Abstract:
A building system is provided such that a building designer, given the various loads a structure must bear, can determine and configure the components of the structure, such as walls, floors and roof trusses, and fabricate those components from chords and clips. The chords and clips are designed in such a way as to permit location of the clips at the desired locations within the chords as required to bear the load. Chords and clips with varying characteristics are provided for assembly of components with varying requirements.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to a beam for use in a frame for building structures such as walls, floors, roofs, etc., the beam having a pair of spaced apart chords joined by clips. In its various aspects, the invention concerns: the clips which join the chords; the assembled beam; the frame including such beams; and methods for assembling the beam and frame. 
       BACKGROUND OF THE INVENTION 
       [0002]    There are a variety of approaches currently taken to the construction of frames for building structures such as walls, floors, ceilings, trusses, etc. One example, a wood beam used as a stud or a joist, is still in common use. Wood is becoming increasingly expensive and should be treated to prevent rot and possible insect infestation. Wood may also warp and may be of inconsistent quality. A general characteristic of a wood beam is that a beam of given dimensions has particular load bearing characteristics, and increasing the load bearing characteristics of a frame constructed of wood beams generally requires using a greater number of beams or beams of increased cross-dimension. Wood, being a solid material, also requires holes to be drilled for the passage of concealed wires, etc., through the beams of a floor, or wall. Wood beams nevertheless have an advantage of being easily cut to fit a particular application, although a certain amount of pre-fabrication of wooden building frames has become common. 
         [0003]    When designing a building structure, an architect or designer determines the load which the structure is required to bear. Load bearing beams are selected from those which are available. Consideration is given to material characteristics, such as weight, cost, beam spacing and dimension required to bear the required load. An architect is limited by these considerations. For example, an architect may prefer to use 6″ deep wood joists in a floor, but finds that to meet the determined load requirement, the joists must be spaced no more than 14″ apart. Standard sub-flooring materials require joists spaced at 48″ intervals. A common solution to this problem would be simply over-build the floor by using the 6″ deep wooden joists spaced 12″ apart. This would result in the use of more material and labor necessary than to simply meet the determined load bearing capacity. An alternative solution might be to use 8″ deep wooden joists spaced 16″ apart, but this changes the depth, i.e. thickness, of the floor which may be undesirable or even not possible within the constraints of a particular situation. In any event, it might still lead to an over-built floor. It would thus be advantageous to have a beam for use in a building structure which beam permits the load bearing capacity of the structure to be conveniently tailored to a particular situation without necessarily requiring alteration of the beam dimension or spacing. Such a beam would provide a structure having material and labor costs more commensurate with the load bearing requirements of the structure. 
         [0004]    One example of providing for a beam for use in a building structure which permits the load bearing capacity to be tailored to a particular situation without requiring alteration of the beam dimension or spacing is found in U.S. Pat. No. 5,761,873 to Slater. The invention disclosed in Slater provides for beams made from metal webs attached to the outside of metal chords, which beams can be used to form building structures, such as walls and floors. While the Slater invention works well in many situations, it would be advantageous to have an improved building system to provide for greater strength with less components and less weight, in an easier and more cost effective composition, while still providing a beam for use in a building structure that permits the load bearing capacity of the structure to be conveniently tailored to a particular situation without necessarily requiring alteration of the beam dimension or spacing. 
       SUMMARY OF THE INVENTION 
       [0005]    The approach of the present invention is to provide load bearing members of a building structure, such as beams for wall studs, floor joists and roof trusses, which are tailored such that the load requirements of a particular building structure are met. Each beam is assembled to include a pair of component chords and at least one clip, which are selected from a set of chords and clips according to a recipe. Given the load bearing requirements of a structure, the recipe indicates beam spacing within the frame, the type of chord, the type of clips and the number and position of clips to be included in each beam. 
         [0006]    The present invention thus provides, in one aspect, a beam kit of parts. The kit includes standard chords and clips. These are assembled into beams according to a recipe and included in the frame of a structure having a required load-bearing capacity according to predetermined criteria. The recipe for beam assembly indicates which type of chords to include in each beam, and the number and type of clips to be included. The predetermined criteria indicate the spacing of beams necessary for the required load bearing capacity of the structure. 
         [0007]    According to a preferred embodiment, the set of chords include generally “T” shaped chords formed from a flat length of metal, being steel, aluminum or other such composite material, by a rolled-form process, or other similar shaping process, leaving an opening at the end of the elongate vertical portion of the “T” shaped chord. Two chords are connected together by clips formed from metal, being steel, aluminum or other such composite material, by a rolled-form process, or other similar shaping process. A clip may be a plate clip, a tubular clip or other clip, depending on the strength requirements of the desired beam. The clips have tag portions which fit inside the opening at the ends of the elongate portion of the “T” shaped chords, at which points the clips may be fastened to the chords by fastening means, such as clinching, screwing or bolting. Clips are preferably dimensioned such that an assembled beam is of a depth which may be used with conventional building materials. 
         [0008]    The present invention also includes methods for assembling beams and constructing frames, walls, floors, ceilings, trusses and other building forms from such beams. 
         [0009]    A method for assembling a beam for use as part of a frame of a building structure having a required load bearing capacity includes selecting a combination of chords and clips according to a recipe; positioning a first clip and chord in a predetermined position; fastening the clip and chord according to a recipe; positioning a second chord in a position parallel to the first chord and for fastening to the clip and fastening the second chord and clip together according to a recipe. 
         [0010]    A method for constructing a frame for a load-bearing building structure includes determining the load required to be borne by the structure; determining beam spacing and beam dimensions required for the frame to bear the load according to predetermined criteria; assembling beams by fastening together standard chords and clips according to a recipe indicating the number of clips and the types of clips and chords to be included in each beam and incorporating so assembled beams as part of the frame to have the determined spacing. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  is a perspective view of a beam fabricated from two chords and a plate clip; 
           [0012]      FIG. 2   a  is a cross-sectional view of a standard chord. 
           [0013]      FIG. 2   b  is a cross-sectional view of an expanded chord; 
           [0014]      FIG. 3   a  is a perspective view of a plate clip; 
           [0015]      FIG. 3   b  is a cross-sectional view of a plate clip; 
           [0016]      FIG. 4   a  is a side perspective view of a tubular clip; 
           [0017]      FIG. 4   b  is a front perspective view of a tubular clip; 
           [0018]      FIG. 5  is a cross-sectional view of a beam fabricated from two standard chords and a plate clip; 
           [0019]      FIG. 6  is a perspective view of an alternate beam fabricated from two expanded chords and a plate clip; 
           [0020]      FIG. 7  is a perspective view of a beam fabricated from two expanded chords and two tubular clips; 
           [0021]      FIG. 8  is a perspective view of a beam connected to a bottom track; 
           [0022]      FIG. 9  is a perspective view of a beam connected to a top track; 
           [0023]      FIG. 10  is a perspective view of a corner detail fabricated from two bottom tracks and two beams; 
           [0024]      FIG. 11   a  is an isometric view of a joist end connection connecting the end of a joist to a top track and a beam; 
           [0025]      FIG. 11   b  is a cross-sectional view of a joist end connection; 
           [0026]      FIG. 12  is an interactive view of a joist end insert into a chord; 
           [0027]      FIG. 13  is a perspective view of a building structure fabricated from beams, tracks and joists; 
           [0028]      FIG. 14  is a perspective view of a truss fabricated from chords, tubular clips and brackets; 
           [0029]      FIG. 15   a  is a perspective view of a beam with a brick connector; 
           [0030]      FIG. 15   b  is a cross-sectional view of a beam with a brick connector; 
           [0031]      FIG. 16  is a side view of a two beams with a concrete floor between them and a brick outer surface attached with the aid of a brick connector; 
           [0032]      FIG. 17  is a side view of a beam with a stucco surface attached to the outer surface of the beam and a drywall surface attached to the inside of the beam; 
           [0033]      FIG. 18  is a side view of a beam with a metal surface attached to the outer surface of the beam and a metal surface attached to the inside surface of the beam; 
           [0034]      FIG. 19  is a perspective view of a window detail; 
           [0035]      FIG. 20  is a perspective view of a door detail; 
           [0036]      FIG. 21  is a perspective view of a cross chord connector; 
           [0037]      FIG. 22  is a perspective view of a building structure fabricated from beams, joists, trusses, a window detail and a door detail; 
           [0038]      FIG. 23  is a view of a truss. 
           [0039]      FIG. 24  is a perspective view of an alternative shape for a plate clip. 
           [0040]      FIG. 25  is a perspective view of an alternative shape for a plate clip. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0041]    Referring to the drawings,  FIG. 1  shows a portion of a preferred embodiment beam  20 . Beam  20  includes a pair of spaced apart chords  22  held together by plate clip  24  secured to each chord  22  by fastening means, such as clinching, screwing or bolting. 
         [0042]      FIG. 2   a  shows the cross-section of a standard chord  22 . The standard chord  22  has a cross-section that is generally “T” shaped which can be formed from a flat length of metal, being steel, aluminum or other such composite material, by a rolled-form process, or other similar shaping process. This forms a standard chord  22  with a top portion  21 , opposing side wall portions  25  of length y, two connecting portions  27  and an elongate portion  29  of length x. An opening  26  is formed at the distal end of the elongate portion  29  of standard chord  22  between two substantially parallel members  23  of the elongate portion  29 . A depression  28  is formed in the top portion of standard chord  22 . 
         [0043]      FIG. 2   b  shows the cross-section of an expanded chord  32 . The expanded chord  32  has a cross-section that is generally “T” shaped which can be formed from a flat length of metal, being steel, aluminum or other such composite material, by a rolled-form process, or other similar shaping process. This forms an expanded chord  32  with a top portion  31 , opposing expanded side wall portions  35  of length y′, two connecting portions  37  and an elongate portion  39  of length x′. An opening  36  is formed at the distal end of the elongate portion  39  of standard chord  32  between two substantially parallel members  33  of the elongate portion  39 . A depression  38  is formed in the top portion of expanded chord  32 . 
         [0044]    The length x and x′ of the chords  22  and  32  as shown in  FIGS. 2   a  and  2   b  is sufficient to permit the entry of the tag portions  64  of plate clip  24  or tubular clip  100 , as shown in  FIGS. 3   a ,  3   b ,  4   a  and  4   b , into the openings  26  and  36  of the standard chord  22  and the expanded chord  32 , respectively. The minimum length y of the side wall portion  25  of the standard chord  22  is ¼ of length x of the elongate portion  29  of the standard chord  22 . Preferably, the minimum length y of the side wall portion  25  of the standard chord  22  is about ¼″ to permit the standard chord  22  to maintain its structural integrity. The length y of the standard chord  22  may be easily expanded to the length y′ of the expanded chord  32  in the forming process. The expanded chord  32  exhibits increased strength as compared to the standard chord  22 . The length y′ may be increased to about 4 times the length x′, or preferably about 4″, while maintaining the benefits of its increased strength with minimal changes in manufacturing. The varying lengths of y′ results in the various chord profiles for use in the present invention. 
         [0045]    As seen in  FIGS. 3   a  and  3   b , a plate clip  24  may be used. The plate clip  24  is comprised of a single flat piece of metal. The plate clip  24  has a pair of tag portions  64  at opposing ends. The tag portions  64  have a thickness that is less than the width of the opening  26  of the standard chord  22  and the opening  36  of the expanded chord  32 , so as to permit entry therein. The plate clip  24  may have an opening  68  formed in its central portion through which wires and cable may be passed. A smooth return  69  is formed around the edge of the opening  68  on one side of the opening  68  by punching the opening  68  using a die to cause a lip to be formed which is then pressed down to form the smooth return  69  to reduce friction on wires and cables passing through the opening  68 . The plate clip  24  has indentations  65  on the non-tag portion. The indentations  65  provide increased strength for the plate clip  24 , while acting as stops for the insertion of the tag portions  64  into the openings  26  and  36  of the standard chord  22  and the expanded chord  32 , respectively. The indentations  65  may be any shape and configuration, while indentations that are elongate and which are at a 45 degree angle to the edges of the tag portions  64  maximize the increased strength to the plate clip  24 .  FIG. 24  illustrates an alternative shape for a plate clip, being trapezoidal with returns  61  on the sides not having the tag portions  64 , and angled indentations  65 , which further increases the strength of a resulting beam.  FIG. 25  illustrates another alternative shape for a plate clip, being rectangular. 
         [0046]      FIGS. 4   a  and  4   b  illustrate tubular clips  100  which are formed from a tubular length of metal or other composite which is flattened at each end to form tag portions  104  at opposing ends of a central portion  102 . As illustrated in  FIG. 7 , two chords  22  are joined together by tubular clips  100  by inserting the tag portions  104  of the tubular clips  100  into the openings  26  of the chords  22  and fixing the tubular clips  100  to the chords  22  by clinching or other fastening means. The angle between two tubular clips may be varied, with an angle of 45 degrees providing the maximum strength for the resulting beam. The length of the central portion  102  may be increased or decreased to provide the desired width between beams. 
         [0047]      FIG. 5  shows a cross-sectional view of beam  20  with the tag portions  64  of a plate clip  24  inserted within openings  26  of chords  22  and fixed together by clinching means applied in the areas and directions indicated by the arrows. 
         [0048]      FIG. 6  illustrates a beam  80  assembled from two expanded chords  32  and a plate clip  24 . 
         [0049]      FIG. 8  illustrates a typical connection of beam  20  installed as a stud in bottom track  110  having bed  112  and walls  114 . As shown in  FIG. 8 , the beam  20  is lowered onto the bottom track  110  and is fixed at point  116  to the bottom track  110  by fastening means, such as screwing or bolting. The bottom track  110  may be fastened directly to a supporting concrete floor, for example, by a concrete anchor. 
         [0050]      FIG. 9  illustrates a typical connection of beam  20  installed as a stud in Top track  120  having bed  122  and walls  124 . As shown in  FIG. 9 , the top track  120  is lowered onto the beam  20  and is fixed at point  126  to the beam  20  by fastening means, such as screwing or bolting. The top track  120  may be fastened directly to a supporting concrete floor, for example, by a concrete anchor. 
         [0051]    An example of a corner arrangement for wall frame members is shown in  FIG. 10 . bottom tracks  110   a  and  110   b  are mitered at a right angle and beams  20   a ,  20   b  and  20   c  are fastened to bottom tracks  110   a  and  110   b , respectively, at the taps  126 , not shown. The beams  20   a ,  20   b  and  20   c  are fastened by screws or other similar fastening means  132  to upstanding track walls  114   a  and  114   b , respectively. 
         [0052]    A joist end connection is shown in  FIGS. 11   a  and  11   b . A beam  20  used as a vertical stud is connected to a top track  120 . A joist beam  140  is assembled from two expanded chords  32   b  and  32   c  and two tubular clips  100   a  and  100   b . A short piece of standard chord  22   a  is fixed to the top of the top track  120  by fastening means, such as a screw, with its opening  26   a  positioned away from the top track  120 . The upper chord  32   b  of the joist beam  140  extends over the top track  120  with its opening  36   b  positioned towards the top track  120 . As shown in  FIG. 11   b , one substantially parallel member  23   a  of the elongate portion  29   a  of chord piece  22   a  is fitted into the opening  36   b  of chord  32   b  and one substantially parallel member  33   b  of the elongate portion  39   a  of chord  32   b  is fitted into the opening  26   a  of chord piece  22   a . The elongate portions  29   a  and  39   b  are fixed together by fastening means, such as clinching, screwing or bolting. 
         [0053]      FIG. 12  illustrates a joist end insert  94  inserted into the end of an expanded chord  32  which may be used to fabricate a beam for use as a joist. The joist end insert  94  may be made from metal or other composite material. The joist end insert  94  may be used to increase the load capacity of a joist. 
         [0054]    A portion of a building frame, having studs and joist made from beams assembled from the present invention is shown in  FIG. 13 . Beams assembled pursuant to the present invention are used as studs, such as beam  20 , and joists, such as joist beam  140 , and are connected to top tracks  120  and bottom tracks  110 . 
         [0055]      FIG. 14  shows a view of a portion of truss  220 . Chords  22   a  and  22   b  are connected together by tubular clips  100 . A truss bracket  222  may be fixed by fastening means  226 , such as clinching, screwing or bolting, to chords  22   a  and  22   b  above top track  120  supported by beam  20  used as a stud. Alternatively, a length of chord  22  may be used in place of a truss bracket  222 . An angle bracket  224  is fixed to chord  22   a  and chord piece  22   c  by fastening means, such as clinching, screwing or bolting. Chord piece  22   c  is fixed to beam  20  by support bracket  228 . 
         [0056]    Sheathing such as drywall, stucco, sheet metal, rigid foam insulation, etc. may be secured to beams in a conventional manner. Drywall screws may be fastened directly into the chords of the preferred embodiment. 
         [0057]      FIGS. 15   a  and  15   b  show a brick connector  150  for beam  20  installed included as a stud as part of a wall frame. Brick connector  150  includes sheet metal trough with walls  152 ,  154  and base  156  secured to beam  20  by fastening means, such as screws. Lateral extension  158  having aperture  160  for receipt of tie wire  162  provides for connection of a brick veneer wall to the beam in a manner familiar to those skilled in the art, and illustrated further below. 
         [0058]    Beam  20  installed as part of an outer wall is illustrated in  FIG. 16 . In addition to the components detailed above, brick veneer  170  connected to beam  20  by way of tie wire  162  is shown. The wall includes exterior sheathing  172  which may be fastened directly to beam  20  by conventional means appropriate for the sheathing. Sheathing may include any conventional building component such as rigid insulation fastened by any suitable conventional manner directly to frame beams. Water barrier  174  inhibits ingress of water into the area of wall-floor joint  176  and flashing  180  directs any water flow to weep holes  182 . The weep holes are located above angle shelf  184  anchored directly to concrete slab  186 , supported by joist  140 , by anchor  188  and elastic sealant  190  and sealant back-up  192  are between upper brick layer  194  and shelf  184 . Material to be concealed within a wall may be installed to pass between chords of a beam without the need for drilling holes, as with solid beams. For example, insulation, not shown, may be located between beams  20  and spaced apart chords  22   a  and  22   b  of beams of the wall frame. It will be appreciated that plate clips  24  connecting inner chords  22   a  and outer chords  22   b  act as a reduced thermal bridge between the outer and inner portions of an external wall than if a unitary metal beam were used. 
         [0059]    Beam  20  may be installed as part of an outer wall as illustrated in  FIG. 17 . In addition to the components detailed above, a primary surface  210 , such as cement board or plywood, may be fixed directly to the outer chord  22   a  of beam  20  by any suitable conventional manner. Rigid insulation  212  may be applied to the primary surface  210  by conventional means. Insulation  218  may be located between beams  20  and spaced apart chords  22   a  and  22   b  of beam  20  of the wall frame. Stucco  214  may be applied to the rigid insulation  212  by conventional means to create a finished outer surface. Drywall  220  may be applied to the inner chord  22   b  to create an inner surface. 
         [0060]    Beam  20  may be installed as part of an outer wall as illustrated in  FIG. 18 . In addition to the components detailed above, a sheathing  230  may be fixed directly to the outer chord  22   a  of beam  20  by any suitable conventional manner. Exterior metal rain screen  232  is fixed to the sheathing  230  by continuous horizontal subgirt  234  by fastening means, such as sheet metal screws  236  between exterior metal rain screen  232  and outer chord  22   a . Insulation  218  may be located between beams  20  and spaced apart chords  22   a  and  22   b  of beam  20  of the wall frame. Sheathing  230  may be applied to the inner chord  22   b  to create an inner surface. 
