US3574920A - Dwelling assembly line and method - Google Patents

Dwelling assembly line and method Download PDF

Info

Publication number
US3574920A
US3574920A US760103A US3574920DA US3574920A US 3574920 A US3574920 A US 3574920A US 760103 A US760103 A US 760103A US 3574920D A US3574920D A US 3574920DA US 3574920 A US3574920 A US 3574920A
Authority
US
United States
Prior art keywords
ceiling
framework
wall
floor
dwelling
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US760103A
Inventor
William G Stirling
David Stirling Jr
Harper Sibley Jr
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
STIRLING HOMEX CORP
Original Assignee
STIRLING HOMEX CORP
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by STIRLING HOMEX CORP filed Critical STIRLING HOMEX CORP
Application granted granted Critical
Publication of US3574920A publication Critical patent/US3574920A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Images

Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B1/34815Elements not integrated in a skeleton
    • E04B1/34838Elements not integrated in a skeleton the supporting structure consisting of wood
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B15/00General arrangement or layout of plant ; Industrial outlines or plant installations
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B2001/34892Means allowing access to the units, e.g. stairs or cantilevered gangways
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49826Assembling or joining
    • Y10T29/49828Progressively advancing of work assembly station or assembled portion of work
    • Y10T29/49829Advancing work to successive stations [i.e., assembly line]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/53Means to assemble or disassemble
    • Y10T29/53313Means to interrelatedly feed plural work parts from plural sources without manual intervention
    • Y10T29/53365Multiple station assembly apparatus
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/53Means to assemble or disassemble
    • Y10T29/534Multiple station assembly or disassembly apparatus
    • Y10T29/53417Means to fasten work parts together

Definitions

  • a dwelling is assembled by: building a floor joist framework upside down; installing service fixtures in the floor joist framework and fastening a subfloor to it; framing and covering walls with interior covering; erecting the interiorcovered walls on the floor; building a ceiling on a jig above the dwelling; inverting the ceiling jig and lowering the ceiling onto the walls; securing service fixtures to the exposed stud and joist frameworks; trimming, covering, and roofing the dwelling; installing lifting hardware, and transporting the dwelling to its site.
  • This invention departs from such old procedures and accomplishes dwelling assembly that is generally inside-out to facilitate service fixture installation, to allow each step of the construction to be done in the most comfortable and convenient working position for increased speed and reduced labor costs, and to take maximum advantage of construction jigs for holding work pieces during assembly.
  • Most parts are precut and located for minimum movement; everything is done in the most convenient and efficient working positions; work-holding jigs eliminate measurement, plan-reading, error and the need for high labor skills; subassemblies are made adjacent their assembly regions for minimum transport; all
  • indoor construction takes advantage of uniform illumination, convenient power supplies for electric and pneumatic tools, glue dispensers fed by pipeline, and other conveniences not available in onsite construction; and the finished dwelling unit is ready for shipping to a construction site where it is merely positioned and connected to services.
  • One small plant with a single assembly line operating according to the invention for an 8-hour shift can produce two complete dwellings for four module units each of more than 1100 square feet, including three bedrooms, two and one-half baths, kitchen and living areas, and including central heating and air conditioning.
  • the objects of the invention include, without limitation, speed, economy, efiiciency, reduced labor costs, high quality, uniform construction, minimum waste of materials, and the capacity to operate day or night in any weather.
  • the inventive assembly line and method includes: interfastening a floor joist framework to form a dwelling floor, inverting the floor joist framework and fastening a subfloor to it; using a jig to interfasten a wall stud framework; covering the wall stud framework with interior wall covering and erecting it on the floor; building a ceiling on a jig above the dwelling; inverting the ceiling jig and lowering the ceiling onto the walls; securing service fixtures to the stud framework outside the interior wall covering; and trimming, insulating, covering, and roofing the dwelling.
  • FIG. 1 is a partially schematic elevational view of an assembly line according to the invention
  • FIG. 2 is a partially schematic elevation view of a ceiling assembly jig for the inventive assembly line
  • FIG. 3 is a plan view of a jig surface of thejig of FIG. 2;
  • FIG. 4 is an elevational view of a wall jig for the inventive assembly line
  • FIG. 5 is an end elevation of the wall jig of FIG. 4;
  • FIG. 6 is a plan view of a shingle jig for roofing dwelling modules made according to the invention.
  • FIG. 7 is a fragment of side elevation of the jig of FIG. 6;
  • FIG. 8 is a fragment of an end elevation of the jig of FIG. 6;
  • FIG. 9 is a side elevation of a trailer transport rig for' carrying dwelling modules to a site
  • FIG. 10 is a fragmentary cross section of the rig of FIG. 9 taken along the line 10-10 thereof;
  • FIG. 11 is a fragmentary cross-sectional view of the rig of FIG. 9 taken along the line "-11 thereof.
  • the illustrative assembly line shown in FIG. 1 includes a track 10 on which dwelling units roll on support members 11 from the floor end of the line to the finished end of the line. Cranes or hoists bring materials or subassemblies to the dwelling modules on track 10, and each work region has pneumatic power lines for pneumatic nailers and staplers, glue dispensers fed by glue lines, and readily accessible electric power for tools and equipment.
