Abstract:
Laminated interlocking stackable wall units are assembled using a large proportion of wood species unsuitable for use in the construction industry. The interlocking stackable wall units are used in combination with a laminated roof beam, and a roof panel to construct an earthquake-resistant buildings. Each building is tied together by composite steel bands that lend the structure flexibility and excellent resistance to wracking forces induced by natural phenomena, such as earthquakes and windstorms. The buildings are rapidly assembled with a minimum of labor, and are inexpensive to construct. The advantage is a high quality building constructed at reasonable cost.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
         [0001]    This is the first application filed for the present invention.  
         MICROFICHE APPENDIX  
         [0002]    Not Applicable.  
         TECHNICAL FIELD  
         [0003]    This invention relates in general to construction elements for assembling buildings and, in particular, to construction elements for assembling an earthquake-resistant building using an interlocking, stackable wall unit and a laminated roof beam.  
         BACKGROUND OF THE INVENTION  
         [0004]    There is a continuing need in the building industry for well-constructed buildings that are resistant to natural forces, such as earthquakes and windstorms. At the same time, it is well recognized that quality building materials are increasingly in short supply. Even though quality building materials are in short supply, building codes continually impose stricter standards respecting structural integrity. There is also a strong demand for quality construction that is aesthetically pleasing and affordably priced.  
           [0005]    It has been long recognized that log constructions have a broad aesthetic appeal. There have, therefore, been many patents issued for various types of log or simulated-log constructions. Most of these constructions, however, require top quality raw materials. Therefore, a problem with most such constructions is the unavailability or cost of quality raw materials and/or the amount of skilled labour required to assemble them. Furthermore, most simulated log structures are no better than frame constructions at resisting the forces of nature.  
           [0006]    There therefore exists a need for building elements constructed, at least in part, from low quality materials that are generally otherwise unusable in the construction industry. There also exists a need for low cost building elements that may be used to construct a building that is resistant to earthquake and windstorm.  
         SUMMARY OF THE INVENTION  
         [0007]    It is, therefore, an object of the invention to provide quality, low-cost construction elements for assembling an earthquake-resistant building.  
           [0008]    It is a further object of the invention to provide a method of constructing an earthquake-resistant building using building elements assembled, at least in part, from lumber species which are generally unsuitable for use in the construction industry.  
           [0009]    The invention, therefore, provides construction elements for assembling an earthquake-resistant building. The construction elements comprise an interlocking, stackable wall unit comprising a load bearing interior laminate, a load bearing exterior laminate and a rigid insulating core bonded between the respective interior and exterior laminates. The building elements further comprise a laminated roof beam. The laminated roof beam includes opposed outer load bearing members having a predetermined width, an inner load bearing member and an elongated metal plate that is laminated together with the load bearing members to form the laminated roof beam. The metal plate is sandwiched between one of the outer load bearing members and the inner load bearing member in order to provide aesthetic appeal. In accordance with a preferred embodiment, the inner load bearing member is not as wide as the outer load bearing members in order to provide a channel between the outer load bearing members that accepts wiring, plumbing or the like.  
           [0010]    The invention further provides a method of constructing an earthquake-resistant building. In accordance with the method, a plurality of steel rods of an appropriate length are connected in a vertical orientation to a foundation for the building. The steel rods are spaced apart a predetermined distance and have respectively threaded top ends. Walls of the building are erected by stacking the stackable wall units  10  described above. The stackable wall units  10  are pre-drilled to accept the spaced-apart, vertical rods so that the vertical rods pass through the insulating core of each stackable wall unit. After the walls are stacked to a desired height, a wall plate is placed over the top of the walls. A ridge pole is then erected to support center ends of laminated roof beams for the building. A roof frame is erected by mounting opposed pairs of the laminated roof beams, constructed as described above. The laminated roof beams are supported in the center by the ridge pole and, on the outer ends, by the side wall plates. The outer ends of the roof beams are positioned adjacent respective ones of the steel rods that extend from the foundation upwardly through the side walls. The roof beams are joined above the ridge pole using steel brackets bolted to the respective beams, and are joined to the wall using steel brackets that are adapted to be received on the respective threaded rods, and bolted to the beam. After the brackets are positioned, washers and nuts are secured to the tops of the threaded rods to tie the foundation, walls and roof together. The steel rods, in combination with the brackets and the metal plates laminated into the roof beams, provide a continuous flexible connection between the foundation, the side walls and the roof, which is extremely resistant to wracking forces induced by earthquakes and/or windstorms.  
           [0011]    The building in accordance with the invention provides a simulated log structure with exceptional weather resistance, wrack resistance and aesthetic appeal. Because the interlocking stackable wall units  10  are assembled using a significant percentage of waste wood, the cost of the building is controlled, and lumber resources are conserved. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]    Further features and advantages of the present invention will become apparent from the following detailed description, taken in combination with the appended drawings, in which:  
         [0013]    [0013]FIG. 1. is a cross-sectional view of the stackable wall unit in accordance with a preferred embodiment of the invention;  
         [0014]    [0014]FIG. 2 is a cross-sectional view of an alternate embodiment of the stackable wall unit shown in FIG. 1;  
         [0015]    [0015]FIG. 3 is a cross-sectional view of a roof beam in accordance with a preferred embodiment of the invention;  
         [0016]    [0016]FIG. 4 is a cross-sectional view of an assembled wall of a building constructed in accordance with the invention;  
         [0017]    [0017]FIG. 5 is a side elevational view of the wall shown in FIG. 4;  
         [0018]    [0018]FIG. 6 is an elevational view of a wall structure showing vertical wall reinforcement details;  
         [0019]    [0019]FIG. 7 is a cross-sectional view of the vertical wall reinforcements shown in FIG. 6;  
         [0020]    [0020]FIG. 8 is a detailed view of rough opening framing in accordance with the invention for doors and windows;  
         [0021]    [0021]FIG. 9 is an elevational view of a joint detail for the stackable wall unit in accordance with the invention;  
         [0022]    [0022]FIG. 10 is a cross-sectional view of the joint shown in FIG. 9;  
         [0023]    [0023]FIG. 11 is an elevational view of a building corner constructed in accordance with the invention;  
         [0024]    [0024]FIG. 12 is a cross-sectional view of the corner detail shown in FIG. 11;  
         [0025]    [0025]FIG. 13 is a cross-sectional view of a roof construction in accordance with the invention, showing the connection of a roof beam to the wall structure;  
         [0026]    [0026]FIG. 14 is a cross-sectional view of the roof construction showing finishing details at the roof ridge; and  
         [0027]    [0027]FIG. 15 is a cross-sectional view of a roof panel in accordance with the invention. 
     
    
       [0028]    It will be noted that throughout the appended drawings, like features are identified by like reference numerals.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0029]    The invention provides building elements used to assemble an earthquake-resistant building suitable as a domestic dwelling, or the like.  
         [0030]    [0030]FIG. 1 is a cross-sectional view of an interlocking, stackable wall unit  10 . The stackable wall unit  10  includes an outer laminate  12 , an inner laminate  14  and a core  16  of a rigid insulation material (a rigid polyurethane foam, for example). The outer laminate  12  includes an outer layer  18  which is preferably a solid wood layer that extends a full length of the stackable wall unit  10  (typically 14′), The outer layer  18  is, for example, a western red cedar plank that is ⅝″ thick. The outer layer  18  is preferably a solid wood for improved weather-resistance and aesthetic appeal. The outer laminate  12  further includes an inner layer  20  which is a glue laminated composite that may be built-up using any species of any length, any width or thickness. The inner layer  20  is edge laminated using finger jointed strips, then re-sawn to size. The inner laminate is glued, for example, using a polyvinyl acetate glue (PVA-150). The wood used is preferably wood that may be unprocessable in the industry or unsuitable for use in the construction industry. The inner laminate  14  includes an interior finish  22  which is bonded to an inner layer  20  described above. The interior finish  22  may be a solid wood layer or a glue laminated layer which is finger jointed and edge glued. Both the inner and outer surfaces of the stackable wall unit  10  are factory finished with a wood sealer and a suitable wood finish, such as a water-based urethane composition which is well known in the art. The outer laminate  12  and the inner laminate  14  are respectively glued to the rigid insulation core  16 . Besides the glue lamination to the rigid insulation core  16 , the inner and outer laminates are interconnected by C-shaped steel reinforcement members  24  which are driven about 1″ into a top surface of each stackable wall unit  10  at a predetermined interval, such as 4′ on center, for example, as shown in FIG. 12.  
         [0031]    A bottom surface of each stackable wall unit  10  includes a pair of longitudinally extending grooves  26 , which extend along a length of each unit  10 . The grooves  26  are flanked by longitudinal tongues  28 , which likewise extend along the length of each unit. A broad groove  30  is located between the respective tongues  28 . A top surface of each stackable wall unit  10  includes elongated grooves  32 . The top grooves  32  receive the tongues  28  of a next stackable wall unit  10  as the wall in assembled. As each layer of a wall is assembled, a weather seal  34  is applied beside each top groove  32  to inhibit the infiltration of air through the wall construction. The weather seal  34  is preferably a foam tape, such as a polyurethane foam tape. Other weather seals may alternatively be used, such as a butyl caulk, or the like.  
         [0032]    [0032]FIG. 2 shows a cross-sectional detail of an alternate configuration of the stackable wall unit  10  in accordance with the invention. The stackable wall unit  10  shown in FIG. 2 is identical to that shown in FIG. 1 with the exception that the outer layer  18  and the interior finish  22  are shaped to simulate round logs rather than the squared logs simulated by the stackable wall unit shown in FIG. 1.  
         [0033]    [0033]FIG. 3 is a cross-sectional view of a preferred construction for a roof beam  36  in accordance with the invention. The roof beam  36  is a laminated structure for which materials are selected in accordance with the requirements of a particular building. In a typical structure, the roof beam  36  is a three-ply laminated beam constructed of 2×6, 2×8, 2×10, or 2×12 lumber, laminated together with a steel reinforcing plate  38 , preferably a  20  gauge steel sheet bonded between two of the three laminate members. Laminated beam  36  includes first and second outer load bearing members  40  and an inner load bearing member  42 . The inner load bearing member  42  preferably has a width that is less than the width of the outer load bearing members  40  to form a conduit recess  44  which may be used to run electrical wires, or the like. The conduit recess  44  is covered by a conduit recess cap  46 , typically a shaped wood cap that is stapled or nailed to the outer load bearing members  40  after wiring or plumbing has been installed. The roof beam  36  is laminated using steel bolts  48 , such as ⅜″ carriage bolts located in pairs spaced 24″ on center. Each end of each bolt  48  is preferably concealed using a wood filler plug  50 . The connection of the roof beam  36  to the building structure will be explained below in detail with reference to FIG. 13.  
         [0034]    [0034]FIG. 4 is a cross-sectional view of an assembled wall or building structure in accordance with the invention. Assembly of the building structure commences by connecting a plurality of steel rods  52  to a concrete foundation for the building. The steel rods  52  may be set into the concrete foundation before the foundation is poured, or installed afterwards using methods well known in the art. A floor  56  is constructed on the foundation in a manner well known in the art. Thereafter, a wall structure in accordance with the invention is constructed by stacking successive rows of the stackable wall units  10  on the vertically oriented steel rods  52 . The stackable wall units  10  are pre-drilled to accept the vertically-oriented steel rods  52 . The vertically-oriented steel rods are preferably located at 4′ on center around a perimeter of the building. Successive courses of the stackable wall units  10  are assembled until the wall is completed, as shown in FIG. 5. To commence the wall, a solid wood starter member  58  is nailed to the floor  56  and the stackable wall units  10  are stacked one on top of the other as described above while placing the weather seals  34  between each course, as described above with reference to FIG. 1. To complete the wall, a pre-drilled top plate  59 , a 2″×8″, for example, is mounted to the top course of the wall and nailed to the respective inner and outer laminates  12 ,  14  (FIGS. 1 and 2) of the top course.  
         [0035]    [0035]FIG. 6 shows the application of wall reinforcement members  60  which are preferably aesthetically positioned around door and window openings, and may be positioned for aesthetic or structural reasons at other locations on a finished wall. The reinforcement members  60  are shown in cross-sectional view in FIG. 7. Each reinforcement member includes a 3½″ metal stud  62 , preferably constructed of 20 gauge steel, positioned on each side of the wall and notched ⅜″ into the stackable wall units  10 . A bottom end of the metal studs is connected to the concrete foundation wall using, for example, 2⅜″ lag bolts (not shown). Each metal stud  62  is covered by a wood plate  64 , such as a 2″×6″ of red cedar, or the like, having parallel grooves for receiving the flanges of the metal studs  62 . The metal studs  62  are installed in wide grooves cut ⅜″ deep in the respective inner and outer surfaces of the stackable wall units  10 , and secured thereto using common nails  63 , for example. Wood plates  64  may be glued, screwed, or nailed to the wall structure.  
         [0036]    [0036]FIG. 8 is a detailed view of the finish for rough openings for doors and windows in a building construction in accordance with the invention. Each door and window opening is framed by solid wood framing members  66 , 2″×8″, for example, which are preferably secured to the stackable wall units  10  using, for example, common nails  68 .  
         [0037]    The stackable wall units  10  in accordance with the invention are conveniently about 14′ long. FIG. 9 shows an elevational view of a joint detail for joining the stackable wall units  10 . The joint  70  is similar to the wall reinforcement member  60  described above. FIG. 10 shows a cross-sectional view of the joint  70  used to butt join two courses of stackable wall units  10 . The joint  70  includes a transverse joint member  72 , typically 2″×8″ lumber, though laminated material may likewise be used. The transverse joint member and opposite ends of the stackable wall units  10  are covered by 3½″ 20 gauge metal studs  62  notched ⅜″ into the stackable wall units  10  and connected to each of the stackable wall units  10  and the transverse joint member  72  by, for example, 3″ common nails  74  at 4″ on center.  
         [0038]    [0038]FIG. 11 shows a preferred corner detail for a building constructed using the stackable wall units  10  in accordance with the invention. Corners are preferably trimmed with trim boards  76  which are, for example, 14″×6″ western red cedar corner trim boards nailed to the stackable wall units  10  as shown in FIG. 12, which illustrates a cross-sectional view of the corner construction. Underlying the trim boards  76  is a galvanized steel angle  78  that is, for example, 20 gauge steel and preferably about 4″×4″ notched ⅜″ into the respective stackable wall units  10 . The steel angle  78  is preferably fastened with 2″ common nails at 4″ on center. The steel angle  78  preferably extends 6″ below a top of the foundation (not shown), and is secured to the concrete with two, 2″×½″ lag bolts.  
         [0039]    [0039]FIG. 13 is a cross-sectional view of a finished wall constructed using stackable wall units  10 , with a roof structure using the roof beam  36  in accordance with the invention.  
         [0040]    [0040]FIG. 14 is a cross-sectional view of the roof structure illustrating a roof ridge detail. The roof is constructed by erecting a ridge beam  80  after the gable walls (now shown) are assembled, using the stackable wall units  10 , for example. Thereafter, opposed pairs of roof beams  36  are positioned at 4′ on center, adjacent the respective steel rods  52  which extend from the foundation up through the side walls assembled using stackable wall units  10 , as explained above. The respective laminated roof beams  36  are connected to the steel rods  52  using an L-shaped bracket  82  (FIG. 13) which connects on one end to the steel rod  52  and on the opposite end to the roof beam  36  using, for example, a ½″ carriage bolt inserted through the bracket  82  and a transverse bore drilled through the roof beam  36 .  
         [0041]    As shown in FIG. 14, the opposed roof beams  36  are connected together using  20  gauge steel plates  84  bolted to each side of the laminated roof beam  36  using ⅜″ carriage bolts. The brackets are installed by boring holes through the laminated roof beams in alignment with complementary holes in brackets on opposite sides of the roof beams, and inserting the carriage bolts through the holes. Consequently, due to the steel reinforcing plate  38  in each roof beam  36 , described above with reference to FIG. 3, once the roof beams  36  are installed, the entire house structure is connected to the concrete foundation by substantially continuous steel ribs spaced at 4′ on center. Due to the tensile strength combined with the flexibility of the steel ribs, the structure is able to withstand significant bending and racking forces exerted by natural forces, such as earthquakes or windstorms.  
         [0042]    The roof is constructed using pre-assembled roofing panels  86  shown in FIG. 15. Each pre-assembled roofing panel includes a pre-finished interior surface  88  which is, for example, a tongue-and-groove wood finish, well known in the art. The opposite side edges of the roof panels are complementary so that, when two adjacent panels  86  are installed atop the roof beams, a continuous finished interior ceiling for the building is formed. The interior surface  88  is connected to 1″×2″ spacers  90  nailed between 1″×8″ panel sides  92 , that surround insulating material  94 , for example, 7″ thick rigid foam insulation. To construct a roof, the roof panels  86  are laid over the roof beams  36  as shown in FIGS. 13 and 14, preferably starting from a bottom of the roof and working upwardly. Each panel  86  is nailed or screwed to the respective roof beams  36  in a manner well known in the art. The panel sides  92  of two adjacent panels form, in combination, a 2″×8″ to which roofing sheathing  96  may be directly secured. Alternatively, strapping  98 , such as 2″×4″ strapping at 24″ on center, may be nailed to the panel sides  92  to provide ventilation space above the insulating material  94 . Thereafter, a suitable roofing finish is applied in a manner well known in the art.  
         [0043]    The invention therefore provides a solid, well insulated building structure which is very resistant to wracking forces resulting from natural phenomena, such as earthquake and windstorm. The building structure is rapidly assembled, and the stackable wall units  10  are constructed using a significant proportion of materials generally unsuited for use in the construction industry, so labour and material costs are controlled.  
         [0044]    The embodiment(s) of the invention described above is(are) intended to be exemplary only. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims.