CA2127880A1 - Improved building structure and method of use - Google Patents

Abstract

An improved building structure and method of use comprising separately fabricated floor (12), wall (42) and ceiling (174) structures capable of withstanding shear and seismic forces. The floor (12) and ceiling (174) structures of the present invention generally comprise I-beams (14) having foam panels (32) extending therebetween. The wall structure comprises an elongate track (44) rigidly secured to the foundation structure (28) of the building having a plurality of posts (56) secured thereto. Disposed between the posts are a plurality of interlocking foam wall sections (126) which encapsulate the posts (56) of the wall structure. Attached to the top surfaces of the posts are header beams (98, 100) which serve as a support structure for the ceiling structure (174).

Description

WO93/1427X ~1?, ~ ~ 8 0 PCT/US93/00271 IMPR~V~D BUILDING STRUCTURE ~ MET~OD OF USE
f Fi~ld of the Invention The present invention relates generally to residential and commercial building structures and methods of forming the same, and more particularly to integrated wall, floor and ceiling structure formed of dimensionally stabile, pre-manufactured structural elements which are rapidly assembled in a manner resulting in 2 monolithic building structure.

Backaround of ~he_Invention As is well known in the construction industry, builder~ of both residential and commercial building structures often face numerous difficulties during the construction process when utilizing forest products due to the~ lack o~ dimensional stability inherent with such products~ In this ~respect~, builders and craftsmen typ~ically::labo~ wit~the wood in an attempt to shape and it~ t~e wooden::components~. However, often times the wood 25: :members twi~t,: warp,~:split or :crack during and subsequent to~completion of~ the~uilding project, thus impairing ~he : qua:li~y~and appearance~of the building stru ture.
: In reIation~ ~o: consumer products; modern material fabrication ~:~nd a sembly techni~ues have permitted 3~0 ~ man~acturers to hold close tolerances and have allowed for the~development~:of~mass production methods which have made possi~le ~or~:consumers to enjoy a wide variety of :pxoducts ::at a~ordable prices. However, such mass production methods~have not successfully found their way ~ , ~::: : :

WOg3/1427g PCT/US93/0027~

into the construction industry on any significant scale.
In this respect, billions of dollars have been spent by the construction industry in an attempt t~ adopt mass production methods to produce housing at more affordable prices. However, such efforts have generally fallen short due to the previously described dimensiona~~~nstability of the wooden components typically utilized in construction, as well as the requiremPnt of utilizing skilled labor to build the structures.
In recent years, some advancements have been introduced to wood construction through the use of reconstituting wood based products with enhanced strength and dimensional stability. O~her ~dvancements in construction techniques have included the gradual conversion to steel, aluminum, plastic and o~her more stable building materials. Additionally, a number of attempt~ have been made to develop building wall structures which integrate framing and wall panels to ~orm a composite wall. Certain ones of these prior ~rt wall structures comprise an assembly of wall panels or wall bricks having hollow passaqes which form a serles of interlocking vertical and hori~ontal passages in the assembly. These passages are filled with concrete, with or without rebar~
to form ~tructural framing, integral with the wall panel or 2~ bric~s. Other types of prior art structures comprise ;~ reinforced~composite wall panels that are interlocked to : ~ ~ form a wall stru~ture~. A third type of prior art structure comprises an a~sembly of foam p~astic forms khat function 'as permanent concrete forms after the concrete has been poured between the forms.
Though many of the aforementioned prior art building materials and systems present improvements over the more traditional prior art materials and buildiny sy~tems, these material5~and ~uilding systems possess cer~ain inherent deficiencies which detract from their overall uti.lity~ In .

WO93/14278 2 ~ 2 ~ ~ ~ a PCT/US93/00271 :

this respect, the aforementioned prior art wall structures, although reputed as being easy to assemble, often require su~stantial planning and piecemeal methods for forming windows and doors. Additionally, these prior art wall structures typically require a substantial amount of concrete which, though being widely availa~l~rin some form, i5 not always of su~ficient structural, load bearing capability. Additionally, the aforementioned materials ~nd building methods are often deficient with regard to critical factors such as cost, material availability, capital requirements for manufacturiny and transporta~ion, technical skills both in the factory and field and ease of construction.
The present invention specifically addresses these and other deficiencies in the prior art by providing an integrated wall, floor and ceiling structures that amploy no concrete and is fabricated from a minimum number of dimensionally stable, standardized framing elements and standard panels to form a resultant monolithic structure.
In this respect, the present invention may be assembled with a minimum ~f kools and d~es not require employment of skilled labor, such as carp~nters, brick layers and concrete pourers.

Summar~ of the Invention In accordan~e with a preferred embodiment of the ~ present inventio~, there is provided an improved building :~ : sys~m including dimensionally ~table, wall~ ~loor and ceiling struc~ures. Tn ~h~preferred embodiment, the wall ~30 struc~ure comprise~ an ~longate ~rack having a generally U-: shaped c onfiguration and defining~a bottom wall adapted to rest on and b :secured to the building foundation and opposing side walls extend~ng upwardly from the bottom wall. The bottom~wall of the track includes a plurality of ~pre-formed, lin~arIy aligned bottom wall apertures at WO93/1427$ : PCT/US93~00~71 ~127~8~

pxedetermined locations along the length thereof fsr receiving fasteners to secure the track to the foundation.
Dimensionally stabile, pre-apertured vertical posts are secured to the track at predetermined locations along the length thereof via flanges extending perpendicularly upward ~rom the bottom wall of the track. T~-~cil`itate the attachment of the posts to the track, each of the flanges include a plurality of pre-formed flange apertures which are precisely located so as to be in registry with pre~
formed lower post apertures disposed in the hottom ends of the posts to receive fasteners such as self-tapping screws.
Advantageously, the bottom ends of the posts include recesses disposed therein to receive the top portions of the fasteners us d to secure the track to the foundation.
By positioning the posts directly over the fasteners used to secure the track to the foundation, the track and post are in effect directly secured to the foundation thereby significantly enhancing the seismic stability of the resultant wall structure. In this respect, during seismic activity the weight of the building is resisted by the inter~ction o~ the foundation to the wall structure wherein the holding power at the lever arms of the posts is maximized.
In the pr~ferred embodiment, the track is fabricated from either sheet metal or from an extruded, rigid polymer material. Where the track is fabricat~d from a rigid polyme~, the battom wall thereof may further include a ; plurality of longitudi~ally extending projections formed on the und~rside thereof for forming a moisture tight seal and thermal barrier against the fsundation when the track is : : secured thereto. Where the track i~ fabricated from sheet metal, a layer of polymer sealing material may be placed :between the botto~ wall of the track and the foundation to ~acilitate a similar moisture tight, thermal barrier.
3S Additionally, the opposing sidewalls of the ~rack is WO93/14278 2 ~ 2 7 ~ ~ ~ P~T/U~93/002~1 preferably provided with pairs of V-shaped notches disposed along ~he upper edges thereof for placing a drilling jig in vertical registry with the bottom wall ~pertures to aid in the attachment of the track to the foundation.
Secured to the top ends of the posts is an elongate lower header beam preferably formed 0i- plural beam segments. Attached to ~he top of the lower header is an elongate upper header beam or top plate having a wi~th preferably exceeding the width of the lower header. In the preferred embodiment, the top ends of each of the posts are attached to the lower header via a pair of header brackets.
Each of the header brackets includes a vertical flange portion having a pair of pre-formed vertical ~lange apertures disposed therein which are oriented so as to be in registry with pre-formed upper post apertures disposed in the top end of the postO The header brackets are interfaced to the top end of the post such that the vertical flange apertures of each header bracket of the pair and thP upper post apertures are coaxially aligned.
The~e coaxially aligned apertures are adapted to receive fasteners to secure the header ~rackets to the top end of the post. Each of the header bracket~ further includes a : horizontal flange portion having a pair of pre--formed horizontal ~lange apertur~s ~isposed therein which are oriented so as to be in registry with pre-formed lower : : header apertures. The coaxially aligned horizontal flange ~ ~ ~apertures and lower header apertu~es are adapted to receive : ~asteners~to secure the lower header to the pair of header 1~ brackets. The upper flange portions of the headex brackets : 30 of~the pair and th~ lower header further include ap~rtures in registry with each other and with a pair of pre-formed upper header apertures to receive fasteners to secure the upper header to the lower header.
:~ Disposed between each pair of adjacent posts is a pre-fabricated wall section. In the preferred embodiment, each WO 93/14278 PCI'/US93/00271 21~738~

of the wall sections in fabricated from polystyrene foam material and includes a vertical tongue formed along a first vertical edge, a vertical 510t formed within a second vertical edge, a lower edge having a pair of parallel grooves foxmed therein for receiving the opposing sidewalls of the track, and an upper edge having a~h~rizontal slot formed therein for receiving the lower header~ Each of the wall sections is disposed between a pair of adjacent pQsts such thak the vertical tongue abuts one of the posts of the post pair with the ~ertical slot receiving and encapsulating the other post of the post pair and the ~ertical tongue of an adjoining wall section. The vertical tongues and ~ertical slots of ea~h of the wall sections further include one or more vertical grooves formed therein for receiving a foam adhesive to form an expanded foam seal between the vertical tongue and the cne post of the post pair and the verti~al slot and the other post of the post pair. Additionally, the horizontal slot and lower edge in~lude horizontal grooves formed therein for receiving a foam adhesive ~o ~orm an expanded foam seal between the horiæontal slo~ and a lower header beam segment and the : lower edge and track. ~d~antageously, the expanded foam adhesive seals interface the posts, track, beam segments and wall sQction~ ~o each other in a manner forming a monolithic s~ructure. In this respect, the interface between ~he posts~track, beam segments and wall sections - ~ produces a synergistic effect by utilizing the aompressive, :: ~en~ile and shear~force properties of the posts, track, !beam egments and the wall sections thus forming the ; 30 monalithic wall tructure.
The floor structure of the present invention .
` preferably cnmprises a plurality of elongate floor joists ~:~ which are attached to the ~oundation and extend in parallel relationO Each of the floor joists is preferably : : 35 configured as an I-~eam and comprises upper and lower ::

