Patent Publication Number: US-2007095005-A1

Title: Methods and system to efficiently design and erect buildings

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
      The present Utility patent application claims priority benefit of the U.S. provisional application for patent Ser. No. 60/719,708 filed on 09/23/2005 under 35 U.S.C. 119(e). The contents of this related provisional application are incorporated herein by reference. 
    
    
     FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
      Not applicable.  
     REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER LISTING APPENDIX  
      Not applicable.  
     COPYRIGHT NOTICE  
      A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or patent disclosure as it appears in the Patent and Trademark Office, patent file or records, but otherwise reserves all copyright rights whatsoever.  
     FIELD OF THE INVENTION  
      The inventive subject matter described herein relates generally to methods and apparatuses for building a structure. More particularly, the present invention relates to a method and system for building a structure that enables an individual to design and erect a building with less involvement of traditional construction professionals than is required when using standard building methods, regardless of the prior construction experience of the individual.  
     BACKGROUND OF THE INVENTION  
      As the amount of affordable housing dwindles each and every year, owning a home is becoming a thing of the past for many American families. Many families may consider various ways to realize the dream of owning a home. One of the ways that may be considered is to build their own homes.  
      Traditional construction practices for building homes rely heavily on the use of construction-related professionals, such as, but not limited to, general contractors, architects, surveyors, subcontractors in various trades, etc. An average person who desires to erect a building or a home is almost guaranteed to incur significant expense in paying these construction-related professionals.  
      A person may try to avoid some of these costs using do-it-yourself techniques for some of the relatively simple aspects of building. For example, without limitation, an individual may decide to paint his own home, rather than paying a painting company to do so. However, other aspects of building have not, traditionally, been suitable candidates for do-it-yourself projects, because these aspects of building may require skills or expertise that is not generally available without substantial training or experience. For example, without limitation, an average person would not be likely to perform the surveying and form-building work that may be involved in building a slab, because these tasks have traditionally been performed by skilled professionals or experienced labor. For these reasons, do-it-yourself projects are more likely to be catered toward remodel projects, rather than toward new construction.  
      In view of the foregoing, there is a need for a method for building a structure that enables an average person to perform technical building tasks.  
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:  
       FIG. 1  illustrates an exemplary grid, in accordance with an embodiment of the present invention;  
       FIG. 2  illustrates an exemplary grid with a building layout and perimeter corners indicated, in accordance with embodiment of the present invention;  
       FIGS. 3A &amp; 3B  illustrate exemplary pieces of marked plywood, in accordance with an embodiment of the present invention;  
       FIG. 4  illustrates an exemplary building layout for a jobsite, in accordance with an embodiment of the present invention;  
       FIG. 5A  &amp;  FIG. 5B  illustrate exemplary plate corners &amp; forming material in accordance with an embodiment of the present invention;  
       FIG. 6  illustrates an exemplary replica raised stem wall, in accordance with an embodiment of the present invention;  
       FIG. 7  illustrates an exemplary sub-floor plumbing system, in accordance with an embodiment of the present invention;  
       FIG. 8  illustrates a cross section of an exemplary floor, in accordance with an embodiment of the present invention;  
       FIG. 9  illustrates exemplary walls built on a taped floor, in accordance with an embodiment of the present invention,  
       FIG. 10  illustrates an exemplary sole plate between stud areas, in accordance with an embodiment of the present invention;  
       FIG. 11  illustrates an exemplary electrical and wiring label, in accordance with an embodiment of the present invention; and  
       FIGS. 12 &amp; 13  illustrate an exemplary marked double top plate, in accordance with an embodiment of the present invention. 
    
    
      Unless otherwise indicated illustrations in the figures are not necessarily drawn to scale.  
     SUMMARY OF THE INVENTION  
      To achieve the forgoing and other objects and in accordance with the purpose of the invention, a method and apparatus for constructing a building structure is described.  
      In one embodiment a construction grid is established. The construction grid is marked with a building plan. Points are located on the building plan. Master corner locations are located on the building plan. Distances and angles from the master corner locations to the points are measured. Master corner plates are constructed at the master corner locations. The master corner plates are marked with the distances and angles. Structure parts are built on the building plan. The master corner plates and the structure parts are transferred to a jobsite. Jobsite master corner locations are located at the jobsite. The master corner plates are placed at the jobsite master corner locations. The structure is assembled at the jobsite by locating positions for the structure parts using the distances and angles.  
      In another embodiment, a step for establishing a construction grid is described. A step for marking a building plan on the construction grid is shown. A step for constructing master corner plates on the construction grid is described. A step for fabricating structure parts on the construction grid is shown. And a step for assembling the structure from the structure parts including a step for locating positions for the structure parts is described.  
