Note: Descriptions are shown in the official language in which they were submitted.
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SYSTEM AND METHOD FOR FREE-STANDING
PREFABRICATED GLUED LAMINATED MODULAR
TIMBER FRAME MEMBERS
FIELD AND BACKGROUND OF THE INVENTION
Embodiments of the current invention are related to a prefabricated
modular frame for use in a free-standing and/or lean-to structure, built as a
timber framing system, and more particularly to a method and system of
framework of load-bearing beams and posts made of prefabricated glued
laminated modular timber frame members.
Timber framing and post-and-beam construction is a general term for
building with heavy timbers¨as opposed to "dimension lumber" such as 2-by-
4's. Traditional timber frameworking has been used for erecting structures
incorporating heavy, squared-off, and carefully-fitted and joined timbers with
secured joints. Forming the framework elements demanded on-site skilled
labor.
Modern timber structures often incorporate metal joinery such as gusset
plates and bolts. Reference is currently made to FIG 1, which is a schematic
moment diagram showing a moment distribution 5 along a prior art beam 6,
supported by prior art posts 7, which are in turn supported on two
foundations,
indicated as inverted triangles, as known in the art. In the moment diagram,
an
ordinate 8 represents moment (i.e. units of N-m, or lbf-ft) due to a force
CA 02836037 2013-12-06
(indicated in the figure by an arrow) applied to beam 6, with zero, positive,
and negative moment values indicated¨all as known in the art.
In prior art methods of constructing post-and-beam structures¨the posts
and/or beams also referred to as "studs"¨ joints between posts and beams are
designed to have essentially zero moments, as shown schematically in FIG 1.
Such current/prior art methods take into account a "zero moment assumption"
to ensure mechanical stability and integrity of plates/bolts, which could
otherwise be damaged and/or ripped away at a joint having a moment
substantially not equal to zero.
A stud functions to support and/or be integrated into a load-bearing wall.
Studs, when incorporated in such a wall, essentially act as a stable frame to
which interior and exterior wall coverings, generally not designed to support
building loads themselves¨and also referred to as "curtain walls"¨are
attached thereupon. Studs are typically expensive elements, traditionally
comprising high quality and expensive wood, and are suitable to bear heavy
loads. Used as posts and beams, studs serve as vertical and horizontal members
of exterior walls and of interior partitions, such as wall plates and lintels.
Studs
additionally serve as a nailing base for covering material, inter alia.
Other wood construction has employed a variety of framing methods,
also known in the art as "light-frame construction" and "framework
construction" methods.
Studs are typically supported on a bottom plate or a foundation sill,
herein referred to simply as "foundation". Studs serve to support a top plate,
as
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known in the art. In tall framework construction buildings, studs which
comprise a frame are usually augmented by additional posts, especially at
corners and/or mid-points of extended walls. Some prior art framework
construction methods use light prefabricated elements, which typically serve
as
walls and ceiling elements and which are integrated into the building at a
construction site. A prior art example of an element of a frame-type structure
is that of Steinberg (the inventor of the current application) in US Patent
no.
8,561,374.
In most current/prior art buildings utilizing lumber framework, during
construction (and sometimes even after building construction) studs and/or
frames serving as walls must be additionally supported by diagonal supports to
ensure stability, at least during construction. In other words, framework
construction walls, as described hereinabove are typically not intrinsically
free-
standing.
In the specification and claims which follow, the term "free-standing",
when used in conjunction with frame construction, is intended to mean studs
and/or frames which serve as walls that do not need additional support to
ensure stability during construction, as described hereinabove. An
integratable
framework, which is prefabricated and which could be constructed in a free-
standing mode, could greatly reduce on-site labor, requiring only semi-skilled
labor, and would reduce labor and material costs and subsequently generally
reduce overall building cost.
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In the specification and claims which follow, the terms "glulam" and
"glued laminated timber" are intended to mean a type of structural timber
element known in the art, composed of several layers of dimensional lumber
bonded together with durable, moisture-resistant adhesives. A single large
elongated glulam structural member is typically fabricated by laminating
several layers of lumber, thereby optimizing the structural value of the
member. Laminated structural members are used as vertical columns or
horizontal beams¨i.e. studs. Glulam beams are frequently used in the
construction industry in place of conventional wood timber to serve as
elements such as: beams; columns; cantilevered supports; and/ or trusses to
provide structural support and integrity. Glulam beams are structurally more
sound and are often less expensive than conventional wood products. Glulam
beams and posts could be therefore incorporated in a frame structure described
hereinabove to afford additional material cost and construction cost
advantages.
