US20140182230A1

US20140182230A1 - Assimilated Wall System

Info

Publication number: US20140182230A1
Application number: US13/730,928
Authority: US
Inventors: Bruce John Borg
Original assignee: Borg Pacific Inc
Current assignee: Borg Pacific Inc
Priority date: 2012-12-29
Filing date: 2012-12-29
Publication date: 2014-07-03

Abstract

This invention creates a superior straw bale wall by the assimilation of light gauge metal framing onto the exterior surface of typical straw bale walls. Production efficiency is increased by using standard straw bale walls constructed in an acceptable manner for that industry, in conjunction with light gauge metal framing material which is a familiar product to construction tradesmen, structural engineers, and building code officials. The increase in efficiency begins with the approval of building permits, to the assembly rates during construction, and on through the processes of plastering, installing drywall, and even to hanging kitchen cabinets long after the walls have been finished and painted.

Description

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

PARTIES TO A JOINT RESEARCH AGREEMENT

Not Applicable

INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC OR AS A TEXT FILE VIA THE OFFICE ELECTRONIC FILING SYSTEM

N/A

PRIOR DISCLOSURES

Provisional Patent Application 61/343,197, Filing date Apr. 26, 2010.

BACKGROUND

Straw bale wall construction is becoming more popular. A growing number of people consider it superior to other contemporary construction techniques in several ways, the most notable being that it gives the wall of the structure a high thermal energy efficiency because of its excellent insulating qualities. However, the current techniques of straw bale construction are labor intensive and unfamiliar to construction tradesmen such as carpenters, plasterers, laborers, and cabinet installation crews.
One technique uses the bales to bear the loads of the roof, snow, and wind. This method is not only unfamiliar to most of the tradesmen in the construction field, but it is also unfamiliar to the building code enforcement officials which makes it difficult to have plans approved in many areas. The construction of this type of straw bale walls requires windows and doors to rely on the bales for support and stability. The bales are also to be the support for the exterior lathe prior to plastering, and the cabinets and other finishes in the interior. This is accomplished by various fastening systems such as bucks, wedges, and other items installed into the straw. The straw itself is not always completely uniform in thickness which provides varying stability and can present problems using the fasteners. The fasteners themselves are also unfamiliar to most building trades such as carpenters, plasterers, laborers, cabinet installation crews, etc.
The second technique is referred to as post-and-beam construction. It uses posts extending from the footing to the roof which are connected at the top to support beams, which in turn support the roof. Straw bales are then stacked between the posts to provide insulation and a surface for finishing. This type of wall is also labor-intensive. The large-dimension lumber or steel for the post-and-beam frame used in this type of wall is difficult to use in conjunction with straw bales due to the need to shape the straw bales around these solid members by cutting out the open sides of the bales. This allows the posts to be inside the plane of the wall.
Another technique by Gard in patent U.S. Pat. No. 5,937,588 uses metal framing as an interior system in conjunction with straw bale wall construction. This “preferred embodiment” (on page 10, FIG. 1 description) is the main focus of 13 pages, as well as 16 figures describing the walls. However, there are two details on one page that briefly allude to a metal framing system as an exo-skeletal casing which would “sandwich” the bales (details 6 & 7 on page 4). Unfortunately, the description on page 11 for FIG. 6 states that it “uses angle irons for structural supports”. These structural steel angle irons are very heavy and typically require expensive welding. The description of FIG. 6 also states that “one leg of each of these angle irons is embedded in the fibrous material as the bale is manufactured” which would mean that the timing and/or method of construction will result in heavy panels that would require larger, more expensive equipment to handle them. The structural steel angles would make an unnecessarily heavy wall potentially increasing building costs on the site. Details 6 and 7 would also make it difficult for a structural engineer to provide calculations on the blueprints to submit to the building authorities due to the fact that these angles are not utilized as vertical structural framing members. Vertical framing members from structural steel are typically posts as called out in technique two above which require labor intensive coordination to get them into the plane of the wall.
Gard touched upon the concept that some type of metal framing and straw bales could be used together to form a system however, a new system with the correct materials, allowing for an acceptable sequence of construction is needed. The technique used in this invention assimilates straw bales with light gauge metal framing, a standard material utilized as vertical structural framing in the current construction of commercial projects, public schools and hospitals. This technique can utilize shop fabrication combined with fabrication on the construction site. Another beneficial factor is that the fasteners for light gauge metal framing are typically screws This also saves time and money compared to welding of structural angles.