      In yet another embodiment, a construction surface is established with a construction grid placed on the construction surface. A building plan is marked on the construction grid. Perimeter corners are identified on the building plan. Two of the perimeter corners are identified as master corner locations. Master corner plates are constructed at the master corner locations. Distances and angles from each of the master corner locations to the other perimeter corners are measured. Each of the master corner plates are marked with the distances and angles measured from the corresponding master corner location. Structure parts are built on the building plan. Each of the structure parts are identified on a floor plan layout. The master corner plates, the structure parts and the floor plan layout are transferred to a jobsite. Jobsite master corner locations are located at the jobsite. The master corner plates are placed on the jobsite master corner locations. Jobsite perimeter corner locations are determined from the distances and angles marked on the master corner plates. And the building structure is assembled at the jobsite by locating positions for the structure parts.  
      The present invention is best understood by reference to the detailed figures and description set forth herein.  
      Embodiments of the invention are discussed below with reference to the Figures. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments. For example, it should be appreciated that those skilled in the art will, in light of the teachings of the present invention, recognize a multiplicity of alternate and suitable approaches, depending upon the needs of the particular application, to implement the functionality of any given detail described herein, beyond the particular implementation choices in the following embodiments described and shown. That is, there are numerous modifications and variations of the invention that are too numerous to be listed but that all fit within the scope of the invention. Also, singular words should be read as plural and vice versa and masculine as feminine and vice versa, where appropriate, and alternatives embodiments do not necessarily imply that the two are mutually exclusive.  
      The present invention will now be described in detail with reference to embodiments thereof as illustrated in the accompanying drawings.  
      Embodiments of the present invention include without limitation, methods and systems for building a structure, such as, but not limited to, a home. Although the terms “home” and “homebuilding” are used herein, it is to be understood that the various methods and systems may be used to build other types of structures, as well such as, but not limited to, barns, garages, commercial buildings, warehouses, etc. The methods and systems according to the embodiments described below may enable an individual to design and erect a building with less involvement of traditional construction professionals than is required when using standard building methods, regardless of the prior construction experience of the individual.  
      In one embodiment a method and system of building a home may be described as comprising a number of basic processes, described below as Process  1  through Process  11 . It is to be understood that, in other embodiments, elements of the processes may be grouped differently or performed in alternate orders, while still achieving the same result.  
      Process  1  begins by establishing a grid in a large area so that the various locations of the homebuilding components can be easily and rapidly determined. For example, without limitation, the grid can be composed of squares that are 1′×1′, 2′×2′, or 3′×3′, although larger or smaller squares may be used. The grid is preferably placed on a hard flat Surface, weather that be cut into concrete, or imprinted on a tarp, rubber mat, or thin carpet, or other stable material which can be used as a building surface.  
       FIG. 1  illustrates all exemplary grid, in accordance with an embodiment of the present invention. In the present embodiment, the grid system is used as the surface for quickly identifying wall locations, plumbing locations, electrical box locations, and other indicia that are used in the construction of a home such as, but not limited to, doors, windows, lighting fixtures, and appliances. All of the various components comprising a home may be built or located by the use of the grid system.  
      In Process  2  the location of the various walls of the home to be built from an approved set of plans, (a set of plans approved by the govt. entity where the building is being built) are marked on the grid. The building plans may be self drawn, purchased or drafted by an architect or draftsman or others etc. etc. Marking may be done by taping the grid with the same width tape as the wall system. Hence, for example, without limitation, a 4″ wide wall could be represented by 4″ wide tape, and a 6″ wide wall could be represented by 6″ wide tape, and so on. A multi story home may be accomplished by either re-taping the grid for each new story, or by using different color tape for each different floor.  
       FIG. 2  illustrates an exemplary grid with a building layout and perimeter corners A, B, C, D, E, and F indicated, in accordance with embodiment of the present invention. In Process  3 , working from the top left corner in a counterclockwise direction, the perimeter corners A, B, C, D, E ,and F of the home outlined on the grid are located. In other embodiments, an individual may work in a clockwise direction and/or start working from a different corner. The perimeter corners may be represented by letters, as shown by way of example in  FIG. 2 , or other indicia such as, but not limited to numbers or symbols.  
      Process  4  begins by finding two perimeter corners of the home from which to use angle and distance formulas to establish the locations of the other perimeter corners of the home. In the present embodiment, these corners are referred to as Master Corner A and Master Corner B. Desirably, other perimeter corners should be identifiable by no more than a 90-degree are from the Master Corners.  
