U.S. patent application number 15/986605 was filed with the patent office on 2019-02-07 for beam and bolting construction system and method.
The applicant listed for this patent is Stephen E.. Hanson. Invention is credited to Stephen E.. Hanson.
Application Number | 20190040629 15/986605 |
Document ID | / |
Family ID | 65229547 |
Filed Date | 2019-02-07 |
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United States Patent
Application |
20190040629 |
Kind Code |
A1 |
Hanson; Stephen E.. |
February 7, 2019 |
BEAM AND BOLTING CONSTRUCTION SYSTEM AND METHOD
Abstract
A beam and bolting construction method and an example dwelling
(10) according to the method are provided. The method involves
preliminary steps of selecting a site and determining a bolt array
(19) and selection of dimensions and materials. Actual construction
steps include forming a foundation slab (14) having vertical bolts
(18) embedded therein in accordance with the bolt array (19).
Alternating layers of beams (B), having aligned bolt bores (52) for
receiving the bolts, are successively laid down over the bolts
(18), with sides meeting at corners (29) with alternating sides
encompassing the corner bolt. Once a desired height is achieved,
washers (72) and nuts (78) are placed on the bolts and are
tightened to desired pressure levels. The dwelling (10) is formed
with beams (42) compressed together by threaded bolts (18) in a
bolt array (19).
Inventors: |
Hanson; Stephen E..;
(Boulder Creek, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hanson; Stephen E.. |
Boulder Creek |
CA |
US |
|
|
Family ID: |
65229547 |
Appl. No.: |
15/986605 |
Filed: |
May 22, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62539546 |
Aug 1, 2017 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04B 2001/3583 20130101;
E04B 2/704 20130101; E04B 2/702 20130101; E04B 2002/0254 20130101;
E04B 2/06 20130101 |
International
Class: |
E04B 2/70 20060101
E04B002/70; E04B 2/06 20060101 E04B002/06 |
Claims
1. A beam and bolting structure comprising: a foundation slab; a
series of vertical bolt segments embedded in said foundation slab
in a predetermined bolt array to extend vertically upward
therefrom; a multiplicity of beam segments with parallel top
surfaces and bottom surfaces, each said beam segment having bolt
bores extending between said top and bottom surfaces, said bolt
bores positioned for fitting over respective ones of said vertical
bolt segments; and bolt couplings for extending multiple bolt
segments as needed and tightening nuts for applying compression to
the topmost of said respective beam segments, wherein multiple ones
of said beam segments are placed on top of one another over said
respective vertical bolt segments to form a wall of a desired
height.
2. The bolt and beam structure of claim 1, wherein multiple ones of
said walls form a structure with walls overlapping at wall corners;
a subset of said beam segments are designated as cross beams, while
another subset of said beam segments are designated as transverse
beams; and ends of said cross beams and said transverse beams meet
at said wall corners.
3. The bolt and beam structure of claim 1, wherein a corresponding
vertical bolt in said bolt array will pass through at least one of
said beam segments at each one of said wall corners.
4. The bolt and beam structure of claim 2, wherein at said wall
corners a transverse beam segment will lie on top of a cross beam
segment while in alternating layers a cross beam segment will lie
on top of a transverse beam segment.
5. The bolt and beam structure of claim 2, wherein in alternating
layers in said walls cross beams will abut against said transverse
beam in one layer while transverse beams will abut against said
cross beams in the adjacent layer; and said bolt array includes
corner bolts which will pass through said alternating cross beams
and transverse beams at each said corner so as to cause said
alternating beam segments to be compressed together by said
tightening nuts.
6. The bolt and beam structure of claim 1, wherein an access gap is
provide above each said tightening nut such that said tightening
nut may be adjusted after construction.
7. The bolt and beam structure of claim 1, wherein said beam
segments are at least slightly vertically compressible and are
formed of materials selected from the following group comprising;
natural wood, wood composites, other composites, and synthetic
materials.
