIG. 20 is a front view of the hip frame of FIG. 19.
[0048] FIG. 21 is a bottom view of a rafter plate to hip rafter
connection of the hip frames of FIGS. 19 and 20.
[0049] FIG. 22 is a view of a clip according to this invention.
[0050] FIG. 23 is a side view of the clip of FIG. 22.
[0051] FIG. 24 is a cross-sectional view of the clip of FIG. 22
taken along the line 24-24.
[0052] FIG. 25 is a front view of a ridge purlin centrally
supported on a ridge connector with a clip of FIG. 22 according to
this invention.
[0053] FIG. 26 is a front view of two purlins supported off the
center of a ridge connector with purlin clips of FIG. 22.
[0054] FIG. 27 is a front view of a purlin and clip secured to the
web portion on a cee-channel with a clip of FIG. 22.
[0055] FIG. 28 is a cross-sectional view of the purlin secured to
the web portion of FIG. 27, taken along the line 28-28.
[0056] FIG. 29 is a front view of a slope butt connector according
to this invention.
[0057] FIG. 30 is a front view of the slope-butt connector of FIG.
29 bolted to upper and lower posts and a slope rafter.
[0058] FIG. 31 is a front view of a slope change connector.
[0059] FIG. 32 is a front view of the slope change connector of
FIG. 31 secured to a main rafter and a lower slope changed
rafter.
[0060] FIG. 33 is a front view of a T-connector according to this
invention.
[0061] FIG. 34 is an end view of the T-connector of FIG. 33.
[0062] FIG. 35 is a front view of an X-connector according to this
invention.
[0063] FIG. 36 is a bottom view of the X-connector of FIG. 35.
[0064] FIG. 37 is a front view of a center post embodiment of this
invention including a post to rafter connector shown connected to a
cee-channel post and rafter, in combination with a joist to
X-connector, shown connected to cee-channel posts, joists and
rafter.
[0065] FIG. 38 is a front view of the post-rafter connector of FIG.
37 without post and rafter.
[0066] FIG. 39 is a cross-sectional view of the post-rafter
connector of FIG. 37 taken along the line 39-39.
[0067] FIG. 40 is a cross-sectional view of the post-rafter
connector of FIG. 37 taken along the line 40-40.
[0068] FIG. 41 is a cross-sectional view of the post-rafter
connector of FIG. 37 taken along the line 41-41.
DETAILED DESCRIPTION OF THE INVENTION
[0069] The objectives, structures and methods of this invention are
described in greater detail in the drawings and following
descriptions.
[0070] The term "post" as used in this application is defined as a
vertical member for supporting the structure.
[0071] The term "joist" as used in this application is defined as a
horizontal ceiling support.
[0072] The term "rafter" as used in this application is defined to
be a primary roof support member.
[0073] The term "purlin" as used in this application is defined to
be a secondary horizontal roof support member.
[0074] The term "girt" as used in this application is defined to be
a secondary horizontal wall support member.
[0075] The term "snug fit" is used in this application to describe
the space between the opposed surfaces of the connectors of this
invention and the cee-channels, round pipes or HSS beams bolted
thereto. A snug fit is defined to denote a maximum contact surface
to opposed contact surface distance of not more than 2 mm.
[0076] The term "channel" as used in this application is defined as
a three-sided piece of metal comprising a web and first and second
parallel flanges, each of the flanges forming a 90.degree. angle
with respect to the web.
[0077] Only one member or each mirrored pair of connectors of this
invention are set forth in the following descriptions. Mirrored
counterparts of these structures have the same but mirrored
construction and are also to be considered within the scope of this
invention.
[0078] The connectors of this invention with the exception of FIGS.
5 and 6 are shown bolted to cee-channels. For stronger structures,
the cee-channels may be replaced with stronger HSS sections or pipe
having round cross-sections, and in that event, the channel
connectors will be replaced with corresponding matching connectors
constructed in a manner which will be readily apparent to a person
skilled in the art. Both the cee-channel and these alternative
structured connectors are intended to be included within the scope
of this invention.
[0079] FIG. 1 is a schematic view of a free-standing clear-span
frame structure of this invention.