There is therefore a need for a system and method of constructing a
employing free-standing prefabricated glued laminated modular timber frame
members to effectively address the problems and provide benefits described
hereinabove.
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SUMMARY OF THE INVENTION
According to the teachings of the present invention there is provided a
system of framework timber construction in a building structure, the system
comprising: a plurality of free-standing prefabricated glued laminated modular
timber frame members, each timber frame member comprising four studs, the
four studs being two posts, each post having a lateral dimension L2 and width
Wp, and two beams, each beam having a lateral dimension L1 and width WB,
each timber frame member further comprising: at least three two-post-two-
beam members, each two-post-two-beam member having two posts, two
beams, and four joints between respective posts and beams, each of the posts
and beams having an elongated rectangular shape defined by respective
elongated lengths Lp and LB, and having respective widths Wp and WB, and
having a thickness, with the at least three two-post-two-beam members having
a crisscross glulam construction; wherein the plurality of free-standing
prefabricated glued laminated modular timber frame members are configured
to form supporting walls of the building structure.
Preferably, the at least three two post-two-beam members having a
crisscross glulam construction are chosen from a list including: series
members
and parallel members. Most preferably, the posts and beams are formed of
wood, the wood grain of the posts being aligned substantially in the direction
of
elongated length Lp and the wood grain of the beams being aligned
substantially in the direction of elongated length LB. Typically, lateral
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dimension L2 is substantially less than 192 inches, lateral dimension L1 is
substantially less than 156 inches, Wg is substantially 4 inches, and the
thickness is substantially less than 5 inches. Most typically, lateral
dimension
L2 is substantially 96 inches, width Wp is substantially 4 inches, lateral
dimension L1 is substantially 96 inches, width Wg is substantially 4 inches,
and
the thickness is 4 inches.
According to the teachings of the present invention there is further
provided a method of fabricating a plurality of free-standing prefabricated
glued laminated modular timber frame members for a building structure, the
method comprising the steps of: determining dimensions, orientation, design
limits, and a total number of the plurality of free-standing prefabricated
glued
laminated modular timber frame members; determining a number "n" for the
total number of two-post-two-beam-members comprising each of the plurality
of free-standing prefabricated glued laminated modular timber frame members
and determining whether series or parallel members are used to form each of
the plurality of free-standing prefabricated glued laminated timber frame
members; building" n" two-post-two-beam-members for each of the plurality
of free-standing prefabricated glued laminated timber frame members;
arranging alternately each of the "n" two-post-two-beam-members for each of
the plurality of free-standing prefabricated glued laminated timber frame
members; and forming each of the plurality of free standing prefabricated
glued
laminated timber frame members in a crisscross configuration using glulam
techniques. Preferably, "n" is at least 3.
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BRIEF DESCRIPTION OF THE DRAWINGS
The invention is herein described, by way of example only, with
reference to the accompanying drawings, wherein:
FIG 1 is a schematic moment diagram showing a moment distribution
along a prior art beam, supported by prior art posts;
FIG 2 is a schematic moment diagram, similar to FIG 1, but showing a
moment distribution of a free-standing prefabricated glued laminated modular
timber frame member, in accordance with an embodiment of the current
invention;
FIGS 3A, 3B , and 3C are pictorial drawings showing a structure of at
least three series two post-two beam members of the free-standing
prefabricated glued laminated modular timber frame member of FIG 2 , in
accordance with embodiments of the current invention;
FIGS 4A, 4B, and 4C are pictorial drawings showing a structure of at
least three parallel two post-two beam members of the free-standing
prefabricated glued laminated modular timber frame member of FIG 2;
FIG 5 is a pictorial drawing of a timber frame structure employing a
plurality of free-standing prefabricated glued laminated modular timber frame
members, in accordance with embodiments of the current invention; and
FIG 6 is a flow chart showing the steps of a method of preparing free-
standing prefabricated glued laminated modular timber frame members for the
structure of FIG 5, in accordance with embodiments of the current invention.
