U.S. patent application number 15/299234 was filed with the patent office on 2017-05-04 for construction method to reinforce masonry walls with wood.
The applicant listed for this patent is Youxuan Jin. Invention is credited to Youxuan Jin.
Application Number | 20170121958 15/299234 |
Document ID | / |
Family ID | 58635372 |
Filed Date | 2017-05-04 |
United States Patent
Application |
20170121958 |
Kind Code |
A1 |
Jin; Youxuan |
May 4, 2017 |
Construction Method to Reinforce Masonry Walls with Wood
Abstract
This disclosure relates to masonry construction of residential
houses using prefabricated masonry panels or blocks, such as
Autoclaved Aerated Concrete (AAC) panels or Concrete Masonry Units
(CMU). Unlike existing masonry construction methods, this masonry
structure is reinforced by common wood studs as join keys. All wood
studs are individually strap-tied directly to the foundation and
horizontally bound together to form a network of cells enclosing
masonry blocks throughout the entire building. Considerations are
given to prevent wood studs absorbing moisture from masonry
material.
Inventors: |
Jin; Youxuan; (Bellevue,
WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Jin; Youxuan |
Bellevue |
WA |
US |
|
|
Family ID: |
58635372 |
Appl. No.: |
15/299234 |
Filed: |
October 20, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62249327 |
Nov 1, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04B 2001/2684 20130101;
E04B 2/562 20130101 |
International
Class: |
E04B 1/04 20060101
E04B001/04; E04B 2/28 20060101 E04B002/28; E04B 1/26 20060101
E04B001/26; E04B 1/41 20060101 E04B001/41 |
Claims
1. A tie-down method in house construction that anchors an entire
building to an array of .OMEGA.-shaped metal rails, which are
embedded in the foundation concrete during pouring with the upper
portion exposed as rings on the foundation top surface, and further
comprising a method that ties the wood studs of walls and floor
joists of the building directly to the exposed part of metal rails
using metal connecting straps and their required nails and
bolts.
2. The method in claim 1 wherein said .OMEGA.-shaped rails are made
from construction steel rebar.
3. A masonry wall construction method that reinforces stack-bound
masonry blocks with wood studs as join keys, and further
comprising: a. a method that connects common wood building
components, such as wood stud walls, windows, doors, lintels, floor
joists, etc., to said masonry wall by anchoring on said wood stud
keys, and b. a horizontal band or the roof wall band, named the top
rail in drawings, that is made of either steel rebar or wood studs
connected by metal straps, and circulates said house wall structure
and straps together said stud keys and hence said blocks.
4. The method in claim 3 wherein said masonry block has four sides:
exterior, interior, left and right side, and two surfaces, top and
bottom surface, and the block shape further comprising, a. a
vertical concave groove in at least one of the four side to
receive, enclose, and interlock with said stud keys in claim 3, and
b. said concave groove that secures said stud key between its two
shoulders, a primary shoulder and a secondary shoulder, where the
secondary shoulder is lower than the primary shoulder exposing said
stud key at one side of the joint, and c. said concave groove that
is tapered-in toward the bottom and has rounded corners or bumps at
the bottom to retain gaps between said blocks and said keys in
claim 3, and d. a mean to keep said wood stud keys dry by filling
the said gaps on the primary shoulder side with moisture-barrier
material, and by keeping the gap on the secondary shoulder side
either open to air flow or covered with only breathable materials
to allow moisture in said keys vaporizing.
5. The method in claim 3 wherein said masonry blocks are aerated
autoclaved concrete panels or blocks.
Description
PROVISIONAL APPLICATION NO.
[0001] 62/249,327
Intl. CI
[0002] E04B 1/04, E04B 1/02, E04B 1/06, E04B 1/08, E04B 1/10, E04B
1/12, E04B 1/043, E04B 2103/02,
E04B 2001/2463, E04B 2001/268, E04B 2001/2684,
E04C 1/00, E04C 1/40, E04C 5/07, E04C 5/12, E02d 27/34.
