CA3112533A1 - Building construction using braced frame slab assemblies having heavy perimeter rails - Google Patents

Abstract

This invention relates to the construction of a building using Braced Frame Slab Assemblies Having Heavy Perimeter Rails that comprise Floor Slab and Wall Slab Assemblies formed of heavy perimeter Rails, with Rail Frame Connectors, such as a plurality of heavy threaded screws, joining the heavy perimeter Rails to form the Floor Slabs and Wall Slabs. The Slab can then be equipped with joists for floors or studs for walls, and with structural sheathing to provide shear load carrying capacity. The Slab to Slab Connectors also secure juxtaposed Floor Slabs and Wall Slabs.

Description

BUILDING CONSTRUCTION USING BRACED FRAME SLAB
ASSEMBLIES HAVING HEAVY PERIMETER RAILS
FIELD OF THE INVENTION
This invention relates to the construction of a budding using Braced Frame Slab Assemblies Having Heavy Perimeter Rails that comprise Floor Slabs and Wall Slabs formed of heavy perimeter Rails, with Rail Frame Connectors joining the heavy perime-ter Rails to form the Floor Slabs and Wall Slabs. Slab to Slab Connectors also secure juxtaposed Floor Slab and Wall Slabs. The structurally interconnected Slabs provide the required structural capacity for the building to resist high lateral shear loads. The prefab-ricated braced frame Floor Slabs and Wall Slabs can be placed into the building under construction using a crane or other load lifting mechanism.
BACKGROUND OF THE INVENTION
The Housing Industry Today In the prior art, the stick-built building is a product that is either custom built ac-cording to individual specifications, or as a builder's spec, or constructed as one of a plurality of pre-existing models in a housing development. These buildings are built in the traditional manner of using framing members (typically dimensional lumber or steel framing members) to fabricate the building on a foundation at the building site according to a set of architectural plans.
A wall, in the stick-built building, is formed with a bottom plate that rests on the underlying structural component of the building, such as a concrete foundation. The basic light-frame wall of stick-built construction is a plurality of vertically-disposed studs connected to the bottom plate, and a top plate or double top plates that are supported by and connect to the vertically-disposed studs. Openings for windows and doorways .. may be incorporated into the light-frame wall. There is a need for shear resistance in a wall, but large openings reduce the lateral (shear capacity) of the wall. In the past, one of the earliest methods for bracing a wall against lateral forces was to incorporate brac-ing into the frame of the wall in the form of diagonal bracing members.
However, this solution is limited by the placement of windows and doors. Another simple means of providing lateral resistance is to provide sheathing to the frame. Plywood sheathing and Oriented Strand Board (OSB) are common sheathing materials used today in conven-tional light-frame construction to provide shear capacity in a wall to resist lateral loads.
Stick-built design differs greatly from the modular and manufactured design of road shippable products. There are few architectural, structural or dimensional limita-tions with stick-built buildings like those imposed on modular and manufactured design by virtue of the roadway transportation limitations of manufactured structures. Trans-portation over public roads involves height, width, length and weight restrictions. In stick-built construction, the characteristics of: height, width, depth, roof pitch, roof over-hang, gabled, dormered, etc. are all completely open to individual tastes limited only by the governing building code restrictions. For example, the ability to produce standard size buildings with substantial design flexibility is the reason that the majority of homes built today are stick-built homes.
Stick-built construction requires a sequenced building format, where item A
must be completed before item B can begin, and in turn, item B must then be completed be-fore item C can begin and so on. For example, the ground level walls must be complet-ed before the second level floor can begin, and the second level walls must be complet-ed before the second level ceiling can begin. While this method of construction has worked for many years, there are inherent inefficiencies in this method that result in sig-nificant cost penalties to the building buyer.
As light-frame construction design became more sophisticated, more robust foundation anchors were added to connect the floor and wall pieces to the foundation. It is also realized that certain walls would lift up under moment reactions caused by lateral forces and so the walls needed to be further anchored with brackets called hold-downs, which attach to the studs of the wall and to anchors set into the foundation.
With proper design and installation, these conventional methods of providing lateral resistance by applying sheathing, foundation anchors and anchored hold-downs to conventional walls can provide acceptable resistance to most lateral forces. However, proper installation can be a problem using conventional methods. The division of labor on job sites can re-sult in improper connections. Furthermore the installer may cut corners and sacrifice re-sistance to lateral forces in return for ease of installation or aesthetic considerations.

