Abstract:
The present invention is directed to improved weight bearing elements and methods relating to same. Some such elements are contemplated as having a web, and a chord connected to the web, the chord perimeter having a cross-sectional shape of a closed multi-sided figure having at least 5 sides, at least two of which are substantially parallel to the web. Some members may have chords which have a pentagonal cross sectional shape, and/or may include load transferring members or end-caps. Other elements may comprise a stiffened rim band having die cut tabs and stiffening ribs. Some such elements comprise pairs of die cut tabs positioned along the length of the member at intervals which are a fraction of the distance used in standard joist positioning. Other elements comprise one or more pairs of die cut tabs positioned directly opposite each other such that one tab is adjacent the top of the rim band while the corresponding tab is adjacent the bottom of the rim band. Still other elements may comprise a diamond shape stiffener extruding from the back of the rim band and possibly formed by punching a slot into the back of the rim band and pushing the ends of the slot out from the back so as to form the diamond shape. In some embodiments, the weight bearing elements disclosed herein may be “roll-formed” from a continuous sheet of material such as light gauge galvanized steel. In other embodiments, they may exhibit one or more of the following feature: improved load bearing capacity; lighter weight; reduced material usage; easier to manufacture and/or install; able to be cut to custom lengths.

Description:
[0001]    This application claims the benefit of U.S. application Ser. No. 09/282306, filed Mar. 31, 1999, which claims the benefit of U.S. Provisional Application No. 60/118952, filed Feb. 5, 1999, each of which is incorporated herein by reference in its entirety. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The field of the invention is weight bearing systems such as studs, joists, beams, and related devices and methods.  
         BACKGROUND OF THE INVENTION  
         [0003]    Weight bearing systems comprise primary weight bearing elements such as studs and joists, and secondary weight bearing elements such as rim bands and end caps. Such weight bearing elements are common components in many constructions. For example, floor and ceiling joists function as weight bearing elements and are frequently found in residential and commercial buildings. Although there is a large variety of weight bearing elements, many weight bearing elements are limited in length and weight bearing capacity due to the material(s) from which they are constructed, and are oftentimes difficult to incorporate into constructions because of their structure or cost.  
           [0004]    Primary Weight Bearing Elements  
           [0005]    Primary weight bearing elements can be grouped in two classes, elements predominantly made from wood, and elements predominantly made from metal. Generally, primary weight bearing elements made from wood are found in older constructions, and were traditionally made from solid saw lumber. However, due in part to a sharp decline in the supply of appropriate solid saw lumber, alternative primary weight bearing members which use less solid saw lumber were developed. Such alternatives generally comprise two chords (a top, compression chord/member and a bottom, tension chord/member extending the length of the primary weight bearing element) coupled together by a web (see U.S. Pat. No. 5,664,393 issued on Sep. 9, 1997 to Veilleux et al., U.S. Pat. No. 5,560,177 issued on Oct. 1, 1996 to Brightwell, and U.S. Pat. No. 4,228,631 issued on Oct. 21, 1980 to Geffe). A commonly found alternative is an I-joist having sawn lumber chords or plywood chords. Such an alternative element advantageously reduces the amount of wood required for construction and thereby reduces the weight of the primary weight bearing element. However, almost all forms of wooden primary weight bearing elements are relatively heavy when compared to equivalent metal structures.  
           [0006]    Moreover, wooden primary weight bearing elements are oftentimes limited to lengths of about less than 24′.  
           [0007]    Generally, primary weight bearing elements made from metal are lighter than comparable wooden elements, may span longer distances and are fireproof. Furthermore, such elements are often available in continuous lengths. Primary weight bearing elements made from metal are common in various forms, including light gauge steel C-profile joists, trichord open web joists and screw fabricated steel truss joists (see U.S. Pat. No. 5,687,538 issued on Nov. 18, 1997 to Frobosilo et al., U.S. Pat. No. 5,499,480 issued on Mar. 19, 1996 to Bass, U.S. Pat. No. 5,457,927 issued on Oct. 17, 1995 to Pellock et al., U.S. Pat. No. 5,157,883 issued on Oct. 27, 1992 to Meyer, U.S. Pat. No. 4,793,113 issued on Dec. 27, 1988 to Bodnar, U.S. Pat. No. 4,729,201 issued on Mar. 8, 1988 to Laurus et al., U.S. Pat. No. 4,159,604 issued on Jul. 3, 1979 to Burrell, U.S. Pat. No. 3,686,819 issued on Aug. 29, 1972 to Atkinson, U.S. Pat. No. 3,541,749 issued on Nov. 24, 1970 to Troutner, U.S. Pat. No. 3,221,467 issued on Dec. 7, 1965 to Henkels, U.S. Pat. No. 2,578,465 issued on Dec. 11, 1951 to Davis, Jr. et al., U.S. Pat. No. 2,387,432 issued on Oct. 23, 1945 to Laney, and U.S. Pat. No. 157,994 issued on Apr. 4, 1950 to Palmer).  