  • Completed units are preferably equipped with lifting hardware and are removed from the finished end of the line, transported to a building site, positioned with preferably several module units forming a single dwelling, and connected to service facilities to complete the construction. Parts of such a total assembly process are obvious and are not discussed. The inventive features of such an assembly are described below, and one particular way to practice them is explained.
  • the inventive assembly line includes a floor assembly region 12, a wall assembly region 13, a ceiling assembly region 14, and several regions represented by regions 15 and 16 for installing service fixtures, insulation, trim, exterior siding, and roofing as desired. Each of these regions includes regions alongside track 10 in which subassemblies are made, materials are provided and tools are located and powered.
  • Floor joist assembly region 12 includes a jig (not shown) that has holders for proper location of floor joists for interfastening.
  • the assembled floor joist framework 17 is of a known type having 2X12 planks nailed together. However, framework 17 is first assembled and fastened together upside down. Then service fixtures such as plumbing, electrical wiring, and heating and air conditioning ducts are installed and secured to framework 17 as desired. Such installation is inverted from the usual orientation and is conveniently made by workmen bending over framework 17.
  • framework 17 is inverted by means of hoist 18 and set down right side up on timbers 11 on track 10.
  • Floor covering such as linoleum or carpeting is laid over floor 17 whenever convenient during later assembly operations.
  • FIGS. 4 and 5 For such purpose the wall jig 20 shown in FIGS. 4 and 5 is used. Surfaces 21 are sloped from the vertical to support stud members such as 2X4s or the like, and holders 22 are arranged on support surfaces 21 to receive and locate such stud members for interfastening. A ledge 23 supports the bottommost member of the wall framework, and precut stud members are placed infholders 22 as shown in FIG. 4 for interfastening to form framework 26. Each holder 22 is a U- shaped bracket sized and positioned to receive the edge of a stud member and hold it in place for fastening.
  • Each support surface 20 is preferably adapted for assembling a plurality of wall frameworks 26 by having holders 22 arranged in different positions for different frameworks.
  • the stud position and corresponding holders on surfaces 21 are preferably painted different colors for each wall framework to be assembled on each support surface. Then workmen can quickly select precut stud members and place them on support surfaces 21 to cover all the regions painted a given color to make a given wall assembly. For walls of a different type, the workmen 'merely place stud members over different colored areas and holders.
  • wall framework 26 After wall framework 26 is secured together, it is covered by an interior wall-covering material 27 of panelling or wallboard material having a finished interior surface.
  • the stud members of framework 26 are covered with glue from a convenient dispenser, and covering material 27 is secured to the glued stud members until the glue sets.
  • One way of doing this is with a few finishing nails 28 driven through cleats 29 into framework 26 and removed after the glue sets to leave only a few, almost unnoticeable, holes in covering 27. This eliminates the usual nailing, countersinking of nails, patching over nailheads, and painting.
  • covering material 27 can be clamped to framework 26 until the glue sets.
  • Covered wall framework 26 is moved by a travelling crane 30 to its proper position over the assembled floor l7 and nailed in place in erect position over floor 17. Two of such erected walls are shown in wall assembly region 13 of FIG. 1.
  • ceiling jig 35 While floor 17 and walls 26 are being assembled, a ceiling is built on ceiling jig 35 best illustrated in FIG. 2.
  • a main body 36 of ceiling jig 35 has two support surfaces 37 and 38 each of which are provided with holders 22, such as previously described for wall fixture 20, for locating and holding the members of a ceiling joist framework 40.
  • Holders 22 and support surfaces 37 and 38 are painted in color coding for assembly of a plurality of different ceiling joist frameworks 40, as desired.
  • Jig 35 is arranged just above the level of a second floor 41, well above track and above the tops of dwelling units passing along track 10. Workmen standing on floor 41 find the upper support surface 37 is at a comfortable working height for laying down precut joist members of framework 40 in holders 22 and securing the framework 40 together.
  • Service fixtures such as vents or ducts 44 for heating or air conditioning units are then secured to framework 40, and a subceiling 42, preferably of plywood, is fastened to framework 40 by glue-and nails. Then an interior ceiling material 43 is stapled to subceiling 42.
  • Jig 35 is rotatable around shaft 45 by means of a gear 46 and a motor 47 for inverting the main body 36 of jig 35.
  • Latches 48 holding body 36 in the working position illustrated in FIG. 2, are moved and motor 47 is driven to turn body 36 180 to invert support surfaces 37 and 38.
  • the assembled ceiling 40 is secured to jig 35 by clamps 49; also dwelling units on track 10 are moved out from underjig 35 to give it a free sweep. After inversion a new ceiling can be built on the top surface ofjig 35 while a completed ceiling awaits lowering from the bottom.
  • a pair of windlasses 50 on which support straps 51 are wound.
  • the ends of straps 51 are nailed to ceiling frame 40, and when a walled dwelling is ready for a ceiling and positioned beneath jig 35, clamps 49 are released and ceiling 40 is lowered by straps 51 under control of a motor (not shown).
  • a motor not shown.
  • Service fixtures such as electric outlet 52 and 53 are installed in the wall stud framework 26 from outside the dwelling unit as shown in FIG. 1. This allows convenient working in the exposed exterior of the dwelling at a comfortable working height so that electric installation is fast and efficient.
  • Other service fixtures such as plumbing, heating, and air conditioning ducts are installed in a similar fashion around the exterior of the dwelling or its subassemblies.
  • insulation 54 and exterior siding material 55 are fastened on to the exterior of walls 26.