[0080] The term "free-standing" is used herein to indicate frames
that are strongly secured to a foundation against lateral, vertical
and torque forces and entirely support the vertical dead weight
associated with building components they support without the
assistance of secondary building components. With the assistance of
cross-bars, these frames entirely supports the building components
against lateral stresses of wind and earthquake, and the torque
forces generated by these lateral forces.
[0081] The term "clear-span" is used herein to identify the novel
approach to small and medium sized building construction made
possible by this invention, where the weight and stress bearing
skeletal components of the building are assembled in spaced
free-standing upright frames in the first stage of the
construction. Spacing between adjacent free-standing frames is
limited only by the needs of the secondary components to be
supported on the frames. Larger spacing is entirely optional if
stronger girts, purlins, and trusses are used to span the
distances.
[0082] The free-standing frames are completely assembled without
the need for on-site welding. The components are entirely assembled
using novel connectors, and conventional bolts and nuts. The frame
is secured to the foundation using novel post plates, and anchor
bolts and nuts.
[0083] Heavy self-tapping screws are used to attach the girts,
purlins, trusses, and other components needed to support walls,
floors, ceilings and roof components to these free-standing
clear-span frames. This structure and method enables increased use
of preassembled components such as reinforced roofs, exterior
walls, and interior walls in the form of completely self-contained
panels that can be secured directly to the frame members with heavy
self-tapping screws.
[0084] FIG. 1 shows a series of free-standing, single story open
span frames 2, 4, 5 and 6. Hip frame 2 comprises channel posts 8
and 10 with their lower ends secured to the foundations 12 and 14
by post base plate connectors 18, details of which are described
with respect to FIGS. 4 and 5 hereinafter. The upper ends of the
posts 8 and 10 are connected to a joist 20 by post-joist connectors
22 and its mirrored structure 23, details of which are described
hereinafter with respect to FIGS. 19-21.
[0085] Frames 4, 5 and 6 are substantially identical. Frame 4
comprises a pair of posts 24 and 26, their lower ends secured to
respective foundations 12 and 14 by post base plate connectors 18,
and their upper ends connected to joist 28 and rafters 30 and 32 by
post-joist-rafter connectors 34 and their mirrored counterpart
connectors 35, details of which are described with respect to FIGS.
8 and 9 hereinafter. The upper ends of the rafters 30 and 32 are
joined together by hip roof ridge connector 33, details of which
are described with respect to FIGS. 16-18 hereinafter.
[0086] Frame 5 comprises a pair of posts 36 and 38, their lower
ends being secured to respective foundations 12 and 14 by post base
plate connectors 18, their upper ends being connected to joist 40
and rafters 42 and 44 by post-joist-rafter connectors 34. The upper
ends of the rafters 42 and 44 are joined by roof ridge connectors
37, details of which are described with respect to FIGS. 10-12, 25
and 26 hereinafter.
[0087] The spacing between posts 8 and 24, between posts 24 and 36
will depend upon the building design selected. Distances of 3 to 14
meters are entirely within the capabilities of this design. The
distance between hip roof posts 8 and adjacent frame post 24 are
selected based on the dimensions of the hip component. The
distances between the posts of each frame and between adjacent
frames are selected from design considerations which take into
consideration the overall size of the building, and the economies
in costs and labor realized balancing the labor savings derived
from use of fewer, more widely spaced frames, and the costs of
stronger secondary structures required to span larger distances. In
locations and circumstances where speed of construction and labor
costs are the most dominant factors, larger spacings are
advantageous. FIGS. 1 and 2 show a hip frame and three standard
single-story frames. The number of frames, the post spacings, and
the frame-to-frame spacings are relatively unlimited as will be
readily apparent to a person skilled in the art, and all numbers
and variations in free-standing open-span frame constructions are
intended to be included with the scope of this invention.
[0088] The posts, joists and rafters used in the frames of FIG. 1
are standard construction components used in the industrial
building industry. Based on the strength needs for a particular
building, they can be steel channels, cee-channels, HSS beams,
Z-beams, I-beams, round beams, or other conventional heavy
structural beams having the requisite strength to span the
distances between the posts and to carry the weights and meet the
stress specifications of the building. For taller buildings and for
larger post spacings, beams having a larger size and/or wall
thickness are used. The beam strengths and thus the corresponding
choice of size and thickness required to meet the code and design
specifications for a building are part of the design parameters of
buildings, and their selection is fully within the skill of a
person skilled in the art of building design.
[0089] FIG. 2 is a schematic view of the free-standing clear-span
frame structure of FIG. 1 with added secondary structures, ridge
beams, hip rafters, and lateral stress cross-bars. The lower end of
the secondary component hip rafters 46 and 48 connect with the
post-joist-rafter connectors 22 and 23 at the upper ends of posts 8
and 10, and their upper ends come together to connect with the hip
roof ridge connector 33. The hip rafters 46 and 48 support sloped
roof components of the hip roof construction.
[0090] Another secondary component is a ridge purlin 50 which
connects the hip roof ridge connector 33 with the roof ridge
connector 37. The ridge purlin 50 supports the roof components.
[0091] To increase the stiffness of the frames and their resistance
to lateral stresses caused by high winds and earthquakes,
cross-bars 52 and 54 can be used to connect the tops and bottoms of
posts 24 and 36, i.e., cross-bar 54 connecting the top of post 24
to bottom of post 36, and cross-bar 52 connecting the top of post
36 to bottom of post 24. Matching cross-bars connect the tops and
bottoms of posts 26 and 38 on the opposite side of the structure.
Cross-bars can also be used to connect roof peaks of one frame to
posts of an adjacent frame to increase roof stiffness. Movement of
a frame with a vector in either direction normal to the plane of
the fame is resisted by tensile strength of at least one of the
reinforcing rods with this cross-bracing design.
[0092] FIG. 3 is a schematic view of a free-standing clear-span
frame structure of this invention with the purlins and girts
attached thereto. In this configuration, the building comprises
four free-standing clear-span frames 60, 62, 64 and 66, constructed
as described hereinabove with respect to FIG. 1. The front frame 60
has posts 68 and 70. Rafters 72 and 74 and horizontal joists 76 and
78 are attached to the posts 68 and 70 by post-joist-rafter
connectors 34 and 35. Secondary studs together with the posts 68
and 70 support horizontal girts, door lintels and jambs, window
sills, lintels and jambs, and horizontal girts are secured to the
rafters 72 and 74. Additional girts and purlins also extend between
posts of end frame 66, and between the opposing posts of adjacent
frames to provide support for external and interior walls, doors,
and windows, and the roof components.
[0093] FIG. 4 is a top cross-sectional view of channel post base of
this invention, and FIG. 5 is a cross-sectional view of the channel
post base of FIG. 4 taken along the Line 5-5. The base plate 80 has
a rectangular shape with longer sides 82 and shorter sides 84. A
section of channel 86 is welded perpendicular to the base plate 80
in the central portion thereof, the channel web 88 oriented
parallel to the shorter sides 84 and the channel flanges 90
oriented parallel to the longer sides 82. Anchor bolts embedded in
the steel reinforced foundation 91 extend through matched holes
(not shown) in the base plate 80, the holes being aligned with the
anchor bolts. The base plate is secured to the anchor bolts with
nuts 92. A cee-channel post 94 is secured to the channel 86 by
standard heavy bolts and nuts (now shown).
[0094] The external web dimension of the channel 86 closely matches
the internal web dimension of the cee-channel so that when bolted
together, they form a snug fit, yielding a strong secure union.
[0095] FIG. 6 is a top cross-sectional view of HSS post base of
this invention, and FIG. 7 is a cross-sectional view of the channel
post base of FIG. 6 taken along the Line 7-7. The base plate 96 has
a rectangular shape with longer sides 98 and shorter sides 100. A
section of HSS 102 is welded perpendicular to the base plate 96 in
the central portion thereof, the four sides of the HSS being
oriented parallel to the respective longer sides 98 and shorter
sides 100. Anchor bolts embedded in the steel reinforced foundation
101 extend through matched holes in the base plate 96 (not shown).
The base plate 96 is secured to the anchor bolts by nuts 103. A HSS
post 104 is secured to the HSS section 102.
[0096] The external dimensions of the channel HSS section 102
closely match the internal dimensions of the HSS post 104 so that
when bolted together, they form a snug fit, yielding a strong
secure union.
[0097] FIG. 8 is a front view of the post-joist-rafter connector
109 of this invention shown as 34 in FIGS. 1-3, and FIG. 9 is a
rear view of the post-joist-rafter connector of FIG. 8.