W093/14278 2 1 2 7 ~ ~ O PCT/US93/~0271 elongate flanges having a strand board web extending perpendicularly therebetween. Disposed between each pair of adjacent joists is a pre-fabricated, polystyrene foam floor section. Each of the floor sections includes first and second horizontal edge portions which are disposed between and abutted against the we~s of ~ floor joist pair. The first and second horizontal edge portions of each floor section further include a plurality of longitudinally extending channels formed therein for receiving a foam adhesive to form an expanded foam seal between the edge portions and the pair of joists.
The monolithic ceiling structure of the present invention preferably comprises a plurality of elongate ceiling trusts which are attached to the header beam and extend in parallel relation. Like the floor joists, each of the ceiling tru~ts preferably has a I-beam configuration and comprises upper and lowzr elongate flanges having a strand board web extending perpendicularly therebetween.
Disposed between each pair of ~djacent ceiling trusts is a : ~ 20 pre-f~bricated, p~lystyrene foam ceiling section which include~ first and second angled edge portions. Each ~eiling ~ection is disposed between a pair of adjacent cei~ing trusts in a manner wh~rein ~he angled edge portions : thereof are ab~tted against and adhesively secured to the webs of each of the~ceiling trusts of the ceiling trust pair~ `
The prese~t inYention further comprises a method of ; fo~ming a monolithic wall structure from a prefabricated : ipost andjbeam frame and `interlocking foam wall sections.
The method comprises ~he steps of securing an elongate track ~o a horizontal foundation and subse~uently ~ecuring :~ the bottom end o~ an ~longate, vertical post to ~he track at a predetermined location thereon via a first pre-: fabricated registration means. A pre-fabricated wall 3~ section is then disposed upon the track in a manner wherein : :

~ ~738 -8-the pair of parallel groove~ formed within a lower edge thereof receive a portion of the track and a vertical tongue formed along a first vertical edge of the wall section abuts the post. A second post is then secured to the track in a manner wherein a vertical slot formed wi.thin a second verkical edge of the wall sect~nr receives and encapsulates the second post. The vertical slot further encapsulates the vertical tongue of a second adjoining ~all section which is abutted against the second post.
Thereafter, at least one elongate, horizontal header beam is received into aligned, horizontal slots formed in the upper edges of the wall sections and secured to the top ends of the posts via a second pre-fabricated registration means.
The preferred method of forming the monolithic wall ~tructure ~urther comprises the step of injecting a foam adhesive into vertical grooves formed in the vertical tongue and vertical slot of each wall section and the horizontal grooves formed in the horizontal slot and lower edge of each wall section to form an expanded foam seal between thQ vertical tongue and one post of the post pair, the vertical slot and the other post of the post pair, the horizontal ~lot and a lower beam segment and the lower edge and the track. As previously specified, in the preferxed method a fir~t vextical post i~ plumbed with all other pos~s being subsequen~ly plumbed due to the dimensional stability o~ the first and second registration mean~ of the :track and header beam. Additionally, in the preferred method the wall struct~re is adapted to be assembled utilizing solely ~crew fasteners and the expansive adhe~ive.
The preferred method further omprises the step of enplacing of plumbing ~anifold and electrical ~ystem into one or more of the wall sections without cutting through : ~ ~5 the posts and/or header beam. The plumbing manifold and : :
':

W0~3/1427~ 7 8 8 a PCT/US93/00271 _g_ electrical system are preferably installed following assembly of the monolithic wall structure. As will be recognized, such installation may comprise the further step of using a foam chase in relation to particular plumbing 5 applications.
A~ter the monolithic wall struoe~rre has been fabricated, a lAyer of finishing material may be applied to the inner and/or outer surf~ces thereof. The finishing material is typically selected from the group of drywalll plywood, and fiberboard and may be affixed to the inner or outer surfaces of the wall structure via the attachment to the header beam or via an adh2sive. Additionally, a layer of netting material may be applied to the outer surfaces of the wall structure with a layer of stucco being lS subsequently applied to the layer of netting material. ~s previously specified, each of the posts is provided with a plurality of linearly aligned apertures disposed alsng the length thereof. ~dvantageously, these apertures may be used to inter~ace pairs of window brackets to the posts for ~0 purposes of attaching a sill member an~ ja~ member between pairs of adjac~nt posts. As will be recogniz~d, ~he sill and ~am members are used for purposes of constructing windows or doors. In those in tances when a window or door is constructed~, the wall sections of the wall structure must be cut to acco~modate the same~
The present inven ion further comprises methods of forming floor and~Geiling:structures. The formation o the floor structure c~mprises the steps of attaching an elonga~ej floor joist to the foundation and subsequently : 30~ abu~ing a first horizon~al~edge portion of a floor section : th~rea~ainst~ A second floor joist is then attached ~o the ~foundation in ~ manner wherein the second joist is abutted :against the second horizonta1 edge portion of the floor ection. Thereafter, a foam adhesive is injected into the longi~udinal chann~Is formed in the first and second :

WO93/14278 PCT/US93/00~7l ~1~7~gO

horizontal edge portions of each floor section to form an expanded foam seal between the horizontal edge portions and each floor joist of the floor joist pair. The method of fabricating the floor structure further comprises the step of applying a layer of finishing material such a plywood over the tops of the floor joists. ~ ~
The method of forming the monolithic ceiling structure comprises the steps of attaching a ceiling trust to ~the header beam and subsequently adhesively securing a first angled edge portion of a ceiling section thereto. A second ceiling trust is then attached to the header beam in a manner wherein the second trust is abutted against and adhesively secured to the second angled edge portion of the ceiling sec~ion. Thereafter, a layer of sheathing is applied to the tops of the ceiling trusts with a layer of roofing material subse~uently being applied to the shea~hing.

B~ief Descri~tion of the Drawin~s These as well as other features of ~he present invention will become more apparent upon reference to the drawings wherein:
Figure ~1 is~a perspective view of a resid~ntial dwelling:aons~ructed~ utilizing the building structures of the present invention, Figure~::2~ a cross-sectional view of the floor structure ta~en:along line 2-2 o~ Figure 1;
Figure~3~is~a ~utaway fragmentary view of the flosr structurç ~f the pre ent invsntion;
~ Figure 4 is~:an elevational view of the floor structure ~ : of:the present invention;
-~ Figure~ 5: is a cutaway fragmen~ary view illustrating the components~comprising the floor and wall structures of the~present invention;

WO93tl427B 21 ~ 7 ~ 8 ~ PCT/US93/00271 Figure 6 is an exploded view of the components comprising the wall structure of the present invention;
Figure 7 is a partial perspective view of the track used in constructing the wall structure;
Figure 8 is a partial persp~ctive vlew illustrating the manner in which the posts of the wa~ structure are secured to the track and header brackets of the wall structure;
Fig~re 9 is a cross-sectional view taken along line 9-9 of Figure 5;
Figure gA is a cross--sectional view illustrating the engagement of the wall structure to the foundation;
Figure 10 is a cross-sectional view taken along line lO-10 of Figure 5;
Figure 11 is a cross-sectional view ta~en along line 11-11 of Figure 5;
Figures 12A, 12B, and 12C are perspective views illustrating the method o~ constructing th~ wall structure of ~he present invention;
: Figure 13 is :a perspective view illustrating the manner in which plumbing and electrical conduits are formed in the wall sections of the wall structur~;
Figure 14 is a partial perspecti~e view of a po~t of the wall~structure~ lustrating the~manner in which jam and 25~ sill:members are~:engaged:thereto for forming a window;
Fig~re~ 15~is a partial perspective view of a wall secti:on illus~rating the manner ~in~:which an electrical system~ s emplaced into the:wall section after conduits are ~ ormed therein in the mahner shown in Figure 13;
:~ 30 : Figure ~6 ~is a cutaway~perspective view illustrating the manner~in~which~layers of finishing materials may be : : appl~iéd:to~the inner or outer~wall surfaces o~ the wall ~; : stru~ture; :~

~ : :

:~

WO g3/1~27~ . ; PCr/USg3/00271 2~27~0 Figure 17 is a cutaway perspective view iliustrating khe manner in which layers of finishing materials may be applied to the outer wall surfaces of the wall structure;
Figure 18 is a cross-sectional view illustrating the ceiling structure of the present invention;
Figure 19 is a cross-sectional view~of thè ceiling structure taken along line 19-19 of Figure 18;
Figures 20 and 21 are perspective views illustrating a track constructed in accordance with a second embodiment of the present invention; and Figure 22 is a partial perspective view illustrating the manner in which a wall section of wall structure is engaged to the ~rack illustrated in Figures 20 and 21.

