PRELOADED STANDARDIZED WALL SECTIONS ASSEMBLED WITH SHEET METAL MEMBERS

Abstract: Wall sections fabricated from sheet metal components are preloaded in a press by an amount of pressure equivalent to that which the wall section will be subjected when used in constructing weight-bearing walls in a building structure. Sheet metal load distribution members (7, 8) having "C", "L", or "Z"-profiles may be used in conjunction with the wall sections in wall construction.

Description: PRELOADED STANDARDIZED WALL SECTIONS ASSEMBLED WITH SHEET METAL MEMBERS FIELD OF INVENTION This invention relates to the use of sheet metal members in wall sections for construction of single and multi level buildings. BACKGROUND OF INVENTION Prior to this invention, prefabricated wall systems available in the construction industry were generally made from wood and required a great deal of highly skilled labour during the assembly of a building. The present invention permits the use of prefabricated wall sections comprising sheet metal members in a load- bearing wall eliminating much of the use of wood, concrete and conventional structural steel in many types of construction. Before this invention, steel stud walls were field assembled and were not relied upon to transfer load from floor to floor without accurate placement of studs directly below each floor joist. Even with such placement of studs, prior steel stud walls were unable to support the full load capacity of their components since gaps would be present between the ends of the studs and the bottom of the channel of a cross-member track in which the ends of the studs are fitted. Thus, in prior steel stud walls, vertical load transfer between the stud and the track would occur primarily through the means used to fasten the stud to the track. Such a wall could buckle under load and the fastening means could shear. This problem resulted in higher framing costs, and required the use of costly concrete or steel load-bearing beams with overhead cranes to install the beams in a building. With the use of wall sections constructed according to this invention and the use of a sheet metal load distribution member, such problems may be avoided. Use of wall sections of this invention that are standardized in height and length will allow construction ranging from single family dwellings to multi-level apartment buildings employing the wall sections in most applications. Use of load distribution members formed from sheet metal will permit custom manufacture and fitting of the members as well as greater ease in handling of the construction materials. Such load distribution members may also be used for aligning and joining the wall sections and to act as an edge form for the placement of concrete on each floor of the building. The wall sections and load distribution members of this invention may be provided in a kit for assembly on a foundation with a minimum of skilled labour. SUMMARY OF THE INVENTION This invention provides a fabricated wall section free of a building structure comprising a plurality of substantially parallel, laterally-spaced sheet metal vertical support members and at least one sheet metal cross-member comprising a channel, wherein ends of the vertical members are engaged in the channel of the cross-member, characterized in that the wall section has been compressed in the direction of the vertical support members. Preferably, the wall section will have at least two cross-members with opposite ends of the vertical support members being engaged in the channels of two cross-members and the vertical support members will be fastened to the cross member. This invention also provides a wall comprising one or more of the above-described wall sections and one or more load distribution members on a top surface of the wall sections. The load distribution member may have a flange or web extending above the wall and may have a flange extending below the top surface of the wall adjacent a cross-member. This invention also provides a building comprising the above-described wall. This invention also provides a kit comprising one or more of the above-described wall sections and one or more load distribution members configured to be supported on a top surface of a wall section. Preferably, the load distribution members will have an L- profile, a C-profile, or a Z-profile in end view. This invention also provides a method of fabricating a wall section comprising the steps of: (a) arranging a plurality of sheet metal vertical support members in substantially parallel and laterally- spaced relationship with ends of the vertical support members being engaged in a channel of a sheet metal cross-member; (b) applying pressure against the cross-member to compress the wall section thereby forcing the ends of the vertical support member into the channel; and (c) fastening the vertical support members to the cross-member. This invention also provides wall sections fabricated according to the preceding method. It is preferable that there be at least two cross-members and that opposite ends of each of the vertical support members are engaged in the channels of the cross-members. It is also preferable that the vertical support members are fastened to the cross-members while the wall section is subjected to the pressure. Preferably, the amount of pressure applied will be at least equivalent to the load of a wall in a building structure. This invention also provides a method of constructing a wall comprising arranging one or more of the