Post-joist-rafter connector 109 shows the basic construction of the
post-joist-rafter connector 34 in FIGS. 1 and 2. The terminal end
of a post channel connector 110 having a post channel web 112 and
first and second post channel flanges 114 and 116 is welded to
rafter connector plate 118 having an angle matching the slope
desired for the rafter 120. A joist channel connector 122 has joist
channel web 124 and joist channel flange portions 126 and 128, one
end of which are welded perpendicular to the first flange 114 of
the post channel connector 110. Post reinforcing plates 130 and 132
are welded to the web 112 and opposed flanges 114 and 116 in
alignment with the flanges 126 and 128 of the joist connector
122.
[0098] A post cee-channel 131 is secured to the post channel
connector 110 by strong bolts and nuts (not shown), the external
dimensions of the web 112 being a close match for the internal web
dimensions of the cee-channel web 134 to form a secure bolt and nut
connection. A joist cee-channel 136 is secured to the joist channel
connector 122 by strong bolts and nuts (not shown), the external
dimensions of the web 124 being a close match for the internal web
dimensions of the joist cee-channel web 138 to form a secure bolt
and nut connection.
[0099] The lower flange 140 of the cee-channel rafter 120 is
secured to the rafter connector plate 118 by bolts and nuts (not
shown).
[0100] The webs 112 and 124 each have a set of bolt holes 125 for
attaching the connectors to their respective cee-channels.
[0101] The external dimensions of the connectors closely match the
internal dimensions of the cee-channel connected thereto so that
when bolted together, they form a snug fit, yielding a strong
secure union.
[0102] Referring to FIGS. 1-3, a mirrored counterpart 35 of the
post-joist-rafter connector 34 is used for connecting the post,
joist and rafters of the opposite side of the frame. Alternative
arrangements of flanges and webs shown in FIG. 9 which achieve the
same overall configuration will be readily apparent to a person
skilled in the art, and these alternative configurations are
considered to be fully within the scope of this invention.
[0103] FIG. 10 is a top view of a ridge connector according to this
invention. FIG. 11 is a cross-sectional view of the ridge connector
of FIG. 10 taken along the line 11-11, and FIG. 12 is a
cross-sectional view of the ridge connector of FIG. 10 taken along
the line 12-12.
[0104] Referring to FIG. 12, the ridge connector connector 150 is
formed from two channel connectors 152 and 154, their ends welded
together to form an angle "a" which corresponds to the angle of the
peak of the roof. Rafter cee-channels 156 and 158 are secured to
the respective rafter connectors 152 and 154 with strong bolts and
nuts 155. The external width dimensions of the rafter connectors
152 and 154 correspond closely with the internal web dimensions of
the rafter cee-channels 156 and 158 so that when bolted together,
they form a snug fit, yielding a strong secure union.
[0105] FIG. 13 is a top view of a splice connector according to
this invention. FIG. 14 is a cross-sectional view of the splice
connector connector of FIG. 13 taken along the line 14-14, and FIG.
15 is a cross-sectional view of the splice connector connector of
FIG. 14 taken along the line 15-15. Referring to FIG. 15, the
splice connector connector is a section of channel 160 to which two
sections of cee-channel 162 and 164 are attached by strong bolts
and nuts 165. The external width dimensions of the channel 160
correspond closely with the internal web dimensions of the
cee-channels 162 and 164 so that when bolted together, they form a
snug fit, yielding a strong secure union.
[0106] FIG. 16 is a top view of a ridge-butt connector according to
this invention, FIG. 17 is a front view of the ridge-butt connector
of FIG. 16, and FIG. 18 is a back view of the ridge-butt connector
of FIGS. 16 and 17. The connector 169 is made of four sections of
channel, two connector sections 170 and 172 constituting roof
rafter connectors. One end of each rafter connector is welded to
the other to form an angle "b" shown in FIG. 18. Angle "b"
corresponds to the angle formed by the peak of the roof. Hip rafter
connectors 174 and 176 converge together, and their converged ends
are welded to the central portion of the rafter connectors 170 and
172. The hip rafter connectors are welded to form the angles and
orientation of the respective hip rafters. Because of the
complexity of the ridge-butt connector connector, it is shown
without the roof and hip rafters connected by the ridge-butt
connector connectors. When installed, cee-channel roof rafters (not
shown) are secured to the rafter connectors 170 and 172 (as shown
in FIGS. 10-12) described hereinabove with strong bolts and nuts
through the bolt holes 171 shown at the end of each connector.
Cee-channel hip rafters are similarly secured to the hip rafter
connectors 174 and 176 with strong bolts and nuts.
[0107] These cee-channel rafters are attached to the corresponding
respective connectors by strong bolts and nuts (not shown), and the
external width dimensions of the channel connectors are selected to
correspond closely with the internal web dimensions of the
respective cee-channel rafters to form strong rigid
connections.
[0108] FIG. 19 is a top view of a hip frame 181 according to this
invention, and FIG. 20 is a front view of the hip frame of FIG. 19.
FIG. 21 is a bottom view of a rafter plate to hip rafter connection
of FIGS. 19 and 20. Main roof rafters 180 and 182 are bolted to the
connectors 170 and 172 of ridge-butt connector 169 shown in FIGS.
16-18. The upper ends 184 and 186 of respective hip rafters 188 and
190 are bolted to the respective connectors 174 and 176 of the
ridge-butt connector shown in FIGS. 16-18. Lower flange sections
192 and 194 of the hip rafters 188 and 190 are bolted to connector
plates 196 and 198 of the hip frame 181.
[0109] The difference between the post-joist-roof rafter connector
of FIGS. 8 and 9 and the post-joist-hip rafter of FIGS. 19-21 is
the hip rafter connecting (upper) surfaces of the connector plates
196 and 198; these surfaces are oriented in the plane of the
lowermost flanges 192 and 194 of the hip rafter cee-channels 188
and 190. Bolt holes 200 are placed to effect a secure bolt
connection between the plates and the respective hip rafters. The
external dimensions of the connectors closely match the internal
dimensions of the cee-channel connected thereto so that when bolted
together, they form a snug fit, yielding a strong secure union.
[0110] FIG. 22 is a view of a clip according to this invention,
FIG. 23 is a side view of the clip of FIG. 22, and FIG. 24 is a
cross-sectional view of the clip of FIG. 22 taken along line 24-24.
The clip is formed from two L-channel flanges 220 and 222 which
form an angle "c" of 90.degree.. The end of one L-channel flange
220 has at least two holes 226 (four holes are shown), for securing
corresponding cee-channel sections thereto by bolts or heavy
self-tapping screws. The opposite end of the other L-channel flange
222 has at least two holes 224 (four holes are shown), for securing
corresponding cee-channel sections thereto by screws.
[0111] FIG. 25 is a front view of a purlin supported centrally on a
ridge connector with a clip of FIGS. 22-24 according to this
invention. The flange 220 of the clip is secured to cee-channel 228
of the converging cee-channels 228 and 230 of roof rafters, these
roof rafters as shown in FIGS. 10-12 are secured to a roof rafter
connector by bolts or self-tapping screws 232. A centrally located
roof peak purlin 234 is secured to flange 222 by bolts or
self-drilling screws 236 which extend through the holes 224 (FIG.
22) into the purlin 234.
[0112] FIG. 26 is a front view of two purlins supported off the
center of a ridge connector with purlin clips of FIG. 22. Two
rafters 240 and 242 are secured to a rafter connector 244 (shown in
FIGS. 10-12) by bolts or self-tapping screws (not shown). Clip 248
is secured to rafter 240 by bolts or self-drilling screws 252
extending through corresponding holes in the clip flange (shown in
FIGS. 22-24). Another clip 250 having an opposite hole
configuration (forming a mirrored duplicate) of clip 248 is secured
to rafter 242 by bolts or self-drilling screws 252 extending
through corresponding holes in the respective flanges. Roof purlins
254 and 256 are secured to the respective clips 248 and 250 by
bolts or self-drilling screws 258 extending through corresponding
holes (shown in FIGS. 22-24) in the clip flanges. The clips 248 and
250 are positioned off the center of the rafter connector 244 and
at an angle perpendicular to the angle of the respective rafters as
required by this roof peak construction. It will be readily
apparent to a person skilled in the art that the orientation of the
clips can be reversed and the angles selected for the clips can be
varied, and these variations are considered to be fully within the
scope of this invention.