       FIG. 3A , and  FIG. 3B , illustrate exemplary pieces of marked plywood A and B, in accordance with an embodiment of the present invention. In order to transfer the locations of Master Corners A and B to the lot where the home is being built, two square plywood pieces A and  13  are used in the present embodiment. In Process  5 , plywood piece A is placed in Master Corner A, and plywood piece B is placed in Master Corner B. Plywood pieces A and B may be, for example, without limitation 3′×3′ or 4′×4′, however, other sizes of plywood may be used. Also, in alternate embodiments, the squares may be various different materials such as, but not limited to, large sheets of paper, cardboard, tarps, metal, or plastic. Preferably, plywood pieces A and B are perfectly square.  
      In the present embodiment, plywood pieces A and B are placed so that the factory edges are located precisely over Master Corners A and B on the grid. Then, a steel tape, for example, without limitation, a 100-150′ steel tape, is pulled from Master Corners A and B on plywood pieces A and B to every other perimeter corner. Then the distance to the other corners are noted along with the angle that the steel tape makes as the steel tape crosses over the plywood pieces. During this process, plywood pieces A and B are labeled with this information. For example, without limitation, in the present embodiment, plywood piece A is labeled with a Corner B mark (angle) and distance, a Corner C mark (angle) and distance, a Corner D mark (angle) and distance, etc. Then the marks (angles) and distances for the various corners are labeled on plywood piece B. The result of this process is two plywood pieces that are fully marked with angles and distances to every other corner. These plywood pieces are used to define the foundation of the home (layout) on the lot on which the home is to be built. Using this method, plywood piece B may be used to check the measurements of plywood piece A.  
      In an alternate embodiment, laser platforms may be placed over each of the Master Corners to perform Process  5 . For example, without limitation, a laser platform may be placed 8″ to 10″ above the ground. On this platform is a laser level that swivels and shoots a beams across the jobsite. In some embodiments, the laser level and beam can be rotated by a remote control. The degrees to locate the various corners are entered, and the laser automatically shoots a beam to those specifications. A distance receiver then indicates the proper distance from the Master Corner to the perimeter corner being established. The height of 8″ to 10″ above grade is used to establish the finished floor height and thus the top of a stem wall. This may be height adjustable for different locales.  
       FIG. 4  illustrates an exemplary building layout on a jobsite, in accordance with an embodiment of the present invention. In Process  6  the layout of the home is achieved. In order to layout the perimeter of the home on the jobsite according to the present embodiment, a lot  400  and home setbacks  401  are defined. Once the front, back, and side setbacks  401  are located, Master Corners A and B are located and plywood pieces A and B are set in their respective places, and the measurements that were attained from the grid are transferred to lot  400  to be built upon. In some instances, nails  405  may be pounded into the exact corner locations on lot  400 , and strings  410  may be attached between nails  405  to identify the perimeter of the home. In some embodiments, lime may be placed on the ground three inches outside of strings  410  to indicate outside boundary foundation trench location.  
      After the floor plan of the home has been taped on the grid floor surface, the perimeter of the home and all of the wall locations are established in Process  7 . The forming system for the foundation is then addressed. A component of the present embodiment is to fabricate plate corners.  FIG. 5A, 501  &amp; use forming panels for the forming of the floor.  FIG. 5B, 503 . A front perspective view of the corner is illustrated in  FIG. 5A, 501  and a side view of a panel in  FIG. 5B, 503 , in accordance with an embodiment of the present invention. In the present embodiment, plate corner  501  is formed from aluminum and is comprised of two plates with measurements of 2′×2′ coupled together at 90-degree angles. However, in alternate embodiments various materials and measurements may be used. Alternate materials include, without limitation, other types of metals, plastic, and wood, etc.  
      These pre-made plate corners  FIG. 5A, 501  are then placed at each perimeter corner as identified by the taped surface. The distance between the pre-made plate corners are then filled-in with the proper forming material  FIG. 5B, 503  used in that specific locale, for example, without limitation, fiberglass, wood, metal etc. This process is repeated for each side of the building. When all of the corners, and all of the panels have been laid out, the corners and panels are placed in numerical order, and tie-down locations  505 , where there are anchor bolts or other foundation hold downs, are indicated on the outside of plate corner  501 , and forming panels,  503 . In the present embodiment the plate corners and forming panels are taken to the lot, and assembled in accordance with the system previously used to label the forms for the foundation. Any reinforcing bar system that need to be placed in the footing can be pre-fabricated or precut from the perimeter outline that is on the (grid) taped floor. Desirably, the pre-made aluminum plate corners are precisely 90-degree corners to help keep the building square.  