US CI
[0003] 52/293.3, 52/204.1, 52/274, 52/250, 52/295, 52/309.1,
52/309.3, 52/309.4, 52/396.08, 52/426, 52/433, 52/565, 52/578,
52/581, 52/582.1, 52/586.1, 52/589.1, 52/698,
Search CI
[0004] 52/293.3, 52/204.1, 52/274, 52/250, 52/295, 52/309.1,
52/309.3, 52/309.4, 52/396.08, 52/426, 52/433, 52/565, 52/578,
52/581, 52/582.1, 52/586.1, 52/589.1, 52/698,
REFERENCES
TABLE-US-00001 [0005] 8,297,021 Jan. 25, 2010 La Luz 6,629,393 Oct.
7, 2003 Pignataro 6,195,955 Mar. 6, 2001 Kostopoulos 5,881,524
March 1999 Ellison, Jr. 9,133,619 September, 2015 Roberts 9,068,581
Jun. 30, 2015 Fleming 8,893,450 Nov. 25, 2014 Zohar 9,267,260 Feb.
23, 2016 MacDonald 4,343,125 Aug. 10, 1982 Shubow 4,219,978 Sep. 2,
1980 Brown 5,033,248 Jul. 23, 1991 Phillips 9,234,349 Jan. 12, 2016
Daiber 7,958,687 Jun. 14, 2011 Dilorenzo 6,955,016 Oct. 18, 2005
Churches 9,097,000 Aug. 4, 2015 Espinosa 5,685,115 Nov. 11, 1997
Colfer
OTHER PUBLICATIONS
[0006] 101. Zhe Qu. et al., Seismic Damage of Masonry Infilled
Timber Houses in the 2013 M7.0 Lushan Earthquake in China,
Earthquake Spectra August 2015, Vol. 31, No. 3 (August 2015) pp.
1859-1874
(http://earthquakespectra.org/doi/abs/10.1193/012914EQS023T) [0007]
102. Anna Brignola. et al., Experimental Evaluation of the In-Plane
Stiffness of Timber Diaphragms, Earthquake Spectra November 2012,
Vol. 28, No. 4 (November 2012) pp. 1687-1709
(http://earthquakespectra.org/doi/abs/10.1193/1.4000088) [0008]
103. Hu Shiping, The Earthquake-Resistant Properties of Chinese
Traditional Architecture, Earthquake Spectra August 1991, Vol. 7,
No. 3 (August 1991) pp. 355-389
(http://earthquakespectra.org/doi/abs/10.1193/1.1585633) [0009]
104. Andreea DUTU. et al., Components interaction in timber framed
masonry structures subjected to lateral forces, Journal of Civil
Engineering Research 2012, Vol. 13 No. 1
(http://www.jourlib.org/paper/2944338#.Vk-fav6FOz1) [0010] 105.
Joa{tilde over ( )}o Azevedo. et al., Seismic Behavior of Blocky
Masonry Structures, Earthquake Spectra May 2000, Vol. 16, No. 2
(May 2000) pp. 337-365
(http://earthquakespectra.org/doi/abs/10.1193/1.1586116)
BACKGROUND OF THE INVENTION
[0011] Field of Invention
[0012] This subject disclosure relates to house construction with
prefabricated masonry building blocks reinforced by common wood
studs instead of metal.
[0013] Discussion of Prior Art
[0014] There are generally two types of masonry constructions,
using blocks, such as Cement Masonry Unit (CMU), and using panels,
such as Autoclaved Aerated Concrete (AAC) panels.
[0015] The challenge in block construction is how to reinforce it.
A lot of practice and inventions exist [U.S. Pat. Nos. 5,881,524,
6,629,393, 8,297,021, 8,893,450, 9,133,619, 9,267,260]. They all
use various forms of metal, such as rebar, prefabricated plate or
brackets, or threaded rods and bolts. Metals are either
prefabricated into masonry blocks or buried among block seams
during. Their construction costs are high due to the high material
cost, need of skilled worker, long building duration, and
inflexibility to customize or extend.
[0016] Prefabricated wall panels are generally more efficient to
use than blocks. They mostly have special peripherals and embedded
metal couplings hardware designed to structurally interface and
bind with adjacent panels [U.S. Pat. Nos. 4,219,978, 4,343,125,
5,033,248, 6,955,016, 7,958,687, 9,068,581, 9,097,000, 9,234,349].
They are hard to cut on site for customization if ever allowed. So,
they are ideal only for large buildings with fewer variations, such
as factories or warehouses. They are generally more expensive too
because, in part, the panel manufacturer has monopoly on all the
building materials and process.
[0017] Other type of panels are on-site cut-able plain panels.
Examples are AAC panels from Hebel Inc (http://www.hebel-usa.com)
and AerCon AAC (http://www.aerconaac.com/). Those plain panels,
such as AAC panels are structurally bound together by applying
special straps, nails and corrugated nails, and with special mortar
or glues. Panels are tied down by foundation straps, or metal
tracks precision-mounted on foundation. Special masonry nails are
directly applied into the panels for binding. But unlike nails in
wood, nails into such panels are subject to loosening due to micro
movements or temperature fluctuation. Nails also cause local stress
to the panel.
[0018] In summary, all the existing masonry constructions practices
and inventions rely on metal connectors, one way or the other, to
achieve structural support to mitigate the brittle character of
masonry.
[0019] This disclosure uses wood studs, instead of metal, in
masonry construction. It provides a solution to couple together two
materials of different characters and takes advantage of both
materials and lower the overall construction cost.
SUMMARY OF THE INVENTION
Objective Overview
[0020] Masonry houses resist to fire, water and moisture, which are
especially critical in the light of recent frequent flooding and
forest fires. Other advantages are its durability, low maintenance,
insect resistance, acoustic break, and environment
friendliness.
[0021] The disadvantages of masonry houses, comparing with wood
frame house, are the high construction cost, especially in US,
where timber products are inexpensive and wood stud houses are
easier to meet stricter earthquake building codes.
[0022] This disclosure is a masonry construction method that
combines wood structure into masonry construction to take
advantages of both materials, lower the overall construction cost,
and still meet the earthquake-proof requirement in US.
[0023] The scope of the disclosure relates to AAC and CMU
construction and including a profile shape design of the masonry
blocks. We will not distinguish the terms panels and blocks in the
rest of this discussion unless being called out in the context.
They both have the same profile shape vary only in height.
[0024] In this method, walls are built in stack bound pattern. Each
stack column can be a stack of CMU blocks, AAC blocks, or one AAC
panel. Each column is joined on its sides by wood stud as keys with
adjacent columns. The blocks have distinct vertical grooves at
sides to receive the wood keys. All keys are strap-tied directly
and individually to the foundation and extended upward to the upper
floor to increase the integrity of the structure vertically between
floor levels.
[0025] All stud keys are further horizontally connected by bands of
metals or wood studs, which acting like the hoops on a wine barrel,
to hold the house together at various elevated levels. The one on
top of the wall is called top rail, which serves as the tie-down
anchor for the roof or upper floor level wall.
[0026] Other house elements, such as windows, doors, floor joists,
lintels, stairs, and even stud walls, can easily anchor to the wood
stud keys with typical wood connections.
[0027] The entire construction is still masonry dominant but with
wood keys embedded inside the masonry blocks. The wood keys and the
masonry blocks are bound together by soft-based construction glue,
which also combined with waterproof sealant or membrane as moisture
barrier to prevent the wood key from absorbing water masonry blocks
and to allow wood natural expansion.
[0028] Floor and roof construction are same as walls, varying only
in extra enforcement for the additional weight bearing needs.
Advantages--A Structurally Stable Hybrid Combination
[0029] The proposed method is a type of hybrid of wood and masonry
construction. Timber framed brick house used in the history of
multiple cultures around the world also combined the two materials.
The historic practice has been proven an effective structure to
stand for earthquakes. Studies also did on such structure [Ref.
101, 102, 103, 104, and 105].
Advantages--A Simpler Construction
[0030] Other panel installations require special construction crew,
and some level of special equipment and hardware. CMU block laying
also requires highly skilled masonry workers and rebar workers.
Both requires special training. Therefore, both are more expensive
and far less available than carpenters and requires strict
scheduling.
[0031] The proposed method, combining wood with blocks, is still
mostly traditional framing carpentry type of work. In case of CMU
for example, workers still lay stack bound blocks, but enforcement
is by carpentry. All hardware materials and tools are currently
available on market. So, the proposed method is very much like that
for the traditional framing carpentry work with less on-site
coordination as needed for traditional masonry project. Inspection
can be done after all framing completed.
Advantages--Easy to Customize and Extend
[0032] Single-family houses often have a lot of variations in
shape, especially interior partition walls and facade. Other panel
construction is hard to customize because panels can't be easily
cut to fit on-site if ever possible. This makes prefabricated
panels practically unpopular for single-family house
construction.
[0033] CMU construction typically using running bound laying
patterns. Block cut to fit at turns or T's are often the most
time-consuming work.
[0034] In both cases, it is difficult to customize for any
variations or integrate with any interior features, especially
those built with wood.
[0035] Utility installation requires cutting channels in the
masonry walls, either AAC or CMU walls. Existing AAC panel
constructions use AAC panel for both walls and floors, which make
utility installation even more challenging. Therefore, utility
contractors will charge a premium for a masonry house job not to
mention a lot of them cannot do such jobs.
[0036] This proposed method exposes wood keys at joins to makes
customization, integration, and utility installation much
easier.
[0037] In summary, the disclosed is a masonry house construction
method using common wood studs as reinforcement. The method takes
advantages of both materials. The method reduces the overall
construction cost. It is faster to build and more flexible to
integration with common wood components. The result is equally
strong to stand against earthquakes. A house built with this method
will be more resistant to fire and flood; the house will be more
environment-friendly, more energy-saving, and more comfortable to
live in.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1. The overview of the masonry construction method
using wood stud as join keys.
[0039] FIG. 2-1. The front horizontal view from inside the house
showing wall components.
[0040] FIG. 2-2. Top sectional view showing how wall panel blocks
are joined together by wood stud keys.
[0041] FIG. 2-3. Top cutaway detail view of panel joint from FIG.
2-2 showing gaps around the wood stud key.
[0042] (Drawings from PPA do not contribute and are omitted
here.)
[0043] FIG. 2-7. Wood floor joists connecting with panel
blocks.
[0044] FIG. 2-8. Side Sectional of FIG. 2-7 with sample
dimensions.
[0045] (Drawings from PPA do not contribute and are omitted
here.)
[0046] FIG. 5-1. Wall panels and wood header/beam integration.
[0047] FIG. 5-2. Wall and wood roof truss joint.
[0048] (Drawings from PPA do not contribute and are omitted
here.)
[0049] FIG. 6. AAC roof panel mounting detail.
DETAILED DESCRIPTION OF THE INVENTION
[0050] The proposed is a construction method to build with
prefabricated masonry building blocks. The method reinforces the
structure with conventional wood studs instead of rebar-reinforced
cement. The wood studs form a skeleton that encloses and holds the
masonry blocks around their entire perimeter. Each studs of the
skeleton are directly tied down to the foundation as seismic
enforcement. The method leverage conventional carpentry skills to
keep the overall building cost low.
Hold Down to the Rails
[0051] FIG. 1 is a 3D overview of the design. An array of .OMEGA.
shape steel rails (2), made from metal, such as construction rebar,
are embodied into the poured concrete foundation (1). The exposed
parts of rail (2) along the foundation wall run in parallel with
the foundation (1) throughout the entire foundation wall. They are
positioned right under the edge of the prefabricated masonry panel
blocks (5) so that the wood stud keys (4) can tied to it directly
using metal strap-ties (3). An example of strap (3) is Simpson
Strong-Ties.
[0052] In FIG. 1, straps (3) tie the studs (4) to the foundation
(1) while straps (3a) tie the top rail (6) to the studs (4). So,
blocks (5) are entirely under the hold-down enclosure. Straps (3b)
tie the roof truss or the second-floor wall to the top rail (6).
Straps (3), (3a), and (3b) are all nailed or bolted to the studs
(4) using conventional carpentry method.
[0053] In FIG. 1, strap (3) are threaded through under rail (2). It
is easier to work with rail (2) than conventional anchor bolts and
hold downs straps. It will not slip or break. It is also flexible
to use. Multiple strap ties can share one rail in all directions,
like tying two boats on one cleat. Strap (3a) and strap (3b) both
are secured on one top rail (6).
[0054] In FIG. 1, rails (2) are the anchors of the entire house
throughout. They are cheaper, easier to work with, and stronger
than conventional hold-down ties with the help of masonry blocks
enclosing them. Top rail (6) serves the same anchoring role to the
second floor as rail (2) to the first floor.
[0055] Top rail (6) runs throughout the house wall perimeter on top
of panel (5) to form a horizontal bound. Rebar used for rail (6) is
welded together. Studs (4) can extend beyond the rail (6) from the
first floor into second floor (not shown in the drawing). The
extension of studs (4) will increase the binding across floor
levels.
[0056] In FIG. 1, the bottom of block (5) has a groove to receive
rail (2). For AAC construction, the groove can be carved out
on-site. For CMU construction, the groove can be a knockout tab.
During construction, a block (5) will sit onto foundation (1)
surface, with moisture barrier and mortar cement (not shown in
drawing) applied in between.
[0057] FIG. 1 shows how rails (2) serve as the anchor of the
building. The same connection also applies to the traditional wood
stick buildings, where each load-bearing stud is tied down to rails
(2) with strap (3) (not shown) in the same way as shown in FIG.
1.
[0058] FIG. 2-1 is a front horizontal view from inside the house
showing how wall blocks (5) are secured between foundation (1) and
top rail (6) stud (4) and straps (3) and 3a). Spacers (7) raise
rail (6) so that straps (3b) can thread through under rail (6).
[0059] The dashed line in FIG. 2-1 represents a soft strip (2-1-1),
such as rubber band, wrapped around the stud (4) every foot or two
to create a gap between block (5) and the stud (4). Strip (2-1-1)
can also be foam tapes or pad to keep a gap in between, which is
important to keep moisture away from entering the wood stud key
(4).
Connect Panels by Wood Stud Keys
[0060] Blocks (5) carry the dead load of the house and studs (4)
carry the shake forces during earthquake and wind. However, wood
and masonry materials have different properties. One important
consideration of this design is to integrate the two and prevent
wood stud key (4) from absorbing moisture from cement. The proposed
solution utilize gaps between the two to absorb force spikes on
wood and to block moisture penetration into wood.
[0061] FIG. 2-2 is a top sectional view of the join. A groove at
the side of block (5) has two uneven shoulders. The exterior side
has higher shoulder (called primary shoulder) that yields a smaller
gap (9), which is filled by construction glue or caulking toward at
the end of construction phase. The interior side has a much lower
shoulder (called secondary shoulder) that exposes most of the wood
stud (4) in gap (8).
[0062] Gap (8) renders space for nailing straps to the studs during
framing. It also makes inspection easy. Gap (8) can also be the
channel for utility routing. Importantly, Gap (8) is the moisture
escape route to keep the stud (4) dry. During finish, the cover of
gap (8) must be breathable, like wood or drywall.
[0063] FIG. 2-3 is the detail of FIG. 2-2 to show how gaps are
made. The groove is tapered in toward the bottom to leave side gaps
(12) on both side of stud (4). The corners at the bottom are
rounded or slightly raised to retain gap (10) at the bottom. Gaps
(10) ensure the minimum contact between the stud (4) and blocks
(5).
[0064] Gaps (10) and (12) are filled with soft based waterproofing
construction sealant or glue during construction, optionally, with
sheet of waterproofing membrane. Therefore, Gaps (10) and (12),
with the waterproof agent, shield moisture from the stud (4).
[0065] FIG. 2-3 also shows toenails (11) applied to enhance the
binding between stud (4) and block (5). Toenails (11) are applied
at an interval along the stud (4). In case of CMU, said toenail
(11) is in fact a metal plate going into the seam of block (5)
stack and nailed to the stud (4).
[0066] In FIG. 2-2, the lower shoulder, could be reduced to
0-height relying only on toenail (11) to secure the stud (4).
Optionally, add-on wedges are used in gap (8) to help secure the
stud (4) (not shown in the drawing.)
[0067] At a 90-degree corner turn, the groove shown in FIG. 2-2
will not be on the ends, but on the inside of the turn. The
adjacent block will join to that groove to form the 90-degree turn.
(not shown in drawings.)
Wood Floor in Platform Frame Construction
[0068] Building code specifies maximum spacing between wood floor
joists (<16'' in US). If the width of block (5) is the same as
the maximum spacing, all joists (41) will line up to and secure to
the studs (4) with nailing or strap-ties.
[0069] When the width of block (5) is wider than the joist spacing,
FIG. 2-7 and FIG. 2-8 show how wood floor joists (41) integrate in
the design. In this case, some joists (41) are off from studs (4)
and run into block (5). A vertical groove (42) is needed at the
bottom of the block (5) to receive joist (41) and hold it upright.
Groove (42) can be either pre-molded into panel (5) or cut on
site.
[0070] FIG. 2-8 includes some sample dimensions for the 8''-thick
block (5) to demonstrate feasibility of the profile with masonry
materials. In other words, block (5) will not be too thin to break
off easily.
[0071] All joists (41) sit on foundation (1) with required
waterproof application and are secured to rails (2) by strap ties
(not shown in the drawing).
Masonry Wall and Wood Integration
[0072] The proposed design makes it easy to join wood building
components with masonry building by anchoring on wood key studs
(4).
[0073] FIG. 5-1 shows how to install a wood header (5-1-1), which
is sit on a column of shorter trimmer block (5-1-2) and secured to
stud (4). Top rail (6) is immediately above the header (5-1-1).
Extra straps (3a) secure the header (5-1-1) to rail (6). The bottom
of a trimmer key (5-1-3) is secured by a horizontal strap (5-1-4)
anchored on the neighboring rail (2), and by a regular strap (3) to
the rail (2) directly under it (not repeated in the drawing). The
top of the trimmer key (5-1-3) connects to the header (5-1-1) in
the typical wood-to-wood connection.
[0074] The header beam can also be made of rebar-reinforcement
masonry lintel (not shown in drawings), which is considered as a
wider block (5), with the same profile at each end to connect to
studs (5).
Wall and Roof Connection
[0075] FIG. 5-2 shows how a wood roof truss (5-2-1) is secured by
strap-tying to the rail (6). Trusses (5-2-1) sit on the risers
(5-2-2) and tied-down by strap (3b).
[0076] FIG. 6 shows how wall made of block (5) join with roof
panels (22), which are often full-length AAC panels. Roof join key
stud (6-1-1) is the same as stud (4) for walls is tied to rail (6)
by strap (6-1-2) and ridge rail (6-1-3) by strap (6-1-4).
Installation Process
[0077] Starting from a corner, a column of block (5) is set. Then,
the stud (4) is attached to the column with applied glue, padding,
and membrane. Strap (3) is nailed to stud (4) looping over rail
(2). Then, repeat the step on the next column of blocks.
[0078] Once the first level wall is completed, install wood floor
joists (41) resting on foundation (1) in gap (8) or in groove (41).
Then, secure them to the rail (2), or to rail (6) for higher
floors.
[0079] Next, add the top rail (6) and secure to it with all studs
(4) with strap (3a), followed by installing roof or upper
floor.
[0080] Interior wood stud walls are anchored to studs (4) in gap
(8). Utility lines can also be routed in gap (8). Every structure
connection subject to inspection is exposed through gap (8).
[0081] Finally, gaps (8) and gaps (9) are covered during finish
work.
* * * * *
References