[0113] FIG. 27 is a front view of a purlin secured to the web
portion on a cee-channel with a clip of FIG. 22, and FIG. 28 is a
cross-sectional view of the purlin secured to the web portion of
FIG. 27, taken along the line 28-28.
[0114] Flange portion 259 of the clip 260 is attached normal to a
cee-channel 262 by bolts or self-tapping screws 264. A purlin 266
is secured to the other flange portion 268 of the clip 260 by bolts
or self-tapping screws 270. It will be readily apparent to a person
skilled in the art that the orientation of the clip can be reversed
and the angle selected for the clip can be varied to fit the design
constraints of the building, and these variations are considered to
be fully within the scope of this invention.
[0115] FIG. 29 is a front view of a slope-butt connector according
to this invention, and FIG. 30 is a front view of the slope-butt
connector of FIG. 29 bolted to upper and lower posts and a slope
rafter.
[0116] The slope-butt connector is useful for connecting lower and
upper posts with each other and connecting to a sloped rafter. The
slope-butt connector 300 is formed with a slope rafter connector
channel section 301 with flanges 302 and 303 and web 304. The ends
305 and 306 of respective flanges 302 and 303, and the end 307 of
web 304 are welded at a slope angle "d" to the flange 308 of post
channel section 309. The ends of reinforcing plates 310 and 311 are
welded to the flanges 308 and 312 and one side of the reinforcing
plates 310 and 311 are welded to web 313 of channel section 309 in
alignment with the flange ends 305 and 306 of the channel section
301. The ends of web 313 each have sets of holes 314 and 315, and
the web 304 has as set of holes through which bolts can be extended
to secure the cee-channel posts and rafter to the slope-butt
connector.
[0117] Referring to FIG. 30, rafter cee-channel 316 is bolted to
the slope rafter connector 301 through holes 315 (FIG. 29) with
bolts 319, and the post sections 317 and 318 are bolted to the post
connector 309 through holes 314 (FIG. 29) with bolts and nuts 321.
The external width dimensions of the post connector 309 and the
rafter connectors 301 correspond closely with the internal
dimensions of the respective post cee-channels 317 and 318 and the
rafter cee-channel 316 so that when bolted together, they form a
snug fit, yielding a strong secure union.
[0118] FIG. 31 is a front view of a slope change connector, and
FIG. 32 is a front view of the slope change connector of FIG. 31
secured to a main rafter and a lower slope changed rafter. The
slope change connector 600 is formed from two rafter channel
connectors 601 and 602. The ends of the flanges 604 and 606 and the
web 608 of one end of channel connector 601 are welded to the
respective ends of the flanges 610 and 612 and the web 614 of
channel connector 602 to form an angle "e" which corresponds to the
angle of the slope change. The ends of webs 608 and 614 have sets
of holes 616 and 618 for securing rafter channels to the
connectors.
[0119] Referring to FIG. 32, rafter cee-channels 620 and 622 are
secured to the respective rafter connectors 601 and 602 by strong
bolts and nuts 624. The external dimensions of the rafter
connectors 601 and 602 correspond closely with the internal
dimensions of the rafter cee-channels 620 and 622 so that when
bolted together, they form a snug fit, yielding a strong secure
union.
[0120] FIG. 33 is a front view of a T-connector according to this
invention, and FIG. 34 is an end view of the T-connector of FIG.
33. The T-connector is useful for connecting lower and upper end
posts of a two-story structure with each other and with a
horizontal joist. The T-connector 339 is formed with a channel
section 340 with flanges 342 and 344 and web 346. The ends 347 and
349 of respective flanges 348 and 350 , and the end 351 of web 352
of channel section 353 are welded at right angles to the flange 342
of channel section 340. Reinforcing plates 354 and 356 are welded
to the flanges 342 and 344 and web 346 of channel section 340 in
alignment with the flanges 348 and 350 of the channel section 353.
The ends of web 346 have sets of holes 358 and 360, and the end of
web 352 has as set of holes 359 through which strong bolts and nuts
can be extended to secure connecting cee-channel joists to the
T-connector.