2 One prior art system to address this lateral shear load problem is disclosed in U.S. Patent No. 8,479,470 which teaches a wall in a light-frame building, having within it a sub-component specifically designed to resist lateral forces imposed on the building, such as those caused by an earthquake or by wind loading. A shear-resisting assembly has top and bottom struts and first and second chords and a planar shear resisting ele-ment connected thereto. The shear-resisting assembly is connected to the top plate of the wall and is also connected to the underlying structural component. These connec-tions allow lateral forces on the top plate of the wall and on the underlying structural component to be transmitted to the shear-resisting assembly.
BRIEF DESCRIPTION OF THE INVENTION
The above described problems are solved, and a technical advance is achieved, by the Building Construction Using Braced Frame Slab Assemblies Having Heavy Pe-rimeter Rails of the present invention. This invention relates to the construction of a building using Floor Slabs and Wall Slabs that are formed of heavy perimeter Rails, with .. Rail Frame Connectors, such as a plurality of heavy threaded screws, joining the heavy perimeter Rails together to form the outside extent of the Floor Slabs and Wall Slabs, each enclosing a predetermined space. The Slab Assembly can then be equipped with joists for floors or studs for walls, and with structural sheathing to provide additional sheer load carrying capacity.
The Slab to Slab Connectors structurally secure juxtaposed Floor Slabs and Wall Slabs to each other. They tie each Slab Assembly to adjoining Slab Assemblies at any location along their juxtaposed Heavy Perimeter Rails by interconnecting the Heavy Pe-rimeter Rails that form the perimeter of Wall Slabs and Floor Slabs. The Floor Slabs are connected to the foundation. The Wall Slabs rest on and are connected to heavy perim-eter Floor Slabs by their respective Heavy Perimeter Rails, so all structural loads on the building are transferred to the foundation. The structurally interconnected Slab Assem-blies provide the required structural capacity for the building to resist high lateral shear loads. The prefabricated braced frame Floor Slabs and Wall Slabs can be placed into the building under construction using a crane or other load lifting mechanism.
These Floor Slabs and Wall Slabs can be constructed on site or manufactured in a factory to

3

4 include utilities, windows, fitted up components installed in the factory, which avoids the impacts of weather, and on site limitations.
The Rail Frame Connectors and the Slab To Slab Connectors look the same, and they are typically close in size to each other. Functionally, they are 100% different from each other at a strategic level of importance, and this is the reason they are named separately and described independently, herein. At its most basic level, there are both Floor Slabs and Wall Slabs with two realities. First, all Slabs have heavy perimeter Rails. Second, all of the Slabs in a building are structurally interconnected with one an-other to create full building shear capacity. The heavy perimeter Rails present in all .. Slabs is the means, in the second case, of interconnecting all the Slabs for the full struc-tural integrated frame of the resultant building.
The Rail Frame Connectors are large screws used to attach the heavy perimeter Rails to one another in a single Slab. They can alternatively be large nails to attach ad-jacent heavy perimeter Rails to one another in a single Slab. They serve a straightfor-ward purpose to build a Slab with a heavy perimeter Rail to enclose a predetermined space.
In contrast, the Slab To Slab Connectors are totally different in function. A
per-formance criteria of huge importance in a structure is that the whole floor, and whole, complete walls, each function as full shear elements (full walls as an integrated shear element, and concurrently full floors as an integrated shear element). The most basic and universally adhered to detailing for this, in conventional framing, is for OSB or ply-wood sheathing in an "brick like" pattern such that the whole floor or whole wall behave as a singular structural body. The "brick like" pattern of the OSB sheets, where the edges of the OSB sheets fall over the joists below in a floor or the studs behind in a wall, structurally eliminate the effect of the OSB edges because the shear loads transfer sheet-to-sheet through the studs behind or joists below and the whole floor or wall is ef-fectively "one shear plane". This is all-important, and buildings would fall down in the first wind storm if not for this.
In a pre-fabricated approach to housing design and construction, where elements of the house are manufactured off site and then shipped to the job as smaller pieces, the biggest structural challenge is, "how do you end up with full floor and full wall inte-grated shear capacity when you are working with "not full size" floor and wall elements with major discontinuities of structure between them?" The total structure, when com-plete, has to resist lateral loads, but seemingly the #1 rule was violated in framing with major structural discontinuities within both the full walls and the full floors.
This sets up the unique, non-obvious, critical, performance function of the Slab To Slab Connectors. These diagonally installed heavy fasteners are capable of high load capacity attachment because heavy perimeter Rails are provided on both sides. The Slab To Slab Connectors attach Floor Slabs to adjacent Floor Slabs to cre-ate the same total integrated full floor shear capacity as the "brick like"
sheathing pat-tern in customary stick construction, despite the seemingly crazy condition of total struc-tural independence of 4-8 Floor Slabs (where the all-important full floor shear dia-phragm appears impossible). The same consideration is present with the full walls in that the Slab to Slab Connectors integrate multiple Wall Slabs into a comprehensive to-tal wall shear element. The same consideration is also present with the connection of multiple Floor Slabs in a total floor, to multiple Wall Slabs in total walls, in that the diag-onally installed Slab To Slab Connectors affix the whole set of Slabs together to be a proper shear integrated whole. The Slab To Slab Connectors achieve this, but only be-cause all individual Slabs are detailed with heavy perimeter Rails such that substantial loading could be achieved in these limited number of connection points, in contrast to a multitude of "low load" connection points as is present with common nailing of studs in conventional construction.
Further, the Slab To Slab Connectors can penetrate finished walls on the inside with drywall installed on the Wall Slabs. A hole the size of a quarter would need to be patched later, which is no big deal. So the Slab To Slab Connector means of integrat-ing pre-manufactured, Slab elements together results in both total structural perfor-mance AND the ability to complete Slabs to a substantial level of finish in the more effi-cient factory setting and still be able to make the basic structural frame attachments at a later time in the field.
Slab Assembly Sheathing The Slabs (also termed Slab Assemblies herein) can also further resist shear when they incorporate sheathing panels which provide shear capacity in the Slab As-s semblies, but the sheathing does not have to be continuous across the full structure, since the Rail Frame Connectors and Slab to Slab Connectors create an adequate load path. The resultant Slab Assembly, for example, is a high performance shear element to transfer shear load incrementally along length of the Wall Slab and/or Floor Slab as if .. it was continuously sheathed even though it is not. The rigidized Slab Assemblies, op-tionally including the fitted up components, can be hoisted into position for insertion in the building under construction and later permanently attached to adjoining Slab As-semblies with Slab to Slab Connectors freely placed on common Heavy Perimeter Rails securing adjacent Heavy Perimeter Rails together to create a total shear box.
The sequential, mutually exclusive and disjunct subcontractor operations of the prior art can therefore be replaced with a partitioning of the construction process to functionally complete the construction of predetermined Slab Assemblies at a manufac-turing facility. Thus, electrical, plumbing, insulation and the finishing may be started earlier than in the traditional stick-built building process while some operations, such as exterior siding, can be done from the exterior of the dwelling when the primary Slab Structure is in place.
Significant time savings can be attained since this subassembly operation is weather independent and Slab Assemblies or large subassemblies can be produced, and then moved with a plurality of hoisting devices. Additionally, significant material cost savings are realized due to an ability to bulk purchase materials and supplies di-rectly from manufacturers without mark-ups to middlemen. Since shipment is also di-rect from the manufacturers to the manufacturing site, there is far less breakage and damage losses because material handling has correspondingly been reduced.
Labor savings are achieved by the hoisting devices which enable a worker to move large quantities of raw materials from the delivery vehicles to storage areas integral to the production lines and hence into the shell of each dwelling being assembled.
The manu-facturing operation is executed within the environmentally controlled volume that is en-compassed by the exterior shell of the manufacturing facility. The use of precision tools, preformed jigs, substantial hoisting devices and hydraulic assemblies are justified and cost-effective since large numbers of quality dwellings are being produced in a short time frame. The use of substantial hoisting devices in the manufacturing facility reduces the labor content, speeds up the manufacturing process as well as enables the use of heretofore nontraditional structural concepts.
Glossary Connectors ¨ There are two classes of Connectors: Rail Frame Connectors and Slab to Slab Connectors. Rail Frame Connectors are the hardware, screws, bolts, plates or similar mechanical attachment means utilized to interconnect the heavy pe-rimeter Rails that form the perimeter of Wall Slabs and Floor Slabs while the Slab to Slab Connectors structurally affix adjacent Slab Assemblies to each other, such that a structurally adequate load path is provided to transmit loads from one Slab Assembly to those adjacent to it.
Floor Slab ¨ a pre-fabricated, framed floor component of interconnected perime-ter Rails and equipped with joists. The Floor Slab derives shear strength from sheathing applied to the upper or lower surface, including the heavy Rails forming its perimeter, which is referred to as 2-Dimensional because of its slab-like configuration.
Rail ¨ the heavy perimeter member present in Slab Assemblies, attached to and reinforced by the sheathing applied to the Slab Assembly and either the floor joists (in a Floor Slab) or wall studs (in a Wall Slab), that enables the placement of Slab to Slab Connectors that structurally attach the Rails of adjacent Slab Assemblies to each other.
Slab Assembly or Slab(s)¨ either a Floor Slab, a Wall Slab, or both, attached to adjacent Slab Assemblies by freely placed Slab to Slab Connectors affixing the Heavy Perimeter Rails of each Slab Assembly to another Slab Assembly.
Slab Structure ¨ a building assembled from Floor Slab and Wall Slab compo-nents.
Standard Size Dwelling - a "normal" or full size dwelling, presently produced on-site by means of stick building technology. This dwelling has an extensive range of de-sign and floor plan flexibility and includes both one and two story single or multi-family structures.
Stick-Built Home - a dwelling built in the traditional manner of using dimensional lumber as framing members to fabricate the dwelling on a foundation at the building site according to a set of architectural plans which have available an extensive range of de-sign and floor plan flexibility and includes both one and two story structures.

Wall Slab ¨ a pre-fabricated, framed wall component of interconnected perimeter Rails and equipped with studs. The Wall Slab derives shear strength from sheathing applied to at least one vertical surface, including the heavy Rails forming its perimeter, which is referred to as 2-Dimensional because of its slab-like configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 illustrates a perspective view of a Wall Slab which is a pre-fabricated, framed wall component of wall studs and the cavity space between them, deriving shear strength from sheathing applied to at least one vertical surface of the Wall Slab, which includes heavy Rails as its perimeter, used as a framing assembly construction element in the construction of a dwelling;
Figure 2 illustrates a perspective view of the interconnection of a Head Rail and an Wall End Rail to form a Wall Slab used as a construction element in the construction of a dwelling;
Figure 3 illustrates a perspective view of the interconnection of two Wall Slabs used in the construction of a dwelling;
Figure 4 illustrates a perspective view of additional details in the interconnection of two Wall Slabs used in the construction of a dwelling;
Figure 5 illustrates a perspective view of additional details in the interconnection of two Wall Slabs used in the construction of a dwelling as shown in Figure 4;
Figure 6 illustrates a side view of additional details in the interconnection of two Wall Slabs used in the construction of a dwelling as shown in Figure 4;
Figure 7 illustrates a perspective view of a Wall Slab with the inclusion of a plu-rality of framing elements;
Figure 8 illustrates a perspective view of a Wall Slab with the inclusion of a plu-rality of framing elements as well as sheathing and inside drywall;
Figure 9 illustrates a perspective view of the Wall Slab of Figure 8 once the sheathing and drywall are affixed to the framing elements;
Figure 10 illustrates a perspective view of a Wall Slab with the inclusion of a plu-rality of framing elements that provide openings for a window and a doorway, with the use of a Heavy Head Rail;

Figure 11 illustrates a perspective view of a Wall Slab with the inclusion of a plu-rality of framing elements as well as sheathing and inside drywall;
Figure 12 illustrates a perspective view of the Wall Slab of Figure 11 once the sheathing and drywall are affixed to the framing elements;
Figure 13 illustrates a perspective view of a Floor Slab used as a construction element in the construction of a dwelling;
Figure 14 illustrates a perspective view of the interconnection of two Floor Edge Rails to form a Floor Slab used as a construction element in the construction of a dwell-ing;
Figure 15 illustrates a plan view of the interconnection of two Floor Slabs used in the construction of a dwelling;
Figure 16 illustrates a perspective view of additional details in the interconnection of two Floor Slabs used in the construction of a dwelling as shown in Figure 15;
Figure 17 illustrates a perspective view of additional details in the interconnection of two Floor Slabs used in the construction of a dwelling as shown in Figure 15;
Figure 18 illustrates a perspective view of a Floor Slab with the addition of a plu-rality of joists therein;
Figure 19 illustrates a perspective view of the Floor Slab of Figure 18 with the application of floor sheathing to the top surface thereof; and Figure 20 illustrates a perspective view of the joining of a Wall Slab with Floor Slabs.
DETAILED DESCRIPTION
The standard framing paradigm used in conventional construction is a "braced frame" structure where the bracing is provided via the OSB sheathing that covers the floors and walls once they are secured in place. Standard framing utilizes a uniform sheathing on both floors and walls (except at door and window openings) to create a braced frame (a.k.a. a diaphragm). The emphasis in this type of construction is the con-tinuity of the OSB sheathing across the full extent of the wall and floor elements. For example, each of the parts in a wall frame is dedicated to a specific purpose ¨ bottom plate, full studs, trimmer studs, headers, top plate, etc. There are no pieces in this structure that support another purpose ¨ i.e. for the primary structural attachment of ad-joining independent panelized components.
In contrast, the present Braced Frame Slab Assemblies Having Heavy Perimeter Rails incorporates heavy perimeter Rails for this purpose, which is a fundamental dis-tinction over the standard framing described above. In the present Braced Frame Slab Assemblies Having Heavy Perimeter Rails, there is no need for surface continuity of the OSB panels, either in floors or walls. In fact, all of the Wall Slabs and Floor Slabs are interrupted with joints between adjacent Slab Assemblies. So shear continuity is achieved by the structural connection between independent Slab Assemblies via the interconnection of the perimeter "heavy" Rail frames of this framing system, because customary shear continuity to the edges of full floor and wall elements with continuous OSB is impossible. This is a non-obvious and novel means to create "braced frame"
integrity in a whole structure. The Slab Structure does this by interconnecting complete-ly independent Floor Slabs and Wall Slabs by joining their perimeter Rails to achieve the same end to end shear element functionality for the full walls and floors that is re-quired.
Conventional, sequenced, individual trade based conventional frame construction "teaches away" from the present Building Construction Using Braced Frame Slab As-semblies Having Heavy Perimeter Rails. The goal of conventional framing is to mini-mize the cost of this individual aspect of the whole house ¨ i.e. just the framing part alone. This is why there are no individual pieces that do not have relevance in the re-quired elements for the whole, completed home. If there were such pieces, they would by definition be wasteful if one looked at the frame without consideration of the entirety of the construction more broadly.
In the present Building Construction Using Braced Frame Slab Assemblies Hav-ing Heavy Perimeter Rails, the frame not only provides the structural integrity for the fin-ished structure, but it also is a primary means of streamlining many (otherwise) inde-pendent aspects of construction. Completed, closed-Wall Slabs can be made with the present Braced Frame Slab Assemblies Having Heavy Perimeter Rails, off foundation in a more efficient plant setting or on-site assembly area, so now incremental efficiency is gained in overall time as well as time, material and logistics related costs to install: elec-trical, insulation, drywall, siding, windows and doors, plumbing, etc.
Braced Frame Slab Assemblies Having Heavy Perimeter Rails Figure 1 illustrates a perspective view of a Wall Slab which is a pre-fabricated, framed wall component that derives shear strength from the sheathing that will cover it including the heavy Rails forming its perimeter that enclose a predetermined space, which is referred to as 2-Dimensional because of its slab-like configuration, used as a framing assembly construction element in the construction of a dwelling, and Figure 2 illustrates of the interconnection of a Head Rail and an Wall End Rail to form a Wall Slab used as a construction element in the construction of a dwelling. This technology is based on Slab Assemblies, primarily 2D (they can also be 3D for planned bathrooms and/or kitchens), of both Wall Slabs and Floor Slabs. All of them have a "heavy" perim-eter of Rails so that they can be structurally attached together to enclose a predeter-mined space. Braced frame Floor Slabs can be affixed to adjoining braced frame Floor Slabs, braced frame Floor Slabs can be affixed to braced frame Wall Slabs, braced frame Wall Slabs can be affixed to adjacent braced frame Wall Slabs, all by attaching the heavy perimeter Rail frame of each via Slab to Slab Connectors, such as long, structural screws. These Slab to Slab Connector screws can be put into Slab Assem-blies independent of whether they are open panels (with no drywall or other covering), and also if the Slab Assemblies are fully covered up with finish materials. If the Slab Assemblies are covered up (ex.: drywall), then you just screw right through the drywall into the heavy perimeter Rails of two adjacent Slab Assemblies, and later patch up the small hole left from the fastening. The use of heavy Rails, reinforced by wall studs or floor joists and the sheathing, allows structural Slab to Slab Connector placement freely at any location along the Rail. This is completely unique and represents the full comple-tion of the Rail apparatus, namely, that the Rail enables adjacent Slab Assemblies to be structurally connected to adjacent Slab Assemblies with Slab to Slab Connector place-ment freely located on these Rails. Normally, in framing the heavy connection hardware must be placed at studs and/or posts and/or solid blocking in a floor to achieve the strength that we get with our continuous heavy perimeter Rails.

The perimeter Rails are different and bigger than traditional framing elements, and serve a unique function that is not present in standard framing. They are also simi-lar to one another, i.e. the Heavy Perimeter Rails in a Floor Slab serve the same pur-pose and are configured in the same perimeter arrangement as the Heavy Perimeter Rails in a Wall Slab, so the names that identify each unique piece carry a commonality with regard to the balance of related pieces.
The word "Rail" connotes a member of size and significance that is different than customary framing pieces in houses. A "Rail" is strong, and an identity element different than the pieces around it that enclose a predetermined space. It can be horizontal (in floors or in the top or bottom of a wall), or vertical (at the terminus of walls). All Wall Slab Assemblies have: a "Head Rail" or "Heavy Head Rail" at the top, depending on whether it was a Wall Slab without windows or one with windows; a "Toe Rail"
at the bottom; "Wall End Rails" at the side of all Wall Slab. On Floor Slabs there are "Floor Edge Rails" on all four sides of all Floor Slab. In all instances of Wall Slab and Floor .. Slab creation there are Rails at the perimeter. In all instances of connection ¨ of any two Slab Assemblies together ¨ a Rail in one Slab is affixed to a Rail in an adjoining Slab. In traditional construction, framing typically uses dimensional lumber, such as 2"x4" or 2"x6" members to create the wall frames. In contrast, the present Braced Frame Slab Assembly Having Heavy Perimeter Rails makes use of Rail members that are heavy to provide a source of stability in the joining of the Wall Slabs and Floor Slabs. These Rail elements can be sawn lumber of greater dimensions than traditional framing members, or manufactured elements, for example, such as Glulam or VersaLam members manufactured by Boise Cascade, or even steel members. These "heavy Rails" provide the sound structure that allows the joining of Slab Assemblies in a secure, solid manner noted above. The Rails also enable the Wall Slabs and Floor Slabs to be capable of hoisting and handling without damage to the Wall Slabs and Floor Slabs and their installed components.
Figure 1 illustrates a basic Wall Slab 100 which consists of a Head Rail 101 which spans the space between Wall End Rails 103, 104 which are affixed to Toe Rail .. 102. The smallest dimension of all of these Rails is greater than used in conventional framing construction and/or of a material that is stronger than untreated lumber. The Head Rail 101 spans the distance between Wall End Rails 103, 104 and functions to rigidly interconnect these elements as well as provide a load bearing capability for the Wall Slab100. Figure 2 illustrates a perspective view of the interconnection of a Head Rail 101 and a Wall End Rail 103 to form a braced frame Wall Slab 100 used as a con-struction element in the construction of a dwelling. The interconnection of Head Rail 101 and Wall End Rail 103 is accomplished by the use of Rail Frame Connectors, such as countersunk long screws 103-1 and 103-2 which penetrate deeply into Wall End Rail 103 to secure these two Rail elements together. A similar interconnection between Wall End Rails 103, 104 and Toe Rail 102 is accomplished via Rail Frame Connectors, such as the use of countersunk screws (not shown) as described with respect to Head Rail 101 and an Wall End Rails 103, 104.
Figure 3 illustrates a perspective view of the interconnection of two Wall Slabs used in the construction of a dwelling; Figure 4 illustrates a perspective view of addi-tional details in the interconnection of two Wall Slabs used in the construction of a dwell-ing; Figure 5 illustrates a perspective view of additional details in the interconnection of two Wall Slabs used in the construction of a dwelling as shown in Figure 4;
and Figure 6 illustrates a side view of additional details in the interconnection of two Wall Slabs used in the construction of a dwelling as shown in Figure 4.
In Figure 3, two braced frame Wall Slabs 100, 110 are illustrated, interconnected at respective juxtaposed ends in an orthogonal orientation. Braced frame Wall Slab 100 consists of Head Rail 101, Toe Rail 102 and Wall End Rails 103, 104, while braced frame Wall Slab 110 consists of Head Rail 111, Toe Rail 112 and Wall End Rails 113, 114. As with braced frame Wall Slab 100, Rail Frame Connectors, such as countersunk screws 113-1 and 113-2 are used to secure Head Rail 111 with Wall End Rail 113. This connection of Wall End Rails 103, 113 is illustrated in additional detail in Figures 4 - 6, where the braced frame Wall Slab 100 is connected to the braced frame Wall Slab 110 via the use of Slab to Slab Connectors, such as a plurality of countersunk screws, of which 113-5 is shown in Figures 4 -6, which penetrate Wall End Rail 113 and into Wall End Rail 103.
The interconnection of Wall End Rails 113 and 103 is preferably accomplished by the use of two screws in one location, at different angles from each other (90 degree offset is strongest), to lock that location in place at a high load capacity (as shown in Figure 17). Also, the screws go in at an angle, so a screw going into a "heavy" perime-ter Rail that is 2 5/8" thick actually intersects that "heavy" perimeter for 3" ¨ 5", depend-ing on the angle of the screw. So even a "heavy" Rail perimeter that is only 2

5/8" thick .. (i.e. not a huge piece) becomes a very strong embedment for the structural screws be-cause they contact that member for 3" ¨ 5" (i.e. plenty of contact length for high capacity connection). These pairs of screws can be used near the distal ends of the two Wall End Rails for best interconnection or can be freely placed at any location along the common Rail boundary between Slabs. In addition, the long structural screws can be, for example, the "Ledger Lock" variety, where the shank next to the screw head has no threads, and the half of the shank near the tip of the screw has heavy threads, so when it is driven into a Rail, it climbs itself into the material in a "self-tapping" manner and soundly sucks the two members together as the threads bite into the "far"
piece and pull it tightly against the "near" piece between the wide screw head on the "near"
piece and the secure bite into the far piece. They lock together with considerable force resulting in a high capacity structural connection ¨ especially with two screws in one location at dif-ferent angles to each other.
Figures 7 - 9 illustrate a perspective view of a braced frame Wall Slab Assembly 100 with the inclusion of a plurality of framing elements 100-1 to 100-8, as well as dry-wall 121, structural sheathing 122 and insulation 123 and once the sheathing is affixed to the framing elements to form a wall module W1.
Braced Frame Wall Panel Having Window and Door Openings Using Rails Figures 10 - 12 illustrates a perspective view of a braced frame Wall Slab As-sembly used as a Wall Slab 200 construction element in the construction of a dwelling with the inclusion of a plurality of framing elements 205-1 to 205-3 that provide openings for a door frame 205 and framing elements 206-1 to 206-4 that provide openings for a window 206, as well as wall studs 200-1 to 200-5 and drywall 221, structural sheathing 222 and insulation 223 and once the sheathing is affixed to the framing elements to form a wall module W2.
In the manner described above with respect to braced frame Wall Slab 100, braced frame Wall Slab 200 consists of a Heavy Head Rail 201 which spans the space between Wall End Rails 203, 204 which are affixed to Toe Rail 202. An of these Rails are members of size (dimensions) that are greater than used in conventional framing construction and/or of a material that is stronger than untreated lumber. The Heavy Head Rail 201 spans the distance between Wall End Rails 203, 204 and functions to rigidly interconnect these elements with the Heavy Head Rail 201 optionally being heav-ier than the Head Rail 101 noted above due the voids created by the presence of a win-dow 206 and a door frame 205 to thereby provide additional rigidity to the Wall Slab 200. As noted above, the interconnection of Heavy Head Rail 201, Toe Rail 202 and Wall End Rails 203, 204 is accomplished by the use of countersunk long screws (not shown) which penetrate deeply into Wall End Rails 203, 204 to secure these elements together.
Braced Frame Floor Slab Using Rails Figure 13 illustrates a perspective view of a braced frame Floor Slab Assembly 300 used as a Braced Frame Slab Assembly Having Heavy Perimeter Rails for a con-struction element in the construction of a dwelling and Figure 14 illustrates a perspec-tive view of the interconnection of Floor Edge Rails 301, 302, 303, and 304 to form a braced frame Floor Slab 300 used as a construction element in the construction of a dwelling. In particular, Floor Edge Rails 301, 302 are interconnected with Floor Edge Rails 303, 304 using Rail Fame Connectors, such as deeply seating countersunk screws 302-1 to 302-3 as described above with respect to Figures 1 - 6.
It should be noted that for large spans,typically, builders use an intermediate beam (not shown) in the middle of the floor structure, framing one side of Floor Slabs into it on both sides. In this way we create a largely column free space in the building and provide the necessary support for the floor.
Figures 15 - 17 illustrate plan and perspective views of additional details in the interconnection of two coplanar braced frame Floor Slab 300, 310 used in the construc-tion of a dwelling. Braced frame Floor Slab 300 consists of Floor Edge Rails 301, 302,303, and 304, while braced frame Floor Slab 310 consists of Floor Edge Rails 311, 312, 313, and 314. These interconnections use Slab to Slab Connectors, such as deeply seating countersunk screws 302-5, 311-5 as described above with respect to Figures 1 - 6. As noted, such an interconnection is best effected using at least two sets of screws, located at or near the distal end of the Floor Edge Rails. Figure 17 illustrates in shadow view the deeply seating countersunk screws 302-5, 311-5.
Figure 18 illustrates a perspective view of a braced frame Floor Slab 300 with the addition of a plurality of joists 305 - 307 therein and Figure 19 illustrates a perspective view of the braced frame Floor Slab 300 of Figure 18 with the application of floor sheathing 308 to the top surface thereof.
Figure 20 illustrates a perspective view of the joining of a braced frame Wall Slab Assembly 100 with the braced frame Floor Slabs 300 and310. This interconnection can be implemented in the context of "balloon framing", where the exterior braced frame Wall Slab 100 are connected to the end of braced frame Floor Slab 300, 310 to form a continuous wall from the foundation to the roof of the building, and are not interrupted by the floor platforms in customary "western platform framing", which is the universal standard for almost all framing. So tall wall sections 10 feet by 21 feet tall can be im-plemented. In this configuration the second floor of a building must affix to the inside of the tall wall section half way up. The reason that you would utilize "balloon framing" is that all exterior finish on these walls can be applied in the factory, installed with the component erection program, and field application of exterior finish could be avoided. If you tried this in "western platform framing" the first and second floor platforms, each about 18 inches thick, would interrupt the finish continuity above and below them, so it really is not practical.
Summary The heavy perimeter Rail framing elements in the braced frame Wall Slab As-semblies are different and bigger than traditional framing elements, and serve a unique function that is not present in standard framing. They are similar to the Rails in the .. Floor Slab, i.e. the heavy perimeter members in a Floor Slab serve the same purpose and are configured in the same perimeter arrangement as the heavy perimeter mem-bers in a Wall Slab. The heavy perimeter is the connection element used to secure all Assemblies to one another, with the interconnection being effected by the use of spe-cialty Slab to Slab Connectors that inherently create concentrated loads requiring the Heavy Perimeter Rails. The Slab to Slab Connectors are heavy threaded screws, freely placed at any location along the common Rail boundary between Slabs.

Claims (19)

International Application No. PCT/US2019/049595What is claimed:

1. A method for constructing a building, comprising:
constructing a plurality of Slabs (100), each Slab (100) formed of a plurality of intercon-nected heavy perimeter Rails (101-104), comprising lumber of greater dimensions than tradition-al framing members, or manufactured elements, that constitute the sides (103, 104), top (101) and bottom (102) of a single Slab (100) that enclose a predetermined space;
and interconnecting each heavy perimeter Rail (101-104) of the plurality of heavy perimeter Rails (101-104) that constitute the sides (103, 104), top (101) and bottom (102) of a single Slab (100) with a juxtaposed heavy perimeter Rail (101-104) using Rail Frame Connectors (103-1 to 103-2 and 113-1 to 113-2 ) that penetrate the heavy perimeter Rail and the juxtaposed heavy pe-rimeter Rail to form a frame that encloses the predetermined space.

2. The method for constructing a building of claim 1, further comprising:
joining a first Slab (300) of the plurality of Slabs (300, 310) to a second Slab (310) of the plurality of Slabs (300, 310) by interconnecting a heavy perimeter Rail (302) of the first Slab (300) to a juxtaposed heavy perimeter Rail (311) of the second Slab (310) using Slab to Slab Connectors (302-5, 311-5).

3. The method for constructing a building of claim 2, wherein the step of joining comprises:
joining the first Slab (300) to the juxtaposed second Slab (310) using Slab to Slab Con-nectors (302-5, 311-5) in at least one location along their juxtaposed heavy perimeter Rails (302, 311).

4. The method for constructing a building of claim 1, wherein the step of construct-ing Slabs comprise:
forming at least one of a Wall Slab (100) and a Floor Slab (300) by incorporating studs and joists into the Slab that extend between heavy perimeter Rails, respectively.
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International Application No. PCT/US2019/049595

5. The method for constructing a building of claim 4, wherein the Wall Slabs (100) are connected to Floor Slabs (300, 310) by their respective Rails, so all structural loads on the building are transferred to the foundation.

6. The method for constructing a building of claim 5, wherein the step of construct-ing a Wall Slab (100) further comprises:
affixing structural sheathing (221, 222) to a one of an exterior face and an interior face of the structural two dimensional slab to provide shear load carrying capacity.

7. The method for constructing a building of claim 5, wherein the step of construct-ing a Floor Slab (300) further comprises:
forming a structural two dimensional slab including structural flooring (308) to provide shear load carrying capacity.

8. The method for constructing a building of claim 1, wherein the step of intercon-necting using Rail Frame Connectors (103-1 to 103-2 and 113-1 to 113-2) comprises:
using a plurality of heavy threaded screws to interconnect heavy perimeter rails.

9. The method for constructing a building of claim 1, wherein the step of intercon-necting using Slab to Slab Connectors (302-5, 311-5) comprises:
using a plurality of heavy threaded screws to interconnect the heavy perimeter rails of juxtaposed Slabs.

10. A building, comprising:
a plurality of Slabs (300, 310), each Slab (300, 310) formed of a plurality of intercon-nected heavy perimeter Rails (301-304, 311-314), comprising lumber of greater dimensions than traditional framing members, or manufactured elements, that enclose a predetermined space that constitute the sides (301, 302), top (304) and bottom (303) of a single Slab;
a plurality of Rail Frame Connectors (302-1 to 302-3) which interconnect each heavy pe-rimeter Rail (302) of the plurality of heavy perimeter Rails (301-304, 311-314) with a juxtaposed Page 18 of 21 ¨ REPLACEMENT SHEET -AMENDED SHEET

International Application No. PCT/US2019/049595 heavy perimeter Rail (303) by penetrating the heavy perimeter Rail and the juxtaposed heavy perimeter Rail to form a frame that encloses the predetermined space; and Slab to Slab Connectors (302-5, 311-5) that penetrate the heavy perimeter Rail and the juxtaposed heavy perimeter Rail for joining a first Slab (300) of the plurality of Slabs (300, 310) to a second Slab (310) of the plurality of Slabs (300, 310) by interconnecting a heavy perimeter Rail (302) of the first Slab (300) to a juxtaposed heavy perimeter Rail (311) of the second Slab (310).

11. The building of claim 10, further comprising:
a first Slab (300) of the plurality of Slabs (300, 310) joined to a second Slab (310) of the plurality of Slabs (300, 310) by interconnecting a heavy perimeter Rail (302) of the first Slab (300) to a juxtaposed heavy perimeter Rail (311) of the second Slab (310) using Slab to Slab Connectors (302-5, 311-5) in at least one location along their juxtaposed heavy perimeter Rails (302, 311).

12. The building of claim 10, wherein further comprising:
at least one of a Wall Slab (100) and a Floor Slab (300) by incorporating studs and joists into the Slab that extend between heavy perimeter Rails, respectively.

13. The building of claim 12, wherein the Wall Slabs (100) are connected to Floor Slabs (300) by their respective Rails, so all structural loads on the building are transferred to the foundation.

14. The building of claim 13, wherein the Wall Slabs (100) further comprise:
structural sheathing (221, 222) affixed to a one of an exterior face and an interior face of the structural two dimensional slab to provide shear load carrying capacity.

15. The building of claim 11, wherein the Floor Slab (300) comprises:
a structural two dimensional slab including joists that extend between heavy perimeter .. Rails.
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International Application No. PCT/US2019/049595

16. The building of claim 15, wherein the Floor Slab (300) further comprises:
a structural two dimensional slab including structural flooring (308) to provide shear load carrying capacity.

17. The building of claim 10, wherein the Slab to Slab Connectors (302-5, 311-5) comprise:
a plurality of heavy threaded screws that tie the first Slab (300) to the juxtaposed second Slab (310) by interconnecting the Rails that form the perimeter of these Slabs.

18. The building of claim 10, wherein the step of interconnecting using Rail Frame Connectors (103-1 to 103-2 and 113-1 to 113-2) comprises:
a plurality of heavy threaded screws to interconnect heavy perimeter rails.

19. The building of claim 10, wherein the step of interconnecting using Slab to Slab Connectors (302-5, 311-5) comprises:
a plurality of heavy threaded screws to interconnect the heavy perimeter rails of juxta-posed Slabs (300, 310).
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