15Detailed_Desc~i~tion of the Preferred Embodiment Referring now to the drawings wherein the showings are :~ ~ for purposes of illustrating a preferred embodiment of the present invention only, and not for purposes of limiting the same, Fi~ure l illustrates a residential structure lO
constructed utilizing thc improved wall, floor and ceiling ~: ~ building structures~of the present:invention. Although the present inventian as will hereinafter be described has speci~ic: utility~ :residential structures, it will be recognized that thé varlou~ buil~lng~s~ructures and methods 2~5 ~ of~fabricating~the~ ame may a~ditio~ally be uti~.ized in conjunction;wi~h~;~commercial building structures as well.
Additionally,~th~ough~the wall, floor and ceiling structures : of~ the:~present~;invention: will be: described as being ;lu~iliz~ed~to~fabricate the residential structur. 10 having the~design depi~ted~,: it will be recognized that such compon~nts~are~o ~sufficient architectural flexibility so : as: to::~be usable~ in conjunction with residential or comme}cial structures having a wide variety of different deslgn con~igurations.

WO93/14278 ~ 12 ~ ~ 8 0 PCT/VS93/00271 The wall, floor and ceiling structures of the present invention are fabricated from dimensionally stable components which allow the structures, and hence the residential structure l0 to be assembled by unskilled labor with a minimal amount of difficulty. Additionally, each of the components utilized to fabricate the ~ll, floor and ceiling structures are pre-fabricated off-site using high tolerance mass production techniques. The present building structures and building technique are adapted to fabricate the residential structure l0 from the foundation to the roof by pro~iding the necessary wall, floor and ceiling structural elements. In the following paragraphs, the wall, flo~r and ceiling structures of the present invention and methods of fabricatinq the same will be separately described.

LOOR STRUCTU~E

Referring now to Figures l 5, ~he floor structure 12 comprises a plurality of floor joists 14 which are attached to a foundation structure 16 in a manner wherein the floor joists 14 extend in spaced, ~arallel relation. Each o the floor joists l4 preferably has an I~beam configuration and comprises an~elongate Upp8~ flange 18 and an elongate lower f1ange 20 having a generally planer strand board web 22 extending perpendicularly therebetween. The upper flange 18~ lower flange 20 a~d web 22 are preferably fabricated ~rom:gang laminated LV~ (laminated ~eneer lumber) material though other materials may be utilized as an alternati~e.
Advantageously, each of the floor joists 14 is given an I-eam Gonfiguration for s-^ength as well as for greater ver~ical and lateral load resi tance.
The foundation structure 16 to which the joists 14 are :~ connec ed compri~es a concrete foundation which is ~35 fabricated in accordance with con~entional foundation W~93/1~27~ P~T/US93/00271 ~:~27~30 construction techniques. To facilitate the attachment of the floor joists 14 to the foundation structure 16, a notch 16 is preferably formed in the inner, upper edge of the foundation structure having a generally rectangular configuration. Disposed within the notch 24 is a foundation bracket 26 having a configurat ~ complementary to the notch 24. Th~ foundation bracket 26 is sized such that when placed in the notch 24, the upper end thereof extends slightly beyond the top surface of the foundation s~ructure 16 to a height substantially flush with the top surface of a mud sill 28 attached to the top surface of the foundation structure 16. Though not shown, the foundation bracke~ 26 i.s rigidly attached to the inner edge of the mud sill 28 via a sill bolt. The use of the mud sill 28, in addition to serving as a support structure for the foundation bracket 26, will be discussed in greater detail below. In attaching the floor ~oists 14 to the foundation structure 16, the floor joists 14 are secured to the foundation bracket 26 in a manner wherein one end of ~he lower flange 20 resides upon the lower, horizontal edge 27 of the foundation~bracket 26, with the outermost ends of both the upper flange l8 and lower flange 20 being abutted against the ver~i~al portion of the foundation br~cket 26.
As seen in Fi~ur~ 2, when the floor joists 14 are securely : 25 inter~aced to the f~u~dation bracket 26, the top surface of the upper flange 18 is substan ially flush with both the ~:: t~p end of t~e ~oundation bracket 26 and top surface of the mud siIl 28. Advantageously, the foundation bracket 26 allows th~ ~loor joists I4 and hence the floor structure 12 to be suspended within the interior of the building structure and ~foundation, thus providing increased seismic : stabi~ity by preventing the floor structure 12 from rol7ing ~ off the foundation during an earthquake. A~ also seen in : Figure 2, additional support may be provided to each of the :

4~78 2 1 ~ 7 ~ ~ O PCT/US93/00271 , ....

floor joists 14 via one or more secondary concrete support walls 30 of the foundation of the residential structure 10.
Disposed between each pair of adjacent joists 14 is a pre-fabricated floor section 32. In the preferred embodiment, each of the floor sections 32 ls fabricated from polystyrene foam and de~ines firs~ and second horizontal edge portions. Each of the floor sections 32 is disposed between an ad~acent pair of floor joists 14 in a manner wherein the first and second horizontal edge portions thereof are each received into a recess defined by portions of the top surface of the lower flange 20, bottom surface of the upper flange 18 and one planer face of he we~ 22 of one:of the floor joists 14 of the pair.
As best see~ in Figures 3 and 4, formed in the first and second horizontal edye portions of ea~h of the floor sections 32 are a plurality of longitudin~lly extending channels 34. ~ Preferably, each of the horizontal edge portions of the fl~or section 32 include four channels formed therein~ When the horizontal edge portions of the 2~0 floor section 32:~are disposed between a pair of adjacent floor:~joists~14, ~one:channel 34 is disposed adjacent the ~:corner de~ined~by~the upper flange 18 and web 22, a second : ~~ channel:is :disposed::adjacent the corner defined by the wer flange~2g~and~:web 22~, with the;remaining two channels 25 : 34~bein~:disposed~adjaaént the central portion of the web 22.~ In~:~the~preferred~embodimsnt~, each o~ the channels 34 are~;adapted~to~ eceive a~quantity of~an adhesive such as a foam~material~:for~;purposes~:of:forming e~panded foam seals 36 between the first and~second horizontal edge portions of :30 ~th~:floor sec~ion 32 and the floor joists 14 of the pair.
Though~the f~loor sect~ion~32 is preferably ~butted against ea~h~ of the~floor~joists 1~4 of the pair when inserted therebetw~en, the~ expanded foam seals 36 are operable to secure~the floor sections to the floor joists and thereby ;: 3~5 inG~easé the compriessive~ strength of ieach foam floor WO93~1427~ PCT/USg3/00271 2~ 27.~80 section 3~ so as to enhance the shear resistance of the floor structure 12. Additionally, the foam seals 36 aid in sealing against the infiltration of moisture, air or harmful radon gas into the residential structure 10 via the floor structure 12 as well as reduce heat transfer across the floor structure.
In assembling the floor structure 12, a first floor joist 14 is attached to the foundation structure 16 via.the foundation bracket 26 in the manner previously described.
Thereafter, one of the horizontal edge portions of a floor section 32 is inserted into the recess defined by the lower flange 20, upp~r flange 18 and strand board web 22 and is secured to the first floor joist 14 via the injection of foam adhesively into the channels 34 of the horizontal edge portion to create ~he foam seals 36. A second floor joist 14 is then attached to the foundation structure 16 such that a recess defined thereby captures the horizontal edge portion of the first floor section 32 not captured in the recess defined by the first floor joist 14. Thereafter, ; : 20 foam adhesiv~ material is injected into the channels 34 of thP second, captured horizontal edge portion to firmly secure the floor section 32 between the adjacent pair of floor joi ts 14. Retaining floor joists 14 and floor ~sections 32 are ;subsequently assembled in an analogous ~: : 25 matPrial throughout:the structureO
After the assembly of the floor joists 14 and floor sections 32, a layer: of f:inishing material such as a plywood~ sheet :~38 is secured to the top surfaces of the :
upper $1ange~ 18. As best seen in Figure 4, when the :30 plywood ~heet 38 is~attached to the upper flanges 18 of the : floor joists 14, a space 40 is defined between the plywood : shee~ 38 and the top surfaces of the floor sections 32.
Advantageously/ the space 40 provides dead-space insulation which, in c~njunckion with the poly~tyrene floor sections ~ 35 32 and foam seals 36, greatly enhances the overall thermal : ~ .

WO93~1427g 2 ~ ~ l g 8 ~ PCT/US93/0027l efficiency of the ~loor structure 12. Additionally, the space 40 serves as electrical/plumbing service conduit as will be described in more detail below.
Though the floor structure 12 has been described for use in conjunction with a plywood sheet 38 serving as the layer of finishing material, it will be reoognized that the design of the floor structure 12 may be modified to accommodate a concrete slab floor as would be used in a commercial building structure. Advantageously, the floor structure 12 of the present invention is designed so as to possess significant seismic stability when seismic forces are applied to the res~dential structure 10. Additionally, since the floor structure 12 does not incorporate cement or any other hy~rophilic material, continual watering as would occur from automatic sprinklers around the base of the residential structure 10 is not easily absorbed into ~he floor structure 12 and thus not transported to the wood componénts there~f. As such, problems associated with mildew, dry rot, fungus and ground settling which are typically en~ountered with conventional floor structures are~ eIiminated by ~the design and material~ used in coniunction with the floor structure 12. As such, the floor s~ructure 12 is particularly adapted to be less susceptible to risk of damage when seismic forces are applied thereto. ~

WkLL S~RUCTU~ -.
Referring now to Figures 5 11, the present invention : ~: 30 further comprises a dimensionally stable, monolithlc wall structure 42 which, like the 1Oor structure 12, i5 . specifica~lly adapte~ to resist shear and to be seismically : stable. As seen in Figure 6, the wall structure 42 is : ~ formed generally~of an elongate track 44, plural posts 56, ~ :35 a lower header 98, upper header or top plate 1009 and : :
:~ ~

WO93/14278 PCT/US93~00271 ~ 27 ~ ~ 0 -18-plural wall sections 126 which are assembled upon the floor. The po5ts 56, and headers 98, 100 are preferably fabricated from dimensionally stabile L~L material or kubular metal and are pre-fabricated off-site. The track 44 is preferably formed having a generally U-shaped configuration definin~ a bottom wall 46 a~ pposing side walls 48 which extend upwardly from the bottom wall 46. As seen in Figure 9, the track 44, and more particularly the bottom wall 46 thereof, is adapted to rest on the plywood sheet 38 or other ~inishing material of the floor structure 12 and is secured to the underlying mud sill 28 via a plurality of faskeners 50 such as self-tapping screws. The fasteners 50 extend through t~e bottom wall 46 via a plurality of pre-formed, linearly align~d bottom wall apertures 51 disposed therein at predetermined locations along the length of the track 44. Dis~osed within the upper edges of the opposing sidewalls 48 of ~he track 44 ~ are pairs of V-shaped notches 53 which are used for placing : a drilling jig or ~imilar structure in vertical registry : : 20 with a respective~ bottom wall: aperture 51. As will be recognized, in~hose instances where the wa~l structure 42 is~not: constructed about the outer periphery of the residentlal:s~ructure 10, ~he fasteners 5Q may extend : : through the pl~wood~shee~ 38 into a support structure other 25: than the~ mud~sill~;28, cuch as the upper flange 18 of a loor~:joist ~14. ~rth r, as seen~in Figure 9AJ the track 44 ;may a~lso~be~ anchored directly~to a portion of the foundation~of~ the~residential structur,e 10 such as the ,Q~ncrete s~upport wall 30 via an anchor bolt 52 which 30~ ~ex~ends from the support:wall 30, through the plywood sheet 38~:and~:track ~44~ with ~the track 44 being ~ecured to the bo~lt:~:52;via a nut;~54.
The wall structure 42 further:comprises a plurality of e~ongate, vertical posts 56 of :predetermined lengths, the ~bottom~ends of~which are secured at predetermined locations 7 ~

--19~
along the length of the track 44. In the preferred embodiment, the bottom ends of the posts ~6 are secured to the track 44 via a plurality of flanges 58 which extend perpendicularly upward from the bottom wall ~6 of the track 44. Each of the flanges 58 preferably include four pre-formed apertures 60 disposed therein in a ~e~eral~ly square configuration which are oriented so as to be in registry with pre-formed lower post aperture~ 62 disposed in ~he bot~om ends of the posts 56. As seen in Figure 9, the posts 56 are secured to the flanges 58 by abutting the bottom ends thereof against the flanges 58 in manner wherein the apertures 60 and 62 are coaxially aligned.
- Thereafter, fasteners 64 such as self-tapping screws are inserted into the lower post apertures 62 and through the posts 56 so as to eng~ge the flanges 58 via the aper~ures 60, thus securing the pos~s 56 to the flanges 58. Though as shown in Figure 8, four fast~ners 64 are utilized to secure each of the posts 56 to a respective ~lange S8, it will be recognized that greater or les~er numbers of fasteners 64 may:~be UtilizedA
Referring now to~Figures 20-22, disclosed is a track 66- constructed in accordance with a second embodiment of the present invention. Track 66, like track 44, also has a generally U-shaped con~iguration and defines a bottom 25~ wall~ 68 ~havi~g~ opposing sidewalls 70 extending perpendicularly~ upward there~rom. To facilitate the at~aGhment;~o~ the~track: 66 ~ta the support structure underlying t~e~ pl ~ ood shee~ 38,~disposed in the bottcm , wall 68~are a ~plurality'of pre-formed, linearly aligned 30 ~ bottom:wall apertures 72.~ As an alternative to the flanges 58::inaluded~with~the track 44, the bottsm ends of the posts 56 are secured to :the track 66 via a plurality of track brackets 74 wh`ich :are attachable to the bottom wall 68 of the~ track 66. Each~ of the track brackets 74 has a ~gPnerally L-shaped~configuration and defines a lower flange ~ ::

2l2~a portion 76 having a pre-formed lower aperture 78 extending therethrough, and a pair of registry tabs 80 formed on the bottom surface thereof. In the preferred embodiment, the registry tabs ~0 are adapted to be receivable into a pair of locator apertures 82 disposed adjacent each of the bottom wall apertures 72. When the regi~t~y tàbs 80 are received intv a respective pair of locator apertures 82, the lower aperture 78 disposed in the lower flange portion 76 is coaxially aligned with the respective bottom wall aperture 72. Thereafter, both the track ~racket 74 and track 66 are simultaneously secured to the underlying support structure via fasteners 84 such a self-tapping screws which are received through the coaxially aligned lower aperture 78 and bottom wall aperture 72. Similar to the track 44, the track 66 includes pairs of V shaped no~ches 86 disposed along the top edges of the opposing sidewalls 70 for placing a drilling jig in ~ertical registry with the coaxially aligned lower aperture 7~ and bottom wall aperture 72.
~: ~ 20 To facilitate their attachment to the bottom ends of the~:posts 56, each of the track ~rackets 74 further încludes an upper- flange portion 88 which extends perpendicularly upward from the bo~tom wall 68 wh n the lower flange~portion 76 is secured thereto. The upper ~lange ~portion 88 includes four pre ~ormed upper flange apertures 90: disposed therein in a generally square configuration~ The upper flange apertures 90 are oriented so as to be~in~:registry with the pre-formed lower post apertures 62 disposed in;the bottom ends of the posts 56.
30: In this respect,~ the posts 56 are secured to the track brackets 74 b~abutting the bottom ends thereof against the upper flange portions 88. l'herea~ter, fasteners 92 such as sel~-tapping~screws are inserted into the lower post apertures 62~and through the pos~s 56 so as to engage the ~`: :

: ~;

WV93/14278 2 ~ ~ r7 3 ~ ^a PCT/US93/OQ271 upper flange portions 88 of the track brackets i4 via ~he upper flange apertures 90.
In the second embodiment, the track 66 is a moisture track which is fabricated from an extruded polymer. Formed on the bottom surface of the bottom wall 68 and on each of the opposed edges of the bottom wall 68 ar~ Iongitudinally extending projections 9~ which are utilized to form a moi~ture-tight seal and thermal barrier against the plywood sheet 38 or other layer of finishing material when the track 66 is rigidly secured to the underlying support structure. Though the track 44 which is preferably fabricated from sheet metal is not provided with such projections, it will be recognized that prior to securing the track 44 to the underlying support structure, a separa~e polymer plate or similar structure may be inserted between the bottom wall 46 and top surface of the plywood sheet 3~ so as to form a moisture-tight, thermal barrier as do the projections 94 of the extruded polymer track 66.
Advanta~eously, the moisture and ~hermal barrier facilitated by the projectionC 94, or polymer plate used in c~njunction wi~h the track ~4, is not violated over a prolonged duration of time~ Though the track 66 is ~a~ricated from a polymer, the track brackets 74 attached : there~o are preferably fabricated from metal, though other material~ may be:utilized as an alt rnative.
As :seen in Figur~s 9 and 9AI in the preferred embodiment, the top ends oiE selected ones of the f asteners 50, 52 whic~ are utilized ~o secure the track 44 to the mud I~;ill 28,1 suppo~t wall 30, floor joist 14 or other 30 underlying support structure are disposed directly under :: the po~ts 56 . In the preferred embodiment , each of the : posts 56 of the wall structure 42 includes a fastener 50, 5~: directly underneath the bottom end thereof. To :: acco~modate the top ends of the fasteners 50, 52 he bottom end of each post 56 is provided with a recess or : ~:

W093/14278 PCT/~S93/0~271 2 ~ a counterbore 96. Advantageously, by placing the fasteners 50, 52 into the underlying support structure directly under the posts 56, the seismic stability of the wall structure 42 is significantly increased. In this respect, during seismic activity the weight of the residentlal structure 10 is resisted by ~he interaction of the fo~ation and the wall structure 42 since the holding power is maximized at the levex arms of the posts 56~ Though each of the posts 56 preferably includes a fastener 50,52 located underneath ~0 the bottom end thereof, the fasteners may only be included under selected ones of the posts 56.
Referring now to Figures 6l 8, and 11, in constructing the wall structure 42, attached to the top ends of the posts ~6 is a lower header beam 98 and an upper header beam or top plate 100. In the preferred embodiment, the lowar header beam 98 is formed in segments 99 extending in abutted end to-end orientation, each spanning ~etwsen and being secured to the top ends of adj~cent posts 56 via a pair of header brack~ts 102. Each of the headex brackets 102 has a generally L-shap~d configuration and includes a ~ertical flange portion 104 having a pair of pre formedl linearly aligned~ vertieal flange apertures 106 disposed therein. The vertical flange apertur s 106 are oriented so as to be~in registry wi~h a pair of~ pre-formed uppex post apertures disposed in the top end of each post 56. Two header brackets 102 are ~ttached: to the top end of each post~56 ~by~abutting~ the vertical flange portions ~Q4 of each bracket 102 ag~inst the top end~such that th~ vertical f~ange: qpertures~106 disposed in each of the vertical :30~ flange~portions-1~4 are coaxially aligned with the upper : post apertures~ of the post 56~ Ther~after, a pair of ; : fasteners 108~such as self-tapping screws are inserted into the: v~rtical flange apertures 106 of one of the header ~; brackets 102 and inserted through the upper post apertures ~;
:
' ~ .

W093/14278 2 ~ PC~/US93/O~t71 so as to engage the other header bracket 102 via the vertical flange apertures 106 thereof.
To facilitate the attachment of a seyment 99 ~f the lower header beam 98 to a pair of header brackets 102 on adjacent posts 56, each of the header brackets 102 of the header bracket pair further includes a~hQrizontal flange portion 110. Disposed in each horizontal flange portion 110 is a pair of horizontal flange apertures 112 which are oriented so as to be in registry with a corresponding pai~
~0 of pre-formed lower header apertures 114 disposed within the segment 99. When the pair of header brackets lV2 are secured to a respective pair of posts 56, the horizontal flange portions 110 thereof and the uppermost ends o~ the posts 56 define a pair of planer surfaces against which the bottom surface o~ the segment g9 is rest d~ When the segment 99 i5 abutted against the horizontal flange portions 110 of the header brackets 102, fasteners 116 such as self-tapping screws are inserted into both pairs of the lower header apertures 114 of the seg~ent 99 and through .~ 20 ~he segmènt 99 so as to engage the headex brack~ts 102 via both pairs of horizontal flange ~pertures 112 thus securing the segment 9~ to ~he header brackets 102.
After the ~egments 99 have been secured to the top ends of the posts 56 via the header bra kets 102 thus for~ing the lvwex header b~am 98, the upper header beam or top plate 100 is disposed upon the top ~urface of the lower header beam 9~8~ and: likewise secured to the horizontal flange portions llO of the header brackets 102. In this : re~p~ct, the ho~izontaL flange portion 110 of each header `~ 30! bracket 102, in addition to including the pair of horizontal flange apertures 112, further includes an aperture 118~. When the brackets 102 are attached to the ~: :posts~ 56, the apertures 118 of the horizontal flange : portions 110 are oriented so as to be in registry with pre-formed upper header apertures 120 disposed in ~he upper :: :

:: :

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WO93/14278 PCT/US93/~0271 2~c 27~80 header beam lOo. Each segment 99, in addition to including the pairs of low~r header apertures 114, also includes aper~ures 122 which are in registry with the apertures 118 of the pair of header brackets 102 when the segment 99 is attached thereto. In attaching the upper header beam 100 to the header brackets 102, inserted into~e upper header apertures 120 are fasteners 124 such as self-tapping screws which extend through the upper header beam 100 and .the apertures 122 of the segments 99 of the lower header beam 98 so as to engage the horizontal flange portions 110 of the header brackets 102 via the apertures 118. As best seen in Figure 11, the top ends of the lower header apertures 114 are preferably counter sunk so that the head portions of the fasteners 116 do not interfere with the upper head2r beam 100 when such is attached to the lower : header beam 98. In the preferred embodiment, the header brackets 102 are fabricated from metal, though other materials may be utilized as an alterna~ive.
Disposed betw~en each pair of adjacent posts 56 is a pre-fabricated wall sections 126. In the preferred embodiment, each of~;the wall:sec~ions 126 is pre-fabricated of~ site ~rom~nominal 6 inch thick polystyrene foam and has ~ a generally rectangular configuration defining a vertical : tongue 128 fo~med along first vertical edge and a vertical sIot 13:0 formed~ within a second ~ertical edge. As best : seen in Figures~6 and 22, each~of the wall sectlons 126 ~urther includes à ~lower ~edge havin~ a pair sf parallel roo~es~132:~formed therein for recei~ing the opposing idewalls 48, 70 of the tracks 44, 66 as will be explained balow. Ea h~wal~l section 126 further includes an upper :edge having a~:horizontal slot 134 formed therein for receiving the lower header beam 98. In the preferred embodiment, each wall section 126 is disposed between a : pair of adjacent posts 56 such that the vertical tongue 12~
abuts~ one the posts 56 of the post pair and the vertical WO 93/1427~ 7 ~ ~ ~ P~/US93/00271 slot 13 0 receives and encapsulates the other post 56 of the post pair and the vertical tongue 128 of an adjoining wall section 126.
As best seen in Figure 10, formed within the vertical 5 tongue 128 and vertical slot 130 of each wall section 126 is a vertical groove 136. Additionally, f~rn~ed wi~hin the lower edge and horizontal slvk 134 of each wall section 126 is a horizontal groove 137. When a wall section 126.is disposed between an adi~2n~ pair of posts 56 and interfaced to an adjoi~ir~g wall section 126 in the aforementioned manner, a liquid foam adhesive is injected into the vertical grooves 136 to form expanded foam seals 138 between the wall sestion 126 and each of the posts 5~
of the post pair. The liquid foam adhesive is also injected into the horizontal grooves 137 to form expanded foam seals 13~ between the wall section 126 and the track 44, ~6 and lower header beam 98 as will be explained below~
Advantageously, the c:reation of the foam seals 138, 139 transforms the wall struc:ture 42 into a monolithic 20 structure and add~ to the overall strength of the wall . structure 42 by enhancing the fundamental shear strength thereof.
To assemble the wall structure 42, the entire track 44, is i~itial~y laid down upon the floor for the entire 25 wall s~ructure 42 oiE the residerltial structure 10 to en~llre roper location. ~Thereafter, the V-shaped notc:he~ ~3, 86 are utilized to register the fasteners 50, 52 within a r~spective bottom wall aperture 51, 72. In the preferred embodiment, the V-shaped notches 53, 86 are disps:~sed at 30 seven irlc:h centers or at se~ren inc:h multiples, i.e. center-to-center distances of f ourteen inches, twenty eight inches, etc. A~ such, the track 44, 66 allows for the exact:and precise positioning and tying in of the track 4~, 66 and hence the wall structure 42 to the foundation of the ~5 residential struoture 10.

