U.S. patent application number 13/568091 was filed with the patent office on 2012-11-22 for express framing system.
Invention is credited to Harry Gittlitz, Robert Schroeder, JR., Robert Schroeder, SR..
Application Number | 20120291378 13/568091 |
Document ID | / |
Family ID | 46583113 |
Filed Date | 2012-11-22 |
United States Patent
Application |
20120291378 |
Kind Code |
A1 |
Schroeder, SR.; Robert ; et
al. |
November 22, 2012 |
EXPRESS FRAMING SYSTEM
Abstract
A light steel framing construction technique for light gauge
load bearing wall type buildings uses specialized brackets to
suspend poured slab floors. Multiple stories of the building can be
erected without waiting for individual concrete slab floors to be
poured and set at each story. During construction, a building is
protected from torsional warping, such as may be occur under wind
loads, by a series of lateral and diagonal bracing structures at
each level affixed in a plane perpendicular to the load bearing
elements. Multiple concrete floor slabs can be poured sequentially
or simultaneously, as desired, during the construction process.
Inventors: |
Schroeder, SR.; Robert;
(Newburgh, NY) ; Gittlitz; Harry; (Spring Valley,
NY) ; Schroeder, JR.; Robert; (Walden, NY) |
Family ID: |
46583113 |
Appl. No.: |
13/568091 |
Filed: |
August 6, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11469528 |
Sep 1, 2006 |
8234827 |
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13568091 |
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Current U.S.
Class: |
52/236.8 ;
29/897.3; 52/742.14; 52/745.05 |
Current CPC
Class: |
E04B 2001/2415 20130101;
Y10T 29/49623 20150115; E04B 5/40 20130101; E04B 2001/2472
20130101; E04B 1/24 20130101; E04B 2001/2484 20130101 |
Class at
Publication: |
52/236.8 ;
52/745.05; 52/742.14; 29/897.3 |
International
Class: |
E04B 1/16 20060101
E04B001/16; E04G 21/02 20060101 E04G021/02; B21D 47/00 20060101
B21D047/00; E04B 1/00 20060101 E04B001/00 |
Claims
1. A method of erecting a building, comprising the steps of
locating vertically extending and oppositely facing walls to form a
set of joist supporting walls of a building, said joist supporting
walls having upper, load bearing surfaces; placing oppositely
located rigid suspended slab joist supporting brackets on said wall
upper surfaces; placing the ends of generally horizontal extending
joists on said rigid suspended slab joist supporting brackets; and
placing a sheet of slab decking on top of said joists, whereby said
decking is supported by said joists and whereby the weight of said
decking is borne by said joist supporting walls.
2. The method of claim 1 including the additional step of locating
a pair of oppositely placed rigid suspended slab deck support
brackets on top of a pair of vertically extending and oppositely
facing walls which are perpendicular to said joist supporting walls
and suspended slab joist supporting brackets.
3. The method of claim 1 including the additional step of bracing
the wall and joist assemblies to reinforce and rigidify said
assemblies and thereby inhibit relative twisting or warping by wind
or other forces.
4. The method of claim 3 wherein said bracing is reinforcing
stiffened strapping.
5. The method of claim 1 including the additional step of pouring a
layer of concrete on top of said decking to thereby form a floor
for the building.
6. The method of claim 1 wherein at least one joist supporting wall
is an exterior load bearing wall.
7. The method of claim 1 wherein at least one joist supporting wall
is an interior load bearing wall supporting symmetrical joist
supporting brackets on opposite sides of said interior wall.
8. The method of claim 1 including the additional step of erecting
a subsequent assembly of load bearing walls, suspended slab joist
and deck support brackets and suspended slab decking prior to the
pouring of one or more concrete slab floors.
9. A building constructed according to the method of claim 1.
10. A method of erecting a building, including the steps of
locating vertically extending and oppositely facing walls to form a
set of joist supporting walls of a building, said joist supporting
walls having upper load bearing locations for affixing oppositely
located rigid joist support angle brackets on said walls, placing
the ends of generally horizontal extending joists on said rigid
joist support angle brackets, placing a sheet of suspended slab
decking on top of said joists, whereby said decking is supported by
said joists and whereby the weight of said decking is borne by said
joist supporting walls.
11. The method of claim 10 including the additional step of
locating a pair of oppositely placed rigid slab deck support angles
parallel to said joists on vertically extending and oppositely
facing walls which are perpendicular to said joist supporting walls
and joist support angles.
12. The method of claim 10 including the additional step of bracing
the wall and joist assemblies to reinforce and rigidify said
assemblies and thereby inhibit relative twisting or warping by wind
or other forces.
13. The method of claim 12 wherein said bracing is reinforcing
stiffened strapping.
14. The method of claim 10 including the additional step of pouring
a layer of concrete on top of said decking to thereby form a floor
for the building.
15. The method of claim 10 wherein at least one joist supporting
wall is an exterior load bearing wall.
16. The method of claim 10 wherein at least one joist supporting
wall is an interior load bearing wall supporting symmetrical pairs
of joist supporting angle brackets on opposite sides of said
interior wall.
17. The method of claim 10 including the additional step of
erecting a subsequent assembly of load bearing walls, joist support
angle brackets, deck support angles and suspended slab decking
prior to the pouring of one or more concrete slab floors.
18. A building constructed according to the method of claim 10.
19. The method of claim 1 wherein said slab floor is eccentrically
suspended from said load bearing walls by means of a cantilevered
support bracket.