[0121] FIG. 35 is a front view of an X-connector according to this
invention, and FIG. 36 is a bottom view of the X-connector of FIG.
35. The X-connector is useful for connecting upper and lower
intermediate posts to each other and to horizontal joists. The
X-connector 370 is formed with a channel section 372 with flanges
374 and 376 and web 378. The two wings of the X configuration are
formed by channel sections 380 and 382. The ends 384 and 386 of
respective flanges 388 and 390, and the end 392 of web 396 of
channel section 388 are welded at right angles to the flange 374 of
channel section 372. The ends 400 and 402 of respective flanges 404
and 406, and the end 408 of web 410 of channel section 382 are
welded at right angles to the flange 376 of channel section
372.
[0122] Reinforcing plate 414 is welded to the flanges 374 and 376,
and to web 378 of channel section 372 in alignment with flanges 388
and 404 of the respective channel sections 380 and 382. Reinforcing
plate 416 is welded to the flanges 374 and 376, and to web 378 of
channel section 372 in alignment with flanges 390 and 406 of the
respective channel sections 380 and 382.
[0123] Each end of web 378 have sets of holes 416 and 418, and the
ends of both webs 396 and 410 have sets of holes 420 and 422
through which strong bolts and nuts can be extended to secure
connecting cee-channel or joists to the wings of the
X-connector.
[0124] FIG. 37 is a front view of an intermediate post embodiment
of this invention including a post to rafter connector shown
connected to a cee-channel post and rafter, in combination with a
joist to X-connector, shown connected to cee-channel posts, joists
and rafter. FIG. 38 is a front view of the post-rafter connector of
FIG. 37 without post and rafter.
[0125] The connectors shown in FIGS. 37 and 38 are useful for posts
positioned between the side posts of a frame because the distance
between the joists and rafter for the center posts requires an
additional post segment and two rafter segments. The lower and
upper posts are joined by the X-connector, and the top of the upper
post is connected to a rafter by the post-rafter connector. Details
of the X-connector are described with respect to FIGS. 35 and
36.
[0126] Referring to FIG. 38, the post and rafter connector 500 is
formed by welding a post connector channel 502 to a flange 503 of
rafter connector channel 504, the end 506 of the post connector
channel 502 being cut at an angle "f" corresponding to the slope of
the roof. The rafter channel 504 welded thereto is thus angled at
the slope of the roof. Reinforcing plate 508 is welded to the
flanges 510 and 512 and web 513 of the post channel 502 at right
angles to the respective flanges and web. Reinforcing plates 514
and 516 are welded to the flanges 503 and 518 and web 520 of the
rafter channel 504 at right angles to the respective flanges and
web. Bolt holes 522 are positioned near the ends of the webs 513
and 520.
[0127] Referring to FIG. 37, the cee-channel posts 525 and 527 are
bolted by bolts and nuts 524 to the top and bottom of web 378 of
the X-connector 370 shown in detail in FIGS. 35-36. Cee-channel
joists 526 and 528 are secured by bolts and nuts 524 to the joist
connector webs 396 and 410 of the X-connector.
[0128] The rafter segments 530 and 532 are secured by bolts 524 to
the ends of web 520 of the rafter channel 504 of the post-rafter
connector 500. The web 513 is secured by bolts 524 to the upper end
of post 525.
[0129] FIG. 39 is a cross-sectional view of the post-rafter
connector of FIG. 37 taken along the line 39-39. The outer
dimensions of the channel flanges 518 and 503, and of the web 520
correspond closely with the inner dimensions of the cee-channel 532
so that when bolted together, they form a snug fit, yielding a
strong secure union.
[0130] FIG. 40 is a cross-sectional view of the post-rafter
connector of FIG. 37 taken along the line 40-40. The outer
dimensions of the channel flanges 388 and 390 and web 396 (FIG. 35)
correspond closely with the inner dimensions of the cee-channel 526
so that when bolted together, they form a snug fit, yielding a
strong secure union.
[0131] FIG. 41 is a cross-sectional view of the post-rafter
connector of FIG. 37 taken along the line 41-41. The outer
dimensions of the channel flanges 376 and 374 and web 412 (FIG. 35)
correspond closely with the inner dimensions of the cee-channel 527
so that when bolted together, they form a snug fit, yielding a
strong secure union.
* * * * *