BRIEF SUMMARY

Exterior walls of a building constructed of metal frame cladding around a straw bale wall with said straw bales providing insulation. Metal stud framing provides a skeleton casing on the exterior of the bales which are stacked end to end, row upon row, in a running bond pattern. The open ends of the pieces of straw within the bale are on the sides rather than the top and bottom. The vertical metal framing is situated outside of the bales with the flanges embedded into the exterior sides of the bales thereby maintaining the straw bale position, and providing fastening of adjacent finishes and/or fixtures.

The figures and summary will help to clarify the statement above.

FIG. 1 is a perspective view of the invention showing an exterior cladding of light gauge metal framing around the straw bale wall interior.

FIG. 2 is a plan view of the wall at the floor surface which shows the layout of the sill plates, the angles and the metal studs in the unique orientation required. One section of straw bale is included to clarify the location of the bales in the finished wall.

FIG. 3 is a cross-section cut through the wall at the floor connection to clarify the layout.

REFERENCE NUMERALS IN DRAWINGS

1. Straw bales
2. Light gauge metal studs
3. Light gauge metal angles
4. Light gauge metal track
5. Wood sill plates
6. Concrete floor below the wall.

DESCRIPTION OF THE INVENTION

This invention is a straw bale wall with an exterior cladding of light gauge metal framing. The framing is installed on opposed side surfaces of the bales, directly in line as a mirror image. The framing provides uniformity to the wall plane, and load bearing structural support to the roofing system. This framing helps to maintain the position of the straw bales, and provides for standard fastening of adjacent finishes and/or fixtures. The utilization of light gauge metal framing is a market standard product in commercial, school, and hospital construction thereby creating efficiency in the approval process of blueprints by building departments, and providing for efficient construction by professional tradesmen whether on the jobsite or in a manufacturing plant. The application of framing on the exterior surface of straw bales allows the use of bales with minimal modifications to the typical bale on the market. This invention will make straw bale walls less labor intensive and more uniform.

DESCRIPTION—FIGS. 1 to 3

FIG. 1 shows a section of wall located on a concrete floor (6). The typical wood sill plates (5) are fastened to the concrete and the light gauge metal angles (3) are fastened to the sill plates or directly to the concrete floor through the sill pales as required by the level of structural integrity needed in the specific application. The metal studs (2) are situated with the webs adjacent to and are to be fastened to the angles (3). The flanges of the studs are embedded into the sides of the straw bales (1). This orientation of the studs (2) is clarified in FIGS. 2 and 3. The orientation of the studs is innovative and atypical to the extent that it is unknown to be used in any other wall application. At the top of the wall, the studs (2) which are on opposing sides of the wall are connected to the metal track (4) as is standard practice in light gauge metal framing.
FIG. 2 is a plan view looking down at the bottom of the wall sitting on the concrete floor (6). The wood sill plate (5) is typically 3-½ inches wide and can be seen protruding out beyond the metal angle (3) which will typically be 1-½ inches wide. The metal studs (2) are on opposed sides of the wall, directly across from each other in a mirror image layout. The studs (2) are oriented with the web adjacent to and are to be fastened to the vertical leg of the angle (3). This is clarified in FIG. 3. The horizontal space between the studs(2) along the plane of the wall is to be directly below the roof trusses or floor joists at the top of the wall, typically 24″ to 16″ respectively. Straw bales (1) will be situated as shown between the metal studs (2) with the sides of the bales (1) flushed up against the interior web surface of the metal studs (2) and the stud flanges embedded into the straw bales (1).
FIG. 3 is a sectional cut through the wall. This view shows the metal angles (3) on top of the sill plates (5), and how the vertical leg of the angle (3) is located to the outside plane of the sill plate below (5). The metal studs (2) are sitting on top of the horizontal leg of the angle (3) and against the vertical leg. Typically, screws will be used to fasten the two together from the outside through the angle (3) into the stud (2). The walls can be fastened to the concrete floor (6) through the sill plates (5) or through both the angles (3) and the sill plates (5).

Claims

1. The Assimilated Wall System with metal framing will make it easier to obtain a building permit than typical straw bale walls. This removes a major market barrier.

2. The plane of the Assimilated Wall System will be straighter and flatter than straw bale walls. Straight and flat walls are far more acceptable to the general public than other, “wavy” walls.

3. The Assimilated Wall System incorporates familiar construction tools and materials which makes it easier for professional tradesmen to build than other straw bale walls, including a method known as post-and-beam framing which requires “slotting” around framing members.

4. The insulation value of straw bale walls, the organic insulation in the “Assimilated Wall System”, is significantly better than standard residential walls and can save energy and therefore money.

5. The Assimilated Wall System will withstand earthquakes significantly better than standard residential walls.

6. The Indoor Air Quality inside a building with organic insulation is better than it is with fiberglass insulation or other standard methods of insulating a building.