20. A method of producing stiffened strapping for use in
construction methods requiring reinforcement, comprising the steps
of de-coiling and flattening a work piece of unstiffened metal
strapping and applying at least one stiffening impression upon the
surface of said work piece, thereby forming a stiffening impression
along the length of said work piece.
21. A method as in claim 20 wherein said stiffening impression is a
flute-shaped impression having a concave arc-shaped impression on
one surface of said stiffened strapping and a complementary convex
arc-shaped impression on the opposite side of said stiffened
strapping.
22. A method as in claim 20 wherein said stiffening impression is a
v-shaped impression having a concave v-shaped impression on one
surface of said stiffened strapping and a complementary convex
v-shaped impression on the opposite side.
23. A method as in claim 20 wherein said stiffening impression is
applied along the centerline of said stiffened strapping work
piece.
24. A method as in claim 20 wherein two or more stiffening
impressions are applied symmetrically along the centerline of said
stiffened strapping work piece.
25. A method as in claim 24 wherein a pair of parallel stiffening
flutes are symmetrically disposed from the center line along the
length of said stiffened strapping.
26. A method as in claim 20 wherein one or more stiffening
impressions are applied parallel to and offset from said centerline
of said stiffened strapping work piece.
27. A method as in claim 20 wherein said stiffening impressions are
mechanically applied to said work piece by devices selected from
the group consisting of stamping, roll-forming and pressing
devices.
28. A method as in claim 20 wherein said stiffened strapping is
fabricated from a roll of steel strapping.
29. A method as in claim 20 wherein said steel strapping has a
galvanized coating.
30. A method as in claim 20 wherein the stiffened strapping has a
length of approximately 2 inches to 30 ft, a width of approximately
1.5 to 12 in and a thickness of approximately 30 to 70 mils.
31. A method as in claim 20, including the additional steps of
installing said stiffened strapping in a construction assembly
requiring reinforcement; and fastening said stiffened strapping to
said construction members to minimize unintended movement.
32. Stiffened strapping made in accordance with the method of claim
20.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of provisional patent
application Ser. No. 60/713,455, filed Sep. 1, 2005 by the present
inventors.
FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable
SEQUENCE LISTING OR PROGRAM
[0003] Not Applicable
[0004] BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] The present invention relates to new building structures and
to an improved method of building construction. In particular, the
invention provides improvements to light gauge steel framed
building construction techniques in load bearing applications.
[0007] 2. Prior Art
[0008] Light gauge steel framed buildings, such as mid-rise
buildings having up to about six stories in height offer
cost-effective construction and a number of additional advantages
including ease of construction as well as warp, fire, rust and pest
resistance.
[0009] Currently, mid-rise buildings, constructed with light gauge
steel stud bearing walls, and concrete slab floors use "Platform
Framing" methodology. Platform framing construction is that type of
building where the floor system rests directly above and upon the
walls below. Therefore, the continuation of the building erection
process depends entirely upon the pouring and curing of each
successive concrete floor. This method requires waiting for the
concrete floor to cure or set in order to support imposed loads
during further construction. Also, the poured slab floor must
attain enough surface hardness to resist damage. If the building is
constructed during winter conditions, providing temporary heat to
protect the curing concrete can be quite cumbersome and costly. The
problem of protecting concrete is exacerbated when the concrete is
open to the weather in the absence of enclosing walls and a ceiling
or roof above. Poured concrete which is subject to rain and wind
exposure can be easily damaged.
[0010] Waiting for the concrete to be poured and to attain optimum
structural properties interrupts the erection of the building
frame, and results in labor force disruptions and rescheduling
problems. The prompt return of work crews such as a displaced
carpentry work force can be problematic. Also, the efficient use of
construction equipment such as cranes is adversely affected by the
interruption of the framing process. Either the crane sits idle,
which is costly, or the crane leaves the site and its timely return
is as problematic as that of the other work crews.
[0011] Therefore, current construction methods result in the
interruption of the carpentry, plumbing, electrical and other
trades, and makes the pouring of concrete inefficient and subject
to inordinate delays.
OBJECTS AND ADVANTAGES
[0012] The express framing building construction system of the
present invention offers numerous advantages for the construction
of mid-rise buildings. The system can drastically reduce the time
required to construct the "shell" of a mid-rise building, perhaps
by as much as two thirds, by allowing the concrete floor slab to be
poured at any convenient time. Furthermore, the slab can be poured
in an enclosed area, protecting the un-cured concrete from rain and
wind. The system allows the un-cured concrete floor slab to be
heated more efficiently during cold weather and eliminates the need
for tenting or temporary shelter. During extreme weather
conditions, the pouring of the floor slabs can be postponed until
auxiliary heating no longer needs to be supplied.
[0013] The express framing system of the present invention is safer
because it allows the pouring of the concrete floor slab to be
performed in a safer, interior environment by providing actual
exterior walls to protect workers from falling from the
building.
[0014] The express framing system allows for the continuous
erection and framing of the building shell. The construction crews
do not have to wait for a slab to be poured or to sufficiently
harden before proceeding to the next story.
[0015] The express framing system eliminates the need for a pour
stop or projected edge on the floor framing. A pour stop is
necessary in conventional platform construction to cover retain the
concrete until it sets. The present method eliminates the need to
sheath the band of concrete at the edge of the slab.
[0016] The express framing system provides continuous walls and
also allows wall insulation to be vertically continuous throughout
the building; thereby insulating the so-called exposed "slab edge".
This method is energy efficient and provides a warmer floor.
[0017] The express framing system reduces the expenses incurred for
equipment and subcontracted services, such as cranes and
construction elevators and hoists, due to the reduction in the time
it takes to construct the building shell.
[0018] The express framing system provides a better connection
between the successive stories of walls because the walls are
connected directly to each other. This is especially advantageous
when connecting the building's walls together vertically. Here, the
elimination of bolts installed through a concrete slab is of
enormous value.
[0019] The express framing system allows the erection of a complete
building shell, properly braced against all gravity and lateral
loading conditions, without the pouring of the concrete floor
slabs. The concrete floor slabs can be poured at a time of the
construction managers choosing. The slabs can be poured under the
cover and protection of the floor system above (i.e., the slab
decking above) and the exterior sheathed walls. If necessary, the
slab can be heated within an enclosed building shell. The
continuous nature of the framing or erection of the building
results in much more scheduling control for the building
construction manager or contractor.
[0020] Other objects, features and advantages of the present
invention will be apparent upon consideration of the following
detailed descriptions and the accompanying drawings, which should
be construed as illustrative and not limiting.
SUMMARY OF THE INVENTION
[0021] A light steel framing construction technique for load
bearing type buildings is provided. Multiple stories can be erected
without waiting for individual concrete slab floors to be poured at
each story. The building under construction is protected from
torsional warping, such as may be expected under wind loads, by
installation of floor decking at each level. Additional torsional
or warp resistance may be provided by a series of lateral and
diagonal bracing structures at each level, affixed in the plane
perpendicular to the load bearing elements. Multiple concrete floor
slabs can be poured simultaneously upon the previously installed
metal decks, or, sequentially as desired, during the construction
process.
[0022] Walls, consisting of light gauge, cold formed steel studs
are erected on a foundation or other super-structure. The walls may
be sheathed with an appropriate sheathing product, and many types
are available. Such walls may be panelized off-site or framed at
the building site.
[0023] The express framing building construction system provides
several types of brackets for supporting joists and floor decking
These brackets are placed on or near the top of the load bearing
walls.
[0024] In one embodiment of the present system, joist support angle
brackets are affixed near the upper portion of parallel walls to
support conventional joist constructions running between such
walls. A second pair of walls perpendicular to the foregoing have
decking support angles affixed near the top of such walls. The
decking support angles are therefore parallel to the joists and
perpendicular to the joist support angle brackets. Both the
brackets and angles, in combination with the requisite joists, are
capable of supporting the floor decking The floor decking is
typically corrugated metal decking Additional bracing may be
utilized to reinforce the wall, bracket and joist sub-assembly.
Thereafter, the foregoing construction may be completed by pouring
a concrete slab floor at any desired time.
[0025] In another embodiment, the express framing building
construction system utilizes a combination of unique bracket
constructions including a suspended slab joist support bracket and
a suspended slab deck support bracket. The suspended slab joist
support brackets may be of an exterior-type or interior-type,
depending on the requirements of the building under construction.
In this context, the expression "suspended slab' refers to the fact
that the poured concrete floor does not rest directly on top of the
load bearing walls, as in conventional platform framing
construction. Rather, in the express framing system, the slab floor
is supported by the joists and decking in combination with the
unique angles and brackets disclosed herein.
[0026] In practice, floor joists are placed atop either the joist
support angle brackets or into the stirrups of the suspended slab
joist support brackets and fastened securely, such as by bolts that
utilize pre-drilled slotted holes in the brackets or stirrups.
[0027] Warp resisting or diaphragm bracing may be applied in
diagonal or other patterns and fastened across or below the floor
joists. Preferred bracing is comprised of reinforcing stiffened
strapping as will be discussed below. The bracing web ends are
fastened at each end and may be attached to light gauge steel clip
angles or other conventional fasteners. Additionally, the bracing
web may be intermittently fastened along its length to construction
members requiring reinforcement. For example, it may be applied to
the joist members to prevent twisting and swaying.
[0028] Similarly, lateral bracing may be applied perpendicular to
and across or below the bottom of the joists. Although the
preferred lateral bracing is stiffened strapping, conventional hat
channel may be used. The ends of the diaphragm bracing may be
attached to light gauge steel clip angles.
[0029] Thereafter, a roof or floor deck, usually a metal deck and
particularly a steel deck, is installed over the joists. The
decking is attached to the joists and to either the horizontal leg
of the suspended slab deck support brackets or to the alternative
decking support angle brackets.
[0030] In general, each building story is constructed of exterior
bearing walls, interior bearing walls, the floor system and the
decking In the present invention, each story is a self-contained
structural element capable of resisting all loads which it has been
designed to carry or resist, as a component of the building as a
whole. Once each story is framed with the present system, the next
higher story can be constructed. This is accomplished by erecting
the next higher set of walls directly above and resting on the
upper load bearing surface of the walls of the preceding lower
story. The process repeats itself until all stories of the building
have been framed or erected.
[0031] In such a system, scheduling the pouring of the concrete
floor slabs is discretionary. The framing and erection of the
building can be performed without interruption and independently of
the need to pour and cure the concrete slab floors.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is an illustration of a foundation upon which load
bearing walls are to be erected.
[0033] FIG. 2 depicts load bearing walls comprised of steel stud
framing and sheathing panels erected on the foundation.