           [0008]    Light gauge steel C-profile joists may be manufactured from roll-formed galvanized steel. However, in order to achieve appropriate rigidity, light gauge steel C-profile joists are oftentimes made from 16-gauge steel, which tends to be more difficult to drill or perforate. Furthermore, additional elements are oftentimes difficult to attach to light gauge steel C-profile joists.  
           [0009]    Trichord open web joists are generally more rigid than light gauge steel with C-profile but often have to be custom manufactured to fit span, load, etc. A further common disadvantage of trichord open web joists is that they are difficult to attach or to join with hangers.  
           [0010]    Screw fabricated steel truss joists often suffer from 4 common drawbacks: They are labor-intensive, expensive in manufacturing, have to be custom made and tend to loosening of screws leading to impaired stability and additional wear.  
           [0011]    Secondary Weight Bearing Elements  
           [0012]    Rim bands are used to couple a structural element such as a joist to an adjacent structural elements such as wall studs. A simple rim band might have a “C” shape comprising one vertical segment and two horizontal segments, with the vertical or “back” segment tending to be substantially longer than the “top” and “bottom” horizontal segments or “legs”. One drawback of many rim bands is the tendency for the back to buckle. This tendency is generally compensated for by mounting the rim band to the side of one or more structural members such as a beam or studs such that compression forces are born primarily by the supporting structural member(s) rather than the rim band. An example of a rim band which is mounted in such a fashion can be found by referring to U.S. Pat. No. 5,956,916 issued on Sep. 28, 1999 to Liss. The rim band/ledger beam of Liss comprises a standard C shape with shear tabs punched out of and folded away from the back segment of the rim band. The rim band of Liss, although suitable in many applications, also suffers from the drawback that the shear tabs comprise a single piece folded out from the center of the back of the rim band. The centered shear tabs do not extend to the portions of the back adjacent to the top and bottom horizontal segments and thus would provide poor, if any, coupling to a joist comprising top and bottom cords as described above. Difficulty in attaching joists is a drawback of many rim bands. Moreover, if the sheer tabs did extend the entire length of the back, the rim band would have a tendency to bend under vertical loads at points where the shear tabs were located as only the horizontal legs of the rim band would be left to provide support at such points. Also, forming the bend causing the shear tabs to be positioned perpendicular to the back of the rim band may require more force than can easily be achieved at a work site. Yet another drawback found in some rim bands is the lack of a common rim band for use in structures having differently spaced joists.  
           [0013]    Thus, there is still a need for improved weight bearing systems and methods to produce improved weight bearing elements.  
         SUMMARY OF THE INVENTION  
         [0014]    The present invention is directed to improved weight bearing elements and methods relating to same. Some such elements are contemplated as having a web, and a chord connected to the web, the chord perimeter having a cross-sectional shape of a closed multi-sided figure having at least 5 sides, at least two of which are substantially parallel to the web. Some members may have chords which have a pentagonal cross sectional shape, and/or may include load transferring members or end-caps.  
           [0015]    Other elements may comprise a stiffened rim band having pairs of die cut tabs and/or stiffening ribs positioned along the member/rim band. Some such elements comprise pairs of die cut tabs positioned along the length of the member at intervals which are a fraction of the distance used in standard joist spacings. Other elements comprise one or more pairs of die cut tabs positioned directly opposite each other such that one tab is adjacent the top of the rim band while the corresponding tab is adjacent the bottom of the rim band. Still other elements may comprise a diamond shape stiffener extruding from the back of the rim band and possibly formed by punching a slot into the back of the rim band and pushing the ends of the slot out from the back so as to form the diamond shape.  