above-described wall sections in end-to-end relationship with the vertical support members of each wall section in a vertical direction, positioning a load distribution member along a top surface of each of said wall sections, and fastening said load distribution member to said wall sections. A fabricated wall section of this invention comprises a support framework of laterally-spaced vertical support members such as conventional sheet metal studs. Preferably, the vertical support members are pressed between upper and lower channel cross-members (referred to herein as upper and lower tracks) resulting in a compressed (preloaded) wall section. The wall sections are preferably standardized in length (e.g. in even feet ranging from 2-14 feet) . The number of vertical support members in a wall section and the lateral spacing of the vertical members will vary according to conventional construction requirements and the load requirements of a wall. The wall sections will typically range from 8 feet to 12 feet in height, often depending on the depth of the joist to be placed on the wall. For example, a 1-story building and a 6-story building may require 8 and 12 inch roof joists, respectively and the height of the joists may be taken into consideration when selecting the appropriate height of a wall section for a particular wall. A wall section of this invention may be assembled and compressed (preloaded) in a press wherein pressure is applied in accordance with the load capacity of the components of the wall section and the amount of preloading that is desired. The tracks may be reinforced by placing an additional cross-member such as a metal sheet or plate of similar gauge to the track along the bottom of the channel of a track prior to engaging the vertical members in the track. While the desired pressure is applied, or after the pressure has been applied, the tracks are fastened to the vertical members by conventional means such as by mechanical fasteners or by welding, thereby creating a preloaded wall section. Through the preloading process, the vertical members become fully seated in the tracks thereby permitting vertical loads to be transferred directly between the vertical members and the tracks and not primarily through the means used to fasten the vertical members to the tracks. The vertical support members of a wall section of this invention are typically elongated channels formed from any suitable sheet metal such as 10-22 gauge sheet steel. Preferably, the vertical support members are conventional sheet steel studs or similarly configured members formed from sheet steel which resist buckling when placed under compression. Conventional sheet metal channel cross-members (tracks) currently used in metal stud wall construction may be employed as the upper and lower tracks of a wall section of this invention. Such tracks are typically formed from similar gauge sheet metal as the vertical members employed in this invention and are dimensioned to provide a close fit of the ends of the vertical support members engaged in the channel of the track. Preferably, the tracks used in this invention will be custom-manufactured to have a channel that is deeper than is currently used in most metal stud wall construction, which allows for the use of a plurality of fasteners to attach the vertical members to the track. The vertical support members in a wall section of this invention will normally be substantially parallel and will normally be of substantially equivalent height (taking into consideration any windows, doors, or other elements that may be incorporated into a wall section) . However, the height of the vertical members in a wall section may differ to provide for non-parallel tracks, providing the change in height between adjacent vertical members is sufficiently constant to provide for proper alignment of the track when the vertical members are pressed into the track. Use of a load distribution member on wall sections of this invention allows for placement of conventional joists anywhere on top of the wall sections, regardless of any window or door openings which may or may not be included in the wall sections. - The load distribution members will also generally eliminate the need for the vertical members having to be placed directly under each joist which saves design, engineering, and construction costs. Load distribution members to be used with the wall sections of this invention may be any conventional beam or other suitable elongate member known in the construction industry. Preferably, the load distribution member will comprise a sheet metal plate, angle or channel of sufficient length to traverse the top of a wall section of this invention and of sufficient width to effectively distribute load on the wall section. Preferably, the width of the portion of the load distribution member placed on the top of a wall section will be a least 75% (most preferably 90%) of the width of the wall section. Further advantages of this invention are provided through use of custom-manufactured load distribution members having "C", "L", and "Z" profiles in end view which are configured to accommodate conventional metal joists. Such preferred load distribution members are typically bent, preferably from 1/8 to 1/2 inch sheet steel or plate. Typical flange and web widths of the "C", "Z", and "L" members range from about 3 inches to dimensions slightly greater than the width of a wall section. The length of the preferred load distribution members should be longer than a single wall section and may be as long as can be practicably handled. Generally a 20 to 40 foot member will be used. The load distribution members are placed on top of the wall sections after the wall sections are erected. For example, when a series of wall sections are straight, plumbed and braced, the load distribution members are cut to fit, welded or fastened together, and securely fastened to the top of the wall sections by welding and/or by mechanical fasteners. Once perimeter walls of a floor area are erected, squared, levelled, plumbed and braced and load distribution members are fastened to the top of the wall sections, beams, joists, trusses, or other conventional spanning members used to support a floor or a roof may be placed on the load distribution members. For example, conventional metal joists may be so placed and the joists may be welded at both ends to the load distribution members, creating essentially a one-piece structure spanning the floor area and running across the top of the walls around the floor area. This invention may also provide an in-place edge form for the pouring of concrete to form a floor or roof of a building. The "C", "Z", and "L" load distribution members of this invention may all serve this purpose, as they may be made to protrude above the wall to support a desired thickness of concrete for a poured roof or floor. An "L"-profile member may be used under minimum load conditions when pouring one floor at a time where the walls of the next floor will sit on the concrete slab. A "Z"-profile member may be used in heavy load conditions as it has two flanges, one of which extends downwards and may be fastened to the wall sections and the other of which will extend upwards and will act as the edge form. These members may also prevent an entire floor from shifting off the walls (such as during an earthquake) since the downward extending flange sits adjacent the side of the wall section and may be constructed to run around the perimeter of the building. A "C"-profile member may be used in multi-level buildings. This will allow the placement of the walls of a higher floor on the top flange of the member, rather than on the concrete slab of the higher floor, thus allowing the erection of a number of floors of wall sections at a time without pouring concrete on any of the floors. The load distribution members in conjunction with the preloaded wall sections make up a unique composite structural system with the strength typically found in structural concrete or structural steel buildings. Floor to floor vertical and lateral load transfer may be enhanced by joining vertically adjacent upper and lower walls using conventional means such as shot pin anchors, hold-down wall bolts, or edge angle fillet welds. The size and strength of the connection means used should be a function of the vertical and lateral loads being transferred. Particular embodiments of the invention will be understood in conjunction with accompanying drawings in which: Figures la, lb, and lc are isometric views of wall section components. Figure la illustrates a steel stud and track before assembly. Figure lb illustrates a steel stud placed in a track in the manner typical of a prior art steel stud wall. Figure la illustrates a steel stud in a track after subjection to the preloading process of this invention. Figure 2a is an exploded pictorial view of the components of a wall section of this invention prior to being pressed together. Figure 2b is a perspective view of an assembled wall section of this invention. Figure 3 is a perspective view of a corner portion of a wall section of this invention showing a track and vertical members. Figure 4 is an elevational view of a hydraulic press used to preload the wall sections according to the present invention. Figure 5 is a perspective view of a preferred embodiment of a "C"-profile load distribution member of this invention. Figure 6 is an isometric view of a portion of a wall section of this invention with the "C" member of Figure 5. Figure 7 is an isometric view of an "L"-profile load distribution member of this invention. Figure 8 is an isometric view of a portion of a wall section of this invention with the "L" member of Figure 7. Figure 9 is a perspective view showing two wall sections of this invention with "C" and "L" members placed end to end at right angles at a corner. Figure 10 is an isometric view showing a wall comprising a plurality of wall sections of this invention placed end to end in linear relationship and an "L" member. Figure 11 is a partial side view showing two overlapped "L" members on a wall section of this invention. Figure 12 is an isometric view of part of a wall of a multi-level building comprising wall sections of this invention with "C" and "L" members supporting conventional metal joists. Figure 13 is a partial side view of a wall section of this invention with an "L" member, a conventional metal joist and decking arranged for pouring of a concrete floor or roof. Figure 14 is an exploded pictorial view of part of a building showing a floor and parts walls above and below the floor comprising wall sections, a "Z"-profile load distribution, and a plurality of conventional metal joists. Figure 15 is a partially cut-away perspective view of part of a building structure showing a concrete floor between wall sections of this invention, the "Z" member shown in Figure 14, and a conventional metal joist with decking. Figure 16 is an isometric view of part of an interior load bearing wall comprising a wall section of this invention with a "C"-profile load distribution member arranged to receive joists from opposite sides of the wall. DESCRIPTION OF THE PREFERRED EMBODIMENTS Detailed views of components and preferred embodiments of a wall section of this invention are shown in Figures 1-3, in which laterally-spaced vertical support members 13 are standard metal studs having ends 30 and are formed from 10-22 gauge sheet steel. Typically, such studs are provided with "knockouts" 14 to accommodate electrical and plumbing installation. Such a standard metal stud will typically range from 3-5/8 inches to 10 inches in width 4 and about 1-3 inches in depth 5, depending upon the number of floors, the weight loads, and building code requirements. Most preferably, the stud will be of the kind that has an approximately 1/3-1 inch return portion or lip 6 providing a partial box-like structure in an end view. The wall section comprises a plurality of the vertical support members engaged between upper and lower tracks 17, which in the embodiments shown, are channels formed from the same or similar gauge sheet steel as the vertical members. In the illustrated embodiments, the bottom of the channel of a track is identified by reference 32. Preferably, the track will have a deep channel defined by high side walls 1. Welds, such as those illustrated at reference points 26, and/or mechanical fasteners, such as self-tapping screws 21 are used to fasten the vertical members to the tracks. Vertical support members may be placed "back to back" and may be joined by conventional means such as by bracket 38 as shown in Figure 3. The track illustrated in Figure 3 has a deep channel with side walls 1 of the channel having sufficient height to accommodate multiple rows of screw fasteners which will minimize rotation of vertical members. Figures la-c illustrate two components of a wall section in a way which compares this invention to assembly of such components in prior art wall structures. Figure la illustrates a standard steel stud 13 positioned above a typical sheet metal track 17 placed at right angles to the stud. As these components are bent from sheet metal, the corners of each component are rounded and have a pronounced corner radius. In the case of track 17, lateral corners 2 adjacent the track channel bottom 32 are sufficiently rounded to prevent seating of the end 30 of stud 13 which has a close fit in the track. As is illustrated in Figure lb, when the stud is pushed into the track, the stud will come to rest on rounded corner 2 resulting in the presence of a large gap 3 between the end of the stud 30 and the channel bottom 32. Because of this characteristic of prior art systems, little care was usually taken to minimize the size of gap 3 and vertical load transfer between the stud and the track was conducted primarily through the means for fastening the stud to the track (e.g. mechanical fasteners or welds) . Figure lc illustrates the same components in a wall section of this invention wherein stud 13 has been pressed into track 17 under sufficient force to push the end 30 into the rounded lateral corners 2 of the track resulting in a fully seated stud. As shown in Figure lc, the rounded corners of the track have been deformed and the end 30 of the stud is close to the channel bottom 32 of track 17. As a result, vertical load may be more effectively transferred directly from stud 13 to the side 1 and bottom 32 of track 17 and there should be no further vertical movement of the stud in the track if the wall section is subjected to a subsequent vertical load. Also, if fastening means are now installed, a subsequent vertical load on the wall section will not be primarily transferred through the fastening means. Figure 2a shows the arrangement of the components of a wall section of this invention prior to preloading and completion of a wall section such as is shown in Figure 2b. In the preloading process, the components of the wall section are pressed together with sufficient force to seat the ends 30 of each of vertical members 13 within the channel of tracks 17 resulting in the compressed or preloaded wall section of this invention. Preferably, the wall section is assembled in a press which is then used to preload the wall section. Figure 4 illustrates an embodiment of a suitable press for preloading wall sections of this invention. The press is arranged in a vertical fashion but a horizontal or other arrangement is also suitable. The press comprises movable cross-member 51 fastened to upright members 54 which rest on base plates 50. In the embodiment shown, cross-member 51 may be fastened at any of a number of positions along upright members 54 by means of hardened steel pins 49 configured to engage through-holes 60 at the ends of cross-member 51 and in upright members 54. A second cross-member 52 is slideably engaged with upright members 54 and may be forced towards cross-member 51 by means of hydraulic cylinders 58 having a combined capacity of about 20 tons, which are braced against a third cross-member 53. A lower track for a wall section is placed along cross- member 52 while hydraulic cylinders 58 are retracted. The ends of a plurality of substantially parallel, laterally-spaced vertical support members are positioned partially within the channel of the lower track and the channel of an upper track is engaged on the ends of the vertical members adjacent cross-member 51. Once the components of the wall section are appropriately positioned, they are pressed together by operating hydraulic cylinders 58 to force cross-member 52 towards cross-member 51. Preferably, pressure is applied incrementally. Wall sections of various heights may be assembled in the press shown in Figure 4 by first adjusting the position of cross-member 51. Framing members for window or door openings may be placed among the wall section components in the press or the framing members may be provided in the wall section after the preloading process. Upper and lower framing members for a window or door may be sections of the same channels as are used for the tracks or may be light gauge sheet steel channels conventionally used for framing applications. The framing member channels may be engaged onto the ends of shortened vertical members of the wall section (stubs). When framing members are included among the components in the press to provide an opening in the wall section, a rigid blank of appropriate size may be placed in the opening to transfer compression load across the opening during the preloading process. The tracks of a wall section may be reinforced by placement of a metal sheet or plate in the channel of the track prior to placement of the vertical members. Illustration of such a reinforcing sheet 31 is shown in Figure 14. It is usually preferable that the amount of pressure applied during the preloading process of this invention be at least as much as or more than the expected vertical load on the wall of a building of which the wall sections are to be part. The amount of expected vertical load of a wall as well as the maximum pressure that may be applied to any particular configuration of wall section of this invention may be readily determined. Generally, wall sections of this invention will have been subjected to pressures in the preloading process of at least 65 pounds per lineal foot, which relates to the minimum dead load on a typical wall. The maximum amount of pressure to be applied in the preloading process will be dependent upon the component strength and the ratio of vertical support members to wall section length in a particular wall section. There may be cases where no further seating of the vertical support member in a track occurs once preloading pressures exceed a certain point, although it will be preferable to preload to at least the expected wall load. It should also be noted that the preload requirements could be reduced in cases where the number of vertical members in a wall section are increased, such as where the vertical members are doubled and placed "back to back". In some cases it may not be necessary to preload a wall section to an amount equivalent to the expected load on a wall in a building when reinforcing sheet 31 is used. The presence of the reinforcing sheet may reduce the amount of pressure required to fully seat a stud in a track as there will be cases where the sheet will, at least in part, fill the region in the bottom of the track bounded by the rounded lateral corners 2. Depending on the thickness of such a reinforcing strip the amount of pressure required may be as low as 10 pounds per lineal foot. By way of example, Table 1 describes typical preload requirements based on a situation where wall sections of this invention comprising 6-inch wide steel studs are placed on 16-inch centres in equivalent gauge tracks, and where there is a 25-foot joist span with each floor comprising 3 1/2-inch concrete with decking. The studs are of a standard 1 5/8-inch depth and have 1/2-inch lips. The minimum load represents the load expected where a single concrete floor or roof will be placed on the wall comprising the wall sections whereas the remaining columns represent situations where the identified number of floors will be built above the wall comprising the wall sections. The load values are in pounds/lineal feet of the wall section. Wall sections of this invention comprising components made from 22 gauge sheet steel may not be suitable for construction in many applications where more than two floors will be built over a wall comprising the wall sections. TABLE 1 Stud & Track Min. 1 2 3 4 5 Gauge Load Floor Floors Floors Floors Floors 22 182 1113 2225 20 220 2225 3338 18 272 3338 4450 16 344 4450 5563 12 611 5563 Once the components of a wall section are assembled and loaded as described above, the tracks are fastened to the vertical members. It is preferable that the fastening take place while the components of the wall section are under pressure in the press. Once the wall section is fastened, it may be removed from the press and be stored or used immediately in construction. The wall sections may be used in the assembly of kits comprising such wall sections and other components described herein. Figures 5 and 7 show two load distribution members for use in this invention. Member 7 shown in Figure 5 has a "C"-profile in end view whereas member 8 shown in Figure 7 has an "L"-profile. Figures 6 and 8 illustrate the load distribution members placed on the top of wall sections of this invention. In Figure 6, "C" member 7 is fastened to the top of the wall section by means of a conventional bolt 23 that is to be engaged in a through-hole 24 passing through the member 8 and track 17. Bolt 23 is intended to be fastened within the channel of track 17 with a nut and washer (not shown). Figure 4 illustrates "L" member 8 fastened to the top of track 17 by welding at the points indicated by reference numbers 25. The preferred load distribution members of this invention will typically be custom-bent from 1/8 to 1/2- inch sheet steel. Typically, the web of the "C" member and the height of one flange of the "L" member will be approximately 4 inches while the flange of the members that will rest on the top of the wall section will cover 75% or more (more preferably 90% or more) of the top surface of the upper tracks. Figure 9 illustrates the placement of adjacent wall sections at right angles to each other at corner 18. One of the wall sections supports a "C"-profile load distribution member 7 while other wall section supports an "L"-profile member 8. In the illustrated embodiment, adjacent load distribution members are joined at a miter at the corner by suitable means such as a bracket with fasteners and preferably by a weld 10. Figure 10 illustrates a wall comprising several wall sections of this invention arranged end to end in a linear relationship. In the figure, joints between adjacent wall sections are indicated by reference number 19. Adjacent wall sections may be joined by any suitable fastening means such as welds 26 or mechanical fasteners 21 applied to vertical members of adjacent wall sections, or by the use of brackets similar to that shown in Figure 3 overlapping vertical members of adjacent wall sections. In Figure 10, load distribution member 8 is a single component running the length of the plurality of wall sections. Figure 12 illustrates part of the wall of a multi-floor building. Wall sections of this invention on each adjacent floor are separated by load distribution members of this invention. In the illustrated embodiment, "C"-profile members 7 are fastened to the tops of wall sections 12 and 15, while the uppermost wall section 16 supports an "L"-profile load distribution member 8. Standard steel joists 20 are supported by and are fastened by any suitable means, preferably by welding, to horizontal surfaces on flanges of the load distribution members. It is intended that the floors will be situated at the levels of the load distribution members and will be supported on joists 20. In the embodiment shown in Figure 12, the walls of the three floors illustrated may be assembled prior to construction of the floors, since the wall sections of an upper floor may be assembled and supported on one of the flanges of "C" member 7. A web or a flange of load distribution members 7 and 8 may act as a form for a poured concrete floor in the manner illustrated in Figure 13. Figure 13 illustrates the construction of a floor at the level of a load distribution member, which in this case, is an "L" member 8. Conventional steel joist 20 is supported on and is welded to the horizontal surface of a flange of member 8. Standard metal decking 43 is placed across the tops of the joists and is fastened to the joists and member 8. Concrete may now be poured on top of the metal decking to the level shown by imaginary line 44 which is defined by the height of the flange of member 8 that extends above the wall section. Figure 14 illustrates the placement of components of wall sections of this invention in a multi- floor structure, wherein the illustrated load distribution has a "Z"-profile in end view with web 36 joining upper and lower flanges 34 and 35. The load distribution members may be joined at corners by welding of a joint between the members such as is illustrated in Figure 9. Joists 20 are supported on and are attached to the horizontal surface of web 36 to support a concrete floor 33. Upper flange 34 acts as a form for pouring the concrete floor. Lower flange 35 extends downward adjacent the upper track of the wall section providing additional strength and means to prevent lateral movement of the floor relative to the walls. The "Z"-profile member may be fastened to the wall sections by fillet welds along the lower edge of flange 35 in the inside of the web and along the edge of the web 36 on the outside of the wall. In the illustrated embodiment, wall sections of the upper floor are placed on the concrete floor 33. Figure 15 further illustrates part of a multi- floor construction of the kind shown in Figure 14. Bolt 37 is shown in a cut-away portion of the lower track 17 of a wall section on an upper floor. The bolt may be made to extend through reinforcing member 31, track 17, floor 33, and web 36. Figure 16 illustrates the use of this invention in construction of an interior load-bearing wall. In the illustrated embodiment, "C"-profile load distribution member 7 is supported on the wall section. Rather than placing member 7 on the wall section as was illustrated in Figure 6, the web of the member is horizontal and is used to support joists 20. Member 7 may be fastened to the wall section by means of fillet welds along lower edges of the two flanges of the member. Vertical support member stubs 13a and track sections 17a are provided in the illustrated wall section to frame a window opening. It is possible for a joist to be placed above the window opening because of distribution of the load by member 7. Figure 11 illustrates the use of two overlapped "L"-profile load distribution members 8 to be similar to that illustrated in Figure 16. Overlapped distribution members may be used in situations where greater strength of the member is sought. Although the present invention has been described in some detail by way of example for purposes of clarity and understanding, it will be apparent that certain changes and modifications may be practised within the scope of the appended claims.

Claims: The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows: 1. A fabricated wall section free of a building structure comprising a plurality of substantially parallel, laterally-spaced sheet metal vertical support members and at least one sheet metal cross-member comprising a channel, wherein ends of the vertical members are engaged in the channel of the cross-member, characterized in that the wall section has been compressed in the direction of the vertical support members. 2. The wall section of claim 1, wherein the vertical members are fastened to the cross member. 3. The wall section of claim 2, having at least two cross-members, and wherein opposite ends of the vertical support members are engaged in the channels of two cross-members. 4. A wall comprising one or more wall sections according to claim 1, 2, or 3, arranged with the vertical support members in a vertical direction, and one or more load distribution members on a top surface of the wall sections. 5. The wall of claim 4, wherein the load distribution member is an elongate sheet metal channel or angle. 6. The wall of claim 5, wherein the load distribution member has a flange or web extending above the wall. 7. The wall of claim 5 or 6, wherein the load distribution member has a flange extending below the top surface of the wall adjacent a cross-member. 8. A building comprising a wall according to claim 4. 9. A kit comprising one or more wall sections according to claim 1, 2, or 3, and one or more sheet metal load distribution members configured to be supported on a top surface of a wall section. 10. The kit of claim 9, wherein the load distribution member has an "L"-profile in end view. 11. The kit of claim 9, wherein the load distribution member has a "C"-profile in end view. 12. The kit of claim 9, wherein the load distribution member has a "Z"-profile in end view. 13. A method of fabricating a wall section comprising the steps of: (a) arranging a plurality of sheet metal vertical support members in substantially parallel and laterally- spaced relationship with ends of the vertical support members being engaged in a channel of a sheet metal cross-member; (b) applying pressure against the cross-member to compress the wall section thereby forcing the ends of the vertical support member into the channel; and (c) fastening the vertical support members to the cross-member. 14. The method of claim 13, wherein there are at least two cross-members and opposite ends of each of the vertical support members are engaged in channels of the cross-members. 15. The method of claim 14, wherein the vertical support members are fastened to cross members while the wall section is subjected to said pressure. 16. The method of claim 15, wherein the pressure applied is at least equivalent to the vertical load of a wall in a building structure. 17. A method of constructing a wall comprising arranging one or more wall sections fabricated according to the method of claim 13, 14, 15, or 16, in end to end relationship with the vertical support members of each wall section in a vertical direction, positioning a load distribution member along a top surface of each of said wall sections, and fastening said load distribution member to said wall sections.

Inventors: BIDINOST CHRISTOPHER L, O'LEARY KEVIN M, BIDINOST, CHRISTOPHER, L., O'LEARY, KEVIN, M.
Applicants: BIDINOST CHRISTOPHER L, LEARY KEVIN M O, BIDINOST, CHRISTOPHER, L., O'LEARY, KEVIN, M.
Application year: 1995
Main classification: E04B1
IPC codes: E04B1, E04B2