  • Interior subassemblies such as cabinets, cupboards, bathroom units, and staircases are made in regions alongside track 10 and installed in the dwelling units.
  • Trim construction such as moldings, and door and window frames, are subassembled and installed.
  • Roofs are constructed over the uppermost modules of the inventive dwelling units, and materials handed down from second floor 41 are preferably used for roof construction. After supports and sloping roof surfaces are constructed. the roof is shingled with the aid ofthe shingling jig shown in FIGS. 6-8.
  • Rails 60 and 61 are laid parallel with each other along the edges of roof 59 from the peak 58 to the bottom edge 57. Abutment surfaces 62 extending below the bottom ends of rails 60 and 61 butt against the bottom edge 57 of roof 59 to locate rails 60 and 61 longitudinally, and the top ends of rails 60 and 61 extend to peak 58. When rails 60 and 61 are accurately positioned, they are fastened to roof 59 by nails 63 through angle iron brackets 64 disposed along the outer edges or rails 60 and 61.
  • a crosspiece 65 fits closely between rails 60 and 61 and rests on roof 59. Extension pieces 66 are fastened to the top of each end of crosspiece 65 to reach over the top surfaces of rails 60 and 61. P'ositioners 67 formed as blocks secured to the top surfaces of rails 60 and 61 are spaced apart by the exposed width of shingles 68 and are arranged in parallel and aligned sets on each rail 60 and 61.
  • crosspiece 65 When extension pieces of crosspiece 65 are placed between the first pair of positioners 67 at the bottom ends of rails 60 and 61, crosspiece 65 is positioned so that the lowermost row of shingles 68 can be'butted against crosspiece 65 and secured to roof 59. Then crosspiece 65 is moved upward on rails 60 and 61 to the next position between positioners 67 where it is correctly located for butting the second row of shingles 68 against crosspiece 65. This process is repeated with each row of shingles 68 until roof 59 is shingled to its peak 58.
  • roof 59 under jig rails 60 and 61 are not shingled until after the modules are positioned on the site and shingle splices or joints are made between adjacent roofs.
  • the jig of P165. 6-8 assures that the rows of shingles 68 are accurately parallel with peak 58 and accurately spaced so that the shingle rows of adjacent modules will line up accurately on the site for a neat appearance avoiding any jags or turns in the shingle joints between adjacent roofs. This is particularly important where several dwelling modules are placed side-by-side to form a common roof extending for many feet. ln onsite construction such a roof would be built in place and its shingles aligned on long chalk lines.
  • the inventive jig is faster and more accurate, and solves the problem of lining up the shingle rows of dwelling modules having roofs built in fairly short lengths that are later joined together.
  • lifting hardware is secured to each module in preparation for its transport to a site.
  • long eyebolts 69 are used for the basic lifting rig, and bolts 69 extend through holes in floorjoist framework 17 as best shown in F105. 9-11.
  • Recesses 70 are cut in the underside'of floor joist framework 17 preferably before it is inverted to receive plates 71 fitting floor joist framework 17 and supporting the heads 72 of eyebolts 69.
  • Eyebolts 69 preferably extend above the tops of dwelling modules as illustrated, and such modules are lifted from above by cranes or lifts hooking onto eyebolts 69.
  • the trailer 80 shown in FIG. 9 is preferably used for transporting completed dwelling modules to a site.
  • Trailer 80 has a hitch 73 at its forward end, a front frame extending back to wheels 74 at the midsection and a rear frame 76 joined to the top of front frame 75 and extending over and beyond wheels 74.
  • Front and rear frames 75 and 76 are preferably formed of relatively light, structural metal materials.
  • lag screws 77 are driven through the side beams 78 of frames 75 and 76 into the bottom of floor joist framework 17 at intervals of 3 feet or so along frames 75 and 76, to hold floor joist framework 17 tightly against trailer frames 75 and 76.
  • Such interfastening stiffens and supports frames 75 and 76 which are braced by the strong and rigid construction of floor joist framework 17.
  • Such strengthening allows trailer 80 to be of lightweight construction and yet be sufficiently strong to carry heavy dwelling modules. This provides advantages such as only a.
  • the front frame 76 forward of wheels 74 for supporting the taller, roofed modules is of comparable length to a low-boy" trailer, but the light construction braced by the strength of the dwelling unit itself allows the additional dwelling module mounted above the wheels 74 on the cantilevered after frame 76.
  • a dwelling factory assembly line comprising;
  • a floor assembly region including:
  • a wall assembly region including:
  • a wall jig having a surface sloped from the vertical for supporting a wall stud framework; 2. means for interfastening said framework;
  • the assembly line of claim 1 including a track and means for moving said dwelling along said track from said floor assembly region past said ceiling assembly region and toward a finishing region.
  • the assembly line of claim 1 including means at said floor assembly region for securing service fixtures to said floor joist framework before inversion thereof.
  • the assembly line of claim 1 including means at said ceiling assembly region for securing service fixtures to said ceiling joist framework before covering said ceiling joist framework with said interior ceiling material.
  • said wall jig supported stud includes a gantry walkway arranged behind said sloped surface and near the top of said sloped surface to support a workman in a comfortable position for fastening the upper portions of said stud framework.
  • said ceiling jig comprises two opposed jig surfaces arranged on a rotatable body, means for rotating said body about a horizontal axis to turn either of said jig surfaces uppermost, and means for latching said body in positions orienting either of said jig surfaces uppermost.
  • the assembly line of claim 1 including windlass strap means arranged on said ceiling jig for fastening to said ceiling to lower said ceiling from the bottom of said ceiling jig.
  • a dwelling assembly method comprising:
  • the method of claim 9 including securing service fixtures to said ceiling joist framework before covering said ceiling framework.
  • the method of claim 9 including positioning said dwelling on a relatively light-construction trailer for transport to a site, and fastening said floor joist framework of said dwelling to said trailer at a plurality of points to strengthen said trailer.
  • the method of claim 12 including using nails holding cleats against the interior surface of said wall covering and passing removably through said wall covering and into said framework to hold said wall covering in place until said glue sets.
  • a dwelling factory assembly line comprising:
  • a floor assembly region including:
  • a wall jig having a surface for supporting a wall stud framework
  • a ceiling assembly region including:
  • a ceiling jig for supporting a ceiling joist framework in inverted position; 2. means for interfastening said ceilingjoist framework; 3. means for covering said ceiling joist framework with interior ceiling material to form a ceiling unit; 4. means for inverting said ceiling unit; and 5. means for positioning said ceiling unit on the tops of said wall frameworks; d. means for securing service fixtures to said wall frameworks outside said interior wall covering; and e. means for securing external covering to said wall frameworks. 19.
  • a dwelling assembly method comprising: a. interfastening a floor joist framework;
  • the dwelling assembly method of claim 9 including arranging said floor joist framework upside down on a plane surface for said interfastening so said subfloor lies substantially in a plane on said right side up floor joist framework.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Conveying And Assembling Of Building Elements In Situ (AREA)
  • Working Measures On Existing Buildindgs (AREA)

Abstract

A dwelling is assembled by: building a floor joist framework upside down; installing service fixtures in the floor joist framework and fastening a subfloor to it; framing and covering walls with interior covering; erecting the interior-covered walls on the floor; building a ceiling on a jig above the dwelling; inverting the ceiling jig and lowering the ceiling onto the walls; securing service fixtures to the exposed stud and joist frameworks; trimming, covering, and roofing the dwelling; installing lifting hardware, and transporting the dwelling to its site.

Description

United States Patent William G. Stirling;
David Stirling, Jr., Avon; Harper Sibley, Jr., Rochester, N.Y.
Sept. 16, 1968 Apr. 20, 1971 Stirling Homex Corporation Avon, N.Y.
lnventors Appl. No. Filed Patented Assignee DWELLING ASSEMBLY LINE AND METHOD 20 Claims, 11 Drawing Figs.
US. Cl 29/430, 29/200 Int. Cl B23p 19/00 Field of Search 29/430, 200
(J), 200 (A), 200 (P), 429
[56] References Cited UNITED STATES PATENTS 3,319,323 5/1967 Groat 29/200 3,399,445 9/1968 Carroll 29/200 3,443,303 5/ l 969 Groat 29/430 Primary ExaminerThomas H. Eager Attorney-Cumpston, Shaw and Stephens ABSTRACT: A dwelling is assembled by: building a floor joist framework upside down; installing service fixtures in the floor joist framework and fastening a subfloor to it; framing and covering walls with interior covering; erecting the interiorcovered walls on the floor; building a ceiling on a jig above the dwelling; inverting the ceiling jig and lowering the ceiling onto the walls; securing service fixtures to the exposed stud and joist frameworks; trimming, covering, and roofing the dwelling; installing lifting hardware, and transporting the dwelling to its site.
Patented .April 13, 1971 3 Sheets-Sheet 1 WILLIAM G- STIRLING DAVID STIRLING Jr HARPER SIBLEYJr 1N VENTORS AT TORNE YS Patented April 13, 1911 3,514,920
I5 Shuts-Sheet 2 3 H i. I h [1 1 1 FIG-3 E FIG- 4 I WILLIAM G- STIRLING DAVID STIRLING Jr HARPER SIBLEY J. 5 INVENTORS r ATTORNEYS Patented April 13, 1971 3,574,920
3 Shoots-Sheet 5 F I G 6 67 l /1 n n n n 66 67 II II II II II I] [I I1 I] II II I II I] II II II II II I] II J1 H II I] M II II H H H H [I [WILLIAM G STIRLING HARPER SIBLEY Jr.
INVENTQRS DAVID STIRLING Jr FIG- :0. ,3 $5 4 ATTORNEYS DWELLING ASSEMBLY LINE AND METHOD THE IMPROVEMENT EFFECTED and laborious methods. Prior art suggestions for factory-built dwellings generally imitate the old manual methods devised to fit the needs of slow construction exposed to weather. The outershell is built to keep the weather out then internal service fixtures, insulation, trim, flooring, etc. are built in. This requires many tasks to be done overhead or in awkward positions, requires considerable moving of materials about, and is generally wasteful of both labor and materials.