           [0016]    In some embodiments, the weight bearing elements disclosed herein may be “roll-formed” from a continuous sheet of material such as light gauge galvanized steel. In other embodiments, they may exhibit one or more of the following feature: improved load bearing capacity; lighter weight; reduced material usage; easier to manufacture and/or install; able to be cut to custom lengths.  
           [0017]    Although joists are only a subset of the primary weight bearing elements to which the disclosed subject matter applies, the term “joist” will be used frequently hereafter to refer to all primary weight bearing elements in order to make this disclosure easier to read. Similarly, the term “rim bands” will be used frequently hereafter to refer to all secondary wait bearing elements. The term polygonal as used herein includes figures in which the bounding line segments are joined by curves as well as more traditional “angular” figures.  
           [0018]    Various objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]    [0019]FIG. 1 is a perspective view of a joist embodying the invention.  
         [0020]    [0020]FIG. 2 is a cross-sectional view of the joist of FIG. 1.  
         [0021]    [0021]FIG. 3 is a perspective view of a joist and load transfer member combination embodying the invention.  
         [0022]    [0022]FIG. 4 is a perspective view of a joist and end cap combination embodying the invention.  
         [0023]    [0023]FIG. 5 is a perspective view of a back-mounted end cap.  
         [0024]    [0024]FIG. 6 is a perspective view of a joist being connected to a “track” type support via a back mounted end-cap.  
         [0025]    [0025]FIG. 7 is a perspective view of a back and bottom mounted endcap.  
         [0026]    [0026]FIG. 8 is a perspective view of the endcap of FIG. 7 being used to connect a joist to a “rail” type support via a back and bottom mounted endcap.  
         [0027]    [0027]FIG. 9 is a perspective view of a rim band embodying the invention.  
         [0028]    [0028]FIG. 10 is a plan view of a cut sheet prior to its being folded into the rim band of FIG. 9.  
         [0029]    [0029]FIG. 11 is a side view of the rim band of FIG. 9.  
         [0030]    [0030]FIG. 12 is a top view of the rim band of FIG. 9.  
         [0031]    [0031]FIG. 13 is a detail view of one of the diecut tabs of the rim band of FIG. 9.  
         [0032]    [0032]FIG. 14 is a front view of one of the stiffeners of the rim band of FIG. 9.  
         [0033]    [0033]FIG. 15 is a side view of one of the stiffeners of the rim band of FIG. 9.  
         [0034]    [0034]FIG. 15 is a perspective view of a rim band and joist according to the claimed invention.  
         [0035]    [0035]FIG. 16 is a perspective view of a rim band and joist according to the claimed invention.  
         [0036]    [0036]FIG. 17 is a perspective view of a support system according to the claimed invention having showing how joists can be coupled to every other pair of diecut tabs to space the joists 16″ intervals.  
         [0037]    [0037]FIG. 18 is a perspective view of a support system according to the claimed invention having showing how joists can be coupled to every third pair of diecut tabs to space the joists 24″ intervals.  
         [0038]    [0038]FIG. 19 is a perspective view of a rim band embedded in a wall and providing support to upper studs.  
         [0039]    [0039]FIG. 20 is a perspective view of a rim band embedded in a solid wall. 
     
    
     DETAILED DESCRIPTION  
       [0040]    Joist  
         [0041]    Referring to FIGS. 1 and 2, a preferred primary weight bearing element/joist  10  comprises top/tension and bottom/compression chords  100  and web  200 . Chords  100  comprise a top supporting side  110 , a left supporting side  120 A, a right supporting side  120 B, and left and right transition sides  130 A, and  130 B. Web  200  comprises body  210 , flanges  220 , fasteners  230 , and chord lips  240 . Referring to FIG. 2, the perimeters of chords  100  of joist  10  can be seen to have a polygonal cross sectional shape having  5  sides, at least two of which are substantially parallel to the web.  
         [0042]    In preferred embodiments, supporting side  110  couples the two parallel sides  120 A and  120 B to each other and provides a load bearing surface. Sides  120 A and  120 B are substantially parallel to each other and to the body  210  of web  200 . Sides  110 ,  120 A,  120 B,  130 A and  130 B can be seen to be planar and to compose parts, via their exterior surfaces  111 ,  121 A,  121 B,  131 A, and  131 B, of the perimeter surface of the chord and to define a cavity  300  via their interior surfaces  112 ,  122 A,  122 B,  132 A, and  132 B, which are not part of the perimeter surface of the chord. Thus, cavity  300  is adjacent to and partially forms a cavity located within the perimeter surface of the chord. Chords  100  are generally parallel to each other, and the cavities  300  contained within them extends the length of the chords  100 .  