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the current invention are related to a prefabricated
modular frame for use in a freestanding, lean-to structure, built as a timber
framing system, and more particularly to a framework of load-bearing beams
and columns made of prefabricated glued laminated modular timber frame
members.
Reference is currently made to FIG 2, which is a schematic drawing
diagram, similar to FIG 1 (with a force, foundations, ordinate 8, and zero,
positive, and negative moment values all indicated¨as known in the art) but
showing a corresponding moment distribution 9 of a free-standing
prefabricated glued laminated modular timber frame member 10, in accordance
with an embodiment of the current invention. Moment distribution 9 can be
seen in the present figure as being substantially not zero at a position of
timber
frame member 10 corresponding to the joints between the post and the beam of
FIG 1. Free-standing prefabricated glued laminated modular timber frame
member 10 is described in more detail in subsequent figures hereinbelow.
Reference is currently made to FIGS 3A, 3B, 3C, 4A, 4B, and 4C,
which are pictorial drawings of a free-standing prefabricated glued laminated
modular timber frame member 20 (FIGS 3A-C) and a free-standing
prefabricated glued laminated modular timber frame member 30 (FIGS 4A-C),
respectively, in accordance with embodiments of the current invention. Apart
from differences described hereinbelow, prefabricated glued laminated modular
timber frame members 20 and 30 are identical in notation, configuration, and
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functionality to that described and shown of free-standing prefabricated glued
laminated modular timber frame member 10 in FIG 2 hereinabove.
Referring to FIGS 3A-C, free-standing prefabricated glued laminated
modular timber frame member 20 comprises at least three exemplary series
two-post-two-beam members 20a, 20b, and 20c, which are formed and
subsequently laminated together, as described hereinbelow, forming laminated
beams 21 and 23 and laminated posts 22 and 24, and having four joints 25.
(Laminated beams 21 and 23 and laminated posts 22 and 24 are collectively
called "studs".) Free-standing prefabricated glued laminated modular timber
frame member 20 has a rectangular or square shape, having lateral dimensions
L1 and L2, as shown in FIG 3C.
Series member 20a is constructed of beams 21a and 23a and posts 22a
and 24a. The posts and beams are all shown facially (i.e. in length and in
width,
but without showing a thickness) in the FIG 3C. The posts and beams have an
elongated rectangular shape, defined by an elongated length Lp and LB,
respectively, and a width Wp and WB, respectively. The thickness of posts and
beams (thickness not shown in the figure) is substantially equal. The posts
and
beams are formed of wood with the wood grain of the posts and beams aligned
substantially in the direction of lengths Lp and LB.
Series member 20a is formed by facially arranging beams 21a and 23a
substantially parallel to each other and by facially arranging posts 22a and
24a
substantially parallel to each other and substantially perpendicular to beams
21a and 23a. As can be seen in FIG 3C, view (a), beam 21a abuts post 22a,
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creating a substantially continuous lateral edge, which includes width Wp of
post 22a and length LB of beam 21a, the continuous lateral edge having a total
length of lateral dimension LI. In similar fashion, post 22a abuts beam 23a,
creating a substantially continuous lateral edge, which includes width Wg of
beam 23a and length Lp of post 22a, with the continuous lateral edge having a
total length of lateral dimension L2. In similar fashion, beam 23a abuts post
24a, creating a substantially continuous lateral edge, which includes width Wp
of post 24a and length LB of beam 23a, with the continuous lateral edge having
a total length of lateral dimension LI. Finally, post 24a abuts beam 21a,
creating a substantially continuous lateral edge, which includes width Wg of
beam 21a and length Lp of post 24a, with the continuous lateral edge having a
total length of lateral dimension L2. Beams and posts in series member 20a are
joined by Glulam techniques, as known in the art, or alternatively by other
fastening methods, to create a joint (not identified in the figure), which is
mechanically firm and stable.
Series member 20b is constructed of beam 21b, post 22b, beam 23b,
and post 24b, and is formed in similar fashion as described hereinabove for
series member 20a. Dimensions L1, L2, LB, LP, WP, Wg, and the thickness are
substantially identical for series member 20b as those indicated for series
member 20a hereinabove.
Series member 20b is formed by facially arranging beams 21b and 23b
substantially parallel to each other and by facially arranging posts 22b and
24b
substantially parallel to each other and substantially perpendicular to beams
CA 02836037 2013-12-06
21b and 23b. As can be seen in FIG 3C, view (b), beam 21b abuts post 22b,
creating a substantially continuous lateral edge, which includes width Wp of
post 22b and length LB of beam 21b, with the continuous lateral edge having a
total length of lateral dimension L1. In similar fashion, post 22b abuts beam
23b, creating a substantially continuous lateral edge, which includes width WB
of beam 23b and length Lp of post 22b, with the continuous lateral edge having
a total length of lateral dimension L2. In similar fashion, beam 23b abuts
post
24b, creating a substantially continuous lateral edge, which includes width Wp
of post 24b and length LB of beam 23b, with the continuous lateral edge having
a total length of lateral dimension L 1 . Finally, post 24b abuts beam 21b,
creating a substantially continuous lateral edge, which includes width WB of
beam 21b and length Lp of post 24b, with the continuous lateral edge having a
total length of lateral dimension L2. Beams and posts in series member 20b are
similarly joined by Glulam techniques, as known in the art, or alternatively
by
other fastening methods, to create a joint (not identified in the figure),
which is
mechanically firm and stable.
Series member 20c is formed identically to series member 20a.
Referring to FIGS 3A and 3B, subsequent series members of free-standing
prefabricated glued laminated modular timber frame member 20 have
alternating configurations of series members 20a and 20b, as described
hereinabove. Alternatively or optionally, standing prefabricated glued
laminated modular timber frame member 20 comprises at least 3 series
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members having alternating configurations of series members 20b and 20a, as
described hereinabove.
Alternating series members are then facially joined using glulam
techniques, as known in the art, to create glued laminated modular timber
frame member 20. Joints 25 have a resultant alternating or "crisscross"
configuration¨as can be seen in FIG 3B. In the specification and claims which
follow, the term "crisscross" is intended to mean a glulam construction of
alternating members in joints 25 and of laminated modular timber frame
member 20¨as described hereinabove.
Referring to FIGS 4A-C, free-standing prefabricated glued laminated
modular timber frame member 30 comprises at least three exemplary parallel
two-post-two-beam members 30a, 30b, and 30c, which are formed and
subsequently laminated together, as described hereinbelow, forming laminated
beams 31 and 33 and laminated posts 32 and 34, and having four joints 35.
(Laminated beams 31 and 33 and laminated posts 32 and 34 are collectively
called "studs") Free-standing prefabricated glued laminated modular timber
frame member 30 has a rectangular or square shape, having lateral dimensions
L1 and L2, as shown in FIG 4C.
Parallel member 30a is constructed of beams 31a and 33a and posts 32a
and 34a. The posts and beams are all shown facially (i.e. in length and in
width,
with thickness not shown) in FIG 4C. The posts and beams have an elongated
rectangular shape, defined by an elongated length Lp and LB, respectively, and
a width Wp and WB, respectively. A thickness of posts and beams (thickness
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not shown in the figure) is substantially equal. The posts and beams are
formed of wood with the wood grain of the posts and beams aligned
substantially in the direction of lengths Lp and LB.
Series member 30a is formed by facially arranging beams 31a and 33a
substantially parallel to each other and by facially arranging posts 32a and
34a
substantially parallel to each other and substantially perpendicular to beams
31a and 33a. As can be seen in FIG 4C, view (a), beam 31a abuts posts 32a
and 34a, creating a substantially continuous lateral edge, which includes
widths
Wp of posts 32a and 34a and length Lga of beam 31a, with the continuous
lateral edge having a total length of lateral dimension L1. In similar
fashion,
beam 33a abuts posts 32a and 34a, creating a substantially continuous lateral
edge, which includes widths Wp of posts 32a and 34a and length LBa of beam
31a, with the continuous lateral edge having a total length of lateral
dimension
L 1 . Posts 32a and 34a each have length Lpa equal to lateral dimension L2.
Beams and posts in parallel member 30a are joined by Glulam
techniques, as known in the art, or alternatively by other fastening methods,
to
create a joint (not identified in the figure), which is mechanically firm and
stable.
Parallel member 30b is constructed of beam 31b, post 32b, beam 33b,
and post 34b, and is formed in similar fashion as described hereinabove for
series member 30a, except for differences noted hereinbelow. Dimensions L1,
L2, Wp Wg ,and the thickness are substantially identical for parallel member
30b as those indicated for parallel member 30a hereinabove. Dimensions Lgb
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Lpb are introduced (in place of LBa , Lpa for parallel member 30a hereinabove)
and are described further hereinbelow.
Parallel member 30b is formed by facially arranging beams 31 b and
33b substantially parallel to each other and by facially arranging posts 32b
and
34b substantially parallel to each other and substantially perpendicular to
beams 31 b and 33b. As can be seen in FIG 3C, view (b), post 32b abuts
beams 31 b and 33b, creating a substantially continuous lateral edge, which
includes widths WB of beams 31b and 33b and length Lpb of beam 32b, with
the continuous lateral edge having a total length of lateral dimension L2. In
similar fashion, post 34b abuts beams 3 lb and 33b, creating a substantially
continuous lateral edge, which includes widths WB of beams 31b and 33b and
length Lpb of post 34b, with the continuous lateral edge having a total length
of
lateral dimension L2. Beams 3 lb and 33b each have length LBb equal to lateral
dimension LI.
Beams and posts in parallel member 30b are joined by Glulam
techniques, as known in the art, or alternatively by other fastening methods,
to
create a joint (not identified in the figure), which is mechanically firm and
stable.
Parallel member 30c is formed identically to parallel member 30a.
Referring to FIGS 4A and 4B, it can be seen that free-standing prefabricated
glued laminated modular timber frame member 30 comprises parallel members
having alternating configurations of parallel members 30a and 30b described
hereinabove. Alternatively or optionally, free-standing prefabricated glued
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laminated modular timber frame member 30 comprises parallel members
having alternating configurations of parallel members 30b and 30a, as
described hereinabove.
Alternating parallel members are then facially joined using glulam
techniques, as known in the art, to create glued laminated modular timber
frame member 30. Joints 35 have a resultant alternating or "crisscross"
configuration¨as can be seen in FIG 4B. In the specification and claims which
follow, the term "crisscross" is intended to mean a glulam construction of
alternating members in joints 35 and of laminated modular timber frame
member 30¨as described hereinabove.
Free-standing prefabricated glued laminated modular timber frames 20
and 30 (subsequently referred to hereinbelow as "free-standing prefabricated
glued laminated modular timber frame 10") have a configuration which allows
for overall lower moments on the frame and for moments to be transferred at
the joints (i.e. joints 25 and 35), therefore fulfilling the definition of
free
standing hereinabove.
The cross section of studs comprising free standing prefabricated glued
laminated modular timber frame 10 is typically smaller to the cross section of
prior art studs because overall moments of the free standing prefabricated
glued
laminated modular timber frame are lower than those of prior art studs. In the
free standing prefabricated glued laminated modular timber frame
configuration described hereinabove a stud cross section may be defined by the
thickness of individual two-post-two-beam members and by the number of
CA 02836037 2013-12-06
two-post-two-beam members (ie 3, 4, 5...). Stud cross section dimensions, as
well as free standing prefabricated glued laminated modular timber frame 10
dimensions are calculated and are scalable according to specific building
loads
and constraints¨as described hereinbelow. Embodiments of the current
invention include approximate typical dimensions and approximate ranges of
dimensions for the variables defined in the description of FIGS 3A-C and 4A-C
hereinabove of free standing prefabricated glued laminated modular timber
frames 20 and 30.
Approx. typical range of
dimension (inches)
Variable Approx. typical minimum maximum
dimension (inches) (inches)
(inches)
L1 96 96 156
L2 96 48 192
Wp 4 4 4
WB 5 4 8
thickness 4 4 5
While the exemplary description of free-standing prefabricated glued
laminated modular timber frame members 10 hereinabove shows three two-
post-two-beam-members, embodiments of the current invention include a
minimum of three two-post-two-beam-members and additional two-post-two-
beam-members (i.e. 4, 5, 6...) may be employed. Alternatively or optionally,
embodiments of the current invention can employ free-standing prefabricated
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glued laminated modular timber frame members 20 and 30 (i.e. series and
parallel structures) in the same building structure.