         [0061]    Exemplary building components including beams of the present invention are shown in  FIGS. 19 and 20 , illustrating a window component  130  and a door component  135 , respectively. The horizontal chord pieces  22   a  are fixed to vertical beams  20  by cross chord connectors  96 , illustrated in  FIG. 21 , and fastening means, such as screwing or bolting. An exemplary building including beams of the present invention is shown in  FIG. 22 , various components being indicated as discussed above. 
         [0062]    The strength of a beam may be tailored to suit a particular framing application by the use of chords of a particular strength and by the use of clips having a particular size and shape and by the use of particular configurations for fastening the clips and chords together. Examples of the manner in which a beam of the preferred embodiment is tailored for particular applications are given below. 
         [0063]    Chords and clips of the illustrated embodiment may be made from galvanized steel, ASTM A513-35Y. The gauge of steel depends upon the strength requirements of the application for which the beam is to be used, and is generally in the range between 22 GA and 14 GA. The chords and clips may also be manufactured from aluminum or other composite materials. 
         [0064]    The preferred embodiment beam is shown in use as part of frames for various building structures. It will be appreciated that in certain contexts the beam is used in place of a conventional stud, joist, etc. but that the beam has additional uses as well. 
         [0065]    It will further be appreciated that beam  20  may be supplied as a “kit of parts” including unassembled chords and clips. The beam may thus be shipped and stored compactly and assembled at a building construction site or possibly by a manufacturer prior to shipment. 
         [0066]    The following examples are provided for purposes of illustrating various aspects of the preferred embodiment of the present invention. It will be appreciated by a person skilled in the art that other and additional configurations can be made by varying the parameters without venturing beyond the scope of the present invention. 
         [0067]    The following examples are provided based on the International Building Code—2006, North American Specification—2001 and ASTM quality standards. It will be appreciated by a person skilled in the art that varying the standards will require other and additional configurations, which can be obtained without venturing beyond the scope of the present invention. 
       EXAMPLE 1 
       [0068]    Example 1 illustrates the fabrication of a wall stud 8 feet in length. The Depth refers to the outside dimension. The Chord Type refers to the nature of the cross-section profile of the chord, where 1 refers to the standard chord with measurement “y” approximately equal to ¼″ and where 2, 3 and 4 refer to the expanded side wall chord with measurement “y1” approximately equal to ½″, 1½″ and 2½″, respectively. The Gauge refers to the thickness of the steel, where 20, 18 and 16 refer to thicknesses of 0.032″, 0.044″ and 0.06″, respectively. The Clip Type refers to the kind of clip to be used, where 1 refers to a tubular clip 1″ in diameter and 2 refers to a plate clip. The clips used in any given wall stud are all of the same dimension from tag portion to tag portion. The number of clips refers to the quantity of clips to be used, where there is always one clip approximately 2″ from each end of the beam and the remaining clips are distributed such that the center points of all clips are equally spaced from one another. Where more than one number is indicated for the number of clips and gauges, the first number of clips is matched with the first gauge number and each subsequent number of clips is matched with each subsequent gauge number. In the event that clips of different gauges are to be used in the same beam, the thicker clip(s) is/are to be affixed in the positions lowest to the bottom of the beam. 
         [0069]    Referring to Table 1 for the fabrication of wall stud of 8 feet in length and 6 inches in depth, the desired wind load is chosen from the table, indicating the appropriate row of information. The type and gauge of chord is referenced in the corresponding column in that row. The number and type and gauge of clips is also referenced from the corresponding column in that row. The wall stud is then fabricated by inserting the clips within the chords in the positions indicated by the above noted recipe and fastening the clips to the chords. 
         [0000]    
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                 Wall Stud 
                 Wall Stud 
                 Specified 
                 Factored 
                 Chords 
                 Clips 
               