         [0043]    In joist/primary weight bearing element  10 , the  5  planar sides  111 ,  121 A,  121 B,  131 A, and  131 B can referred in a number of ways. It is contemplated that referring to side  111  as the top mounting surface of chord  10 , side  121 A as the left mounting surface of chord  10 , side  121 B as the right mounting surface of chord  10 , side  131  A as the left transition surface of chord  10 , and side  131 B as the right transition surface of chord  10  may be beneficial. Using such terms to distinguish between the sides, it can be seen that joist  10  and its sides have the following features: the left side mounting surface  121 A and the night side mounting surface  121 B are each substantially parallel to body  210  of web  200 ; the top mounting surface  111  is substantially perpendicular to the web body  210 ; the left side mounting surface  121 A, the right side mounting surface  121 B, the left transition surface  131 A, and the right transition surface  131 B each comprise a top edge and a bottom edge with the top edge of each of the left side mounting surface  121 A and right side mounting surface  121 B being coupled to the top mounting surface  111 , the bottom edge of the left side mounting surface  121 A being coupled to the top edge  111  of the left transition surface  131 A, and the bottom edge of the right side mounting surface  121 B being coupled to the top edge of the right transition surface  131 B; the left and right transition surfaces  131 A and  131 B extend away from all of the top mounting surface  111 , the left mounting surface  121  A, and the right mounting surface  12   1 B; and the bottom edge of each of the left transition surface  131 A and right transition surface  131 B are coupled to the web  200 .  
         [0044]    It is contemplated that alternative embodiments of primary weight bearing elements may have A planar sides where A is one of 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, or A is greater than 15.  
         [0045]    Because chords  100  comprise planar, i.e. relatively flat and thin, sides connected together, it is possible to form chords  100  from a sheet of thin material such as galvanized steel by simply bending the material into the pentagon shape of the chords  100 . It is contemplated that alternative embodiments may utilize various gauges of steel including, but not necessarily limited to 18 gauge and 20 gauge. It is also contemplated that alternative embodiments of primary weight bearing elements may have sides which are less than N inches thick where N is one of 1, 0.75, 0.5, 0.25, 0.125, and 0.1.  
         [0046]    The cavity  300  within one or more of chords  100  may be filled with a material  300 A so as to increase the weight or modify the weight distribution of the joist/primary weight bearing element  10 . Thus, some embodiments may be ballast (from top to bottom) weighted as in a floor joist, or a drag (from bottom to top) weighted as in a ceiling joist. The material or materials used may be uniform throughout the cavity or may comprise separate elements located within the cavity  300 . The materials used may also be used to modify other features of the joist other than weight including, but not limited to, buoyancy and rigidity.  
         [0047]    Web  200  is preferred to be formed from the same sheet of material as chords  100 . It is also preferred that web  200  be “open” in the sense that portions of the web body  210  are removed, preferably by punching, to create the pattern shown in FIGS. 1 and 2, as well as to form flanges  220 . Web  200  is also preferred to comprise fasteners  230  for fastening chord lips  240  to body  210 .  
         [0048]    End Cap  
         [0049]    It is also contemplated that joists  10  may be used in combination with load transferring studs  400  as shown in FIG. 3, or couplers  500  as shown in FIGS.  4 - 8 . Load transfer studs may be comprised of flat plates and/or more 3-dimensional shapes such as that shown in load transfer stud  400  of FIG. 3. The size and dimensions of various embodiments of transfer studs  400  may vary, as may the method and materials used to form them, so long as they serve to transfer load forces from one chord to another so as to lessen the load on web  200 . Couplers  500  can be used to couple joist  10  to a second joist or to some other object. It is contemplated that in some embodiments, a particular device may function as both a load transfer stud  400  and a coupler  500 . As with transfer studs  400 , the size and dimensions of various embodiments of couplers  500  may vary, as may the method and materials used to form them, so long as they serve to couple a joist  10  to a second joist or another object. Transfer studs  400  and couplers  500  may also vary as to the manner in and/or location at which they are coupled to joist  10 . Some embodiments may thus attach at the ends using screws, while others may be coupled to a non-end portion of the joist, may be fastened by welding or some other means, and may be coupled to one or more sides of chords  100  or to a portion of web  200 . Various methods of using transfer studs  400  and couplers  500  are pictured in FIGS.  3 - 8 .  