[0034] FIG. 3 illustrates a suspended slab joist support bracket
having an upside-down L-shape, and including a welded stirrup to
receive a joist.
[0035] FIG. 4 illustrates a suspended slab deck support bracket
having a Z-shaped element, which receives the edges of the deck
sheathing and forms a seal for containing the eventual poured
slab.
[0036] FIG. 5 is a detail of a joist support stirrup.
[0037] FIG. 6 illustrates pairs of suspended slab joist support
brackets installed opposite each other, atop parallel load bearing
walls; and pairs of suspended slab deck support brackets installed
perpendicular to the joist brackets, atop the remaining walls.
[0038] FIG. 7 illustrates joist assemblies installed between the
suspended slab joist support brackets.
[0039] FIG. 8 illustrates diagonal or diaphragm bracing reinforcing
the structure before a suspended slab deck is laid down and a slab
floor is poured.
[0040] FIG. 9 illustrates additional reinforcement with lateral
bracing.
[0041] FIG. 10 illustrates metal decking which will receive a
poured slab installed atop the joists. In FIG. 10, the metal
decking is surrounded by two sets of parallel suspended slab joist
brackets and, parallel to these, two other sets of parallel
suspended slab deck support brackets, thereby creating a form or
mold for a poured slab deck.
[0042] FIG. 11 illustrates a second story of load bearing walls
erected atop the first story prior to the first deck slab being
poured. FIG. 11 also depicts the first slab deck or sheathing,
suspended from the first story load bearing walls.
[0043] FIGS. 12-13 illustrate construction details.
[0044] FIG. 14 depicts a cross-section of stiffened reinforcement
strapping, having arc-shaped flutes for added strength, and used
for lateral or diagonal bracing. FIG. 14a depicts a length of the
stiffened reinforcement strapping having continuous arc-shaped
flutes.
[0045] FIG. 15 is a detail depicting the attachment of the
stiffened bracing to a clip angle.
[0046] FIG. 16 is a detail depicting installation of a double or
interior type suspended joist saddle bracket installed atop an
interior load bearing wall.
[0047] FIG. 17 is a cross-section of an installed double or
interior type suspended joist saddle bracket construction
assembly.
[0048] FIG. 18 is a perspective view of a joist support angle
bracket.
[0049] FIG. 19 is a perspective view of a reinforced joist support
angle bracket.
[0050] FIG. 20 is an elevation view of a joist support angle
bracket installed on stud framing and securing a joist seen in
cross-section.
[0051] FIG. 21 is a cross-section of a joist support angle bracket
installed on stud framing and securing a joist and decking
assembly, also seen in cross-section.
[0052] FIG. 22 is a cross-section of a decking support angle
bracket installed on stud framing and securing a decking assembly,
also seen in cross-section.
[0053] FIG. 23 is a cross-section depiction of prior art platform
framing.
DETAILED DESCRIPTION AND PREFERRED EMBODIMENTS
[0054] The express framing construction system provides a method of
erecting a building, and includes the steps of locating vertically
extending and oppositely facing walls to form a set of joist
supporting walls of a building, the joist supporting walls having
upper load bearing surfaces; placing oppositely located rigid
suspended slab joist supporting brackets on the wall upper
surfaces; placing the ends of generally horizontal extending joists
on the rigid suspended slab joist supporting brackets; and placing
a sheet of slab decking on top of the joists. The decking is
supported by the joists and the weight of the decking is borne by
the joist supporting walls. In an alternative method, the suspended
slab joist supporting brackets are replaced with joist support
angle brackets affixed to load bearing elements of the joist
supporting walls.
[0055] The method may include the additional step of locating a
pair of oppositely placed rigid suspended slab deck support
brackets on top of a pair of vertically extending and oppositely
facing walls which are perpendicular to the joist supporting walls
and the suspended slab joist supporting brackets. Alternatively,
the slab deck support brackets may be replaced with lengths of slab
deck support angles attached to the upper region of the
perpendicular walls.
[0056] An additional step of bracing the wall and joist assemblies
to reinforce and rigidify the assemblies and to inhibit relative
twisting or warping by wind or other forces may be used. The
bracing is preferably the reinforcing stiffened strapping described
below.
[0057] Thereafter, the method may continue with the additional step
of pouring a layer of concrete or similar floor material on top of
the decking to thereby form a floor for the building.
[0058] The method works equally well with either exterior or
interior load bearing walls.
[0059] An interior load bearing wall will support symmetrical joist
supporting brackets on opposite sides of the interior wall.
[0060] The method may include the additional step of erecting a
subsequent assembly of load bearing walls, suspended slab joist and
deck support brackets and suspended slab decking prior to the
pouring of one or more concrete slab floors. A building constructed
in accordance with the foregoing method is thereby provided.
[0061] In the express framing system, a building sub-assembly
includes a lower set of vertically extending walls, an upper set of
vertically extending walls, the upper set of walls resting on the
lower set of walls, a bracket affixed to the lower walls, the
bracket having a cantilever portion extending away from its
corresponding lower wall panel, a horizontal joist extending from
and having one end supported by the cantilever bracket portion, a
generally horizontal decking lying atop and supported by the joist,
whereby concrete may be poured at any time on the decking to form a
concrete floor. This sub-assembly may include a second sub-assembly
mounted on top of the first mentioned sub-assembly, thereby
yielding two vertically spaced horizontal deckings, the respective
walls of the two building sub-assemblies being coplanar, and
whereby concrete may be poured on the two spaced horizontal
deckings sequentially or simultaneously.
[0062] The construction method of the present invention utilizes a
number of unique components in combination with conventional
building materials. The conventional components typically include
light gauge steel stud walls, sheathing, floor and roof joists,
steel roofing and floor decking, and miscellaneous light gauge
steel framing accessories such as angles, fasteners, clips, etc.
Fasteners are generally selected as appropriate from among
conventional screws, rivets and nut, bolt and washer
assemblies.
[0063] In one embodiment, the first unique element utilized in the
express framing system of this invention is a suspended slab joist
support bracket. It may be of an exterior or interior type. This
bracket is for the support of the floor joists which subsequently
support the decking and poured slab. It is characterized herein as
a "suspended slab" joist support bracket because, unlike
conventional platform framing methods, the slab flooring is not
installed atop the load bearing walls. Thus, the bracket supports
or hangs the joists so that the load on the joist is eccentric to
the centerline of the wall that is carrying the joist load. This
bracket may form a continuous support for the floor joists and
readily provides automatic "on center" distance locations for the
placing of the joists.
[0064] The eccentricity of the joist support allows the walls for
successive stories to be placed on and fastened to the walls
directly above and below each other. And unlike conventional
platform framing mentioned above, construction of successive
stories need not await the pouring and curing of concrete slab
flooring. Rather, sufficient warp and twist resistance is provided
by installation of the joist support brackets, the joists, the
floor decking, and any bracing material which is utilized.
[0065] The suspended slab joist support bracket 8 of FIG. 3 is an
inverted L-shape having a horizontal and vertical leg with a formed
"stirrup" welded to the vertical leg. The stirrup is located at the
"on center" points of a load bearing wall and receives the floor
joists. The stirrup is located below the horizontal leg of the
bracket at a distance which equals the thickness of a subsequently
poured concrete slab. The vertical face of the bracket acts as a
leveling screed or pour stop to prevent the liquid slab concrete
from exiting the desired area. The distance from the top of the
bracket to the stirrup can be varied to achieve different results.
Matching a desired slab depth with a specific stirrup location
represents a typical application for bracket 8.
[0066] In this embodiment, the suspended slab joist support bracket
8 is fastened through the vertical leg of the bracket to a track
atop the conventional metal studs of a bearing wall. Fastening the
bracket through the vertical leg allows the coplanar wall for the
next story to rest on an upper load bearing surface that is flat
and free from projections such as screws. The wall of the story
above is fastened through its bottom track, the horizontal leg of
the bracket and the top track of the wall below. The horizontal leg
of the bracket is the same width as the metal stud bearing wall
upon which it rests.
[0067] In this first embodiment, a second unique element of the
express framing system is an interior-type slab joist support
bracket. This bracket is used on interior load bearing walls. If
this bracket is made as an integral unit, stirrups are welded on
both sides of an inverted U-shaped element. It is preferred
however, that instead of a single integral interior bracket, a pair
of symmetrical half-units will be used as described below. The
vertical legs of the bracket face downward, and the horizontal leg
rests on top of the upper track of the bearing wall. The interior
bracket is otherwise similar to the exterior joist support
bracket.
[0068] Also in this embodiment of the express framing building
construction system, another unique element utilized is a suspended
slab deck support bracket. These brackets are for the support of
the metal decking at those of its perimeter edges which are
perpendicular to those decking edges which are supported by the
suspended slab deck support brackets. The bracket supports the edge
of the metal decking and is located parallel to the direction of
the floor joists. It forms a continuous support for the decking and
also provides an automatic ledger for the slab, where no additional
measuring is required.
[0069] The suspended slab deck bracket is a Z-shaped steel element
having upper horizontal, vertical and lower horizontal legs. An
upper horizontal leg sits on top of the wall, the vertical leg
equals the depth of the concrete slab, and the lower horizontal leg
supports the metal decking. The horizontal leg that supports the
decking is typically about 2 in. wide. The upper horizontal leg
equals the width of the bearing wall. The vertical face of the
bracket also acts as a pour stop to prevent the liquid slab
concrete from exiting the desired area.
[0070] The suspended slab deck bracket is fastened through the
vertical leg of the bracket to the upper portion of the metal studs
or top track of the bearing wall. Fastening the bracket through the
vertical leg allows the wall for the next story to rest on a
surface that is flat and free from projections such as screws. The
wall of the story above is fastened through its bottom track, the
horizontal leg of the bracket and the top track of the wall below.
The upper horizontal leg of the bracket is the same width as the
metal stud bearing wall upon which it rests. The suspended slab
deck support brackets are installed on the walls that are parallel
to the floor joists.
[0071] In an alternative embodiment of the express framing building
construction system, the suspended slab joist support brackets may
be replaced with joint support angle brackets which are affixed
near the top of the bearing walls which support the joists. In this
embodiment, deck support angles may be utilized and affixed near
the top of the perpendicular walls, to receive and support the
floor decking Both such sets of brackets, in combination with the
joist system and bracing, support the floor decking and the
subsequently poured slab.
[0072] In both of the foregoing embodiments, and in contrast to
conventional platform framing, the decking is suspended from,
rather than resting upon, the load bearing walls.
[0073] Building constructions typically require the addition of
reinforced bracing members. As currently used and produced,
conventional flat light gauge steel strapping is quite elastic,
unstable when handled improperly, and is subject to damage because
it cannot support its own weight when held horizontally. Currently,
it requires two carpenters to stretch flat strapping across floor
and roof joists.