             
          
           
               
                 Height 
                 Depth 
                 Wind Load 
                 Vert. Load 
                 Chord 
                 Steel 
                 Clips 
                 Clip 
                 Steel 
               
               
                 (Feet) 
                 (Inches) 
                 (lb/ft) 
                 (lbs) 
                 (Type) 
                 (Gauge) 
                 (Quantity) 
                 (Type) 
                 (Gauge) 
               
               
                   
               
             
          
           
               
                 8 
                 6 
                 20 
                 3000 
                 2 
                 20 
                 3 
                 2 
                 20 
               
               
                 8 
                 6 
                 30 
                 3000 
                 2 
                 20 
                 5 
                 2 
                 20 
               
               
                 8 
                 6 
                 40 
                 3000 
                 2 
                 20 
                 7 
                 2 
                 20 
               
               
                 8 
                 6 
                 50 
                 3000 
                 2 
                 20 
                 9 
                 2 
                 20 
               
               
                 8 
                 6 
                 60 
                 3000 
                 2 
                 20 
                 8/1 
                 2 
                 20/18 
               
               
                 8 
                 6 
                 70 
                 3000 
                 2 
                 20 
                 8/2 
                 2 
                 20/18 
               
               
                 8 
                 6 
                 80 
                 3000 
                 2 
                 20 
                 9/2 
                 2 
                 20/18 
               
               
                 8 
                 6 
                 90 
                 3000 
                 2 
                 20 
                 9/2/1 
                 2 
                 20/18/16 
               
               
                 8 
                 6 
                 100 
                 3000 
                 2 
                 20 
                 10/2/1 
                 2 
                 20/18/16 
               
               
                   
               
             
          
         
       
     
       EXAMPLE 2 
       [0070]    Example 2 illustrates the fabrication of a floor joist 10 feet in length. The Depth refers to the outside dimension. The Chord Type refers to the nature of the cross-section profile of the chord, where 1 refers to the standard chord with measurement “y” approximately equal to ¼″ and where 2, 3 and 4 refer to the expanded side wall chord with measurement “y1” approximately equal to ½″, 1½″ and 2½″, respectively. The Gauge refers to the thickness of the steel, where 20, 18 and 16 refer to thicknesses of 0.032″, 0.044″ and 0.06″, respectively. The Clip Type refers to the kind of clip to be used, where 1 refers to a tubular clip 1″ in diameter and 2 refers to a plate clip. The number of clips refers to the number of sets of two clips to be used, where a set of clips comprises two tubular clips attached to the bottom chord at approximately the same location at an angle to each other that is approximately 90 degrees. The clips used in any given joist are all of the same length. The clip sets are positioned with the outer upper connection of a clip set approximately 2″ from each end of the top chord. The remaining clip sets are spaced such that the center of the bottom connection points are equidistant from each other. 
         [0071]    Referring to Table 2 for the fabrication of a floor joist of 10 feet in length and 8 inches in depth, the desired factored load is chosen from the table, indicating the appropriate row of information. The type and gauge of top chord and bottom chord is referenced in the corresponding column in that row. The number of clip sets and gauge of clip is also referenced from the corresponding column in that row. The floor joist is then fabricated by inserting the clips within the chords in the positions indicated by the above noted recipe and fastening the clips to the chords. 
         [0000]    
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
             
           
               
                 TABLE 2 
               
             
             
               
                   
               
               
                 Joist 
                 Joist 
                 Factored 
                 Top Chord 
                 Bottom Chord 
                 Clips 
               
             
          
           
               
                 Span 
                 Depth 
                 Load 
                 Chord 
                 Steel 
                 Chord 
                 Steel 
                 Clip 
                 Clip 
                 Steel 
               
               
                 (Feet) 
                 (Inches) 
                 (lb/ft) 
                 (Type) 
                 (Gauge) 
                 (ID) 
                 (Gauge) 
                 (Quantity) 
                 (Type) 
                 (Gauge) 
               
               
                   
               
               
                 10 
                 8 
                 100 
                 2 
                 18 
                 2 
                 20 
                 5 
                 1 
                 20 
               
               
                 10 
                 8 
                 120 
                 2 
                 18 
                 2 
                 20 
                 5 
                 1 
                 20 
               
               
                 10 
                 8 
                 140 
                 3 
                 20 
                 2 
                 20 
                 6 
                 1 
                 20 
               
               
                 10 
                 8 
                 160 
                 3 
                 18 
                 2 
                 20 
                 5 
                 1 
                 20 
               