         [0050]    It should be noted that the use of parallel sides  120 A and  120 B on chords  100  provide a flat surface to which sides  430  of transfer studs  400  and sides  530  couplers  500  can be attached. It is contemplated that some embodiments will include pre-drilled holes in chords  100  and in the back  410  and sides  430  transfer studs  400 , and in the back  510  and sides  530  of couplers  500  to facilitate the fastening of such studs  400  and couplers  500  to joists  10  via chords  100  through the use of screws or other fasteners.  
         [0051]    Referring to FIGS.  5 - 8 , alternative forms of couplers/end caps  500  are shown. It is contemplated that an end cap  500  such as that of FIG. 5 is particularly suitable for mounting via sides  530  to a joist  10  and via back  510  to another support such as a joist  10  or the track support  610  of FIG. 6. It is also contemplated that an end cap  500  such as that of FIG. 6, because it comprises flanges  520 , will be particularly suitable for mounting to a rail support  620  of FIG. 8.  
         [0052]    Rim Bands  
         [0053]    Referring to FIG. 9, a secondary weight bearing element/rim band  800  comprises a C shape comprising back/vertical segment  810 , upper leg/horizontal segment  820 , and lower leg/holizontal segment  822 . Rim band  800  also comprises stiffeners  840 , upper die cut shear tabs  831  and lower die cut shear tabs  832 .  
         [0054]    Back  810  may vary in height but is preferred to be approximately 12″ high. Similarly, the width of upper leg  821  and lower leg  822  may vary, but upper leg  821  is preferred to have a width of 2″ while lower leg  822  is preferred to have a width of 2″. Thus, a preferred rim band can be formed by folding a sheet of metal approximately 16″ wide into a C shape having sides of 2″, 12″, and 2″. Less preferred embodiments may comprise a single side/back  810  without legs  821  and  822 . It is contemplated that alternative embodiments may utilize various gauges of steel including, but not necessarily limited to 18 gauge and 20 gauge. It is contemplated that any length, width, or height may fall within a range of plus or minus 6″ or smaller of the specified length, width or height unless such variation is expressly prohibited herein.  
         [0055]    Die cut shear tabs  831  and  832  comprise pairs of tabs positioned opposite each other long the rim band with each pair of tabs being used to couple a joist to the rim band. A given pair of tabs will comprise one upper tab  831  positioned adjacent the upper leg  821  of rim band  832  so that it can readily be coupled to the upper chord of a support member  10 , and a lower tab  832  positioned adjacent the lower leg  822  of rim band  832  so that it can readily be coupled to the lower chord of a support member  10 . In preferred embodiments where back  810  is 8.5″ high, shear tabs  831  and  832  will be separated from each other by a distance of 8.5″, and each will be separated from the nearest leg by less than 0.5″ or less than 0.25″.  
         [0056]    In alternative embodiments, sets of tabs having more than two sets of tabs per set may be utilized. It is contemplated that in such embodiments the tabs would be vertically aligned in a fashion similar to the pairs of tabs of FIGS.  9 - 20  for use on structural members having sufficient side surface area for coupling to all of, or at least a subset of the tabs. Thus embodiments comprising sets of vertically aligned tabs wherein the sets comprise 3, 4, 5, 6, or more tabs are contemplated wherein all or a subset of tabs may be suitable for use with a given joist type.  
         [0057]    Die cut shear tabs  831  and  832  are preferred to be uniform in size throughout rim band  800  although they may very in size and shape in less preferred embodiments. Die cut shear tabs are preferred, referring to FIG. 13, to be formed by creating 0.16″ wide, U-shaped cut in back  810  of rim band  800 , with the “U” having a base width of 1.2″ of one side and a height of 1.9″ for the remaining two parallel sides. The size and shape of shear tabs  831  and  832 , either individually or in plural may vary in size and/or shape.  
         [0058]    Each shear tab  831  or  832  is preferred to comprise a plurality of holes positioned long the length of the tab parallel to the sides of rim band  800  such that fasteners such as screws and or nails can pass project through the holes into and in a line parallel to the chords of joist  10 .  
         [0059]    Referring to FIGS.  10 - 13 , shear tabs  831  and  832  are preferred to be spaced along the length of rim band  800  such that the separation between centers of adjacent shear tabs is such that it is a fraction of at least two standard joist spacings. As an example, joists are typically spaced at 16″ and 24″ intervals. By spacing shear tabs  831  and  832  at 8″ intervals, a single rim band can be used regardless of whether 16″ or 24″ spacing is chosen by placing joists and every other or every third pair of shear tabs. Cutting tabs at 9.6″ centers to accommodate placing joists at 19.2″ centers is also contemplated.  
         [0060]    Stiffening members  840  are, referring to FIGS. 14 and 15, preferred to comprise a diamond shape having a cutout center. By punching, cutting, or otherwise creating an elongated aperture  841  in back  810 , the sides of the aperture thus formed can be pushed or otherwise forced away from the back  810  of rim band  800  so as to form a diamond shape comprising sides  841   a - c , perimeter outer perimeter  843 , and inner perimeter  844 . Although the actual dimensions of stiffening member  840  may vary, preferred embodiments will have a length between tips of the outer perimeter  843  of 8″, and approximately 3″ for inner perimeter  844 . Stiffening members  840  are also preferred to extrude from back  810  for a height of 0.4″ at their centers, and 0.15″-0.2″ near the upper and lower points of perimeters  843  and  844 . A preferred diamond shape consists essentially of four sides forming two Vs positioned adjacent to each other but with opposite orientations. Each V has an angle formed by its two sides which is greater than 5 or 10 degrees, but less than or equal to 45 degrees, and the angles between adjacent sides of the Vs where they are coupled together are preferably greater than or equal to 135 degrees but less than 170 or 180 degrees. Less preferred embodiments may have different angular relationships between sides and/or may utilize more or less than four sides.  
         [0061]    Less preferred embodiments may utilize smaller stiffening members shaped similarly to those described above. Such embodiments may utilize two or more vertically aligned stiffening members rather than a single larger stiffening member, or may utilize smaller stiffening members arranged in some other pattern.  
         [0062]    It is contemplated that weight bearing systems comprising rim band  800  will benefit from reduced shear. It is also contemplated that the tabs  831  and  832  help strengthen rim band  800 . It has been observed that a rim band with and effective 8″ track/back height is stiffer than one with a 10″ track.  
         [0063]    Weight Bearing Elements in General  
         [0064]    It is contemplated that weight bearing elements according to the subject matter disclosed herein may vary greatly in size. Thus smaller primary weight bearing elements may be used in, among others, prosthetic devices including but not limited to dental implants covering multiple teeth and long bone replacements, household utensils, cars, small planes, scaffolding, and furniture. Larger elements may be used in, among others, bridges, oil tankers, large planes, and lightweight ladders.  
         [0065]    It is contemplated that various embodiments of the weight bearing elements disclosed herein may be formed from one or more materials. Such materials may include, but are not necessarily limited to: a metal such as stainless steel, aluminum, galvanized steel, and iron; polymers such as PVC, thermoplastic, inflexible polyethylene, and polycarbonate, polypropylene, and polyethylene (such polymers may be provided in granules, in an unpolymerized for, and/or in sheets of flexible polymers); fibrous man-made material including, but not limited to, glass-/carbon fibers hardened with resins; and elemental metals including magnesium.  
         [0066]    Methods of Formation  
         [0067]    It is contemplated that weight bearing elements according to the subject matter disclosed herein may be formed in a number of methods involving steps which include, but not limited to: pre-forming such as by rolling from a coil and/or plates of precut lengths; and preprocessing such as by coating, cutting, and/or punching.  
         [0068]    One method of forming a primary weight bearing element/support member  10  according to the claimed subject matter might simply involve roll forming a sheet of metal into the shape shown in FIGS. 1 and 2 by bending each side of the sheet six times so as to form a pentagonal chord  100  and chord lip  240 , and then fastening, possibly through the use of adhesives, screws, welding, or a clench press, chord lip  240  to body  210 . Such a method could also include a step of punching out portions of body  210  so as to form a web pattern and flanges  220  as shown in the figures.  
         [0069]    Another method involves the use of polymers which may be deformed from a sheet into a pentagonal shape and then fixed by heat and/or glue. Similarly, granules or unpolymerized material may be filled into a mold and symmetrical portions cast with such portion then being fixed together by heat, ultrasound, glue, etceteras. In yet another example, a fibrous man-made material is wrapped around templates to create a first, immature form, which will be modified into a second, mature form by applying resin or other polymer to harden the fiber mats. In yet one more example magnesium may be poured into a mold to obtain a first, immature form of the product which will then be fixed by heat to form a second, mature form.  