[0074] A further unique element of the present system is stiffened
strapping for lateral or diagonal bracing. Light gauge steel
strapping may be stiffened by forming one or more continuous
stiffening impressions, or beads, parallel to the long dimension of
the strap. Stiffening impressions, such as flutes, enable the
strapping to be easily handled. The flutes greatly add to the
rigidity and structural properties of the strapping.
[0075] The stiffened strapping provided herein may be used in a
wide variety of applications requiring enhanced reinforcement. It
is particularly useful in the subject express framing construction
method where, when installed below the suspended joists and secured
thereto, it serves to prevent swaying and twisting of the hanging
joists.
[0076] The stiffened strapping may be used for lateral or diagonal
bracing and is preferably formed from a coil of steel, which is
preferably galvanized steel conforming to the requirements of ASTM
A 653, having a yield strength of 33 or 50 ksi and a minimum of
G-60 galvanized coating. For convenience in handling, the steel
coil is decoiled and flattened by conventional means before the
stiffening impressions are imparted.
[0077] The stiffening impressions may be applied to any length of
coil but generally the dimensions of the strapping will be selected
in accordance with the specified construction requirements and ease
of handling. A typical installation will utilize 12 foot lengths of
stiffened strapping having dimensions of about 2 in width and
thickness of 54 mils (16 gauge). In other applications, lengths
from about 2 in to 30 feet may be used as required and the width of
the strapping may vary from about 1.5 in to 12 in while the
thickness may vary from about 30 to 70 mils.
[0078] One or more stiffening impressions are imparted to the web
by conventional mechanical metal pressing, rolling or stamping. Hot
or cold methods may be utilized as appropriate.
[0079] The preferred stiffening impressions are flute-shaped
impressions, but other shapes may be utilized depending upon the
chosen methods of fabrication. It should be possible, for example,
to create a v-shaped stiffening impression which ought to function
similarly in appropriate applications. All such shapes and channels
effective for stiffening the strapping are contemplated for use as
the stiffening impressions. The preferred flute-shaped stiffening
impressions are generally semi-circular in shape since an arc is
readily impressed during fabrication.
[0080] The flutes are generally centered along the length of the
strapping, or symmetrically oriented from the center line when more
than a single flute is utilized. It will be recognized, however,
that the stiffening flutes may be offset from the center if a
larger flat edge of the strapping is required for some other
function, such as securing an edge along its length.
[0081] A single stiffening impression such as a flute can be
effective in some applications, especially less critical
applications or where strapping lengths are minimized. Three or
more stiffening impressions can be used for longer lengths of
stiffened strapping or where applications will benefit from
additional stiffening strength. In the subject express framing
construction system, a pair of parallel flutes was impressed upon
the stiffened strapping and these were found to be
satisfactory.
[0082] The stiffened strapping can be readily cut to order in the
fabricator's shop and transported in flat bundles to a worksite. At
the worksite, the stiffened strapping is readily installed using
conventional fasteners including machine and metal screws, bolts,
etc. Rivets could be utilized but are no longer a popular
choice.
IN THE DRAWINGS
[0083] FIG. 1 illustrates a concrete or masonry foundation 1A
having a flat surface 1 upon which load bearing walls are to be
erected. An outline of the location of an alternative steel beam
bearing 2 is also indicated by the dotted lines.
[0084] FIG. 2 depicts panelized load bearing walls 5 comprised of
steel stud framing 6 and sheathing panels erected on surface 1 of
foundation 1A.
[0085] FIG. 3 illustrates a rigid suspended slab joist support
bracket 8 having an inverted L-shape, and includes a welded-thereto
joist stirrup 9 to receive the joists. The joist stirrup 9 is
generally U-shaped, as detailed in FIG. 5. The bracket 8 also
includes pre-drilled holes 10, while a rear edge of bracket 8 is
denoted as 11. The horizontal width of the top surface of bracket 8
is denoted as 12 and matches the upper load bearing surface of a
wall upon which it is installed. The downward width of bracket 8 is
denoted as 13 and varies with the desired depth of the poured slab
flooring. In this figure, the on-center distance between
later-installed studs is denoted as 14. The bracket is fastened to
thee vertical studs with screws through pre-drilled holes 10.
[0086] FIG. 4 illustrates a rigid suspended slab deck support
bracket 20 which is generally Z-shaped, and which receives the
edges of the deck sheathing and forms a seal for the later poured
concrete slab. Slab deck support bracket 20 includes pre-drilled
holes 21. The later-installed stud on-center distance is denoted as
22. A horizontal rear edge of bracket 20 is denoted as 23. The slab
deck support bracket 20, placed atop a wall parallel to the joists,
has a first or upper horizontal edge or width 24, a vertical edge
25, and a second or lower horizontal edge or width 27. Deck support
lip 26 lies in a horizontal plane.
[0087] FIG. 5 is a detail of a joist support stirrup 9 of FIG. 3.
Reference numeral 9 denotes a joist stirrup which in this
embodiment has typical dimensions of 4 in by 3 in by 2.5 in.
Reference numeral 9a denotes either of two vertical side portions,
while 9c denotes a flat, cantilever portion. Pre-drilled attachment
holes 10 are in a vertical portion of 8, while the stirrup 9 is
welded at 30 to provide a slab joist support. Crimped reinforcing
ribs 32 are provided on the outside walls of stirrup 9.