      Based Upon the processes discussed above, it is possible to build a complete foundation from the measurements taken from the grid using the present embodiment of a building method, which may be summarized as follows. First, the grid is set up. Then, it is taped according to the approved building plans. Perimeter corner locations from the taped Surface are then established and the corners are marked, for example, without limitation with letters, to designate specific corners. After the corners are established, Master Corners are assigned. Preferably, all other corners are encompassed within a 90-degree arc from the Master Corners. Then, Master Corner locator plates are made and marked using angle and distance measurements from the taped floor. Then, pre-made aluminum plate corners are placed at each corner of the home and identified according to the method that the corners were labeled when the perimeter corners were established. The forming material is then assembled and identified, and tie-down locations are marked on the outside of the plate corners &amp; panels. The forming material is then transported to the lot and assembled to create the foundation form.  
       FIG. 6  illustrates an exemplary replica stem wall  601 , in accordance with an embodiment of the present invention. In Process  8 , after the footings are poured and the stem walls are in place, all of the plumbing systems that are located below the finished floor are placed. These under slab plumbing systems also may be fabricated with the aide of a grid floor  605 . Since the floor has been taped to resemble the floor plan of the home, it is easy to identify all of the locations where the vertical plumbing pipes are to be located. Once these locations are identified a jig is erected whereby the conditions that exist beneath the finished floor may be simulated. In the present embodiment, this is done by providing replica stem wall  601 , and by raising replica stem wall  601  off of the taped floor approximately 4 to 6 feet, or more. Replica stem wall  601  is placed exactly over the taped grid floor  605 .  
       FIG. 7  illustrates an exemplary sub-floor plumbing system  701 , in accordance with an embodiment of the present invention. Various height props may be provided to simulate the downward flow of sewage,  710 . Once the situations and circumstances are reproduced in an assembly environment, the various sub-floor plumbing systems are assembled. After assembly, various points of these sub-floor plumbing systems are noted, for example, without limitation, where the vertical plumbing breaks the floor, and the various distances of the vertical plumbing, pipes from the edges of a replica stem wall,  601 ,  705  of the home being built. These notations identify where to dig the underground sewage trench on the building site and identify the height of plumbing in relation to finished floor.  
       FIG. 8  illustrates a cross section of all exemplary floor, in accordance with an embodiment of the present invention. After the installation of the sub-floor plumbing systems, the lot is prepared for the pouring of the concrete floors in Process  9 . In order to help individuals with the preparation of the sub base for concrete, a device called a grade-aide may be used. The grade-aide is used to establish a depth of 3 and ⅝ inches to 4 inches. It is a tool that is made up of blocks  801  that attach to the edge of the forms of stem walls  805  on each side of the home. A string  810  is then strung between blocks  801 , and lightweight plastic hangers  815  are attached to string  810 . Hangers  815  hang down from string  810  approximately 3 and ⅝ inches. This replicates the thickness of the concrete floor. Starting at one end of the home, the grade-aid may be attached to stem walls  805 , and; as the grade is finished, blocks  801  are moved across the top edge of stem walls  805  to the other side of the home.  
      To a certain degree, this completes the construction of the foundation of a home. An unskilled individual, with the exception of pouring and finishing the cement floor, may accomplish all of the tasks described above using embodiments of the methods. Also, by using the grid, the use of a tape measure is greatly reduced, and therefore, construction time may be shortened.  
       FIG. 9  illustrates exemplary walls built on a taped floor, in accordance with an embodiment of the present invention. In Process  10  of the present embodiment, the building of the walls for the home is accomplished by using the taped floor as the surface upon which the walls are built. A skilled rough framing carpenter may be called upon to mark the taped floor for every stud location, every door opening, and every window location, and any blocking necessary to assemble the home. All of the various walls taped on the floor (grid) are identified by letters or other indicia such as, but not limited to, numbers or symbols, so that the individual knows that, for example, without limitation, the wall section labeled “D” is perpendicular to and is connected to the wall section labeled “E”. Once all of the wall sections have each stud placement indicated, the individual is then able to build and assemble the walls.  
      In an alternate embodiment, pre-made Plexiglas™ templates may be used to place the walls. In this embodiment, these Plexiglas™ templates are 4″ wide and/or 6″ wide, come in various lengths, and are indicated with 16″ centers or 24″ centers. In order to find a 4″ wide wall, the individual places the 4″ template over the taped area of the grid. Then, the individual can find the wall width and determine weather the wall has a 16-inch or a 24-inch center, and place the Plexiglas™ template over the taped area in the grid. Special templates for various sized doors and windows may then be placed over the aforementioned Plexiglas™ wall templates wherever there is a door or window opening. In another alternate embodment, computer wall framing, machines may build the walls of the home. In this embodiment, all wall sections are identified, and a floor plan layout, as shown by way of example in  FIG. 9 , with corresponding wall labels is provided to the individual building the home so that the individual knows where to place the finished walls.  
      When an individual is building the wall systems from the layout on the grid system according to the preferred embodiment the individual identifies all of the areas where two wall systems are joined together. Some wall systems are joined to form a corner, and those may be obvious, but other wall systems may butt into another wall in the middle of the second wall. When this occurs, it is desirable to mark the space where the abutting wall will be, so that wood members can be installed for the purposes of attaching the two walls together, and providing sheetrock nailers.  
       FIG. 10  illustrates an exemplary sole plate  1001  between stud areas, in accordance with an embodiment of the present invention. In the present embodiment, a wall system is basically comprised of a top plate, sole plate  1001 , and studs  1005 . In order to identify abutment areas, an indicator, such as, but not limited to, a black ×1010, is marked on sole plate  1001  in the area between studs  1005   
       FIG. 11  illustrates an exemplary electrical and wiring label, in accordance with an embodiment of the present invention. In Process  11  of the present embodiment, labels are placed on the rough framing for the electrical wiring. This is done after all of the walls are built, and TACKED together. The labels may be placed on the studs below the box with details such as, but not limited to, “HOME=the wire goes to the main electric panel: 3 GANG=a 3 gang, box: CIRCUIT #  3 =a specific circuit of the home, All circuit #  3 &#39;s are wired together, #  1 =the first box, #  2 =the 2nd box, #  3 =the 3rd box, and so On, and Gauge=the proper gauge wire for that specific circuit.” In an alternate embodiment, directions for the electrical system can be documented. E.G. Usually a home has 15 to 20 circuits in it. Documentation would be 15 pages for a 15-circuit home, and 20 pages for a 20-circuit home. Each electrical circuit would be documented on its own sheet of paper specifically instructing the worker how to wire each circuit.  
      After the walls are built, identified, and labeled for electrical, as discussed by way of example in accordance with  FIG. 11 , the walls may be stacked on a flatbed trailer, and transported to the home site. The walls are then assembled in accordance with the identification system. A crane may be used, if desired.  
      In Process  12  of the present embodiment, the trusses of the home are delivered to the building site. In some embodiments, an individual may use the grid in the construction of a roof system. In these embodiments, a double top plate is pre-marked for truss locations from the grid. The walls of the home may be comprised of a sole plate, studs, a top plate, and a double top plate.  
       FIG. 12  illustrates an exemplary marked double top plate, in accordance with an embodiment of the present invention. The double top plate is placed over the tape on the PERIMETER of the home on the grid, and marked for all of the truss locations, and the complete roof system with indicia such as, but not limited to letters, numbers or symbols. In the present embodiment, the double top plate is labeled with symbols to indicate where the roof trusses are to be placed. This double top plate may also be marked for order as to the placement on top of the walls as illustrated by way of example in  FIG. 13 . After complete marking; the double top plate is transported with the walls to the building lot.  
      After the frame of the home is complete, the remainder of the construction of the home may be completed using traditional methods. The grid system according to embodiments of the present invention, enables an individual builder to achieve many aspects of homebuilding. Also, a desired square ness of the building may be achieved, and most building materials may be pre-cut. Modifications to the embodiments discussed above may be made while achieving the same result. In addition, materials may be substituted while achieving the same result. Such modifications are intended to be included within the scope of the inventive subject matter.  
      Building a home is a large endeavor. However, substantial savings may be achieved if an individual is able to do two or three of the trades himself. This may be achieved by using the methods of the various embodiments described above, enabling more people to build their own homes.  
      Various embodiments of methods and systems for building a structure have been described. The foregoing description of specific embodiments reveals the general nature of the inventive subject matter sufficiently that those skilled in the art, in light of the present teachings, may readily modify and/or adapt these methods for various applications without departing, from the general concept. Therefore, such adaptations and modifications are within the meaning and range of equivalents of the disclosed embodiments.  
      Having fully described at least one embodiment of the present invention, other equivalent or alternative means for implementing methods and systems for building a structure according to the present invention will be apparent to those skilled in the art. The invention has been described above by way of illustration, and the specific embodiments disclosed are not intended to limit the invention to the particular forms disclosed. The invention is thus to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the following claims.