8. A method and protocol for constructing a bolt and beam wall
structure, comprising: i) preparatory steps, which may be performed
simultaneously or in any order, including (a) selecting a site; (b)
designing a specific predetermined bolt array system for supporting
and aligning the walls in the proposed structure; (c) selecting
materials and dimensions; and ii) construction steps to be
performed generally in order, including (a) preparing a foundation
frame about a foundation cavity; (b) mounting a plurality of top
brackets and bottom brackets, each having an alignment slot, on
said foundation frame to form an alignment system corresponding to
said predetermined bolt array; (c) placing and securing a bolt
segment in said alignment slot of each corresponding pair of said
top and bottom brackets such that each said bolt segment extends
vertically upward and is aligned with a particular bolt anchor
location in said bolt array; (d) pouring said foundation slab into
said foundation cavity so as to fix in place each of said bolt
segments, and smoothing and leveling the upper surface of said
foundation slab; (e) placing a series of layers of beam segments,
each said beam segment having a top surface parallel to a bottom
surface, serially upward upon said bolt segments, extending said
bolt segments as needed by inserting bolt couplings and additional
bolt segments, until a desired height of a said wall structure is
achieved; and (f) tightening each said nut of said bolt segments on
the uppermost beam segment so as to compress adjoining beam
segments in said series together.
9. The method and protocol for constructing a bolt and beam wall
structure of claim 8, and further including: as part of step ii)
(e) constructing multiple ones of said wall segments including
cross wall segments and transverse wall segments at least some of
which intersect at least one respective corner, and at least one
corner bolt in said bolt array will extend through a beam segment
in each layer wherein in alternating layers at each said corner, a
cross wall segment will extend to said respective a corner and a
transverse wall segment will abut against it, while on vertically
adjacent layers a transverse wall segment will extend to a
respective corner and a corresponding cross wall segment with abut
against it.
10. The method and protocol for constructing a bolt and beam wall
structure of claim 9, wherein: the said wall segment which extends
to said corner in each layer further extends beyond said
corner.
11. The method and protocol for constructing a bolt and beam wall
structure of claim 9, wherein: at each said corner in each said
layer the ends of each said beam segment mate against each other at
said corner; and a corresponding one of two said corner bolts
respectively extends through the end portion of each abutting beam
segment.
12. The method and protocol for constructing a bolt and beam wall
structure of claim 9, wherein: at least a portion of said bolt
array denies an exterior boundary of a horizontally enclosed
structure including multiple corners.
13. A dwelling in the form of a generally rectangular cabin
structure, comprising a flat level foundation slab; a predefined
bolt array including a plurality of vertically aligned threaded
bolts embedded and secured in said foundation slab, said bolt array
defining an exterior frame having a plurality of corners and an
enclosed interior; a plurality of beam segments, each said beam
segment having a flat top surface and a parallel flat bottom
surface adapted to abut flushly against a top and a bottom surface
of any vertically adjacent ones of said beam segments, each said
beam segment further including spaced-apart bolt bores extending
vertically therethrough, said bolt bores corresponding to the
spacing of said vertical bolts in said bolt array; and securing
nuts for mating with said vertical bolts and washers for said
securing nuts; wherein said beam segments are vertically stacked in
layers with corresponding ones of said vertical bolts extending
through corresponding bolt bores in each said beam to form a
vertical wall until a desired wall height is achieved; and said
washers having a horizontal extend exceeding the diameters of said
respective bolt bores such that when said securing nuts are
tightened said washers apply pressure to force said layers
together.
14. The dwelling according to claim 13, wherein said beam layers
include alternating off layers and even layers; said beams include
beams identified as cross beams and transverse beams; at each said
corner said bolt array includes a one of said vertical bolts
designated as a corner bolt; at corners of each even layer said
cross beam extends such that said corner bolt extends through said
cross beam while said transverse beam abuts flush against said
cross beam; and at corners of each even layer said transverse beam
extends such that said corner bolt extends through said transverse
beam while said cross beam abuts flush against said transverse
beam.
15. The dwelling according to claim 13 and further comprising: a
roof extending at least over all of said enclosed interior; wherein
an access gap is provided at the top of each said wall over each
said securing nut such that each said securing nut may accessed
from said interior after construction to adjust the pressure
applied by said securing nut.
16. The dwelling of claim 13 wherein access to said interior is
provided by utilizing truncated beams in selected locations and
layers in said walls as necessary to facilitate openings for doors,
windows and the like.
Description
[0001] This is a non-provisional application, with priority from
Ser. No. 65/539,556, by the same inventor, filed 1 Aug. 2017.
TECHNICAL FIELD
[0002] The present invention relates generally to construction
methods and system apparatus for uniform cross-section beam and
bolting construction, particularly as applied to single story
dwellings.
BACKGROUND ART
[0003] Like nearly all other areas of knowledge and commerce, the
field of dwelling construction is subject to continual improvements
in techniques, use of materials, and related structural designs.
This is certainly the case in the construction of dwelling such as
cabins and small houses.
[0004] Although the concept of wooden dwellings goes back into
prehistory, these have always been subject to problems, both in the
construction methods and in the resulting products. For example,
traditional "log cabins" were difficult in finding sufficiently
uniform logs and requiring caulking materials (often requiring
frequent renewal) to protect the inhabitants from the elements.
[0005] Wood constructions have many advantages, particularly since
natural woods, with the exceptions of some hardwoods, have at least
some degree of flexibility and compressibility. This allows for
better weather sealing, and for better resistance to earthquake and
wind damage. Better methods of improving these aspects are highly
desirable.
[0006] Accordingly, there is significant room for improvement and a
need for stronger and more easily constructed walls and frames for
buildings.
DISCLOSURE OF INVENTION
[0007] Accordingly, it is an object of the present invention to
provide a method for constructing beam and bolting vertical
walls.
[0008] Another object of the invention is to provide a method and
protocol for building cabins and other buildings utilizing
preformed wood beams.
[0009] A further object of the present invention is to provide for
walls which are held together with adjustable pressure bots and
nuts.
[0010] Yet another object of the invention is to provide secure
corners in beam construction.
[0011] A further object of the present invention is to provide
cabins and other buildings which are sturdy and resistant to
elemental degradation.
[0012] Still another object of the invention is to provide a
structure which is extremely stable in response to high winds,
earthquakes, and other destructive forces.
[0013] A further object is to create a structure which utilizes a
virtual lamination technique, a "Bolt-Lam" to maintain beam members
in a pressure abutment structure which has synergistic advantages
in weather sealing, combined strength, and durability.
[0014] Another object of the invention is that all intersecting
walls are multidirectional shear walls, highly resistant to
deformation of any kind.
[0015] Briefly, one preferred embodiment of the present invention
is a method (M) for constructing beam and bolting walls and
structures. The method involves preliminary steps of selecting a
site and determining a bolting array and selection of dimensions
and materials. Actual construction steps include forming a
foundation slab having vertical bolts embedded therein in
accordance with the bolting array. Alternating layers of beams,
having aligned bolt holes for receiving the bolts, are successively
laid down over the bolts, with sides meeting at corners with
alternating sides encompassing the corner bolt. Once a desired
height is achieved, washers and nuts are placed on the bolts and
are tightened to desired pressure levels. The nuts and threaded
bolt ends are situated to have an access gap such that the pressure
may be adjusted as conditions change. The method and protocol may
be used in forming structures such as cabins, houses, outbuildings
and the like.
[0016] Other preferred embodiments are product by process
structures constructed in accordance with the method (M).
[0017] An advantage of the present invention is that it provides a
relatively rapid and secure protocol for raising a set of
walls.
[0018] Another advantage of the invention is that it provides for
constructing a building which may be made with preformed beams,
having spaced-apart bolt holes for receiving vertical bolts.
[0019] An additional advantage of the invention is that embedding
elongated threaded bolts in a foundation slab provides an array
upon which beams may be vertically installed thereon.
[0020] A further advantage of the construction method (M) is that
the "Bolt-Lam" virtual lamination by pressure has a synergistic
effect superior to prior art techniques.
[0021] Yet another advantage of the present invention is that the
structure is much stronger and sturdier than one created with
conventional stick framing.
[0022] Still another advantage of the present invention is that the
intersecting walls together form a moment frame for the entire
building.
[0023] A further advantage of the present invention is that a
completed frame is integral and very highly resistant to separation
of a portion thereof by forces such as wind.
[0024] These and other objects and advantages of the present
invention will become clear to those skilled in the art in view of
the description of the best presently known modes for carrying out
the invention and the industrial applicability of the preferred
embodiments as described herein and as illustrated in the several
figures of the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The purposes and advantages of the present invention will be
apparent from the following detailed description in conjunction
with the appended drawings in which:
[0026] FIG. 1 is a front plan view of an example dwelling
constructed in accordance with the present invention;
[0027] FIG. 2 is a perspective view of a construction site at an
early stage, prior to installation of any beams, showing a typical
bolting array;
[0028] FIG. 3 is a plan view of the left side/end of the example
dwelling;
[0029] FIG. 4 is a rear plan view of the example dwelling;
[0030] FIG. 5A is a truncated perspective view of an example beam
according to the present invention;
[0031] FIG. 5B is a cross sectional view of the beam of FIG. 5A,
taken along line B-B;
[0032] FIG. 6 is a plan view of the right side of the example
dwelling, showing a roof mounting approach;
[0033] FIG. 7 is cutaway side view of an alternate dwelling,
showing another roof mounting approach;
[0034] FIG. 8 is a fanciful cross-sectional illustration of a
segment of a wall showing an interstitial bolt anchored in the
foundation slab and extending upward to pass through the bolt holes
in the beams;
[0035] FIG. 9 is a fanciful cross sectional view of a section of
the foundation slab, an elongated bolt anchored in the slab and
extending through bolt holes, and an alternate washer plate
providing an external spacing and securing bracket;
[0036] FIG. 10 is a side view of a prototype partial corner section
of two very short exterior walls, showing the layering and bolting
techniques;
[0037] FIG. 11A shows a system for precise anchoring of an
elongated threaded bolt in the foundation slab;
[0038] FIG. 11 B is a top plan view of a top (or bottom) mounting
bracket for the system of FIG. 11A; and
[0039] FIG. 12 shows in examples A, B, C, and D, four envisioned
corner bracing configurations.
BEST MODE FOR CARRYING OUT THE INVENTION
[0040] The present invention is a method of construction (M) for
dwellings and other buildings utilizing beam and bolting and of the
structures resulting therefrom. An example dwelling 10, in this
case a cedar or redwood beam cabin, is illustrated in a front view
of FIG. 1. The structure is defined in terms of the spatial
relationships (shown in phantom) including a primary vertical plane
11, a transverse vertical plane 12 perpendicular to the primary
plane 11, and a horizontal plane 13 perpendicular to the vertical
planes.
[0041] The preferred process (M) involves a series of steps in
constructing and maintaining a beam and bolting building/dwelling.
A brief summary of the steps is set forth below:
[0042] Select site and prepare layout, including bolting array
positioning;
[0043] Locate corners for bolting on foundation slab;
[0044] Precisely locate bolt anchor locations for foundation
slab;
[0045] Determine height of walls;
[0046] Select locations for gaps in walls (doors, windows,
etc.);
[0047] Determine whether corners will have extended beam segments
and sequential order of beam vertical overlap at corners;
[0048] Select materials;
[0049] Choose gauge and length of vertical bolts and choose nuts
and washer plates;
[0050] Choose materials for beams (e.g. cedar, redwood, composite,
etc.);
[0051] Determine cross-sectional structure of beams;
[0052] Determine default beam length;
[0053] Prepare foundation slab;
[0054] Situate and secure vertical bolts in predetermined bolt
anchor locations defined by the bolting array;
[0055] Construct foundation slab to provide a flat upper surface
and secure vertical bolt in precise vertical orientation;
[0056] Prepare beams;
[0057] Provide bolt bores through each beam in accordance with
spacing of the predetermined vertical bolt locations;
[0058] Cut beam segments (truncated beam segments) to accommodate
corners and wall gaps according to plans;
[0059] Vertically lower first beam in corner overlap sequence
(cross beam) onto respective vertical bolts, including the selected
corner bolt and at least one interstitial bolt, through respective
bolt bores until it rests upon the foundation slab, with, if
selected, extending beyond the corner bolt;
[0060] Vertically lower second beam in the corner overlap sequence
(truncated transverse beam) onto respective interstitial vertical
bolts such that it rests upon the foundation slab with a beam end
abutting against the cross beam at the corner;
[0061] Repeating steps set forth in the two immediately preceding
paragraphs, inserting bolt couplings and additional bolt segments
as required, until all corners are completed;
[0062] If necessary, laying down beam segments on interstitial
bolts to fill in any gaps not corresponding to doors, or the like
in the layer;
[0063] Laying down additional layers until the desired wall heights
are achieved, alternating the functions of the cross beam and the
transverse beam in each successive layer such that the corner bolts
alternatively pass through cross and transverse beams;
[0064] Upon achieving desired wall height:
[0065] Laying down washer plates (pressure distribution plates)
encompassing each of the vertical bolts on top of the beams;
and
[0066] Applying and tightening nuts to each of the treaded bolts to
force all of the beams together to a desired pressure (creating a
"Bolt-Lam") in order to achieve a desired "seal" and a secure
structure.
[0067] Installing a desired roof above the walls, maintaining an
access gap above all bolts and nuts to allow subsequent pressure
adjustment.
[0068] Oher steps, which are not critical to the present invention,
may also be performed.
[0069] Considering a product (in this case a building or dwelling)
constructed in accordance with the above-described method (M) the
example dwelling 10 is further explained below. For the purposes of
simplified description, and since these are a matter of choice not
critical to the invention, most architectural details and all
interior details are omitted from the description. The preferred
example dwelling (cabin) 10 illustrated in FIGS. 1-4 includes a
foundation slab 14, which is carefully aligned to be parallel to
the horizontal plane 13. The initial actual construction step
(after site and layout and materials selection) in the method (M)
is to provide the flat (level) and horizontal (perpendicular to
gravitational force) foundation slab 14 with bolt anchor locations
16 in which elongated vertical threaded bolt segments (vertical
bolts) 18 are countersunk and secured in precise vertical
orientation (see FIGS. 2, 7-9 and 11). The foundation slab 14 is
typically poured concrete but other sturdy structural approaches
may be used. The vertical bolts 18 are threaded at at least the
ends, are held in the bolt anchor locations 16 and are situated in
a precise bolt array 19 corresponding to the dwelling design (an
example array--not congruent to the example dwelling 10) is shown
in FIG. 2). The array 19 includes corner bolts 20 and interstitial
bolts 21 situated between corner bolts 20.
[0070] A further step in the construction method (M) relates to
completing vertical walls mounted upon the vertical bolts 18. For
simplicity of explanation, the example cabin 10 is rectangular, but
a myriad of other configurations are possible. In the example
dwelling 10 illustrated in FIGS. 1, 3, 4, and 6, a set of four
exterior vertical walls 22 are provided. A front wall 23 and a rear
wall 24 are aligned parallel to the primary vertical plane 11, and
consequently with each other. Similarly, a left wall 26 and a right
wall 28 are aligned parallel to the transverse vertical plane 12,
and to each other. Each of the walls 22 will overlap at opposing
ends with the respective perpendicular transverse walls at a corner
29, as described below. Each of the exterior walls 22 is
constructed in accordance with the construction method (M).
[0071] A roof 30, of generally conventional construction, is
mounted on and above the exterior walls 22 as described below. For
at least a significant amount of the expanse, an access gap 32
separates the top of each exterior wall 22 from the roof 30 and any
other overhead components, as explained below. Various other
exterior details, not pertinent to the primary inventive concepts,
are also shown and provided. These details include a fireplace 34
with an associated chimney 36, and doors 38 and windows 40 as
desired.
[0072] The exterior walls 22 of the present invention are
constructed with beams 42 as illustrated in more detail in FIG. 5A
and 5B. FIG. 5A is a perspective view of an example beam 42 while
FIG. 5B is a cross sectional view taken along line B-B. The beams
42 are selected to have a beam top 44 and a beam bottom 46 which
are flat and parallel to each other, and a pair of beam ends 48.
The beams 42 also have beam edges 50 which may also be flat and
parallel so that the beam has a rectangular cross section (square,
as illustrated in FIG. 5B) but may also be beveled or otherwise
shaped for aesthetic purposes as these surfaces are not critical to
the effectiveness of the construction. In the example dwelling 10
the beams 42 are uniform in cross sectional dimensions, but may
vary in thickness as breadth as desired for particular
purposes.
[0073] Each beam 42 includes series of bolt bores 52 vertically
passing therethrough between the beam top 44 and beam bottom 46
surfaces. These bolt bores 52 are strategically spaced and located
so as to correspond and mate with the specific bolt array 19. Each
bolt bore 52 has a diameter slightly greater than the diameter of
the selected vertical bolt segments 18.
[0074] Although all of the beams 42 in the example dwelling 10 are
substantially similar for the purposes of construction method (M)
it is convenient to refer to them separately for the purposes of
description. Thus, some beams, which are aligned with the primary
vertical plane 11 (e.g. front wall 23 and rear wall 24) are
referred to as cross beams 54 while those aligned with the
transverse vertical plane 12 (e.g. left wall 26 and right wall 28)
are designated as transverse beams 56. An unmodified beam 42 such
as is illustrated in FIG. 5A is referred to as a full beam 58,
while a beam that is cut short so as to abut against a full beam 58
at a corner 29 is designated as a truncated beam 60. A beam segment
62 is defined as a section of a beam used to fill in gaps in the
structure.
[0075] As described above in respect to the steps of the preferred
method (M) the exterior walls 22 are constructed in a vertically
ascending series of layers, as the beams are fitted onto the
respective vertical bolts 18. The layers are designated as an odd
layer 64 (the lowest of which abuts against the foundation slab 14)
and an even layer 66 which rests on top of an odd layer 64 to
create a vertical overlap 68 of beams in adjacent layers at each
corner 29. The discussion below with regard to FIG. 12 shows four
envisioned corner overlap schemes for suitable stable corners
29.
[0076] For the purposes of description of a preferred embodiment
(FIG. 12, depiction D), and referring to the left end of the front
wall 23 (and the rear wall 24), the cross beam 54 in an odd layer
64, will be mounted to include a corner bolt 20, as illustrated in
FIGS. 3 and 4. In the preferred corner 29 in the example dwelling
10 (as shown in FIG. 10), the cross beam 54 includes an integral
extended segment 70 which extends outward beyond the corner 29.
[0077] For the odd layers 64 the transverse beams 56 are truncated
beams 60 which are mounted only on interstitial bolts 22 and have
one beam end 48 which abuts against a cross beam 54 at each corner
29. For even layers 66, the roles are reversed (see FIGS. 4, 5, and
10) and the transverse beams 56 include extended segments 70 and
are mounted to include a corner bolt 20, while the cross beams are
truncated beams 60, and are mounted only on interstitial bolts
21.
[0078] In order to facilitate construction it is ordinarily
necessary to insert bolt couplings 71 at a convenient working
height above the foundation slab 14. Workers can usually only
effectively lift and position beams 42 on and over the vertical
bolt segments 18 to a certain height which is usually consistent
with the height of the bolt segment above the foundation slab 14.
As the typical threaded bolt segment 18 is about six feet long in
US constructions, and since bottom of the lowermost bolt segments
is typically embedded about one foot into the foundation slab 14,
the most common location to insert a coupling 71, with another bolt
segment 18' in the same vertical alignment, will be at a height of
about five feet above the foundation slab 14. The upper bolt
segment 18' will then extend to slightly above the typical ten foot
height of each wall 22, and placement of the beams 14 will then be
accomplished with the aid of scaffolding or mechanical lifts,
[0079] The alternating layers continue until the desired wall
height is reached. At this stage rigid washer plates 72 are placed
over the elongated bolt 18' and against the top layer of the beams
42. Right angle corner plates 74 are situated on corner bolts 20 to
lay against both abutting beams while elongated plates 76 are
placed over interstitial bolts 21, preferably extending between two
or more interstitial bolts. Nuts 78 are then threaded onto the
respective elongated bolts 18' and tightened to the desired
pressure levels, forcing the beams against the foundation slab 14
and each other to form a "Bolt-Lain".
[0080] A prototype shortened corner segment of intersecting walls
is shown in FIG. 10. This shows the alternating levels, with
extended segments 70 at appropriate levels of the cross beam 54 and
transverse beam 56, as well as the corresponding abutment of a
truncated beam 60 of the respective beam type for each level.
Although shown without an elongated vertical bolt 18 anchored in a
foundation slab 14 this also shows the washer plate 72 and nut 78
attached to be tightened to force the beams in adjacent layers
together. This prototype (FIG. 10) has been wind-tunnel tested and
was shown to successfully withstand gale and hurricane force winds
(from many angles and with winds of 50 to 150 mph) without any
compromise of integrity.
[0081] FIGS. 8 and 9 illustrate, in fanciful cross sectional views,
the anchoring of elongated bolts 18 in the foundation slab 14 and
extending upward through the bolt holes 52 of each beam in the
layer. In FIG. 8 an alternate washer plate 72', adapted to connect
to an element above the wall, is shown being held in place by a nut
78. In FIG. 9 a spacing/securing bracket 80 is illustrated
providing spacing between the foundation slab 14 and the bottom
beam 42' and also engaging the bottom beam 42' to hold it securely
in position.
[0082] FIGS. 6 and 7 illustrate potential methods/arrangements for
mounting a roof 30 onto a dwelling. It is emphasized in method (M)
that any roof or ceiling structure requires that an access gap 82
is provided such that each nut 78 may be accessed from inside the
structure in order to adjust the pressure level and compensate for
the slight material deformations over time. It is also necessary
that the roof 30 be secured to the wall structures. In order to
typically accomplish this a series of roof spacer blocks 84 (beam
segments including bolt bores 52) are placed on top of the wall 22
intermediate the access gaps 82. These roof spacer blocks 84 and
rafters 86 and other connective portions of the roof 30 are then
secured to the top and potentially lower beams. The securing method
includes roof bolting 88 having involving threaded bolt segments
18'' with an additional coupling 71 to extend through the upper
beams 42 to beyond and through and above the spacer blocks 84 and
rafters 86 and provided with washer plates 72 and nuts 78 to
tighten the wall and roof elements together in a stable and secure
fashion. Depending on the nature of the roof 30, the rafter bolting
88 and roof spacer blocks 84 may only be needed on some of the
exterior walls 22.
[0083] As other roof construction details are not strictly
pertinent to the invention or method (M) these are not addressed
herein.
[0084] FIGS. 11 (A & B) and 12 (A, B, C, and D) show examples
of helpful construction details and alternate corner bolting
configuration in accordance with the present invention.
[0085] FIG. 11 illustrates, both in cut away view (11A) and top
view (11B), an alignment system 90 for placing and aligning each
bottom vertical bolt 18 in the desired bolt anchor location 16 in
the foundation slab 14. Prior to pouring the foundation slab 14, a
foundation frame 92 is placed around the desired border. This is
typically in the form of a wooden border, in the illustration a
4.times.8 board. The foundation frame rests outside a foundation
cavity 94, into which the concrete or other solid filler will be
poured once the bolt array 19 is prepared. A nut 78 is threaded
onto the vertical bolt segment above the level of the foundation
frame 92, while a further nut 78 and washer plate 72 are situated
well below, near the nether end of the bolt segment 18.
[0086] A top bracket 96 and a bottom bracket 98 are adapted to fit
about the upper and lower surfaces of the foundation frame 92 and
extend into the foundation cavity 94. The top bracket 96 and lower
bracket 98 each include a right angle flange 100 to abut against
the outside of the foundation frame to form a horizontal plate 102,
with a centering notch 104 at its interior end in order to receive
the bolt segment 18. When the brackets 96 and 98 are properly
placed and aligned, the bolt segment 18 is placed to vertically fit
into the centering notches 104 of both brackets, with the exterior
nut 78 tightened to secure the bolt segment 18 into position and
alignment. When all necessary alignment systems 90 are set up
around the perimeter (and in portions of the interior when interior
walls or the like are included in the plan), the foundation slab 14
may be poured to set each bolt segment into the bolt anchor
locations 16 of the array 19. The top bracket 96 and bottom bracket
98 may either be left in place or laterally slid out as the
foundation slab hardens.
[0087] FIG. 12 shows (in sub-Figures A, B, C, and D) four possible
desirable corner 29 structures, each including one or more "L"
brackets 106 situated on the interior or exterior angle, or both.
In three of the example corners 29 (B, C, and D), the corner bolt
20 extends through the actual corner location and through the
alternating layers 64 and 66 of the beams. In the upper right
example (FIG. 12A) there are two offset corner bolts 20' passing
through respective cross beams 54 and transverse beams 56, each of
which is trimmed at a forty-five degree angle so as to abut each
other at the apex of the corner 29. The lower left example (FIG.
12D) is the top view of a corner 29 as described above for the
example dwelling 10.
[0088] The materials selected for the components of the building
constructed according to the Method (M) are structurally strong.
The preferred foundation slab 14 is poured concrete, but other
materials may also suffice. The preferred elongated threaded bolts
18 are formed of construction steel and have dimensions as
described above. The preferred beams 42 are selected from stable,
yet slightly deformable woods, such as cedar or redwood, while
other types of slightly compressible materials, such as synthetic
and composite materials, all having compatible upper and lower
surfaces, may also be suitable, The beams 42 are most simply
elongated and have square cross sections. Uniform thickness of
alternating layers is preferred but differing height (thickness) of
the layers may be feasible, so long as each layer has a uniform
thickness. Bolt hole 52 separation and locations in the beams 42
may be standardized and prefabricated beams 42' may be provided
such that onsite drilling is avoided and time is saved.
[0089] It is noted that the bolt array 19 defines an exterior frame
108 for the dwelling 10 and the exterior frame 108 defines an
interior 110 for the dwelling 10.
[0090] Many modifications to the above embodiment may be made
without altering the nature of the invention. The dimensions and
shapes of the components and the construction materials may be
modified for particular circumstances.
[0091] While various embodiments have been described above, it
should be understood that they have been presented by way of
example only, and not as limitations.
INDUSTRIAL APPLICABILITY
[0092] The Beam and Bolting Construction Method (M) and the walls
and buildings constructed according to the method (M), such as
example dwelling 10, according to the present invention are adapted
to be constructed precisely and quickly with potentially
prefabricated material components, thus greatly enhances the
effectiveness of building construction.
[0093] Greater effectiveness in cabin and other simple building
constructions results in significant economic advantages. In
addition, the ability to adjust vertical pressure on the vertical
layers in a wall to compensate for deterioration and environmental
variations is a significant advantage in minimizing the need to any
caulking or other sealing remedies, and is especially effective
with redwood materials.
[0094] For the above, and other, reasons, it is expected method (M)
and products by process 10 according to the present invention will
have widespread industrial and construction applicability.
Therefore, it is expected that the commercial utility of the
present invention will be extensive and long lasting.
* * * * *