WOg3/14278 PCT/~93/00~71 ~ 2~8~a Referring now to Figures 12A, 12B, and 12C, after the track 44, 66 is secured to the underlying support structure in the desired configuration for the residential structure 10, the bottom end of a first post 56 is secured to the track 44, 66 via a flange 58 or track bracket 74 in the aforementioned manner. After a first post~ 56 has been secured to the track 44, 66, a first wall section 126 is lowered upon the ~rack 44, 66 such that the opposing sidewalls 4~, 70 of the track 44, 66 are received into the parallel grooves 132 Pormed in ~he lower edge of the wall section 126. Importantly, the wall section 126 is oriented such that the vertical slot 132 faces the first attached post 56. Thereafter, the wall section 126 is slid toward the first post 56 such that the post 56 is received into the vertical slot 130 and firmly abutted against the innermost surface 140 ~hereof. When the post 56 is received into the vertical slot, the horizontal flange portion llG of one of header brackets 102 of the pair ~lr ady secured to the top end of the first post 56 wilI be received into the horizontal slot 134 and abutted against the lowermost surface 142 thereof.
After the first post 56:has been received into the vertic~l 510t 130, a second post 56 is secu~ed to the track ~4~ 66~in ~ manner wherein the second posk 56 is firmly , a~u~ted against the outermost sur~ac~ of the vertical tongue~128. ~dvantageously, the flang~ 58 or track bracket 7~ ~ which the bo~tom end sf the second post 56 is secured : is specifically oriented such ~hat the second post 56 will abut thelvertical tongue 12B in the aforementioned manner when ~ecured there~o. After the second pos~ 56 is secured to the track 44, 66, the wall ~ection 126 will be firmly disposed, i.e. compressed between the pair of adjacent posts 56. Thereafter, liquid foam is injected into the ~: vertical grooves 136 to fo~m the foam seals 138 between the ~: 35 wall section 126 and pair of posts 56. The liquid fo~m is W0~3~14278 2 ~ ~ 7 ~ ~ O PCT/US93/00271 "'~1 , -27-also injected into the horizontal groove 137 in the lower edge to form the foam s~al 139 between the wall section 1~6 and the track 44, 66. A second wall section 126 is then placed upon the track 44, 66 in the same manner previously described and oriented such that the vertical slot 130 thereof faces the vertical tongue 128~ ~of the first installed wall section 126 and second installed post 560 The second wall section 126 in then slid toward the first wall section 1~6 to a position whereat both the second post 56 and vertical tongue 128 of the first ~all section 126 are received into the vertical slot 130 thereof.
Thereafter, a third post 56 is affixed to the track 44, 66 so as :to abut ;the vertical tongue 128 of the second installed wall section 126 in the same manner previously described. Liquid foam adhesive is then injected into the vertical grooves 13:6 of t~e second wall section 126 and , horizontal groove 1~7, in the lower edge to form the foa~.
seals, 138, 139~ between the second;wall se~tion 126 and those~posts 56~between which it is orien~ed and the second ~wall~ se~.ion ~126~and :th~ track 44, 66. As will be recognizcJd~,~third~and~subsequent:wall sections 126 used to the~orm:the~wall structure 42 are added in the sa~i manner previ~usly:~described.~ :~
After a~;~wall~section 12~ ha~ ~een orianted between a ,pair~ of~posts 56,,~a~segment 99 of the lower header beam 98 is;~disposed~ into~ the horlzonta~slot 134 of the wall se~tion~12~6~ an~secur~d~o~the~;horizontal fla~ge portions llO~ of~a~pair~of~:~the header~bra ~ ets:102~in the manner pre~iou~ly described. ~ The liquid foam i~ then injected 30~ into ~he~horizontal~groove~:137~of :the horizontal slot 134 to~orm~ he foam~sea~ 139~between the ho~izontal slot 134 and~ the ~:segment,~99. ~:~After the~desired ~u ~ er of wall secti~ons;:lZ6~have:been assembled~ in the wall structure 42 and~the lower~header beam 98-formed by the receipt of the 35~ ~segments~ 99~ into~ the horizontal slots 134 in the 2~27~0 aforementi~ned manner, the upper header 100 is placed upon the lower header 98 and likewise secured to the horizontal flange portions 110 of the header brackets 102 in the aforementioned manner. As best seen in Figure 11, the width of the upper header beam is substantlally identical to the overall width of the wall sections~Z6.
As will be recognized from the aforementioned construction process, when the wall structure 42. .is erected, khe foam wall sections 126 are entrapped, i~e.
encapsulated, by the posts 56, lower he~der beam 98 and upper header beam 100, thus becoming an integral part of the wall structure 42. Advantageously, the wall sections 42 and upper header beam 100 provide uniform surfaGes to which may be applied final wall finishes. Importantly, the extension of the foam wall sections 126 outward from both sides of the post 56 and the interlock of the wall sections 126 facilitated by the overlap of the vertical tongues 128 and vertical slots 130, provides ~he foam wall sections 126 with compressive strength to resist shear, which is increased by the expanded foam seals 138, 13g. In thi~
respect, by entrapping the foam wall sections 126 between the track 44, 66, posts 56 and upper and lower header beams g8 ~ 100 r the shear ~trength capability of ~he foam wall :sections 126 are maximized due to the p~ysical interaction : 25 of the c:omponents.~Additiona~ly, the aforementioned manner of construction; eliminates slop and prevents moisture :
~deterioratIon.
A~ previo~sly~specified, the wall sections 126 and upper header beam l00 provide uniform surfaces to which may : 30 ~ be~applied final wall finishes. In this respect, dry wall :may be applied to the interior wall surfaces of the wall ~: ~ : sections 126 by securing the top edge thereof to the inner :~ : edge 143 of the upper header beam 100 or by applying the :`; drywall to ~he inner wall surfa~es of the wall sections 126 ~ 35~ via an adhesiveO Additionally, as seen in Figure 17, a ::

W093/14278 2 ~ 2 7 ~ 8 0 PCT/US93/00271 wall finish such as a sheet of plywood 144 may be applied to the outer wall surfaces of the wall sections 126 by securing the upper edge thereof to the outer edge 146 of the upper header beam 100 via fasteners such as nails 1~
and/or ~y utilizing an adhesive 150 applied to the outer wall surfaces of the wall sectîons 126. A~er the plywood sheet 144 has been secured to the outer wall surfaces of the wall sections 126, materials such as aluminum or wood siding 152 may be applied to the plywood sheet 144. As ~n alternative to the plywood sheet 144, other materials such as steel, vinyl, etc. may be applied to the inner and/or outer wall surfaces of the wall sections 126.
Additionally, as seen in Figure 16, a layer of netting 15~
may be applied to khe inner and/or outer wall surfaces of the wall sec~ions 126 via securing the ~ame to the upper header beam 100 or utilizing an adh~sive, the netting 154 serving as a support material for a polymer based marble filled, stucco-appearing coating 156 for ornamental fini~hes. ~mportantly, irrespective of the particular finishi~g material applied to the inner a~d/or outer wall : : surfaces of the wall sections 126, the foam core of the wall structure;;42 :facilitated by the wall sections 126 maximi:zes the ~hermal, acoustioal and insulation qualities of the wall ~structure 42 and provides the necessary moisture barrier, ~resulting in~ a rigid, flat, smooth, squa~e a~d~plu~b~tructure.
Referring now~to Figures 13 and 15, subsequent to the ::se¢u~ing o~the~wall sections 126 be ween the posts 56 and upper and lower ~eader beams 9B, 100, ona or more of the wall sect~ions~l26~may be provided with conduits ~58 for : imp~acing a plumbing anifold or electrical ~ystem into the wall sections 126.: Typically, the conduits 158 are formed via the~u~ zation of ~ tool such as a hot knife 160, though~other forming methods may be utilized~ Through the ;35 use of ~he hot knife 160, oth r recesses may be formed :: :

:~ :
:

~093~14278 PCT/US93/00271 ~12 7 8 8 ~3 within the wall sections 126 to accommodate components such as electrical outlet boxes 162. Advantageously, the one and one~half inch foam overlay of the wall sections 126 facilitated by the vertical slots 130 allows for the emplacement of the plumbing and electrical systems into the wall ~ections 126 only and eliminates th~- need to cut through the posts 56 and/or upper and lower header beams 98, 100. In relation to parkicular plumbing applications, a foam chase may be utilized. Additionally, as seen in Figure 15, after the plumbing or electrical system ~omponents have been inserted into the conduits 158, taping materials 164 may be utilized to cover the conduits 158 so as to provide uniform inner or outer wall surfaces for the wall sections 126 so that finishing materials may be applied thereto.
Referring now to Figure 14, each post 56 is provided with a plurality of pre-formed, linearly aligned apertures 166 which sre disposed along substantially the entire le~gth of the post 56. In the preferred embodiment, the ~ 20 apertures 166 in each of the posts 56 are used for purposes : of forming windows and doors between pairs of posts 56.
Particularly, windows are formed via the utilization of a Il member 168 and a jam member 170, each of which are interfaced to the~ posts 56 via pairs of window brackets 2S 172. The window~:bracke~s 172 each have a generally L
~ ~ :
shaped con~iguration and are secured to either the sill member 168 or~:jam~member 170 via the receipt of fasteners ` :into~a~pair of~:~apertures di posed~in one of the two planarportions,thereof~ Therea'fter, the sill member 168 and jam : : : 30 member I70, ~ach; having a pair of window brackets 172 attached thereto, are horizontalIy oriented between and secured to a pair of posts 56. The attachment to the posts 56 is facilitated by the receipt of fasteners into pairs of apertures disposed ~n the other planar portion of each of :35 ~ the window bra kets 172 in~o corresponding, coaxially WO93/14278 2 ~ 2 7 ~ 8 0 P~T/~S93/00~71 alig~ed pairs of apertures 166 disposed within the posts 56. Advantageously, due to the placement of the apertures 166 within the posts 56, the window may be constructed ha~ing a multitude of different heights. Additionally, by cutting out central portions of one or more lnterior posts 56, the windows may be constructed havin~-~y of a number of desired widths~ As will be recognized, when a window is formed within the wall structure 42, one or more wall sections 126 must be cut so as to accommodate the window.
As pre~iously specified methods similar to those previously discussed may be utilized to form doors within the wall structure ~2.

ROOF STRUCTURE
1~
Referring now to Figures 18 and 19, the building system of the present invention further co~prises a roof structure 174 fo~med in substantially the same manner as the floor structure 12.. In the preferred embodi~ent, the ~20 roo~ structure 174 comprises a plurality of ceiling trusts : 176 which are attached between the upper he~der beam 100 and a central suppor~ beam 178 in spaced, parallel relation. In:the preferred embodiment, each of the ceiling trusts 176 has an~ I-beam con~iguration and includes an upper flange~180 and a lower flange 182 having a strand : ~ board web 184 extending perpendicularly therebetween. Like :the floor joists~ he ceiling trusts 176 are fabricated from gang laminated::LVL (laminated veneer lumber) and are provided wi~h an I-beam configuration for strength and for :30 greater:vertical an~ lateral load r~sistance.
: Disposed between each pair of adjacent ceiling trusts 176~is a pre fabricated ceiling section 186, which like ~he ~floor sections 32 and wall sections I26 is fabricated from :~ ;;p~lystyrene foam. Each of the ceiling sections 186 further ~35 includes first ~nd;second angled ed~e portions which are :
: ~: :: ~

WO93/14Z7~ PCT/US93/00271 21 2 78 ~ ~ -32-abutted against the ceiling trusts 176 of the ceiling trust pair when disposed therebetween. In the preferred embodiment, the first and second angl~d edge portions of each ceiling section 186 are glued in th~ recesses of the ceiling tru~ts 17~ of the pair which are defined by portions of the lower surface of ~he up~ flànge 180, upper surface of the lower flange 182 and web 184. Thus, each of the ceiling sections 186 is rigidly maintained.in position between th~ adjacent pair of c~iling trusts 176.
In the preferred embodiment, the ceiling sections 186 are fabricated from six inch thick foam. When inserted between the pair of ceiling trusts 176, the upper plane of the ceiling section 186 is flush with the bottom surface of the upper flange 180 while the lower plane is flush with the top surface o~ the lower flange 182.
In the preferred embodiment, the roof structure 174 is constructed in a manner substantially identical to the manner by which the floor structure 12 is constructed.
Initially, a first ceiling tru~t 176 is attached to the upper header beam 100 and central support beam 178.
Thereafter, either the first or second angled edge portions of a ceiling section 186 are secured within the recess :~ defined by the upper and lswer flanges 180, 182 and web 18~
of the first ~ru~t 176 Yia an adhe~ive. A second ceiling 2~ trust 176 is then oriented so as to capture the angled edge portion of the:ceiling s~c~ion ~86 not disposed within the : recess of ~he:first ceiling trust 176. The second edge portion then i~ adhesively affixed within the recess of the second ceiling trust 17~ ~in the same manner previously :~ ~ 30 descri~d. Subsequent ceiling sections 186 and ceiling : ~: trusts 176 are a~ded to the roof structure 174 in ~he .
aforementioned:manner.
~ : After the:ceiling trusts 176 and ceiling sections 186 : ha~e been assembled, a layer of sheathing 188 is then:
: 35 secured to the ceiling trusts 176/ and more particularly .

w~ 93/1427~ ~ ~ 2 7 ~ ~ O PCT/US93/0027l the upper flanges 180 thereof~ Thereafter, a layer of roofing material 190 is applied to the layer of sheathing 188. As seen in Figure lg, when the sheathing 18B is applied to the upper flanges 180, a space 192 is formed S between the upper plane of the ceiling sectlons 186 and the sheathing 188. As seen in Figure 18,~is space 192 created between the ceiling sections 186 and sheathing 188 forms an air pathway for ventilating and cooling the roof surface when eave and ridge vents are installed.
~dvantageously, flat, shed and gabled roofs are easily designed utilizing the roof structure 174 of the present invention. As can be appreciated, ventilation of the roof structure 174 facilitated by the air pathway carries off heat and prevents heat buildup on the roof surface thus extending khe life of the layer of roofing l90.
Additionally, the fresh air introduction and circulation within th~ roof structure 174 is provided by a natural chimn~y effect without electric fans and without compromising the insulatio~.
20Due to the mann~r in which the floor structure 12, . wall structure 42 and roof structure 174 of the present ; invention are pre~fabricated, all wall, flooring and roof portions:of the residential structure 10 may be assembled : utilizing only~screw fasteners and a drill. Additionally, : 25 due to the dimens~ional stability associated with the pre-apertured tràcks ~4, 66, posts 56 and beams 98, 100 as well : ~ as the interlocking overlay of the wall panels 126, the residential:structure 10 may be constructed with unskilled labor in:la minimal amount of time and with a minimal amount :~ : 30 of difficulty. In this respect, in fabricating the wall structure 42, one post 56 may be first plumbed with all : other posts~56~heing subsequently au~omatically plumbed due : to khe dimensional sta~ility associated with the pre-:~ fabricated registration means of the tracks 44, 66, i.e.
the flanges 58 and track brackets 74. Further; the manner ~12~881~

of forming the floor, wall and ceiling strutures of the present invention promotes increased resistance to shear and enhanced seismic stability due to the formation of monolithic structures which take advantage of the compressive strength of the foam components thereof.
Further, those skilled in the art wil~ecognize that the present invention takes a substantial departure from the prior art by providing a pre-fabricated, pre-apertured building system which is assembled by progressively working solely from one side of the structural posts, with all fasteners being inserted from one side of all posts. This feature permits unskilled labor and is only a~hieved by the high tolerance pre-fabrication of the structural building elements.
Additional modifications and improvements of the present invention may also be apparent to those skilled in the art. Thus, the particular combination of parts ~escribed and illustrated herein is intsnded to represent only one embodiment of the invention, and is not intended 2Q to serve as limitations of alternative devices within the spirit and scope of the invention.

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Claims (46)

WHAT IS CLAIMED IS:

1. An improved building system including a dimensionally stable, monolithic wall structure, said wall structure comprising:
an elongate track adapted to rest on and be secured to a horizontal foundation means;
a plurality of elongate, vertical posts of predetermined lengths having top ends and bottom ends, said bottom ends being securable at predetermined locations along the length of said track;
at least one elongate, horizontal header beam securable to the top ends of said posts; and a plurality of pre-fabricated wall sections, each of said wall sections being disposed between a pair of adjacent posts and including first and second vertical edge portions which abut the posts of the post pair;
the abutment of said first and second vertical edge portions against the posts of the post pair being operable to produce a synergistic effect by utilizing the compressive, tensile and shear force properties of said posts and said wall sections, thus forming a monolithic wall structure.

2. The device of Claim 1 wherein said track has a generally U shaped configuration defining a bottom wall adapted to rest on and be secured to said foundation means and opposing sidewalls extending upwardly from said bottom wall.

3. The device of Claim 2 wherein said bottom wall of said track includes a plurality of pre-formed, linearly aligned: bottom wall apertures disposed therein at said predetermined locations along the track for receiving a fastener to secure said track to said foundation means.

4. The device of Claim 3 wherein said track further comprises a plurality of flanges extending perpendicularly upward from said bottom wall, each of said flanges including a plurality of pre-formed flange apertures disposed therein which are oriented so as to be in registry with pre-formed lower post apertures disposed in the bottom ends of each of said posts to receive fasteners to secure said posts to said track.

5. The device of Claim 4 wherein said track is fabricated from sheet metal.

6. The device of Claim 3 further including a plurality of track brackets attachable to said bottom wall of said track, each of said track brackets comprising:
a lower flange portion having a pre-formed lower aperture extending therethrough and a pair of registry tabs formed thereon, said bottom wall further including pairs of locator apertures disposed therein adjacent each of said bottom wall apertures for receiving said pair of registry tabs, said lower aperture being coaxially aligned with a respective one of said bottom wall apertures when said registry tabs are received into the corresponding locator apertures, said coaxially aligned lower and bottom apertures being adapted to receive a fastener to simultaneously secure said track bracket to said bottom wall and said track to said foundation means; and an upper flange portion extending perpendicularly upward from said bottom wall, said upper flange portion including a plurality of pre-formed upper flange apertures disposed therein and oriented so as to being registry with pre-formed lower post apertures disposed in the bottom ends of each of said posts to receive fasteners to secure said post to said upper flange portion of said track bracket.

7. The device of Claim 6 wherein said track is fabricated from an extruded rigid polymer.

8. The device of Claim 7 wherein said bottom wall of said track further includes a plurality of longitudinally extending projections formed thereon for forming a moisture tight seal and thermal barrier against said foundation means when said track is secured thereto.

9. The device of Claim 8 wherein said track brackets are fabricated from metal.

10. The device of Claim 3 wherein the opposing sidewalls of said track include pairs of V-shaped notches disposed therein for placing a drilling jig in vertical registry with said bottom wall apertures.

11. The device of Claim 3 wherein the bottom ends of said posts include recesses disposed therein to receive portions of the fasteners used to secure the track to the foundation means.

12. The device of Claim 3 wherein said at least one horizontal header beam comprises a lower header attached to the top ends of said posts and an upper header attached to said lower header.

13. The device of Claim 12 wherein each of said posts is attached to said lower header via a pair of header brackets, each of said header brackets comprising;
a vertical flange portion including a pair of pre-formed vertical flange apertures disposed therein which are oriented so as to be in registry with pre-formed upper post apertures disposed in the top ends of each of said posts, said vertical flange apertures of the header bracket pair and said upper post apertures being adapted to receive fasteners to secure said header bracket pair to the top end of said post;
and, a horizontal flange portion including a pair of pre-formed horizontal flange apertures disposed therein which are oriented so as to be in registry with pre-formed lower header apertures to receive fasteners to secure said header bracket pair to said lower header.

14. The device of Claim 13 wherein each horizontal flange portion of said pair of header brackets and said lower header further include apertures in registry with each other and with a pair of pre-formed upper header apertures to receive fasteners to secure said upper header to said lower header.

15. The device of Claim 12 wherein each of said pre-fabricated wall sections comprises:
a vertical tongue formed along said first vertical edge;
a vertical slot formed within said second vertical edge;
a lower edge having a pair of parallel grooves formed therein for receiving the opposing side walls of said track; and an upper edge having a horizontal slot formed therein for receiving a portion of said lower header;
each of said wall sections being disposed between a pair of adjacent posts such that the vertical tongue abuts one of the posts of the post pair and said vertical slot receives and encapsulates the other post of the post pair and the vertical tongue of an adjoining wall section.

16. The device of Claim 15 wherein each of said wall sections is fabricated from polystyrene foam.

17. The device of Claim 16 wherein the vertical tongues and vertical slots of each of said wall sections include a vertical groove formed therein for receiving foam to form an expanded foam seal between the vertical tongue and one post of the post pair and the vertical slot and the other post of the post pair to form a monolithic wall structure.

18. The device of Claim 3 wherein each of said posts include a plurality of linearly aligned apertures disposed along the length thereof for interfacing said posts to pairs of window brackets.

19. The device of Claim 1 wherein said building system further comprises:
a plurality of elongate floor joists attached to said foundation means and extending in parallel relation; and a plurality of pre-fabricated floor sections, each of said floor sections being disposed between a pair of adjacent joists and including first and second horizontal edge portions which abut the joists of the joist pair;
the abutment of said first and second horizontal edge portions against the joists of the joist pair being operable to produce a synergistic effect by utilizing the compressive, tensile and shear force properties of said joists and said floor sections thus forming a monolithic floor structure.

20. The device of Claim 19 wherein each of said floor joists is configured as an I-beam and comprises elongate upper and lower flanges having a web member extending perpendicularly therebetween.

21. The device of Claim 20 wherein the first and second horizontal edge portions of each of said floor sections includes a plurality of longitudinally extending channels formed therein for receiving foam to form expanded foam seals between said first and second horizontal edge portions and the joists of said joist pair.

22. The device of Claim 21 wherein said floor joists are fabricated from wood and said floor sections are fabricated from polystyrene foam.

23. The device of Claim 1 wherein said building system further comprises:
a plurality of ceiling trusts attached to said header beam and extending in parallel relation; and a plurality of pre-fabricated ceiling sections, each of said ceiling sections being disposed between a pair of adjacent ceiling trusts and including first and second angled edge portions which abut the trusts of the trust pair;
the abutment of said first and second angled edge portions against the trusts of the trust pair being operable to produce a synergistic effect by utilizing the compressive, tensile and shear force properties of said trusts and said ceiling sections thus forming a monolithic ceiling structure.

24. The device of Claim 23 wherein each of said ceiling trusts is configured as an I-beam and comprises upper and lower elongate flanges having a web member extending perpendicularly therebetween.

25. The device of Claim 24 wherein said ceiling trusts are fabricated from wood and said ceiling sections are fabricated from polystyrene foam.

26. The device of Claim 1 wherein said posts and said at least one header beam are fabricated from wood.

27. A method of forming a monolithic wall structure from a post and beam frame and interlocking foam wall sections wherein a synergistic effect is achieved utilizing the compressive, tensile and shear force properties of the frame and wall sections, comprising the steps of:
securing an elongate track to a horizontal foundation means;
securing the bottom end of a first elongate, vertical post to the track at a predetermined location thereon via a first pre-fabricated registration means;
disposing a first pre-fabricated wall section upon said track in a manner wherein a vertical slot formed within a first vertical edge of the first wall section is abutted against and encapsulates said first post;
securing the bottom end of a second post to the track at a predetermined location thereon via said first registration means in a manner wherein said second post is abutted against a vertical tongue formed along a second vertical edge of said first wall section;
disposing a second wall section upon said track in a manner wherein a vertical slot formed within a first vertical edge of the second wall section receives and encapsulates the second post and the vertical tongue of the first wall section; and securing at least one elongate, horizontal header beam to the top ends of the posts via a second pre-fabricated registration means.

28. The method of Claim 27 further comprising the step of injecting foam into vertical grooves formed in the vertical tongue of said first wall section and vertical slots of each wall section to form expanded foam seals between the vertical tongue and the second post and the vertical slots and the first and second posts.

29. The method of Claim 27 wherein the first vertical post is plumbed with the second and other posts being subsequently plumbed due to the dimensional stability of the first and second registration means.

30. The method of Claim 27 wherein said wall structure is adapted to be assembled utilizing solely self-tapping screws and a drill bit.

31. The method of Claim 27 further comprising the step of enplacing a plumbing manifold and electrical system into said wall sections without cutting through said posts and said header beam.

32. The method of Claim 31 further comprising the step of using a foam chase.

33. The method of Claim 27 further comprising the step of forming a monolithic floor structure utilizing a floor frame and pre-fabricated foam floor sections wherein a synergistic effect is achieved utilizing the compressive, tensile and shear force properties of the floor frame and floor sections.

34. The method of Claim 33 wherein the formation of the floor structure comprises the steps of:
attaching a first floor joist to said foundation means;
abutting a first horizontal edge portion of a first pre-fabricated floor section against the first joist; and attaching a second floor joist to the foundation means in a manner wherein a second horizontal edge portion of the first floor section abuts the second joist.

35. The method of Claim 34 further comprising the step of injecting foam into longitudinally extending channels formed in the first and second horizontal edge portions of said first floor section to form expanded foam seals between the first and second horizontal edge portions and the first and second joists.

36. The method of Claim 27 further comprising the step of forming a monolithic ceiling structure utilizing a ceiling frame and pre-fabricated foam ceiling panels wherein a synergistic effect is achieved utilizing the compressive, tensile and shear force properties of the ceiling frame and ceiling panels.

37. The method of Claim 36 wherein the formation of the ceiling structure comprises the steps of:
attaching a first ceiling trust to said header beam;

adhesively securing a first angled edge portion of a first pre-fabricated ceiling section to the first ceiling trust, and attaching a second ceiling trust to the header beam and adhesively securing the second trust to a second angled edge portion of the first ceiling section.

38. The method of Claim 27 further comprising the step of applying a layer of finishing material to the inner and outer surfaces of the wall sections.

39. The method of Claim 38 wherein the finishing material is selected from the group consisting of:
dry wall;
plywood; and fiberboard.

40. The method of Claim 38 wherein the layer of finishing material is applied to the inner and outer surfaces of the wall panels via the attachment thereof to said header beam.

41. The method of Claim 38 wherein the layer of finishing material is applied to the inner and outer surfaces of the wall panels via an adhesive.

42. The method of Claim 38 further comprising the step of applying a layer of netting material to the outer surfaces of the wall sections and subsequently applying a layer of stucco to the layer of netting material.

43. The method of Claim 34 further comprising the step of attaching a layer of plywood to the floor joists.

44. The method of Claim 37 further comprising the step of applying a layer of sheathing to the ceiling trusts and subsequently applying roofing to the layer of sheathing.

45. The method of Claim 27 further comprising the step of:

extending a sill member horizontally between a pair of posts and attaching the sill member to each post of the post pair via a first pair of window brackets; and extending a jam member horizontally between the pair of posts in an orientation above said sill member and attaching the jam member to the posts via a second pair of window brackets;
said adjacent posts, said sill member and said jam member forming a window in said wall structure.

46. The method of Claim 45 further comprising the step of cutting selected ones of said wall sections in a manner wherein said wall sections do not obstruct the window formed by said adjacent posts, said sill member and said jam member.