Pre-drilled, elongated holes 33 are provided at the bottom, flat
portion of the stirrup.
[0088] FIG. 6 illustrates several suspended slab joist support
brackets 8 installed in pairs opposite each other, atop parallel
load bearing walls, and also includes several suspended slab deck
support brackets 20 installed perpendicular to the slab joist
support brackets and atop the remaining walls which run
lengthwise.
[0089] FIG. 7 illustrates several joist assemblies 40 installed
between the suspended slab joist support brackets 8, the joist ends
resting in respective stirrups 9. Each joist may include a lower
strut 40a such as may be utilized for supporting a suspended
ceiling or to affix reinforcing bracing. The bracing may be
stiffened strapping described herein.
[0090] FIG. 8 illustrates several diagonal bracing members 55
reinforcing the structure before a deck and concrete slab are
installed. Such bracing is preferably stiffened strapping which is
fastened to conventional clip angle 50.
[0091] FIG. 9 illustrates additional reinforcement with lateral
bracing 60, the latter attached to respective pairs of opposite
walls 5. Again, the preferred bracing is stiffened strapping.
[0092] FIG. 10 illustrates decking 65 which is usually corrugated
metal decking and which is installed atop underlying joists and
which will receive a poured slab on top thereof. The decking is
peripherally surrounded by slab joist brackets 8 and slab deck
support brackets 20 to create a form or mold for the poured slab
deck. The concrete may be poured at any convenient time on decking
65.
[0093] FIG. 11 illustrates the construction of a second story 67A
atop a lower load bearing first story 67. The first and second
stories are comprised of wall sections 5 and 5A, respectively. The
walls are sheathed with conventional sheathing panels or sections.
Decking 65 is ready to receive concrete to form a poured slab deck.
The illustrated second or upper story 67A utilizes steel stud
framing 6A interior to the sheathing panels which together comprise
the load bearing wall construction which supports any subsequent
stories.
[0094] FIG. 12 is a cross-section of the suspended slab joist
support bracket 8, taken along 12-12 of FIG. 11, installed between
lower wall 70 and upper wall 70a and secured with screw fasteners
71. For clarity, seams 75A and 76A are exaggerated. Fluted metal
decking 65 supports poured concrete deck slab 66. An end of a joist
40 is inserted into joist stirrup 9 and secured with bolt, nut and
washer assembly 73. One end of joist 40 is supported by cantilever
portion 9c of stirrup 9.
[0095] FIG. 13 is a cross-section detail of the suspended slab deck
support 20 installed between lower light gauge wall 72 and upper
light gauge wall 72a and secured through wall tracks 77 and 78 with
screw fasteners 71. Seams 77A and 78A are exaggerated for clarity.
It will be noted that the suspended slab deck support 20 and walls
72 and 72a depicted in FIG. 13 are perpendicular to walls 70 on 70a
and suspended slab joist support 8 illustrated in FIG. 12. Also
depicted in FIG. 13 is concrete decking slab 66 poured atop metal
decking 65.
[0096] FIG. 14 depicts a cross-section of a stiffened reinforcement
strapping 80, the latter provided with continuous and parallel
stiffening impressions which in this embodiment are flutes 81 and
82. The stiffened strapping used for the lateral and diagonal
bracing is seen for example as diagonal bracing 55 in FIG. 8 and
lateral bracing 60 in FIG. 9. The strapping width in this figure
has a width of about 2 inches. FIG. 14A is a perspective view of
the stiffened reinforcement strapping 80, further illustrating its
parallel strengthening flutes, 81 and 82. Holes 85 may be used to
fasten the stiffened strapping.
[0097] FIG. 15 is a detail depicting the attachment of lateral
bracing 80 to clip angle 50. Diagonal bracing is similarly
attached. Fasteners 71 pass through preformed openings to secure
the bracing to the angle. Conventional fasteners, clip angles,
screws and the like are selected as may be appropriate in a given
application.
[0098] FIG. 16 is a detail perspective depicting installation of an
interior-type suspended slab joist saddle bracket 83 installed atop
an interior load bearing wall 84. The saddle bracket may be a
single, symmetrical unit or may be comprised of a pair of
symmetrical half-units as illustrated in FIGS. 16 and 17. In either
case, joists hang on opposite sides of interior load bearing wall
84. The joists are herein depicted with struts 79 and lower joist
tracks 40A.
[0099] FIG. 17 is a cross-section showing symmetrical interior
suspended joist saddle brackets 83 installed atop an interior load
bearing wall 84. It will be observed that lower wall 84 and upper
wall 84A of FIG. 17 are substantially coplanar. That is, each lies
in the same vertical plane. This also the case for walls 70 and 70A
of FIG. 12, and for walls 72 and 72A of FIG. 13. In FIG. 17, joists
40 are secured to brackets 83 by nut and bolt assemblies 73.
Corrugated decking 65 and poured slab 66 are shown. Bearing walls
84 and 84A are capped with tracks 85 and 86 and secured with screw
fasteners 71.
[0100] In an alternative embodiment of the present invention, the
suspended slab joist support brackets described above may be
replaced with joist support angle brackets. FIG. 18 is a
perspective view of a joist support angle bracket 100 having holes
102 for fastening a joist to bracket 100, typically via a bolt, nut
and washer assembly. In the figure, bracket 100 also has holes for
fastening the bracket to the top track of a bearing wall or stud.
Holes 104 may receive bolts or other fasteners but will typically
utilize screws for securing brackets 100 to the track or studs.
[0101] FIG. 19 is a perspective view of an alternative reinforced
joist support angle bracket 101 additionally having reinforcing
member 101A. Reinforcing member 101A is typically a metal wedge
welded in placed or forged in the initial fabrication of the
bracket.
[0102] FIG. 20 is an elevation view of joist support angle bracket
100 installed with fasteners 140 on left and right stud framing
members 105 and 105A. In this embodiment, fasteners 140 may be
metal screws. In this figure, left and right portions of a joist
section 109 and 109A are seen in cross-section and are secured to
joist support angle bracket 100 by nut, bolt and washer assemblies
107 and 107A.
[0103] Construction details for installation of a joist support
angle bracket and related assemblies are shown in FIG. 21. Joist
support angle bracket 100, shown in cross-section, is installed on
lower wall stud framing member 110 and secured thereon by fasteners
140. The vertical portion of this bracket may be a 4 in by 5 in
flange which attaches to the studs with six 5/16.sup.th in screws.
The horizontal joist ledger portion of the bracket can attach the
joist seat with 1/2 in bolts which are 31/2 in on-center. In this
detail, joist members 150, 152 and 154 are shown in cross-section.
The joist is secured to joist support angle bracket 100 by bolt 130
having bolt head 138, washers 134 and 136, and nut 132. A
cross-section of corrugated decking 156 is shown atop joist portion
154. In this figure, concrete decking slab 158 has been poured atop
deck sheathing 156.
[0104] In this construction, lower framing member 110 is capped
with upper rail 111 shown in cross-section and supports upper
framing member 112 and its associated lower rail 113. These framing
members are preferably metal framing studs having conventional
framing hardware. These upper and lower members are securely
fastened, as by screws 114. In this figure, exaggerated seam 119 is
shown only for clarity between the sections. In practice, the seam
is eliminated when the upper and lower sections are secured
together. Lower and upper sheathing panels 116 and 118 are depicted
in cross section on the vertical wall panel opposite the joist. It
will be understood that the concrete slab decking is poured up to
the wall members, but not between them. Sheathing panels 116 and
118 may be gypsum board or other suitable panelized sheathing
product.
[0105] Construction details for installation of a deck support
angle and related assemblies are shown in FIG. 22. Deck support
angle 160, shown in cross-section, is installed on lower wall 110'
and secured thereon by fasteners 145 which may be metal screws. In
this detail, decking 162 is shown in cross-section. The suspended
slab deck support angle is continuous conventional angle, e.g. 3 in
by 3 in, trimmed to suitable lengths for ease of handling and
effective for supporting the edge of the suspended decking and
acting as a pour stop for the concrete floor. The decking is
secured to deck support angle 160 by fastener 145. In this figure,
concrete decking slab 158 has been poured atop deck sheathing 162.
In this construction, as in FIG. 21, lower framing member 110' is
capped with upper rail 111' shown in cross-section and which
supports upper framing member 112' and its associated lower rail
113'. These upper and lower members are securely fastened, as by
screws 114. In this figure, exaggerated seam 147 is shown only for
clarity between the sections. In practice, the seam is tight and
essentially eliminated as the upper and lower sections are secured
together. Lower and upper sheathing panels 116' and 118' are here
depicted in cross section on the vertical wall panel opposite the
decking 162 and deck support bracket 160. In this embodiment,
sheathing panels 116' and 118' are gypsum board. Once again it will
be understood that the concrete slab decking is poured up to the
wall members, but not between them as is the case in prior art
constructions.
[0106] FIG. 23 is a cross-section of a prior art platform framing
construction including exterior sheathing a, an upper load bearing
wall b, a lower load bearing wall c, a concrete deck d, a joist
hanger e, and a joist f. It is noteworthy that in such a
construction, the poured slab floor d is located between the upper
and lower load bearing walls b and c and therefore must be
installed prior to construction of the upper walls. FIG. 23 shows
that each concrete floor d must be poured and set prior to the
formation of the next and, above, story. In stark contrast, the
present invention permits all of the concrete floors to be poured
at the same time, or as may be optimally desired.
[0107] The express framing system provides buildings comparable to
those provided by other light gauge steel methods, such as the
aforementioned platform framing technique. For example, such a
building may have one or more load bearing quadrilaterals of about
100 ft by 100 ft. In such a building, an interior load bearing
quadrilateral section might then be 50 ft by 100 ft. The typical
height per story is 10 ft. The typical number of stories is 2 to 4,
with 6 stories being the maximum for this type of light gauge steel
mid-rise construction. Additionally, the joists run either
lengthwise or widthwise, as the structure design dictates.
[0108] Specifications for construction members and hardware are
typical of light gauge steel framing techniques. The preferred
grades of steel vary with the parts and application. For example,
the specification for joists, joist brackets, decking hangers,
decking, support fixtures and other rolled structural steel shapes
is ASTM A572. The specification for structural steel plates and
items made from such plates is ASTM A36. The specification for
structural steel tubes is A500 Gr. B. The specification for cold
formed light gauge steel, used for the stiffened strapping, is ASTM
A653 with yield strength of 33 ksi or 50 ksi, and galvanized to a
G-60 coating as per ASTM C955. The specification for bolts, joints,
fittings, etc. is ASTM A325 TC, with hardened nuts & washers.
In typical applications, any grade or type of concrete slab would
be suitable.
* * * * *