Reference is currently made to FIG 5, which is a pictorial drawing of a
timber frame structure 240 employing a plurality of free-standing
prefabricated
glued laminated modular timber frame members 10, in accordance with
embodiments of the current invention. Apart from differences described
hereinbelow, prefabricated glued laminated modular timber frame members 10
are identical in notation, configuration, and functionality to that described
and
shown of free-standing prefabricated glued laminated modular timber frame
members 10, 20, and 30 in figures hereinabove. As indicated in the figure, and
as described hereinabove, free-standing prefabricated glued laminated modular
timber frame members 10 are shown having various sizes.
Timber frame structure 240 is shown in the present figure as a ground
floor having foundations 18 as known in the art. While not shown in the
present figure, timber frame structure 240 could alternatively or optionally
be a
second and/or successive floor supported by a previously constructed
supporting structure.
Reference is currently made to FIG 6, which is a flow chart showing
the steps of a method 100 of preparing free-standing prefabricated glued
laminated modular timber frame members for structure 240 of FIG 5, in
accordance with embodiments of the current invention. Method 100
additionally refers to the detailed description hereinabove of free-standing
prefabricated glued laminated modular timber frame members 20 and 30 (ref
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FIGS 3A-C and FIGS 4A-C, respectively), collectively called laminated
modular timber frame members 10.
In step 110, "Determine 2-beam-2-post size, orientation, and "n"
layers", the dimensions, orientation, and design limits of free-standing
prefabricated glued laminated modular timber frame members 10 are
determined, as known in the art, for building structure 240. Additionally, the
total number of free-standing prefabricated glued laminated modular timber
frame members 10 is determined. (By way of example only, the total number
of free-standing prefabricated glued laminated modular timber frame members
10 in building structure shown in FIG 5 is 13.) A number "n" , representing
the
total number of the two-post-two-beam-members for each free-standing
prefabricated glued laminated modular timber frame member is determined,
where n is equal or greater to 3, as well as whether the prefabricated glued
laminated modular timber frame member is formed with series or with parallel
members, as described hereinabove.
In step 115, "Build "n" total alternating layers", the "n" alternatingly-
configured two-post-two-beam-members in the free-standing prefabricated
glued laminated modular timber frame members are constructed, as described
hereinabove. In step 120, "Arrange initial layer, I = 1", a first two-post-two-
beam member is facially oriented (by way of example, such as member 20a of
FIG 3B) with additional alternating two-post-two-beam members to be
subsequently oriented thereto.
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In step 125, "Add next (alternate) layer", the next two-post-two-beam
member is facially arranged on the previous two-post-two-beam member, as
described hereinabove oriented (by way of example, such as member 20a and
then member 20b of FIG 3B). In step 130," 1 = I + 1", a counter I is
incremented to count the currently-oriented two-post-two-beam member. In
step 135, "I = n?", the counter I is compared with n. If I equals n ("yes"),
then
all of the two-post-two-beam members (meaning at least 3) have been arranged
and control is transferred to step 140. If the counter does not equal n ("no")
then one or more additional two-post-two-beam members must be arranged,
and control is transferred to step 125, "Add next (alternate) layer". At step
140,
"Glulam layers to form frame and repeat step 115 for next frame until
complete", the current prefabricated glued laminated modular timber frame
member is formed by glulam techniques, using the crisscross
configuration/arrangement of the two-post-two-beam members of previous
steps. Control then reverts to step 115, where the process begins again for
the
next prefabricated glued laminated modular timber frame member to be
formed. Method 100 is complete when the last prefabricated glued laminated
modular timber frame member is formed (not indicated in the figure).
Embodiments of the current invention, employing free-standing
prefabricated glued laminated modular timber frame members , provide for a
prefabricated modular and scalable framework, allowing faster and easier
assembly on site compared to prior art methods. The free-standing
prefabricated glued laminated modular timber frame members, as described
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hereinabove, comprise a crisscross construction of glued laminated lumber
framing of post and beams in an integrated, load bearing structure. Moreover,
embodiments of the current invention provide for a superior moment-bearing
joint attachment for posts and beams.
It will be appreciated that the above descriptions are intended only to
serve as examples, and that many other embodiments are possible.