               
                 10 
                 8 
                 180 
                 3 
                 18 
                 2 
                 20 
                 5 
                 1 
                 20 
               
               
                 10 
                 8 
                 200 
                 3 
                 16 
                 2 
                 20 
                 5 
                 1 
                 20 
               
               
                 10 
                 8 
                 220 
                 3 
                 16 
                 2 
                 20 
                 5 
                 1 
                 20 
               
               
                 10 
                 8 
                 240 
                 3 
                 16 
                 2 
                 20 
                 5 
                 1 
                 20 
               
               
                   
               
             
          
         
       
     
       EXAMPLE 3 
       [0072]    Example 3 illustrates the fabrication of a truss 30 feet in span. The Height refers to the distance between the bottom chord of the truss and the peak of the truss. The Chord Type refers to the nature of the cross-section profile of the chord, where 1 refers to the standard chord with measurement “y” approximately equal to ¼″ and where 2, 3 and 4 refer to the expanded side wall chord with measurement “y1” approximately equal to ½″, 1½″ and 2½″, respectively. The Gauge refers to the thickness of the steel, where 20, 18 and 16 refer to thicknesses of 0.032″, 0.044″ and 0.06″, respectively. The Clip Type refers to the kind of clip to be used, where 1 refers to a tubular clip 1″ in diameter and 2 refers to a plate clip. The Quantity refers to the number of clips used in the truss. The clips used in any given truss are not all of the same length. The truss clips are positioned according to the configuration chosen from those which are commonly known in the art, depending on the span, pitch and loads required. 
         [0073]    Reference is made to  FIG. 23 , where clip positions a, b and c are indicated. Where double or triple clips are indicated in the table by a letter, the clips at the positions indicated are either double or triple clips. A double clip is two clips that are placed side-by-side within the plane created by the chords such that the position equidistant between the centers of each clip is centered on the position that would otherwise be occupied by a single clip. A triple clip is three clips that are placed side by side within the plane created by the chords such that the position of the center of the middle clip is centered on the position that would otherwise be occupied by a single clip. 
         [0074]    Referring to Table 3 for the fabrication of a truss of 30 feet in span and 5′6″ inches in height, the desired loads are chosen from the table, indicating the appropriate row of information. The type and gauge of top chords and bottom chord is referenced in the corresponding column in that row. The number of clips and gauge of clip is also referenced from the corresponding column in that row. The truss is then fabricated by inserting the clips within the chords in the positions indicated by the above noted recipe and fastening the clips to the chords. 
         [0000]    
       
         
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
               
               
               
               
             
           
               
                 TABLE 3 
               
             
             
               
                   
               
               
                 Truss 
                 Truss 
                 Live 
                 Snow 
                 Wind 
                 Top Chord 
                 Bottom Chord 
                 Clips 
                   
               
             
          
           
               
                 Span 
                 Height 
                 Load 
                 Load 
                 Load 
                 Chord 
                 Steel 
                 Chord 
                 Steel 
                   
                 Double 
                 Triple 
                   
                 Steel 
               
               
                 (Feet) 
                 (Inches) 
                 (lb/ft) 
                 (lb/ft) 
                 (mph) 
                 (Type) 
                 (Gauge) 
                 (ID) 
                 (Gauge) 
                 Quantity 
                 Clips 
                 Clips 
                 Type 
                 (Gauge) 
               
               
                   
               
             
          
           
               
                 30 
                 5′ 6″ 
                 20 
                 20 
                 90 
                 3 
                 18 
                 2 
                 20 
                 14 
                 a 
                 n/a 
                 1 
                 18 
               
               
                 30 
                 5′ 6″ 
                 20 
                 20 
                 150 
                 3 
                 18 
                 2 
                 18 
                 14 
                 a, b 
                 n/a 
                  1* 
                 18 
               
               
                 30 
                 5′ 6″ 
                 20 
                 50 
                 90 
                 3 
                 16 
                 2 
                 16 
                 14 
                 c 
                 b 
                 1 
                 18 
               
               
                   
               
               
                 *1.5″ diameter