         [0070]    One method of forming a secondary weight bearing element/support member  800  according to the claimed subject matter might simply involve (1) folding the sides of a sheet of metal to form a standard C shape comprising upper leg/horizontal segment  821 , lower leg/horizontal segment  822 , and back/vertical segment  810 ; (2) making the die cuts to form upper shear tabs  831  and lower shear tabs  832 ; and (3) forming stiffeners  840 , possibly by a combined punch and press operation. Shear tabs  831  and  832  can either be folded outward from back  810  during manufacture, or, more preferably, can be folded out as needed during weight bearing system assembly. The actual order of formation of the various components of element  800  may be varied. Although die cutting the tabs is preferred, any method which allows for formation of sets of vertically aligned tabs along the length of the rim band may be utilized.  
         [0071]    Methods of Use  
         [0072]    In addition to the methods explicitly and inherently disclosed above, weight bearing systems according to the claimed invention may be used in building a structure by, referring to FIG. 19: (1) providing a rim band  800 ; (2) positioning the rim band on top of one or more lower studs  912 ; (3) coupling one or more joists  10  to the rim band such that the combination of rim band  800  and lower studs  912  at least partially supports the one or more joists  10 ; (4) positioning one or more upper studs  911  on top of the rim band  800  such that the combination of rim band  800  and lower studs  912  at least partially supports the upper studs  911 . In some methods, the rim band  800  provided may comprise upper and lower horizontal segments  821  and  822  wherein the lower horizontal segment  822  rests on and is coupled to the lower studs  912  and the upper studs rest on and are coupled to the upper horizontal segment  911 . In other methods, the end of a joist  10  is positioned between the upper and lower segments  821  and  822  of the rim band  800  such that it is directly above a lower stud  912  and directly below an upper stud  911 . In such methods it is preferred that one side of each of the upper stud  911 , the lower stud  912 , and the joist  10  have a side positioned in or adjacent to a common vertical reference plane A, or, even more preferably that a second side of each of the upper stud  911 , the lower stud  912 , and the joist  10  also have a side positioned in or adjacent to a second common vertical reference B plane, the second vertical reference plane being parallel to the first vertical reference plane. In many instances, the end of joist  10 , the back of rim band  800 , and a third side of studs  911  and  912  will be positioned in or adjacent to a third vertical reference plane C where C is perpendicular to reference planes A and B.  
         [0073]    It is contemplated that vertically aligning a lower stud  912 , and upper stud  911 , and a joist  10  permits rim band  800  to support upper stud  911 . In such an instance it is contemplated that joist  10  obtains support from lower leg  822  and possibly back  810  of rim band  800  while providing sufficient support to upper leg  812  to prevent it from bending or otherwise deforming under the load transferred to it via upper stud  911 . Although alternative embodiments may not match joists  10  to pairs of vertically aligned upper and lower studs  911  and  912  on a one for one basis, it is preferred that embodiments placing upper stud  911  on top of rim band  800  have at least one joist vertically aligned which each pair of vertically aligned studs. Track  913  may also be incorporated into the system so as to provide additional stability to upper and/or lower studs  911  and  912  and to facilitate coupling the studs to the rim band  800  and/or another structural member such as floor  930 .  
         [0074]    Referring to FIG. 20, another method of use of a rim band as described herein is to at least partially imbed it within a wall (or floor or other structural member), possibly by using as a form member during formation of a concrete wall. Although many types of rim bands may be suitable for such a use, the rim band described herein is particularly suitable as the die cut shear tabs can be folded out as necessary after the wall has been formed to provide ready attachment of joists without requiring insertion of fasteners into the wall. Although the need for stiffening members  840  is less apparent when back  810  is supported by an adjacent surface, stiffeners  840  may function to prevent lateral movement of rim band  800  after the wall is formed, and may prevent buckling of the rim band during wall formation.  
         [0075]    In preferred methods, the rim band and/or joists will comprise one or more of the rim bands or joists as previously described and as claimed herein.  
         [0076]    Thus, specific embodiments and applications of primary and secondary weight bearing elements and related methods have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced.