Note: Descriptions are shown in the official language in which they were submitted.
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[001]SYSTEM AND METHOD FOR MODIFYING EXISTING STRUCTURES TO
PROVIDE IMPROVED RESISTANCE TO
EXTREME ENVIRONMENTAL CONDITIONS
[002] This application is claims benefit of U.S. Provisional Application
Serial No.
61/144,880 filed January 15, 2009 which is a continuation-in-part of U.S.
Patent
Application Serial No. 12/061,994 filed April 3, 2008 which is a continuation-
in-part
of U.S. Patent Application Serial No. 101776,565 filed on February 11, 2004.
[003] FIELD OF THE INVENTION
[004] The present invention relates to a method and apparatus for the
modification
of existing structures to provide improved resistance to extreme environmental
conditions and, in particular, a system of common modular components for
modifying existing buildings such as houses to provide improved resistance to
extreme environmental conditions such as hurricanes, tornados, fires and so
on.
[005] BACKGROUND OF THE INVENTION
[006] Recent environmental events such as the damage to New Orleans and other
coastal region communities from hurricanes such as Katrina and recent major
tornado, storm, forest and brush fire, flood and earthquake damage in
communities
in virtually every region of the country and in virtually every country have
emphasized a long standing need for structures, such as houses, schools,
stores,
governmental, public service and medical facilities and similar structures,
having
significantly improved resistance to extreme environmental conditions. It is
also
recognized that the advent of global warming will result not only in shifting
meteorological patterns and conditions, but more extreme weather conditions.
For
example, there is substantial support for the expectation that ordinary storms
will
become stronger and more frequent with higher winds and heavier rainfall, that
category 4 and 5 hurricanes will become relatively common ratherthan rare,
with the
possibility of at least occasional hurricanes of even higher effective
categories, and
tornados and forest and brush fires will become larger, stronger and more
common
over larger areas, as will tornadoes and floods.
[007] Rapidly accumulating evidence clearly shows that traditional methods for
constructing houses, schools, stores, governmental, public service and medical
facilities and similar structures are not adequate to meet the increased
demands
presented by more extreme weather conditions and that while such structures of
have been and are presently built in a number of ways, the traditional methods
have
proven unsatisfactory for various reasons. For example, structures such as
houses
have commonly been built from wood, such as 2x4s and plywood nailed together
or masonry elements, such as bricks, concrete blocks or concrete slabs, held
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together by mortar and connected to wood elements by nail-like fasteners or
adhesives. While nailed wooden structures are relatively light, strong and
inexpensive and while the individual components comprising the structures,
such
as 2x4s and sheets of plywood, are individually relatively strong, their
strength is
limited by the inherent properties of the materials. Wooden frame structures
are
also weakened, and tend to be excessively flexible, by the relatively large
number
of joints necessary to assemble the individual components. Also, nails are
commonly used to assembly the individual components of wooden structures
because nails are cheaper and easier to use than other forms of fasteners.
Nails,
however, do not provide joints that are as secure and rigid as those provided
by
more expensive forms of fasteners and nailed joints tend to flex or come apart
relatively readily under various common forms of structural stress. Such
measures
as are typically taken to make the joints in such structures stronger and more
rigid,
however, such as bolts, screws, clenched nails and adhesives and combinations
thereof, rapidly increase the cost and construction time of the structures. It
should
also be noted that some of the alternate forms of fasteners, such as the web
plates
that are often used to assemble rafters and joists and that have large numbers
of
short protruding spike elements that are driven into abutting joists,
typically provide
a joint that has strength along only one axis or plane.
[008] Masonry structures, which are typically constructed from a combination
of
wooden structural elements, such as roofs and floors, and masonry elements
such
as bricks, blocks and slabs bound together and to the wooden elements by
mortar
or specialized fasteners, suffer from similar problems, as well as being
heavier and
more expensive to construct. While such structures may be initially stronger
and
more rigid than wooden structures, such structures often include even more
joints
than wooden structures, such as the joints between bricks and blocks, and
mortar,
for example, is very subject to cracking and sudden failure once a stress
limit is
reached. In addition, masonry structures are susceptible to stresses that more
flexible wooden structures will survive, such as stresses caused by earth
movements, such as caused by earthquakes or by wave or landslide erosion, and
masonry buildings, unlike wooden structures, will often fail catastrophically
and
almost completely once failure has started. It must be further noted that
masonry
structures of often subject to cracking with temperature induced expansion and
contraction, as well as settling, and often present ventilation problems,
resulting in
excess humidity, condensation and possible mold growth.
[009] Structures such as houses, schools, stores, governmental, public service
and
medical facilities and similar structures have also been constructed from
modular
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iron or steel elements fastened together, for example, with metal pins or
bolts or by
welding. While this type of structure is generally stronger and more rigid in
both the
elements and joints than wooden or masonry structures, the significantly
greater
cost and weight of the structures and the fact that such structures are
significantly
more difficult, complex and time consuming to construct typically renders such
structures impractical except in specific, special circumstances. Other
implementations of such structures may use somewhat different materials, such
as
aluminum or plastic, but have all been found to suffer from one or more of the
above
discussed disadvantages.
[010] The above discussed problems are compounded in the case of already
existing structures, many of which lack adequate resistance to hurricanes,
tornadoes, storms, forest and brush fires, floods and earthquakes. In some
instances it is possible to replace existing structures with new construction
meeting
the necessary environmental resistance criteria. In many cases, however, it is
not
possible or feasible to replace existing structures because of, for example,
economic, legal, zoning or site restrictions and it is necessary to modify or
adapt the
existing structures to provide improved resistance to environmental factors.
The
adaptation or modification of an existing structure to provide improved
structural
resistance against wind, fire, flood or earthquake damage is a very different
matter
from the construction of a new structure as it is necessary to work around an
existing structure, which will often restrict or interfere with the necessary
structural
modifications.
[011] The modular structural system of the present invention as described
herein
below provides solutions to these and other problems of the prior art.
[012] SUMMARY OF THE INVENTION
[013]
[014] TO BE PROVIDED AFTER FINAL REVIEW AND APPROVAL OF THE
SPECIFICATION, DRAWINGS AND CLAIMS
[015] BRIEF DESCRIPTION OF THE DRAWINGS
[016] The invention will now be described, by way of example, with reference
to the
accompanying drawings in which:
[017] Figs. 1 A and 1 B are illustrative diagrammatic representations of a
generalized
structure constructed with the modular structural components and connection
structures of the present invention;
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[018] Figs. 2A is a side and a cross sectional view of a chord of the present
invention;
[0191 Fig. 2B is a side and a cross sectional view of a forming strip of the
present
invention;
[020] Figs. 2C, 2D 2E and 2F are diagrammatic illustrations of purlin
structural
components;
[021] Figs. 2G and 2H are diagrammatic illustrations of roofing structural
components;
1022] Figs. 21, 2J and 2K are diagrammatic illustrations of lattice truss
structural
components;
[023] Figs. 2L, 2M and 2N are diagrammatic illustrations of brace structural
components;
[024] Fig. 20 is a diagrammatic illustration of a stub structural component;
[025] Figs. 2P, 2Q, 2R, 2S, 2T, 2U and 2V are diagrammatic illustrations of
bracket
structural components;
[026] Figs. 3A and 3B are cross section views of a chord of the present
invention;
[027] Fig. 3C is a cross section view of a forming strip of the present
invention;
1028] Fig. 3D is a cross section view of a structural component have a forming
strip
of the present invention;
[029] Fig. 3E is a cross section view of several forming strips mating with a
chord
and bolts fastening forming strips to the chord;
[030] Figs. 4A and 4B are diagrammatic illustrations of the main structural
components and assembly of an extreme environmental condition resistant (EECR)
structure generally similar to the structure 10 illustrated in Figs. 1A and 1
B;
[031] Figs. 5A and 5B are respectively diagrammatic representations of an EECR
roof ridge section and an EECR double eave section;
[032] Fig. 5C is a diagrammatic illustration of an EECR double beam connector;
[033] Fig. 5D is a diagrammatic illustration of an EECR ridge section;
[034] Fig. 5E is a diagrammatic illustration of an EECR eaves section;
[035] Fig. 5F is a diagrammatic illustration of an EECR section;
[036] Fig. 6A is an isometric diagrammatic illustration of a modular
structural
assembly comprising a modular wall assembly;
[037] Fig. 6B is a diagrammatic cross section view of the modular structural
assembly comprising a modular wall assembly of Fig. 6A,
[038] Figs. 7A and 7B are illustrative diagrammatic representations of the
reinforcement of a generalized previously existing structure;
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(0391 Figs. 8A and 8B are illustrative diagrammatic representations of
reinforcing
wall panel assemblies; and,
[040] Fig. 9 is an illustrative diagrammatic representation of a platform
segment
assembly.
[041] DETAILED DESCRIPTION OF THE INVENTION
[042] The following describes a system and method for the construction of
structures having improved resistance to extreme environmental conditions and,
in
particular in the present case, for a system and method for adapting and
modifying
existing structures to provide improved resistance to extreme environmental
conditions.
[043] As will be described in the following, the system and method of the
present
invention for constructing a structure or for adapting or modifying an
existing
structure to provide improved resistance to environmental conditions is based
upon
modular structural components. The modular structural components are of light
weight and high strength, and the number of different types of component parts
are
limited but allow great flexibility in constructing or modifying a wide
variety of
buildings from a limited set of common components.
[044] The following will first describe the structural components and methods
of
assembly of a structure such as a house constructed according to the system
and
method of the present invention. Section A of the following description will
then
describe a set of modular structural components as employed in the present
invention to construct any generalized structure, such as a generalized house
meeting conventional requirements. Sections B and C of the following
description
will then present more detailed descriptions of a set of primary modular
structural
components of the present invention, such as chords, forming strips and stub,
and
the mating of these components for construct a generalized structure of any
desired
form. The following descriptions will then describe the forms and assembly of
the
structural components and assemblies discussed in Sections A - C, but as
employed according to the present invention to construct a structure having
improved resistance to extreme environmental conditions, such as a hurricane-
proof
house.
[045] The following will then describe the structural components and methods
of
assembly that, used in conjunction with the previously described structural
components and methods of assembly, allow the adaptation or modification of an
existing structure to provide improved resistance to extreme environmental
conditions.
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[046] Referring to Figs. 1A and 1 B, therein are shown diagrammatic views of a
structure 10, specifically a house, constructed according to the system and
method
of the present invention. As illustrated in particular in Fig. 1 B, structure
10 is of two
floors l OA and 10B and an attic space 10C with first floor 10A being raised
above
ground level on piled foundations comprised of piers 10D with connecting ring
beams, balconies on all four sides of the structure 10 and at least one stair
10F
extending from ground level to a balcony.
[047] As illustrated in Figs. 1 B, the most basic components 12 of the house
10
structure include wall framing elements and assemblieslOF forming the wall
framing, floor framing elements and assemblies 10G forming the floor framing,
roof
framing elements and assemblies 10H forming the rafters and beams supporting
roofing 101, and a relatively small range of detail elements and assemblies
10M
performing specialized structural functions, such as joining wall purlins and
forming
corners, eaves, rafter/wall joins and roof peaks.
[048] It will be understood that other elements of a structure 10 as
illustrated in
Figs. 1A and 1 B will include foam support/insulation material injected into
all wall
and floor spaces for insulation, soundproofing and additional structural
support and
exterior and interior wall sheathing. In this regard, it should be noted that
the
exterior wall sheathing may be comprised, for example, of plywood or any other
suitable sheathing material bolted or adhered to the wall framing elements and
interior wall sheathing may be comprised, for example, of wallboard or other
suitable
interior sheathing attached to the wall framing by, for example, self-tapping
screws
or adhesives. It will also be understood that electrical, water, waste
disposal,
heating and cooling facilities and similar systems will be installed in or on
the walls,
floors, ceilings and so on in any relatively conventional or suitable manner,
depending on the purposes, functions and intended characteristics of the
structure
10.
[049] It will be appreciated, however, that a structure such as house 10
illustrated
in Figs. 1A - 1G represents only a limited part of the range of various types
of
structures that may be constructed according to the present invention.
[050] Next considering the components 12 that can be used to construct a
structure
10, Figs. 2A-2Y are diagrammatic illustrations of many of the components 12 of
the
system of the present invention of modular common components for constructing
temporary structures such as environment resistant houses 10. As will be seen,
the
components 12 of the present invention form a complete set of different types
of
modular components 12 necessary and adequate to construct virtually any
desired
Structure 10, although it will be appreciated that the selection of components
12 for
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a given circumstance will vary, depending on the requirements and intended
characteristics of the structure. As illustrated in Figs. 2A-2Y, the selection
of
components 12 typically include a number of basic, fundamental structural
components 12 that are typically common to almost all structures 10, together
with
certain special or limited purpose components 12 as required for a particular
situation.
[051] It should also be noted that certain of the components 12 described
herein
below are described as being of various standard lengths, which are selected
to
provide the maximum flexibility in constructing structures 10 while requiring
the
minimum number of different lengths necessary to achieve the maximum
modularity
in both the components 12 and the structures 10. In a present embodiment of
the
invention, for example, the lengths of components 12 may vary between 3 and 12
feet and may include, for example, intermediate modular lengths of 4, 6 and 9
feet.
[052] A. Modular Common Components 12
[053]
[054] According to the present invention, and as will be discussed in detail
in the
following, the components 12 are, in turn, comprised of one or more of a
limited
number of different types of common structural elements 12E having shapes and
functions as defined according to the present invention and wherein the term
common component refers to a component shared among or appearing among or
as part of a number of other components. As will be described, structural
elements
12E will generally include main elements 14, connection elements 16 and
reinforcing elements 18 wherein one or more main elements 14 comprise the main
structural members of a component 12 and may be comprised of structural
members referred to as chords 14C and forming strips 14F. Connection elements
16 in turn comprise the means by which components 12 are connected together to
form a structure 10 and are typically formed of forming strips 14F or stubs
16S.
Reinforcing elements 18, in turn, are are structural members permanently
connected
between, for example, the main elements 14 of a component 12, to provide
additional strength or form to the basic structure of the component 12 and are
typically formed, for example, of sections of pipe or other tubular elements,
referred
to as reinforcements 18R, or flat metal plates, referred to as gussets 18G.
[055] Next referring to certain of the varieties of components 12
individually, as
shown in Fig. 2A a chord 14C is an elongated member having a variable length
and
the chord 14C cross section illustrated in Fig. 2A while a forming strip 14F
is an
elongated member of variable length having the forming strip 16FS cross
section
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illustrated in Fig. 2B. It will be understood after the following discussions,
however,
that components 12 may include yet other standard structural shapes where such
other elements would be more suitable for the intended purpose.
[056] In the method and apparatus of the present invention, a typical set of
components 12 will include those components 12 most commonly used in a typical
structure 10. Such components 12 will typically include straight chords 20 of
various
lengths, as shown in Fig. 2A, wherein a straight cord 20 has a single main
element
14, which is a single chord 14C that is usually positioned vertically and that
has a
number of bolt holes 14B extending through the diameter of the chord 14C near
the
ends to engage with one or more connecting elements 16. A straight chord 20
will
also typically include bolt holes 14B located along the length of the chord
14C at
standard distances or intervals to enable connections to other components 12.
[057] Components 12 may also include various forms of purlins 22 wherein a
purlin
22 is a generally beam-like structure. In this regard, it should be noted that
the term
"purlin" once referred to a specific type of horizontal structural member. The
term
"purlin" has, in more recent common usage, assumed a general meaning as any
type of horizontal structural member and could be extended to include
vertically
oriented structural members and will be used in this broader sense in the
present
discussions and descriptions of the invention.
[058] As shown in Figs. 2C, 2D, 2E and 2F, the various types of purlins 22
typically
include single purlins 22A, as shown in Fig. 2C, which are each comprised of a
single horizontally positioned main element 14 comprised of a single chord 14C
of
standard length with a connection element 16 located at each end of the chord
14C.
In a typical single purlin 22A, the connection elements 16 are comprised of
sections
of forming strips 14F attached transversely to the ends of the single purlin
22A, and
the main element 14 may in certain alternate embodiments be comprised of a
forming strip 14F of the desired length rather than of a chord 14C.
[059] Standard purlins 22B of various lengths are, as shown in Fig. 2D,
comprised
of upper and lower horizontal main elements 14 with generally vertical
reinforcing
elements 18 running between the horizontal main elements 14 and a connection
element 16 at each end of each of the main elements 14. In a typical
implementation of a standard purlin 22B, the horizontal main elements 14 may
be
comprised of forming strips 14F or chords 14C, the reinforcing elements 18 are
typically formed of piping of an appropriate diameter and wall thickness, and
the
connection elements 16 are each comprised of a vertical section of forming
strip
14F extending between the upper and lower horizontal main elements 14.
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[060] Platform deck purlins 22C, shown in Fig. 2E, are intended for use as the
supporting structures for horizontal platforms or decks, such as may be used
to form
work platforms, stair landings, exterior deck floors, floors between levels of
a
structure 10, a runway or slanted ramp between level platforms, and so on. A
platform deck purlin 22C is thereby comprised of a parallel pair of
horizontally
positioned and horizontally spaced apart main elements 14 that are typically
comprised of chords 14C but that may be comprised of forming strips 14F, and
that
are connected by reinforcing elements 18 formed of forming strips 14F
extending
horizontally between and a right angles to the main elements 14. A connection
element 16 comprised of a forming strip 14F extending between and attached to
the
main elements 14 is located at each end of the platform deck purlin 22C, so
that the
platform deck purlins 22C may be connected to, for example, horizontally
positioned
standard purlins 22B. Decking or platform components, such as various types of
deck or interior floor materials or underflooring and top finish flooring of
all types,
may then be laid upon or attached to the top surface of one or more adjacent
platform deck purlins 22C to form, for example, a balcony or deck floor or a
floor
between levels of a structure 10.
[061] Finally, purlins 22 may include ridge purlins 22D which, as shown in
Fig. 2F,
are configured to form a roof ridge for roofs having various degrees of slant
and
various lengths. Ridge purlins 22D are of one or more standard lengths and are
each comprised of a ridge pivot 24 having two rotating attachment plates 26
rotatably attached to each end to allow the attachment of roof elements to the
ridge
pivot 24 at the desired or necessary slant angle. In this regard, it should be
noted
that ridge purlins 22D are designed for a specific purpose as a roof ridge
element
for roofs having various slant angles rather than as a general use elements,
although ridge purlins 22D may be used for other purposes, such as providing a
rotating connection. Ridge pivots 24 may be comprised, for example, of piping
of
a suitable diameter and wall thickness, while rotating attachment plates 26
are
simple plates rotatably attached to the ends of ridge pivots 24 and with bolt
holes 14B for the attachment of the roof members.
[062] Related roofing components 12 include roofing components 28, which may
include ridge chords 28A and double eave sections 28B, shown in Figs. 2G and
2H,
which are respectively used to form a roof peak at a fixed slant angle and to
form
the eaves of a roof. As illustrated, a ridge chord 28A is comprised of two
main
elements 14 comprised of chord 14C sections attached at a desired angle and
may
be constructed with or without a reinforcing gusset 18G in the interior angle
between
the two chord 14C sections. A double eave section 28B, in turn, is comprised
of
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main elements 14 comprised of chord 14C sections arranged as shown in Fig. 2H
and may or may not include reinforcing gussets in the interior angles between
the
chord 14C sections.
[063] Other components 12 include, for example, various lattice trusses 30 and
braces 32 wherein lattice trusses 30 are in many respects similar to purlins
22 but
which are designed primarily as a structural strengthening component rather
than
as a connecting or attachment element. As such, one of the primary differences
between lattice trusses 30 and purlins 22 is that, in accordance with their
intended
function, the reinforcements 18R are positioned at an angle to the main
elements
14 rather than perpendicular to the main elements 16. As illustrated in Figs.
2G, 2H
and 21, small ridge lattices 30A, small eave latices 30B and lattice trusses
30c are
generally comprised of two vertically spaced apart, parallel, horizontal main
elements 14 interconnected by a number of reinforcements 18R extending at an
angle between the main elements 14 and having connection elements 16 extending
vertically between the main elements 14 at the ends of the main elements 14.
[064] As may be seen from Figs. 21, 2J and 2K, the primary differences between
the various forms of lattice trusses 30 are in the dimensions and outline
forms of the
lattice trusses 30, with, for example, a lattice truss 30C forming an
elongated
rectangle while small ridge lattices 30A and small eve lattices 30B and
proportionally
shorter in the horizontal direction and have one end at an angle with respect
to the
overall rectangular shape of the lattice. In general, the main elements 14 of
lattice
trusses 30 may be comprised of forming strips 14F, while connection elements
16
are normally comprised of sections of forming strips 14F and the reinforcing
elements 18 are most typically comprised of piping reinforcements 18R of an
appropriate diameter and wall thickness.
[065] Braces 32, shown in Figs. 2L, 2M and 2N, may include knee braces 32A,
cross-tie braces 32B and diagonal braces 32C, each of which is comprised of a
main element 14 running at an angle between two other structural components 12
as a reinforcement 18, such as between a purlin 22 and a straight cord 20.
Each
brace 32 also includes a connection element 16 mounted at each end of and at
an
angle to the longitudinal axis of the main element 14 to form a mating
connection
with the components 12 supported by the brace 32. The main elements 14 of
braces 32 are typically comprised of sections of chords 14C, forming strips
14F or
reinforcements 18 and the connection elements 18 are typically comprised of
sections of forming strip 14F.
[066] Yet other components 12, illustrated in Figs. 2P and 20, include stubs
34 and
brackets 32 wherein stubs 34 provide axial connections between, for example,
two
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straight chords 20 or between a straight chord 20 and a bracket 32 or between
two
chord 14C elements. A stub 34 is comprised of a length of square cross section
tubing dimensioned to slidingly fit within the square cross section
longitudinal
opening in a section of a chord 14C, as illustrated, for example, in the
following Figs.
3A-3E. A stub 34 is also typically provided with two transverse openings,
identified
as bolt holes 14B, located in one half of the length of the stub 30 and
corresponding
to bolt holes 14B through a section of chord 14C to affix the stub 30 into a
mating
engagement with the section of chord 14C by means of, for example, a T-bolt or
a
standard hex bolt passing through the transverse openings, as also further
illustrated in the following Figs. 3A-3E as well as in Figs. 2A-2Y.
[067] As indicated in Figs. 2P-2W, brackets 32 may include drop brackets 32A,
male and female stub brackets 32B and 32C, male and female brackets 32D and
32E, ridge drop brackets 32F, bottom truss brackets 32G and single base plates
32H, all of which are designed to facilitate an attachment of one component 12
to
another by means of a stub 30. As illustrated, each bracket 32 includes at
least one
main element 14 comprised of a section of a chord 14C and one or more
connection
elements 16 for attachment of the bracket 32 to another component 12 wherein
each connection element 16 may be comprised, for example, of a section of a
forming strip 14F or of a flat plate welded to a main element 14 and having
bolt
holes 14B for attachment by means of, for example, T-bolts or standard hex
bolts.
[068]
[069] B. Prima Structural Elements 12E - Chords 14C. Forming Strips 14F and
Stubs 34
[070]
[071] Referring again to Figs. 2A-2Y will be apparent from the above
descriptions
of the components 12 of the system of modular common components for
constructing temporary structures of the present invention that components 12
and
the sub-components of components 12 are essentially comprised of certain
primary
structural elements 12E, together with certain common elements, such as tubing
for
reinforcing elements, and a few relative rare elements, such as wheel
assemblies.
As described, the primary structural elements 12E include chords 14C of
various
lengths, forming strips 14F of various lengths, connection elements 16 and
stubs 34.
[072] Cross sectional views of chords 14C, forming strips 14F and stubs 30 are
illustrated and discussed with respect to Figs. 3A-3E wherein Fig. 3A is a
cross
sectional view of a chord 14C, Fig. 3B is a cross sectional view of a chord
14C with
a stub 34 inserted therein and with bolt holes 14B, Fig. 3C is a cross
sectional view
of a forming strip 14F, Fig, 3D is a cross sectional view of, for example, a
purlin 22,
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a lattice truss 30 or a brace 32, and Fig. 3E is a cross sectional view of a
chord 14
with multiple forming strips 14F mated thereto and secured with a hex-bolt 40H
and
a T-bolt 40T. The following descriptions will refer to all of Figs. 3A-3E
concurrently
as certain aspects and elements of the present invention will be shown in one
of
Figs. 3A-3E and not another solely for clarity of illustration, presentation
and
understanding and to avoid the complexity and crowding arising from the
showing
of all features in each individual figure. It must be understood, however,
that the
showing of one feature or aspect of the present invention in one of Figs. 3A-
3E and
not another is not intended to be limiting and should not be taken to be
limiting and
that any given feature or aspect of the invention may otherwise appear in any
or all
of Figs. 3A-3E and in any combination.
[073] As illustrated in Figs. 3A, the main body 42 of a chord 14C is defined
by four
main walls 42W surrounding a generally square central opening, identified as
bore
42B, forming a generally square cross section, having four Interior main
surfaces 421
and four exterior main surfaces 42E extending the length of the chord 14C, the
Interior surfaces 421 and exterior surfaces 42E being spaced apart by the wall
thickness 42T of main walls 42W.
[074] The exterior main surface 42E of each main wall 42W further includes a T-
slot structure 44 extending along the length of the chord 14C and centered on
the
exterior main surface 42E. Each T-slot structure 44 is formed by two parallel
slot
side walls 44S extending outwardly in parallel from the exterior main surface
44E
and along the axis of the exterior main surface 44E and two slot face walls
44F
extending inwardly towards each other from the tops of slot side walls 44S and
parallel to exterior main surfaces 44E.
[075] The structural elements of each T-slot structure 44 thereby form an
interior
T-slot 46 opening extending along the length of the T-slot structure 44, that
is, the
length of the chord 14C. Each T-slot 46 has a T-shaped cross section that
includes
a shaft T-slot 46S portion extending perpendicularly from the outer surface of
the
T-slot structure 44 and inwardly towards bore 42B of main body 42 and a cross
T-
slot 46C extending at right angles to either side of shaft T-slot 46S at the
inner end
of shaft T-slot 46S and terminating shaft R-slot 46C.
[076] The dimensions and shape of a T-slot structure 44 and the interior
dimensions and shape of a T-slot 46 are determined so that a T-slot 46 will
accept
either a conventional hex bolt 40H or a T-bolt 40T, with the head of the hex-
bolt 40H
or the head of the T-bolt 40R being accepted into and fitting within the cross
T-slot
46C. The shape and dimensions of T-slot 46 are specifically designed for use
with
hex bolts 40H, which as well known and as indicated by phantom lines in, for
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example, Fig. 3E, has a rectangular head wherein the head is generally
slightly
longer than the width of cross T-slot 46C and approximately as wide as the
width of
shaft T-slot 465. The shape and dimensions of the head of a T-bolt 40T are
thereby
such that the head of a T-bolt 40T may pass through shaft T-slot 46S and into
cross
T-slot 46C when the long axis of the rectangular T-bolt 40T head is aligned
along
the longitudinal axis T-slot 46. The T-bolt 40T may then be rotated about the
axis
of the shaft of the T-bolt 40T until the head of the T-bolt 40T is transverse
to the
longitudinal axis of the T-slot 46. At this point, the T-bolt 40T cannot be
withdrawn
from the T-slot 46 as the length of the T-bolt 40T head in this orientation is
greater
than the width of the shaft T-slot 46S. In addition, the T-bolt 40T can be
rotated to
form an interference fit with the walls of cross T-slot 46C, thereby
preventing
movement of the T-bolt 40T along the T-slot 46 or at any angle to T-slot 46.
The T-
bolt 40T can be removed only by rotating the T-bolt 40T until the long axis of
the T-
bolt 40T head is aligned with the longitudinal axis of the T-slot 46.
[077] T-slots 46 may also accept standard hex-bolts 40H but the shape and
dimensions of the head of a hex-bolt 40H will generally prevent the insertion
or
removal of the head of the hex-bolt 40H through shaft T-bolt 46S at any point
along
the length of the T-slot 46, and will generally require that the hex-bolt 40H
be
inserted or removed at one end of the T-slot 46 and moved along the T-slot 46
to
the desired location. It will also be recognized that the shape of the head of
a hex-
bolt 40H will generally not permit effective use of the rotating cam locking
action, as
with a T-bolt 40T, unless the head of the hex-bolt 40H is specially adapted
for this
purpose.
[078] Further in this regard and as also illustrated in Figs. 3A-3E and as has
been
discussed, chords 14C, forming strips 14F and stubs 14S include bolt holes 14B
located along their lengths to allow the components 12 to be attached to one
another by, for example, hex-bolts 40H. The arrangement of bolt holes 14B in a
structural element 12E, such as a chord 14C, a forming strip 14F or a stub
14S,
usually takes the form of a pair bolt holes 14B at or near each end of the
structural
element 12E, with the two bolt holes 14B being arranged in series along the
structural element 12E and spaced a first standardized distance apart. Other
single
bolt holes 14B may also be spaced along the structural element 12E, and will
typically be spaced a second standard distance apart where the second standard
distance is typically larger than the first standard distance.
[079] The bolt holes 14B in a chord 14C for T-bolts 40T are illustrated
generally in
Fig. 3E and 3B, wherein a bolt hole 14B is shown as extending transversely
through
the width of the chord 14C. As indicated, the bolt hole 14B is comprised of
the
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passage formed by the shaft T-slots 46T located on opposing sides of the chord
14C and two matching holes 14H formed in main walls 42W, which thereby connect
the two shaft T-slot 46T through the main body 42 of the chord 14C to form the
single bolt hole 14B passage. As indicated, the head 40HH of the hex-bolt40H,
and
often a washer of some form, will thereby bear against the outer surface of
the slot
face walls 44F of one of the T-slot structures 44 while the hex nut, and again
possibly a washer, will bear against the outer surface of the slot face walls
44F of
the opposing T-slot structure 44.
[080] As further illustrated in Fig. 3B, a stub 34 may be inserted into the
central
bore 42B of a chord 14C with bolt holes 14B in opposite faces of the stub 34
corresponding to and being aligned with corresponding passages on opposite
sides
of the chord 14C. As shown, the passage on each side of chord 14C is comprised
of a bolt hole 14B in a main wall 42W of the chord 14C in alignment with the
shaft
T-slot 46S of the corresponding T-slot structure 44, thereby allowing a hex-
bolt 40H
to be secured through the chord 14C and stub 34. As described previously,
stubs
34 thereby allow chords 14C to be connected lengthwise to yet other components
12, such as another chord 14C or a wheel assembly.
[0811
[082] C. Mating Of A Forming Strip 14F To A Chord 14C
[083]
[084] Next considering the mating of a chord 14C with a forming strip 14F,
such as
a connection element 16, and as illustrated in particular in Fig. 3E and in
Figs. 3B
and 3C considered jointly, it will be apparent that the cross section forms of
a chord
14C and of a forming strip 14F result in a plurality of bearing surfaces to
support
compressive, tensional and torsional forces resulting from the assembly of
components 12 into a structure 10.
[085] First considering chords 14C, for example, each exterior main surface
44E
of a chord 14C provides two chord bearing surfaces 48, indicated as main body
bearing surfaces 48A and 48B, wherein each of main body bearing surfaces 48A
and 48B is located between a exterior side of a slot side wall 44S and the
outer
edge of the adjacent exterior main surface 44E and extends the length of the
exterior main surface 44E. The slot side walls 44S and slot face walls 44F of
each
T-slot structure 44 form side wall bearing surfaces 48C and 48D and face wall
bearing surfaces 48E and 48F for each exterior main surface 44E. As indicated,
side wall bearing surfaces 48C and 48D and face wall bearing surfaces 48E and
48F are formed by the exterior surfaces of slot side face surfaces 44S and
slot outer
face surfaces 440.
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[086] Lastly with respect to chords 14C, it must be noted that the inner
surfaces of
each T-slot 46, that is, the inner faces of slot side walls 44S and slot face
walls 44F,
form further bolt bearing surfaces 48G and 48H to support the compressive
forces
resulting from tensional and torsional forces imposed through T-bolts 40T. In
this
regard, it must also be noted that the plane defined by the inner face of each
cross
T-slot 46C, that is, the face parallel and adjacent to the corresponding
Interior main
surface 421 of the main wall 42W of the chord 14C, is not co-planar with the
corresponding exterior main surface 42E of the main wall 42W. Instead, the
plane
defined by the inner face of each cross T-slot 46C is offset inwardly towards
the
central axis of the chord 14C with respect to the exterior main surface 42E,
thereby
effectively being within the thickness of the main wall 42W. As may be seen
from
examination of Figs. 3A-3E, not only are the planes of the inner face of each
cross
T-slot 46C and the corresponding exterior main surface 42E of the main wall
42W
not co-planar, but the wall thickness through the diagonal shortest path
between
these planes, that is, between the adjacent corners terminating these planes,
is
maximized so that the geometry of these elements provides increased strength
at
a potential point of maximum stress.
[087] Referring now to forming strips 14F as illustrated in cross sectional
view in
Figs. 3C, 3D and 3E, each forming strip 14F is comprised of a single strip
plate 50P
having a standard width and a variable length that is typically greater than
its width
and that may range from the entire length of a purlin 22, for example, to the
length
necessary to form an attachment between, for example, a purlin 22 or truss 30
and
a chord 14C. As illustrated in the cross sectional views of a forming strip
14F, the
cross section of a forming strip 14F is comprised of a plurality of strip
segments 50S
running the length of the forming strip 14F and forming a succession of faces
mating
with corresponding faces formed by the cross section of a chord 14C.
[088] As shown, each strip segment 50S in succession across the strip plate
50P
is perpendicular to the preceding and succeeding strip segments 50S, so that
successive strip segments 50S are joined by right angle corners, identified as
strip
corners 50C. Strip segments 50S may in turn be viewed as forming three primary
regions, indicated in order across the strip segments 50S as comprising a
corner
region 50RC, a face region 5ORF and an attachment region 50RA.
[089] As illustrated, corner region 50RC is comprised of strip segments
50SA, 52SB and 52SC, thereby forming a "zig-zag" or "w shaped" structure
mating
with a corner formed by the main wall 42W of the face of the chord 14C with
which
the forming strip 14F is mating and an adjacent main wall 42W of that chord
14C.
Corner region 50RC thereby forms bearing surfaces 52A, 52B and 52C that
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respectively mate with corresponding main body bearing surfaces 48A and 48A
and
a wall bearing surface 48C of the chord 14C.
[090] Face region 50RF is formed of the single strip segment 50SF which mates
against the two slot Outer face surfaces 440 of the T-slot structure 44 of the
main
wall 42W of the face of the chord 14C with which the forming strip 14F is
mating.
As may be seen, therefore, face region 5ORF provides a bearing surface 52D/E
that
mates with face wall bearing surfaces 48E and 48F of the T-slot structure 44.
[091] Finally, attachment region 50RA is comprised of strip segment 50SG,
which
extends directly outwards from the chord 14C along one side of the forming
strip
14F and which does not bear against any surface of the chord 14C. Instead,
attachment region 50RA provides a structural element for stiffening and
reinforcing
the forming strip 14F and as a possible attachment point or attachment
reinforcement point for other structural elements that are permanently
attached to
the forming strip 14F. For example, attachment region 50RA may serve as the
attachment point for cross forming strips 14F running between longitudinal
forming
strips 14F, for the attachment and bracing of various other reinforcing
elements,
such as the piping sections of a lattice, or for the attachment of decking
plates or
grids.
[092] In this regard, Fig. 3D is an exemplary cross sectional view of a
component 12 wherein various elements, such as reinforcing elements 18, are
connected between two forming strips 14F which comprise the main structural
elements of the component 12. Examples of such may include various forms of
purlins 22 and lattice trusses 30. As shown therein, the reinforcing elements
18 are
attached to a strip attachment face 52AF in the face region 50RF area of a
forming
strip 14F wherein strip attachment face 52AF is "outer" side of face region
50RF,
that is, the side of face region 5ORF that normally faces away from a chord
14C
when the forming strip 14F is mated to the chord 14C as described above.
[093] It will, therefore, be seen from Figs. 3A-3E that one or more forming
strips 14F or segments of forming strip 14F functioning as connection elements
16
can be concurrently mated to any or all of the four faces of a chord 14C or a
segment of a chord 14C, thereby allowing great flexibility in designing and
assembling components 12 into a structure 10. In the illustrative example
shown
in Fig. 3E, for example, three forming strip 14F sections are mated to a
single
section of a chord 14C wherein the forming strip 14F sections are, for
example,
connection elements 16 of other components 12. As shown, two of the forming
strip
14F sections are mated in a mirror orientation to opposite sides of the chord
14C
and are mechanically fixed to the chord 14C by at least one hex-bolt 40H
extending
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through the chord 14C between the outer faces of their respective face regions
50RF. The third forming strip 14F is mated against a third face of the chord
14C,
and is mechanically fixed to the chord 14C by a T-bolt 40T inserted into the
corresponding T-slot 46 of that face of the chord 14C.
[094] It will be appreciated from examination of Fig. 3E, however, that the
limitation
of the configuration illustrated in Fig. 3E is solely due to the chosen
orientations of
the forming strips 14F with the faces of the chord 14C and that up to four
forming
strips 14F functioning as, for example, connection elements 16, can be
accommodated. For example, it may be seen in Fig. 3E that the limitation of
the
configuration to three forming strips 14F arises solely because the corner
regions
50RC of the two mirror oriented forming strips 14F bear against the same face
of
the chord 14C, so that if an attempt were made to mate a fourth forming strip
14F
with the unoccupied face of the chord 14C the corner region 50RC of one or the
other of the two already present forming strips 14F would mechanically
interfere with
the corner region 50RC of the fourth forming strip 14F. It will also be
apparent from
Fig. 3E, however, that if the orientation of the forming strip 14F on the side
on which
the hex-bolt 40H nut is located were reversed, that is, if the forming strip
14F were
rotated about the hex-bolt 40H so that its corner region 50RC occupied the
presently
unoccupied corner of the chord 14C, a fourth forming strip 14F could be
accommodated. Stated another way, if the forming strips 14F mating with a
chord
14C are oriented with respect to the faces of the chord 14C such that each
corner
of the chord 14C were occupied by a corresponding one of the corner regions
50RC
of the forming strips 14F, then the maximum number of forming strips 14F, that
is,
four forming strips 14F, can be mated against the four faces of the chord 14C.
It will
be recognized, of course, that any lesser number of forming strips 14F can
also be
mated to a chord 14C when the forming strips 14F are oriented with respect to
the
faces of the chord 14C such that each corner of the chord 14C is occupied by a
corresponding one of the corner regions 50RC of the forming strips 14F.
[095] Next considering the interaction of the bearing surfaces of the forming
strips
14F and the chords 14C, and referring in particular to Fig. 3E and Figs. 3B
and 3C
jointly, it will be apparent that the design and cross section configuration
of a forming
strip 14F and a chord 14C are such that the two elements will mate along a
plurality
of bearing surfaces 48A-48H and corresponding forming strip bearing surfaces
52A-
52F. It will also be noted that the mating bearing surfaces are oriented along
either
of two mutually perpendicular axis wherein, for each face of the chord 14C,
one axis
is perpendicular to the face of the chord 14C and the second axis is parallel
to the
face of the chord 14C.
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[096] As a consequence, a forming strip 14F and a chord 14C provide a large
mutual bearing surface which permits a forming strip 14F and a chord 14C to
securely carry corresponding large compression and tension forces. In
addition, the
distribution of the bearing surfaces along two mutually perpendicular axis
also
greatly increases the amount of torsional or rotational forces that the
forming
strip 14F and chord 14C are able to resist and support.
[097] In this regard, it will also be noted that in addition to preventing
lateral
movement between, for example, a chord 14C and a segment of forming strip 14F
functioning as a connection element 16, that is, a movement or slip of the
forming
strip 14F along the chord 14C, T-bolts 40T and hex-bolts 40H exert compressive
forces between a chord 14C and a forming strip 14F, thereby resisting tension
forces between the chord 14C and forming strip 14F. That is, and as may be
seen
from Fig. 3A, a hex-bolt 40H will exert a compressive force between the outer
face
of the face region 5ORF of a forming strip 14F bearing against one face of the
chord
14C and either the outer face of the face region 5ORF of a forming strip 14F
bearing
against the opposite face of the chord 14C or the outer face of the T-slot
structure
44T of the opposite face of the chord 14C. In the case of a T-bolt 40T, the
compressive force will be applied between the outer face of the face region
50RF
of a forming strip 14F bearing against one face of the chord 14C and the
inward
facing surfaces of the slot face walls 44F of the T-slot structure 44T of the
same
face of the chord 14C. It should also be noted that the resistance to lateral
movement of the components 12 in the case of a hex-bolt 40H fastening is
provided
by mechanical interference between the shaft of the hex-bolt 40H and the walls
of
the bolt holes 14B. In the instance of a fastening by a T-bolt 40T, the
resistance to
lateral movement along the chord 14C is friction between the mating bearing
surfaces while the resistance to lateral sidewise movement is by mechanical
interference between the shaft of the T-bolt 40T and the longitudinal sides of
T-slot
46.
[098] Lastly considering mechanical connections or attachments between forming
strips 14F and chords 14C, and as discussed herein above, a forming strip 14F
will
typically include one or more bolt holes 14B to allow a forming strip 14F,
such as a
segments of forming strips 14F employed as connection elements 16 on the ends
of other components 12, to be secured to, for example, a chord 14C or segment
of
a chord 14 by means of T-bolts 40T or hex-bolts 40H. The number an spacing of
such bolt holes 14B will depend on the length and intended use of the forming
strip
14F or segment of forming strip 14F, by will correspond to the locations,
spacings
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and dimensions of bolt holes 14B in the mating components 12, as discussed
herein
above.
[099] As shown in Figs. 3C, 3D and 3E, a bolt hole 14B or bolt holes 14B will
be
located in the face region 50RF area of a forming strip 14F, and will be
aligned with
the corresponding shaft T-slot 46S and any corresponding bolt holes 14B
through
the two facing main walls 42W of the chord 14. This arrangement allows the
forming strip 14F to be secured to the chord 14C by means of one or more T-
bolts
40T secured into the T-slot 46 or by means of a T-bolt 40T in combination with
a
Hex-bolt 40H extending through the forming strip 14F and the chord 14C, as
discussed above, or by means of one or more hex-bolts 40H .
[100] In this regard, it will be apparent that the number of bolts 40 in a
connection
or mating between a forming strip 14F and a chord 14C will depend upon the
location of the connection along the chord 14C. As discussed previously, for
example, a chord 14C or forming strip 14F will typically have a pair of
relatively
closely spaced bolt holes 14B at the ends of the chord 14C or forming strip
14F and
a number of single bolt holes 14B spaced apart by a fixed interval along the
length
of the chord 14C or forming strip 14F. In presently preferred implementations
of the
present invention, single bolt hole 14B connections along the length of a
chord 14C
or forming strip 14F are preferably accomplished by means of single T-bolts
40T
while connections by means of the paired bolt holes 14B at the ends of the
elements
are preferably accomplished by a single T-bolt 40T and a single hex-bolt 40H
or by
two T-bolts 40T, although these connections may be varied according to
circumstances.
[101]
[102] D. Extreme Environmental Condition Resistant (EECR) Structures, Basic
Structural Elements
[103]
[104] As described above the present invention is directed to a method and
apparatus for modular construction of extreme environmental condition
resistant
(EECR) structure, such as houses, and, in particular, a system of common
modular
components for constructing buildings such as houses having high resistance to
extreme environmental conditions, such as hurricanes, tornados, fires and so
on.
The following will now describe the adaptations and modifications of the above
described components and assemblies of the present invention to the
construction
of EECR structures.
[105] It will be apparent from the above descriptions of the generalized
components
and assembly methods for the construction of structures that components 12 of
the
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present invention include a limited number of different types of structural
elements
12E having shapes and functions as defined according to the present invention
and
that this "library" of shapes allows the construction of a wide range of
structures 10,
including, as described in the following, extreme environmental condition
resistant
(EECR) structures 10E such as houses having improved resistance to extreme
environmental conditions. As in the generalized components and assembly
methods described above, the basic array of components 12 for EECR structures
1 OE will generally include main elements 14 and connection elements 16 of
various
forms have common contours or shapes and dimensions and wherein the basic
structural members of a component 12 will again generally include the
structural
members referred to as chords 14C and forming strips 14F. Connection elements
16 in turn again comprise the means by which components 12 are connected
together to form ab EECR structure 1 OE, and are typically formed of or
incorporate
forming strips 14F or stubs 16S.
[106] To briefly summarize the above described components and assembly
methods of the present invention as applied to the generalized construction of
structures, which will include EECR structures 1 OE, a chord 14C as shown in
Fig.
2A is an elongated member having a variable length and the chord 14C cross
section illustrated in Fig. 2A while a forming strip 14F is an elongated
member of
variable length having the forming strip 16FS cross section illustrated in
Fig. 2B,
although components 12 may include yet other standard structural shapes where
such other elements would be more suitable for the intended purpose.
[107] As also described, a set or library of components 12 will typically
include
straight chords 20 of various lengths, as shown in Fig. 2A, wherein a straight
cord
20 has a single main element 14, which is a single chord 14C that is usually
positioned vertically and that has a number of bolt holes 14B extending
through the
diameter of the chord 14C near the ends to engage with one or more connecting
elements 16. A straight chord 20 will also typically include bolt holes 14B
located
along the length of the chord 14C at standard distances or intervals to enable
connections to other components 12.
[108] Other commonly used components 12 may also include various forms of
purlins 22 wherein a purlin 22 is a generally beam-like structure. In this
regard, it
should be noted that the term "purlin" once meant as a specific type of
horizontal
structural member, but that the term "purlin" has, in more recent common
usage,
assumed a general meaning as any type of horizontal structural member and
could
be extended to include vertically oriented structural members.
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[109] As was described with reference to Figs. 2C, 2D, 2E and 2F, the various
types of purlins 22 typically include single purlins 22A, as shown in Fig. 2C,
which
are each comprised of a single horizontally positioned main element 14
comprised
of a single chord 14C of standard length with a connection element 16 located
at
each end of the chord 14C. In a typical single purlin 22A, the connection
elements
16 are comprised of sections of forming strips 14F attached transversely to
the ends
of the single purlin 22A, and the main element 14 may in certain alternate
embodiments be comprised of a forming strip 14F of the desired length rather
than
of a chord 14C.
[110] Standard purlins 22B of various lengths, as was shown in Fig. 2D, are
comprised of upper and lower horizontal main elements 14 with generally
vertical
reinforcing elements 18 running between the horizontal main elements 14 and a
connection element 16 at each end of each of the main elements 14. In a
typical
implementation of a standard purlin 22B, the horizontal main elements 14 may
be
comprised of forming strips 14F or chords 14C, the reinforcing elements 18 are
typically formed of piping of an appropriate diameter and wall thickness, and
the
connection elements 16 are each comprised of a vertical section of forming
strip
14F extending between the upper and lower horizontal main elements 14.
[111] Platform deck purlins 22C, in turn, as shown in Fig. 2E, are intended
for use
as the supporting structures for horizontal platforms or decks, such as may be
used
to form work platforms, stair landings, exterior deck floors, floors between
levels of
a structure 10 or EECR structure 10E, a runway or slanted ramp between level
platforms, and so on. A platform deck purlin 22C is thereby comprised of a
parallel
pair of horizontally positioned and horizontally spaced apart main elements 14
that
are typically comprised of chords 14C but that may be comprised of forming
strips
14F, and that are connected by reinforcing elements 18 formed of forming
strips 14F
extending horizontally between and a right angles to the main elements 14. A
connection element 16 comprised of a forming strip 14F extending between and
attached to the main elements 14 is located at each end of the platform deck
purlin
22C, so that the platform deck purlins 22C may be connected to, for example,
horizontally positioned standard purlins 22B. Decking or platform components,
such
as various types of deck or interior floor materials or under-flooring and top
finish
flooring of all types, may then be laid upon or attached to the top surface of
one or
more adjacent platform deck purlins 22C to form, for example, a balcony or
deck
floor or a floor between levels of a structure 10 or EECR structure I OE.
[112] It will be appreciated that yet others of the above described components
12
may be used as necessary to construct a house-like structure 10 or EECR
structure
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10E, including, for example, roofing, truss and bracing components 12 and
components 12 forming, for example, the joins between roof and wall elements
or
floor and wall elements, and so on.
[113] Therefore next considering an exemplary EECR structure 10E, such as a
hurricane resistant house, Figs. 4A and 4B are diagrammatic illustrations of
the
main structural components and assembly of an extreme environmental condition
resistant (EECR) structure 10E.
[114] Referring first to Fig. 4A, it may be seen that an EECR structure 10E
corresponds generally to a structure 10 as illustrated in Fig. 1 B except
that, as may
be seen in Fig. 4A, the structural components of an EECR structure 10E are of
increased strength, such as doubled chords 14C as opposed to single chords
14C,
and the presence of additional reinforcing elements, such as added reinforcing
pillars 1 OR located between main wall assemblies 1 OF.
[115] Fig. 4B in turn is an additional cross sectional view of an EECR
structure I OE
comparable to that illustrated in Fig. 4A, but illustrating the
support/insulation
material ION, which is injected into all wall and floor spaces for insulation,
soundproofing, and structural support, and exterior and interior wall
sheathing 100
and 1 OP that further provides structural reinforcement to the EECR structure
1 OE.
In this regard, it should be noted that the insulation ION is, in a presently
preferred
embodiment, a foam that is preferably continuous across adjacently connecting
walls, floors and roof structures, thereby providing additional support to the
overall
structure. In addition, the structural elements of an EECR structure 1 OE will
typically
further include an exterior wall sheathing 100 which may be comprised, for
example, of plywood bolted or adhered to the wall framing elements, and an
interior
wall sheathing 1 OP which may be comprised, for example, of wallboard attached
to
the wall framing by, for example, self-tapping screws or adhesives, and so on,
both
of which provide further structural reinforcement to the structure.
[110] Considering the adaptations, modifications and changes to the structural
elements 12E of non-extreme environment structures 10 to form the EECR
structural elements 12EE of an EECR structure 10E, it will be noted that, as
shown
in Figs. 4A and 4B, the primary EECR structural elements 12EE include double
chord beams 54B and double chord connectors 54C. As will be described below,
these elements are essentially the primary structural elements of an EECR
structure
10E and respectively form the primary structural beam elements of the walls,
floors,
ceilings and roofs and the elements for joining the double chord beams 54B to
one
another and to other structural elements.
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[117] Therefore first considering the structure and construction of double
chord
beams 54B, Figs. 5A and 5B are respectively an end cross sectional view of a
double chord beam 54B and a spacer 54S for use in constructing a typical
embodiment of a double chord beam 54B. As shown therein, a double chord beam
54B is comprised of a pair of parallel chords 14C spaced apart by one or more
double ended beam spacers 54S, and typically by a plurality of double ended
beam
spacers 54S. In a presently preferred embodiment, each double ended beam
spacers 54S may be comprised of a spacer element 56 extending between the
chords 14C of the double chord beam 54B and attached to each chord 14C by a
corresponding forming strip 14F. As shown, each forming strip 14F is affixed
to the
end of the spacer element 56 to be perpendicular to the axis of the spacer
element
56 and parallel to the axis of the mating chord 14C and thereby mates with the
corresponding chord 14C of the double chord beam 54B in the manner described
in Section C herein above. It should also be noted that spacer elements 56 may
alternately be comprised, for example, of reinforcements 18R arranged between
the
chords 14C or any other form of structural connecting members, such as flat
plates,
tubular members, and so on, and may be permanently affixed to the chords 14C
of
the double chord beam 546, such as by welding, to form a unitary permanent
structural element.
[118] Next considering double chord connectors 54C, as illustrated in Fig. 4A
double chord connectors 54C are employed, for example, to join double chord
beams 54B at the intersections between floor and wall beams or between floor
and
floor or wall and wall beams. It will be noted that, as illustrated in Fig.
4A, certain
EECR double chord connectors 54C, such as those joining three double chord
beams 54B as in the instance of the intersection a single double chord beam
54B
floor beam and two double chord beam 54B wall beams at an outside wall, may
include mating elements for three rather than four double chord beams 54B.
[119] Fig. 5C is a diagrammatic illustration of a single plane, four way EECR
double
chord connector 54C for four double chord beams 54B arranged in a cruciform
configuration in one plane, such as formed by the joining between a vertical
upper
double chord beam 54B, a vertical lower double chord beam 54B and two
opposingly extending double chord beams 54B. As shown therein, a single plane,
four way EECR double chord connector 54C is comprised of a double ended,
double beam connector 54CD comprised of a pair of parallel chords 14C' spaced
apart by a two or more spacers 54S wherein spacers 54S may, for example, be
comprised of a forming strip 14F extending between and attached to the chords
14C' by forming strips 14F, reinforcements 18R arranged between the chords
14C'
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or any other form of structural connecting members, such as flat plates
attached to
the chords 14C'.
[120] An EECR double chord connector 54C further includes at least one single
ended, double beam connector 54CS comprised of a pair of parallel chords 14C"
connected at one end to one of the chords 14C' of double ended, double beam
connector 54CD and spaced apart by at least one spacer 54S. The configuration
illustrated in Fig. 5C, for example, includes a second single ended, double
beam
connector 54CS connected to and at right angles to the axis of the other of
the pair
of chords 14C' of the double ended, double beam connector 54CD. Again, spacers
54S of the single ended, double beam connectors 54CB may be comprised, for
example, of a forming strip 14F extending between and attached to the chords
14C',
reinforcements 18R arranged between the chords 14C' or any other form of
structural connecting members.
[121] As indicated generally in Fig. 5C and as described in Sections B and C
herein
above, structural elements such as double chord beams 54B used as floor or
wall
beams or other structural elements of the present invention may be attached to
an
EECR double chord connector 54C, or to each otherthrough an EECR double chord
connector 54C, by means of stubs 14S inserted into the chords 14C' and 14C' of
the
EECR double chord connector 54C, as described herein above, or by forming
strips
14F bolted to the chords 14C or 14C" of the EECR double chord connector 54C,
as also described herein above.
[122] It should also be recognized that an EECR double chord connector 54C as
illustrated in Fig. 5C can be readily modified or extended into various
configurations,
including three dimensional configurations. For example, the double chord
connector 54C illustrated in Fig. 5C may be adapted to the junction of floor
and wall
beams at the outer wall of an EECR structure I OE, where there is a double
floor
beam 54A only one one side of the junction, merely by eliminating one of the
horizontally extending single ended, double beam connector 54CS. In a further
example, a double chord connector 54C may be adapted for use in the interior
of
a structure at a juncture where double floor beams 54A extending at right
angles to
each other intersect at a common junction with upward and downward extending
double wall or support beams 54A. This adaptation would be accomplished by the
addition of one or more single ended, double beam connectors 54CS to the
chords
14C' and 14C" of the double chord connector 54C, but extending at right angles
to
the plane of the double ended, double beam connector 54CD and single ended,
double beam connectors 54CS of the embodiment of a double beam connector 54C
as illustrated in Fig. 5C. The adaptation of the basic embodiment of a double
chord
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connector 54C illustrated in Fig. 5C to yet further configurations will be
apparent to
those of ordinary skill in the arts.
[123] Lastly, it should also be recognized that rather than being constructed
as a
permanent assembly of elements, such as welded components, an EECR double
chord connector 54C may also be constructed by the assembly of individual
components as described in Sections A, B and C herein above.
[124] It will also be apparent that others of the elements 12E described in
Sections
A, B and C herein above may likewise be adapted for use with EECR double chord
beams 54A and double chord connectors 54C. Examples of such include ridge
chords 28A of Fig. 2G and double eave sections 28E of Fig. 2H which have been
modified and adapted as shown in Figs. 5D and 5E to form EECR roof ridge
sections 28AE and EECR double eave sections 28EE to mate with double chord
beams 54A and double chord connectors 54C. In this regard, it must also be
noted
that structural elements 12E adapted for use with double chord beams 54A and
double chord connectors 54C may also be employed with single chord 14C beams
as illustrated in Fig. 5E wherein a roof ridge section 28AE and a double eave
section
28EE are connected by two separate single chore 14C beams.
[125]
[126] E. Extreme Environmental Condition Resistant (EECR) Structures, Exterior
Main Structural Assemblies and Exterior/interior Sheathing
[127]
[128] Referring again to Figs. 4A and 4B, it is shown therein that the
structural
elements and assemblies of an EECR structure 10E, like that of a structure 10,
will
typically include provision for both inner and outer sheathing of the walls
and often
the roof and floor assemblies, space within the wall and roof elements and
often
within the floor assemblies for insulation, and space within the walls and
often the
roof and floor assemblies for piping, such as plumbing or gas lines, and
wiring.
[129] In addition, certain primary structural elements of an EECR structure
10E
such as an exterior wall assembly 10F, a floor/ceiling assembly 10G or a roof
assembly 101 and possible certain other interior structural elements, such as
certain
interior walls 10R, are constructed in a form providing additional structural
strength
and integrity and additional environmental protection to the interior spaces
of the
structure. As will be described in the following, such structural elements of
an
EECR structure 10E are based upon main structural assemblies 58, which are
respectively designated in Figs. 4A and 4B as modular wall assemblies 58W,
modular floor/ceiling assemblies 58F and modular roof assemblies 58.
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[130] Referring to Figs. 6A and 6B, Fig. 6A is a diagrammatic isometric view
of an
EECR modular structural assembly 58 comprising an exterior modular wall
assembly 58W and Fig. 6B is a cross section view of the exterior modular wall
assembly 58W. It must be recognized that the structural components shown in
Figs. 6A and 6B, such as modular structural assembly 58, double chord beams
54B,
spacers 54S, purlins 22 and other elements such as bolts or other fasteners,
are
represented therein in simplified, diagrammatic form to provide a simpler and
clearer
representation of the features to be discussed in the following descriptions.
Detailed
illustrations of these elements are, however, presented in the preceding
figure and
descriptions and reference should be made to the preceding figures and
descriptions as necessary.
[131] As illustrated in Figs. 6A and 6B for the exemplary case of an EECR
modular
structural assembly 58 comprising a modular wall assembly 58W, an EECR modular
structural assembly 58 is based upon a double chord beam 54B which is in turn,
as
described above, comprised of a pair of parallel chords 14C spaced apart by
beam
spacers 545. In the case of a modular wall assembly 58W, for example, the
double
chord beams 54B of an EECR modular assembly 58 are arranged so that the
parallel chords 14C of the EECR modular structural assembly 58 are parallel to
the
plane of the wall and the spacers 54S connecting the parallel chords 14C are
perpendicular to the plane of the wall. The two chords 14C of an EECR modular
modular structural 58 thereby form perpendicular inner and outer face beams
581F
and 580F located, respectively, on the inner and outer faces of the wall, and
are
spaced apart by horizontally extending interior wall spacers 58S formed of the
spacers 54S. Modular floor/ceiling assemblies 58F and modular roof assemblies
58R are constructed in generally the same manner, with appropriate differences
in
the orientations of the chords 14C and spacers 545, and the thickness of a
wall, or
of the ceiling, floor or roof, is therefore determined by the length of
spacers 58S as
well as the cross section dimensions of the chords 14C.
[132] Again referring to Figs. 6A and 6B, and as illustrated, a modular wall
assembly 58W is comprised of at least a pair of double chord beams 54B
connected
by purlins 22 wherein the purlins 22 extend between the inner face beams 581F
or
between the outer face beams 58OF and define the inner and outer surfaces 601
and 600 of the wall 1 OF. As also shown, the purlins may be located at the top
and
bottom of a modular wall assembly 58W, that is, at the intersection of the
plane of
the wall with, for example, the ceiling and floor assemblies, and in
equivalent
locations in modular floor/ceiling and roof assemblies 58F and 58R. It should
also
be noted that additional purlins 22 may be located at any point along the
length or
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height of the chords 14C of a EECR modular structural assembly 58, for example
to provide additional structural strength or reinforcement or to provide
framing for a
window or door assembly or the like. Again, modular floor/ceiling assemblies
58F
and modular roof assemblies 58R are constructed in generally the same manner,
with appropriate differences in the orientations of the EECR modular
structural
assemblies 58.
[133] As shown in Fig. 4A, and in addition to connecting adjacent EECR modular
structural assemblies 58 into an integral structural unit and determining the
spacing
between EECR modular structural assemblies 58, purlins 22 also provide inner
and
outer structure surfaces 601 and 600 for attaching outer and inner sheathings
621
and 620, such as plywood, wallboard and finishing materials, to the wall, roof
and
floor sections, wherein inner and outer sheathings 621 and 620 may be attached
to
surfaces 601 and 600 by, for example, bolts, screws, nails, adhesives, and so
on.
[134] Referring in particular to Fig. 6B, outer sheathing 620 may may be
comprised, for example, of a base sheathing 620B formed, for example, of
plywood
fixed to the purlins 22 by fasteners 62B, for example, bolts or adhesives, and
a
finish sheathing 620F comprised, for example, of stucco or metal paneling
affixed
to base sheathing 620B or to outer purlins 22 by, for example, bolts, threaded
fasteners, nails or adhesives. In this regard, it should be noted that in
addition to
providing additional structural strength, the selection of finish sheathing
620F will
have a significant effect in determining the environmental resistance and
strength
of the wall assembly 1 OF and thus of the EECR structure 10E. For example,
stucco
coatings and metal paneling are fire resistant as well as providing additional
resistance to penetration by wind, rain or snow and such hazards as wind-blown
debris. It should also be noted that the structural elements or panels
comprising
outer sheathing 620 may and will typically extend horizontally over multiple
modular
wall sections 58W, thereby coupling adjacent modular wall sections 58W to one
another and providing further structural strength to the wall. It will also be
noted that
additional coatings or finish layers may be added to the outer surface of
outer
surface 601 of the wall as needed or desired, such as paint or further
finishing
materials having desired structural or cosmetic properties.
[135] Inner surface 601 of modular wall section 58W will typically be covered
by an
inner sheathing 621 that may be comprised, like outer sheathing 620, of an
inner
base sheathing 621B and an inner finish sheathing 621F, such as plywood and
wallboard, respectively, or of an inner finish sheathing 621F alone, dependent
on the
structural and finish requirements of the inner side of the modular wall
section 58W.
As in the case of outer sheathing 620, the structural elements or panels
comprising
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inner sheathing 621 may and will typically extend horizontally over multiple
modular
wall sections 58W, thereby connecting adjacent modular wall sections 58W to
one
another and providing further structural strength to the wall. It will also be
noted that
additional coatings or finish layers may be added to inner surface 601 of the
wall,
such as paint, wallpaper or plaster or any combination thereof as needed or
desired
and having desired structural or cosmetic properties.
[136] As described, a modular wall section 58W, and in particular an exterior
wall
section, will also typically include of a layer of insulation 10N, preferably
a foam,
bonded to the inner surfaces each modular wall 58W section, that is, to the
inner
sides of base sheathing 620B and the purlins 22 defining outer surface 600 and
the
sides of the main structural assemblies 58 forming the inner sides of the
modular
wall section. Insulation 10N is preferably "foamed in place" and is composed
to
bond to the inner sides of outer base sheathing 620B and the inner sides of
main
structural assembles 58 and outer purl piping, such as plumbing or gas lines,
and
wiring ins 22. Insulation 10N may alternatively, however, and for example, be
comprised of rigid panel foam affixed to the inner surfaces of a modular wall
section
58W by adhesives or of soft insulation materials, such as conventional
fiberglass
panels or blown fiberglass, where the additional strength of a rigid
insulation
structurally integral with the wall is not required.
[137] Insulation 10N may fill the entire inner space between the inner sides
of the
structural elements forming the outer surface 600 and inner surface 601 of the
modular wall section or, as illustrated in Fig. 6B, may be deposited as a
layer on the
inner sides of outer base sheathing 620B, the purlins 22 defining outer
surface 600
and the inner sides of the main structural assemblies 58 forming the inner
sides of
the modular wall section 58W to form an inner space 64S within the modular
wall
section 58W. Inner space 64S amy then be used for services 66, such as water,
gas and plumbing lines, wires, vents and ducts, cables, and so on.
[138] Lastly, it must be noted that while the floors, ceilings and roofs of an
EECR
structure 10E will be respectively comprised of modular floor/ceiling
assemblies 58F
and modular roof assemblies 58R wherein modular floor/ceiling assemblies 58F
and
modular roof assemblies 58R are generally similar to modular wall assemblies
58W
as described above. The primary difference will be that in the case of modular
floor/ceiling assemblies 58F the main structural assemblies 58 and the purlins
22
will extend generally horizontally and in the case of modular roof assemblies
58R
the main structural assemblies 58 and the purlins 22 may be oriented
horizontally
or, more commonly, at an angle to the horizontal. In addition, modular roof
assemblies 58R will typically include insulation 10N will modular
floor/ceiling
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assemblies 58F may not have a layer of insulation 10N, and modular
floor/ceiling
assemblies 58F and modular roof assemblies 58R may or may not include spaces
64S, depending upon whether it is necessary or not to accommodate services 66
therein.
[139]
[140] F. Modification and Adaptation of Existing Structures to Provide
Increased
Resistance to Extreme Environmental Conditions
[141]
[142] The following will next consider the application of the system and
method of
the present invention to existing structures to improve their resistance to
environmental conditions, such as hurricanes, tornadoes, storms, forest and
brush
fires, floods and earthquakes. According to the present invention, the
elements and
assemblies of an existing structure are overlaid with or replaced by
corresponding
structural elements and assemblies of the present invention with certain
elements
of the existing structure being employed, at least temporarily, as supports
and
templates during the installation of the new structural elements or
assemblies.
[1431 The method by which the elements and assemblies of the existing
structure
such as illustrated in Figs. 1A and 1 B are overlaid with or replaced by the
structural
elements and assemblies of the present invention are illustrated in Figs. 7A,
7B and
7C. Figs. 1A and 1 B may be taken as illustrating an originally existing
structure 10
wherein, as illustrated in Figs.1 B, the basic components of the exemplary
house 10
structure include wall framing elements and assemblies10F forming the wall
framing
an sheathing, floor framing elements and assemblies 10G forming the floor
framing
and sheathing, roof framing elements and assemblies 10H forming the rafters
and
beams supporting roofing 101, and a foundation 10J.
[144] Figs. 7A and 7B, in turn, illustrate progressive steps in the adaptation
or
modification of the house 10 structure to provide increased environmental
resistance according to the present invention. For example, and referring to
Fig. 7A,
the initial steps in modifying an existing house 10 structure include
constructing a
ring foundation 68F surrounding previously existing foundation 10J to both
reinforce
original foundation 10J and to provide a foundation for the subsequent
addition of
structural elements and assemblies of the present invention to the existing
house
structure.
[145] Further steps include securing wall panel assemblies 68W to the exterior
sides of wall studs, that is, to the uprights 10S of wall framing
assemblies10F, by
means of wall brackets 68B and to ring foundation 68F, and the securing of
platform
segments 68P, which comprise new and reinforced floor assemblies, to upright
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members of wall panel assemblies 68W. In this regard, it will be noted that
the
primary upright structural members of wall panel assemblies 68W, which will be
described in detail in the following, are secured to and supported by ring
foundation
68F as well as uprights 10S of previously existing wall framing assemblies
10F. It
will also be noted that in a presently preferred embodiment of the invention
platform
segments 68Pare installed above original floor elements and assemblies 10G so
as
to be supported by floor elements and assemblies 10G during this step of the
process. It may therefore been seen that the original structural elements and
assemblies of the original structure 10, and in particular th exterior wall
and floor
structures, are used as templates and supports for the addition of new
reinforced
elements and the replacement of the original structures by new reinforced
structures.
[146] It should also be noted that these initial steps also include the
removal of roof
framing elements and assemblies 10H and roofing 101 in preparation for the
replacement of these original elements by new elements of the present
invention.
In this regard, it will be noted that the original roofing structures are not
required for
structural support during the reinforcement of the house 10 structure. The
original
roofing structures may therefore be removed in preparation for the
installation of
new roofing structures at any time during these initial steps, which provides
greater
access to the remaining elements, such as the original and replacement wall
and
floor elements, during the replacement modification of the original wall and
flooring
elements.
[147] As illustrated in Fig. 7B, roof framing elements and assemblies 10H and
roofing 101 of the previously existing structure 10 are replaced with
corresponding
roof framing elements and assemblies 28 of the present invention, as has been
described herein above.
[148] The previously existing floor elements and assemblies 10G are also
removed, leaving reinforced floor elements and assemblies based upon platform
segments 68P of the present invention. In this regard, it will be noted that
the
replacement of the previously existing floor elements and assemblies 10G by
platform segments 68P and the necessary floor finishing components, such as
underlayment and planks, tiles or carpet or other materials, results in new
floor
surfaces that are raised with respect to the original floor surfaces by a
distance
approximately equal to the thickness of platform segments 68P. Since the lower
sides of platform segments 68P then form the new ceilings of the next lower
floors,
the ceilings are also generally raised by this distance, thus preserving the
approximate original ceiling height throughout the structure 10. The possible
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exceptions are the lowest floor, particularly if a basement, if the floor of
that level is
not raised by the insertion of platform segments 68P, and the highest floor,
where
the ceiling height may be determined by the floor of an attic space or the
lower
surface of a roof assembly rather than the lower sides of platform segments
68.
[149] Lastly with regard to Figs. 7A and 7B and as indicated generally in Fig.
7B,
the interior spaces formed by wall panel assemblies 68W, uprights 10S of wall
framing assemblies 1 OFand wall framing assemblies 10F are filled with foam
insulation 681, as are all interior wall, floor and ceiling spaces. Foam
insulation 681
thereby not only provides thermal and sound insulation between the interior of
structure 10 and the exterior environment and between vertically or
horizontally
adjacent rooms of structure 10, but also provides additional structural
reinforcement
to the modified structure 10.
[150] Next considering the structural elements and assemblies of the present
invention that are particularly designed and adapted for the purpose of
reinforcing
already existing structures, a diagrammatic isometric view of an exemplary
wall
panel assembly 68W is illustrated in Fig. 8A. It must be noted that the
structural
components shown in Fig. 8A, and in certain of the following figures, such as
chords 14C, spacers 54S, purlins 22, forming strips 14F and other elements
such
as bolts or other fasteners, are represented therein in simplified,
diagrammatic form
to provide a simpler and clearer representation of the features to be
discussed in the
following descriptions. Detailed illustrations of these elements are, however,
presented in the preceding figure and descriptions and reference should be
made
to the preceding figures and descriptions as necessary.
1151] As illustrated in Fig. 8A, which is a diagrammatic planar illustration
of two
adjacent and adjoining wall panel assemblies 68W, each wall panel assembly 68W
is based upon two parallel vertical chords 14C spaced apart horizontally and
connected by two or more horizontally oriented purlins 22 that will include at
least
an upper and a lower purlin 22 located at the top and bottom of the wall panel
assembly 68W and may include one or more purlins 22 spaced vertically apart
between the upper and lower purlins 22. Adjacent wall panel assemblies 68W, as
illustrated in Gig. 8A, will thereby share a common chord 14C, and chords 14C
may
extend vertically over more than one wall panel assembly 68W so that
vertically
adjacent wall panel assemblies 668W may likewise share vertical chords 14C.
When chords 14C extend vertically for a single wall panel assembly 68W height,
however, vertically abutting chords 14C will be joined in the manner described
generally herein above, such as by stubs 34 or forming strips 14F extending
over
the joint between vertically adjacent chords 14C.
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[152] As illustrated in Fig. 8A, each chord 14C of a wall panel assembly 68W
is
secured to a corresponding upright 10S of a corresponding wall framing
assemblies10F by one or more wall brackets 68B wherein each wall bracket 68B
extends inward horizontally between a chord 14C and a corresponding upright
10S.
Each chord 14C will typically be secured to the corresponding upright 10S by
at
least wall brackets 68B located at the upper and lower ends of the chord 14C
and
the upright 10S and may be additionally secured by additional wall brackets
68B
spaced apart between the upper and lower wall brackets 68B. It should be note
that
each upright 10S may be comprised, for example, of a conventional 2x4 stud,
but
may be comprised of any other preferably dimensioned element serving the
functions of conventional studding in the previously existing wall structure
of the
structure 10. As indicated in Fig. 8A, each such wall panel assemblies 68W
comprises a single bay, and multiple wall panel assemblies 68W may be arranged
and connected side by side, with each adjacent pair sharing one vertical chord
14C,
to form a multiple may wall assembly.
[153] As shown in Fig. 8B, a wall bracket 68W may typically be comprised of a
horizontally oriented spacer element 56 having a vertically oriented forming
strip 14F
at one end for attachment to a chord 14C in the manner described herein above
and
at the other end a U-shaped stub bracket 68S dimensioned to fit around an
upright
10S and typically including appropriate openings to receive a transverse
fastener
68F, such as a bolt or nail, to secure fastener 68F with upright 105. It will
be
appreciated that the dimension s of stub bracket 68S may be adapted to the
dimensions of any upright 10S, including 4x6's, 2x6's, uprights 10S comprised
of
multiple elements or having cross sections that are not rectangular, uprights
1 OS
comprised of materials other than wood, such as concrete uprights, and so on.
It
should also be appreciated that uprights 105 may also be added to an existing
structure or parts of an existing structure to provide a means for the
attachment of
wall panel assemblies 68W thereto.
[154] As also illustrated in Fig. 8B, the space between adjacent chords 14C,
an
outer wall sheathing 680 of wall panel assembly 68W and the inner surface or
boundary defined by the interior sides of uprights 10S is filled with foam
insulation
681 to provide both thermal and sound insulation and structural reinforcement.
It
should be noted that the inner and outer surfaces of wall panel assemblies 68W
may, as discussed herein above, include single or multi-layer sheathings 621
and
620, such as plywood, wallboard and finishing materials, to the wall, roof and
floor
sections, wherein inner and outer sheathings 621 and 620 may be attached by,
for
example, bolts, screws, nails, adhesives, and so on. The outermost layer of
outer
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sheathing 620 may further be comprised, for example, of stucco or metal
paneling
affixed to a base sheathing or to purlins 22 by, for example, bolts, threaded
fasteners, nails or adhesives. In this regard, it should be noted that in
addition to
providing additional structural strength, the selection of 620 sheathing will
have a
significant effect in determining the environmental resistance and strength of
a wall
panel assembly 68W. For example, stucco coatings and metal paneling are fire
resistant as well as providing additional resistance to penetration by wind,
rain or
snow and such hazards as wind-blown debris. It should also be noted that the
structural elements or panels comprising outer sheathing 620 may and will
typically
extend horizontally over multiple wall panel assemblies 68W, thereby coupling
adjacent modular wall sections 58W to one another and providing further
structural
strength to the wall. It will also be noted that additional coatings or finish
layers may
be added to the outer surface of the wall as needed or desired, such as paint
or
further finishing materials having desired structural or cosmetic properties.
[155] As described in general herein above, the inner surfaces of wall panel
assemblies 68W will typically be covered by an inner sheathing that may be
comprised of an inner base sheathing and an inner finish sheathing, such as
plywood and wallboard, respectively, or of an inner finish sheathing alone,
dependent on the structural and finish requirements of the inner side of the
wall
panel assembly 68W. As in the case of outer sheathing 620, the structural
elements or panels comprising the inner sheathing may and will typically
extend
horizontally over multiple wall panel assemblies 68W, thereby connecting
adjacent
modular wall sections 58W to one another and providing further structural
strength
to the wall. It will also be noted that additional coatings or finish layers
may be
added, such as paint, wallpaper or plaster or any combination thereof as
needed or
desired and having desired structural or cosmetic properties.
[156] Next referring to Fig. 9, therein is shown a diagrammatic isometric view
of
multiple platform segments 68P assembled into a floor platform assembly 70.
Platform segments 68P as illustrated in Fig. 9A are intended for use as the
supporting structures for horizontal platforms or decks, such as may be used
to form
work platforms, stair landings, exterior deck floors, floors between levels of
a
structure 10, a runway or slanted ramp between level platforms, and so on. As
illustrated, a platform segment 68P is comprised of horizontally oriented,
parallel
upper and lower pairs of horizontally positioned and horizontally spaced apart
main
elements 14 that are typically comprised of chords 14C but may be comprised,
for
example, of forming strips 14F.
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[157] The main elements 14 of the upper pair of main elements 14 and the main
elements 14 of the lower pair of main elements 14 are spaced apart and
connected
by horizontal connection elements 16 extending horizontally between and at
right
angles to the main elements 14 at each end of the main elements 14, with one
or
more additional horizontal connection elements 16 being connected between the
pairs of horizontal main elements 14 between the ends of the main elements 14
as
desired or as necessary. Each upper main element 14 is similarly spaced apart
from and connected to the corresponding parallel lower main element 14 by
vertically oriented connection elements 16 located at the ends of the upper
and
lower main elements 14, with additional vertical connection elements 16 again
being
located between the ends of the upper and lower main elements 14 as necessary
or as desired. As discussed herein above, connection elements 16 may typically
be
comprised of chords 14CA or forming strip 14F.
[158] As described briefly herein above, the platform segments 68P forming a
floor
or deck structure are preferably installed while the previously existing floor
elements
and assemblies 1 OG are still in place, so that the previously existing floor
elements
and assemblies 1OG can be used as supports and working platforms during the
installation of the reinforcing structural elements of the present invention,
including
wall panel assemblies 68W and platform segments 68P. For this reason, platform
segments 68P are typically installed on and are supported by the upper
surfaces of
the previously existing floor elements and assemblies 10G. As discussed above,
this method results in each floor level that is replaced by an assembly of
platform
segments 68P being raised by the thickness of the platform segments 68P. As
also
discussed above, the raising of each floor level by the thickness of platform
segments 68P typically does not reduce the original ceiling heights of the
rooms,
however, because all floors are normally raised by the same distance, with the
sole
possible exceptions being the ceilings below the lowest floor and above the
uppermost floor, if any.
[159] It must also be noted that in the final reinforced structure 10 the
upper and
lower main elements 14 of each platform segment 68P are connected to the
vertical
chords 14C of wall panel assemblies 68W in the manner described herein above
for
connecting horizontal chords 14C and double horizontal chords 14C to vertical
chords 14C. It must also be noted that vertical chords 14C of wall panel
assemblies
68W are exterior to the previously existing exterior wall assemblies 1OF and
floor/ceiling assemblies 10G. Therefore, while much of the assembly of
platform
segments 68P structures may often be performed without disturbing the original
structure, it is necessary at some point to penetrate the original exterior
walls 1 OF,
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including the upright structural beams at each corner, to connect the
horizontal
elements 14 of platform segments 68P and floor platform assemblies 70 to the
upright chords 14C of wall panel assemblies 68W. Preferably, however, the
connections between the horizontal elements 14 of platform segments 68P and
wall
panel assemblies 68W at each floor may be made in a sequence such that the
platform segments 68P are essentially supported by the wall panel assemblies
68W
before the original main structural corner beams are penetrated or severed.
For
example, the connections between platform segments 68W and the upright
elements 14C of wall panel assemblies 68W may start at some point along the
wall
away from the original corner upright and proceed until only the connections
at the
corners remain to be made, at which point the original structural uprights may
be cut
and the final connections made.
[160] Lastly in this regard, it should be noted that, as described previously,
decking
or platform components, such as various types of deck or interior floor
materials or
underflooring and top finish flooring of all types, may then be laid upon or
attached
to the top surface of one or more adjacent platform segments 68P to form or
finish,
for example, a balcony or deck floor or a floor between levels of a structure
10.
[161] Since certain changes may be made in the above described method and
system without departing from the spirit and scope of the invention herein
involved,
it is intended that all of the subject matter of the above description or
shown in the
accompanying drawings shall be interpreted merely as examples illustrating the
inventive concept herein and shall not be construed as limiting the invention.