This invention departs from such old procedures and accomplishes dwelling assembly that is generally inside-out to facilitate service fixture installation, to allow each step of the construction to be done in the most comfortable and convenient working position for increased speed and reduced labor costs, and to take maximum advantage of construction jigs for holding work pieces during assembly. Most parts are precut and located for minimum movement; everything is done in the most convenient and efficient working positions; work-holding jigs eliminate measurement, plan-reading, error and the need for high labor skills; subassemblies are made adjacent their assembly regions for minimum transport; all
operations are coordinated for a steady-flow assembly line;
indoor construction takes advantage of uniform illumination, convenient power supplies for electric and pneumatic tools, glue dispensers fed by pipeline, and other conveniences not available in onsite construction; and the finished dwelling unit is ready for shipping to a construction site where it is merely positioned and connected to services.
One small plant with a single assembly line operating according to the invention for an 8-hour shift can produce two complete dwellings for four module units each of more than 1100 square feet, including three bedrooms, two and one-half baths, kitchen and living areas, and including central heating and air conditioning.
The objects of the invention include, without limitation, speed, economy, efiiciency, reduced labor costs, high quality, uniform construction, minimum waste of materials, and the capacity to operate day or night in any weather.
SUMMARY OF THE INVENTION The inventive assembly line and method includes: interfastening a floor joist framework to form a dwelling floor, inverting the floor joist framework and fastening a subfloor to it; using a jig to interfasten a wall stud framework; covering the wall stud framework with interior wall covering and erecting it on the floor; building a ceiling on a jig above the dwelling; inverting the ceiling jig and lowering the ceiling onto the walls; securing service fixtures to the stud framework outside the interior wall covering; and trimming, insulating, covering, and roofing the dwelling.
THE DRAWINGS FIG. 1 is a partially schematic elevational view of an assembly line according to the invention;
FIG. 2 is a partially schematic elevation view of a ceiling assembly jig for the inventive assembly line;
FIG. 3 is a plan view of a jig surface of thejig of FIG. 2;
FIG. 4 is an elevational view of a wall jig for the inventive assembly line; 7
FIG. 5 is an end elevation of the wall jig of FIG. 4;
FIG. 6 is a plan view of a shingle jig for roofing dwelling modules made according to the invention;
FIG. 7 is a fragment of side elevation of the jig of FIG. 6;
FIG. 8 is a fragment of an end elevation of the jig of FIG. 6;
FIG. 9 is a side elevation of a trailer transport rig for' carrying dwelling modules to a site;
FIG. 10 is a fragmentary cross section of the rig of FIG. 9 taken along the line 10-10 thereof; and
FIG. 11 is a fragmentary cross-sectional view of the rig of FIG. 9 taken along the line "-11 thereof.
DETAILED DESCRIPTION The illustrative assembly line shown in FIG. 1 includes a track 10 on which dwelling units roll on support members 11 from the floor end of the line to the finished end of the line. Cranes or hoists bring materials or subassemblies to the dwelling modules on track 10, and each work region has pneumatic power lines for pneumatic nailers and staplers, glue dispensers fed by glue lines, and readily accessible electric power for tools and equipment. Completed units are preferably equipped with lifting hardware and are removed from the finished end of the line, transported to a building site, positioned with preferably several module units forming a single dwelling, and connected to service facilities to complete the construction. Parts of such a total assembly process are obvious and are not discussed. The inventive features of such an assembly are described below, and one particular way to practice them is explained.
The inventive assembly line includes a floor assembly region 12, a wall assembly region 13, a ceiling assembly region 14, and several regions represented by regions 15 and 16 for installing service fixtures, insulation, trim, exterior siding, and roofing as desired. Each of these regions includes regions alongside track 10 in which subassemblies are made, materials are provided and tools are located and powered.
Floor joist assembly region 12 includes a jig (not shown) that has holders for proper location of floor joists for interfastening. The assembled floor joist framework 17 is of a known type having 2X12 planks nailed together. However, framework 17 is first assembled and fastened together upside down. Then service fixtures such as plumbing, electrical wiring, and heating and air conditioning ducts are installed and secured to framework 17 as desired. Such installation is inverted from the usual orientation and is conveniently made by workmen bending over framework 17.
Then framework 17 is inverted by means of hoist 18 and set down right side up on timbers 11 on track 10. A subfloor covering 19, preferably of plywood, is fastened to the top of the framework 17, preferably with both glue and nails to complete subfloor 17. Floor covering such as linoleum or carpeting is laid over floor 17 whenever convenient during later assembly operations.
Meanwhile walls are framed in subassembly areas of wall assembly region 13. For such purpose the wall jig 20 shown in FIGS. 4 and 5 is used. Surfaces 21 are sloped from the vertical to support stud members such as 2X4s or the like, and holders 22 are arranged on support surfaces 21 to receive and locate such stud members for interfastening. A ledge 23 supports the bottommost member of the wall framework, and precut stud members are placed infholders 22 as shown in FIG. 4 for interfastening to form framework 26. Each holder 22 is a U- shaped bracket sized and positioned to receive the edge of a stud member and hold it in place for fastening.
Between support surfaces 21 is a gantry walkway 24 reached by a ladder 25 to support a workman in a comfortable position for nailing or fastening the uppermost portions of stud framework 26. A man on walkway 24 with a pneumatic nailing machine can rapidly fasten the upper portions of framework 26 together. Another workman at the bottom of jig 20 can quickly secure the bottom portions of framework 26 together. Each support surface 20 is preferably adapted for assembling a plurality of wall frameworks 26 by having holders 22 arranged in different positions for different frameworks. For such multiframework jigs, the stud position and corresponding holders on surfaces 21 are preferably painted different colors for each wall framework to be assembled on each support surface. Then workmen can quickly select precut stud members and place them on support surfaces 21 to cover all the regions painted a given color to make a given wall assembly. For walls of a different type, the workmen 'merely place stud members over different colored areas and holders.
After wall framework 26 is secured together, it is covered by an interior wall-covering material 27 of panelling or wallboard material having a finished interior surface. The stud members of framework 26 are covered with glue from a convenient dispenser, and covering material 27 is secured to the glued stud members until the glue sets. One way of doing this is with a few finishing nails 28 driven through cleats 29 into framework 26 and removed after the glue sets to leave only a few, almost unnoticeable, holes in covering 27. This eliminates the usual nailing, countersinking of nails, patching over nailheads, and painting. Alternatively, covering material 27 can be clamped to framework 26 until the glue sets.
Covered wall framework 26 is moved by a travelling crane 30 to its proper position over the assembled floor l7 and nailed in place in erect position over floor 17. Two of such erected walls are shown in wall assembly region 13 of FIG. 1.
While floor 17 and walls 26 are being assembled, a ceiling is built on ceiling jig 35 best illustrated in FIG. 2. A main body 36 of ceiling jig 35 has two support surfaces 37 and 38 each of which are provided with holders 22, such as previously described for wall fixture 20, for locating and holding the members of a ceiling joist framework 40. Holders 22 and support surfaces 37 and 38 are painted in color coding for assembly of a plurality of different ceiling joist frameworks 40, as desired.
Jig 35 is arranged just above the level of a second floor 41, well above track and above the tops of dwelling units passing along track 10. Workmen standing on floor 41 find the upper support surface 37 is at a comfortable working height for laying down precut joist members of framework 40 in holders 22 and securing the framework 40 together.
Service fixtures such as vents or ducts 44 for heating or air conditioning units are then secured to framework 40, and a subceiling 42, preferably of plywood, is fastened to framework 40 by glue-and nails. Then an interior ceiling material 43 is stapled to subceiling 42.
Jig 35 is rotatable around shaft 45 by means of a gear 46 and a motor 47 for inverting the main body 36 of jig 35. Latches 48 holding body 36 in the working position illustrated in FIG. 2, are moved and motor 47 is driven to turn body 36 180 to invert support surfaces 37 and 38. Before doing this the assembled ceiling 40 is secured to jig 35 by clamps 49; also dwelling units on track 10 are moved out from underjig 35 to give it a free sweep. After inversion a new ceiling can be built on the top surface ofjig 35 while a completed ceiling awaits lowering from the bottom.
Recessed into the longitudinal edges of body 36 are a pair of windlasses 50 on which support straps 51 are wound. The ends of straps 51 are nailed to ceiling frame 40, and when a walled dwelling is ready for a ceiling and positioned beneath jig 35, clamps 49 are released and ceiling 40 is lowered by straps 51 under control of a motor (not shown). When ceiling 40 is properly positioned over a dwelling unit the ends of straps 51 are pried free and ceiling 40 is nailed in place on top of walls 26.
Service fixtures such as electric outlet 52 and 53 are installed in the wall stud framework 26 from outside the dwelling unit as shown in FIG. 1. This allows convenient working in the exposed exterior of the dwelling at a comfortable working height so that electric installation is fast and efficient. Other service fixtures such as plumbing, heating, and air conditioning ducts are installed in a similar fashion around the exterior of the dwelling or its subassemblies.
Then, insulation 54 and exterior siding material 55 are fastened on to the exterior of walls 26. Interior subassemblies such as cabinets, cupboards, bathroom units, and staircases are made in regions alongside track 10 and installed in the dwelling units. Trim construction such as moldings, and door and window frames, are subassembled and installed.
Roofs are constructed over the uppermost modules of the inventive dwelling units, and materials handed down from second floor 41 are preferably used for roof construction. After supports and sloping roof surfaces are constructed. the roof is shingled with the aid ofthe shingling jig shown in FIGS. 6-8.
Rails 60 and 61 are laid parallel with each other along the edges of roof 59 from the peak 58 to the bottom edge 57. Abutment surfaces 62 extending below the bottom ends of rails 60 and 61 butt against the bottom edge 57 of roof 59 to locate rails 60 and 61 longitudinally, and the top ends of rails 60 and 61 extend to peak 58. When rails 60 and 61 are accurately positioned, they are fastened to roof 59 by nails 63 through angle iron brackets 64 disposed along the outer edges or rails 60 and 61.
A crosspiece 65 fits closely between rails 60 and 61 and rests on roof 59. Extension pieces 66 are fastened to the top of each end of crosspiece 65 to reach over the top surfaces of rails 60 and 61. P'ositioners 67 formed as blocks secured to the top surfaces of rails 60 and 61 are spaced apart by the exposed width of shingles 68 and are arranged in parallel and aligned sets on each rail 60 and 61.
When extension pieces of crosspiece 65 are placed between the first pair of positioners 67 at the bottom ends of rails 60 and 61, crosspiece 65 is positioned so that the lowermost row of shingles 68 can be'butted against crosspiece 65 and secured to roof 59. Then crosspiece 65 is moved upward on rails 60 and 61 to the next position between positioners 67 where it is correctly located for butting the second row of shingles 68 against crosspiece 65. This process is repeated with each row of shingles 68 until roof 59 is shingled to its peak 58.
The edges of roof 59 under jig rails 60 and 61 are not shingled until after the modules are positioned on the site and shingle splices or joints are made between adjacent roofs.
The jig of P165. 6-8 assures that the rows of shingles 68 are accurately parallel with peak 58 and accurately spaced so that the shingle rows of adjacent modules will line up accurately on the site for a neat appearance avoiding any jags or turns in the shingle joints between adjacent roofs. This is particularly important where several dwelling modules are placed side-by-side to form a common roof extending for many feet. ln onsite construction such a roof would be built in place and its shingles aligned on long chalk lines. However, the inventive jig is faster and more accurate, and solves the problem of lining up the shingle rows of dwelling modules having roofs built in fairly short lengths that are later joined together.
In the final stages of construction of dwelling modules according to the invention, lifting hardware is secured to each module in preparation for its transport to a site. Preferably, long eyebolts 69 are used for the basic lifting rig, and bolts 69 extend through holes in floorjoist framework 17 as best shown in F105. 9-11. Recesses 70 are cut in the underside'of floor joist framework 17 preferably before it is inverted to receive plates 71 fitting floor joist framework 17 and supporting the heads 72 of eyebolts 69. Eyebolts 69 preferably extend above the tops of dwelling modules as illustrated, and such modules are lifted from above by cranes or lifts hooking onto eyebolts 69.
The trailer 80 shown in FIG. 9 is preferably used for transporting completed dwelling modules to a site. Trailer 80 has a hitch 73 at its forward end, a front frame extending back to wheels 74 at the midsection and a rear frame 76 joined to the top of front frame 75 and extending over and beyond wheels 74. Front and rear frames 75 and 76 are preferably formed of relatively light, structural metal materials.
As best shown in P10. 10, lag screws 77 are driven through the side beams 78 of frames 75 and 76 into the bottom of floor joist framework 17 at intervals of 3 feet or so along frames 75 and 76, to hold floor joist framework 17 tightly against trailer frames 75 and 76. Such interfastening stiffens and supports frames 75 and 76 which are braced by the strong and rigid construction of floor joist framework 17. Such strengthening allows trailer 80 to be of lightweight construction and yet be sufficiently strong to carry heavy dwelling modules. This provides advantages such as only a. few wheels 74 close together in the midsection of trailer 80 are required and a relatively long length of trailer and dwelling modules can be cantilevered behind wheels 74; and the overall height of the loaded trailer is relatively low and the total weight of trailer 80 and its dwelling modules is relatively small to meet licensing and highway requirements for vehicles. The prior art trailers for hauling heavy objects have always been strong enough to be the sole support of the cargo. Such a trailer for the inventive dwelling units would have to be the low-boy-type with a massive platform carried low between the hitch and a rear axle having many wheels. Such a trailer would far outweigh trailer 80 and could only haul one dwelling module. The front frame 76 forward of wheels 74 for supporting the taller, roofed modules is of comparable length to a low-boy" trailer, but the light construction braced by the strength of the dwelling unit itself allows the additional dwelling module mounted above the wheels 74 on the cantilevered after frame 76.
Persons wishing to practice the invention should remember that other embodiments and variations can be adapted to particular circumstances. Even though one point of view is necessarily chosen in describing and claiming the invention, this should not inhibit broader or related applications within the spirit of the invention. For example, different materials and fastening means can be used, and the inventive jigs and fabrication methods can be adapted to such variations; operations can proceed simultaneously or in different orders; and the movement of subassemblies can be varied.
We claim:
1. A dwelling factory assembly line comprising;
a. a floor assembly region including:
1. means for interfastening a floor joist framework in upside down position;
2. means for turning over said floor joist framework; and
3. means for fastening a subfloor to the top of said turned over floor joist framework to form a floor unit for said dwelling; b. a wall assembly region including:
1. a wall jig having a surface sloped from the vertical for supporting a wall stud framework; 2. means for interfastening said framework;
3. means for fastening interior wall covering on said supported framework; and
4. means for erecting said covered wall framework on said floor unit;
c. a ceiling assembly region above said line including;
1. a ceiling jig for supporting a ceiling joist framework upside down;
2. means for interfastening said ceiling joist framework;
3. means for covering said ceiling joist framework with interior ceiling material to form a ceiling unit;
4. means for turning over said ceiling jig with said covered ceiling unit secured thereto; and
5. means for lowering said ceiling unit onto the tops of said wall frameworks;
d. means for securing service fixtures to said wall frameworks outside said interior wall covering; and
e. means for securing external covering to said dwelling.
2. The assembly line of claim 1 including a track and means for moving said dwelling along said track from said floor assembly region past said ceiling assembly region and toward a finishing region.
3. The assembly line of claim 1 including means at said floor assembly region for securing service fixtures to said floor joist framework before inversion thereof.
4. The assembly line of claim 1 including means at said ceiling assembly region for securing service fixtures to said ceiling joist framework before covering said ceiling joist framework with said interior ceiling material.
5. The assembly line of claim 1 wherein said wall jig supported stud includes a gantry walkway arranged behind said sloped surface and near the top of said sloped surface to support a workman in a comfortable position for fastening the upper portions of said stud framework.
6. The assembly line of claim 5 wherein a pair of said wall jig support surfacesare arranged on opposite sides of said gantry walkway.
7. The assembly line of claim 1 wherein said ceiling jig comprises two opposed jig surfaces arranged on a rotatable body, means for rotating said body about a horizontal axis to turn either of said jig surfaces uppermost, and means for latching said body in positions orienting either of said jig surfaces uppermost.
8. The assembly line of claim 1 including windlass strap means arranged on said ceiling jig for fastening to said ceiling to lower said ceiling from the bottom of said ceiling jig.
9. A dwelling assembly method comprising:
a. interfastening a floor joist framework in upside down position;
b. turning over said floor joist framework;
e. fastening a subfloor to the top of said turned-over floor joist framework to form a floor unit for said dwelling;
d. moving said floor unit to a wall assembly region;
e. interfastening stud frameworks for walls of said dwelling;
f. fastening interior wall covering on said wall stud frameworks;
g. securing said covered wall frameworks in erect positions on said floor unit;
h. interfastening a ceiling joist framework supported in upside down position on the surface of a ceiling jig above the top of said dwelling;
i. covering said ceiling joist framework with interior ceiling materials to form a ceiling unit;
j. turning over said ceiling jig with said covered ceiling unit secured thereto;
k. moving said dwelling under said ceilingjig;
l. lowering said ceiling unit onto said erected wall frameworks;
m. securing said ceiling unit to the top of said erected wall frameworks;
n. fastening services fixtures to said wall frameworks outside said interior wall covering; and
o. securing external covering to said dwelling.
10. The method of claim 9 including securing service fixtures to said floor joist framework before turning over said floor joist framework.
ll. The method of claim 9 including securing service fixtures to said ceiling joist framework before covering said ceiling framework.
12. The method ofclaim 9 including gluing said interior wall covering to said wall stud framework.
B. The method of claim 9 including:
a. laying a pair of parallel rails to extend from the peak to the lower edge of the roof of said dwelling along the respective side edges of said roof, said rails having corresponding sets of positioners parajel with said peak and spaced apart by the width of the shingle rows for said roof;
b. arranging a crosspiece successively between said positioners;
c. butting a row of shingles agains said crosspiece in each position of said crosspiece; and
d. securing each row of said shingles in place on said roof.
[4. The method of claim 9 including securing lifting hardware to said floor joist framework and lifting said dwelling from overhead by said hardware for positioning said dwelling.
15. The method of claim 9 including positioning said dwelling on a relatively light-construction trailer for transport to a site, and fastening said floor joist framework of said dwelling to said trailer at a plurality of points to strengthen said trailer.
16. The method of claim 15 including turning a plurality of lag screws through the frame of said trailer into the bottom of said floor joist framework to fasten said dwelling to said trailer.
17. The method of claim 12 including using nails holding cleats against the interior surface of said wall covering and passing removably through said wall covering and into said framework to hold said wall covering in place until said glue sets.
18. A dwelling factory assembly line comprising:
a. a floor assembly region including:
1. a wall jig having a surface for supporting a wall stud framework;
2. means for interfastening said supported stud framework;
3. means for fastening interior wall covering on said supported framework; and 4. means for erecting said covered wall framework on said floor unit; c. a ceiling assembly region including:
1. a ceiling jig for supporting a ceiling joist framework in inverted position; 2. means for interfastening said ceilingjoist framework; 3. means for covering said ceiling joist framework with interior ceiling material to form a ceiling unit; 4. means for inverting said ceiling unit; and 5. means for positioning said ceiling unit on the tops of said wall frameworks; d. means for securing service fixtures to said wall frameworks outside said interior wall covering; and e. means for securing external covering to said wall frameworks. 19. A dwelling assembly method comprising: a. interfastening a floor joist framework;
b. fastening a sub floor to the top of said floor joist framework to form a floor unit;
c. moving said floor unit to a wall assembly region;
d. interfastening stud frameworks for walls of said dwelling;
e. fastening interior wall covering on said wall stud frameworks;
f. securing said covered wall frameworks in erect positions on said floor unit;
g. interfastening a ceiling joist framework supported in inverted position on a surface ofa ceilingjig;
h. covering said ceiling joist framework with interior ceiling materials to form a ceiling unit;
i. inverting said ceiling unit;
j. positioning said ceiling unit on said erected wall frameworks;
k. securing said ceiling unit to the tops of said erected wall frameworks;
l. fastening service fixtures to said wall frameworks outside said interior wall covering; and
m. securing external covering to said wall frameworks.
20. The dwelling assembly method of claim 9 including arranging said floor joist framework upside down on a plane surface for said interfastening so said subfloor lies substantially in a plane on said right side up floor joist framework.

Claims (37)

1. A dwelling factory assembly line comprising; a. a floor assembly region including: 1. means for interfastening a floor joist framework in upside down position; 2. means for turning over said floor joist framework; and 3. means for fastening a subfloor to the top of said turned over floor joist framework to form a floor unit for said dwelling; b. a wall assembly region including: 1. a wall jig having a surface sloped from the vertical for supporting a wall stud framework; 2. means for interfastening said supported stud framework; 3. means for fastening interior wall covering on said supported framework; and 4. means for erecting said covered wall framework on said floor unit; c. a ceiling assembly region above said line including; 1. a ceiling jig for supporting a ceiling joist framework upside down; 2. means for interfastening said ceiling joist framework; 3. means for covering said ceiling joist framework with interior ceiling material to form a ceiling unit; 4. means for turning over said ceiling jig with said covered ceiling unit secured thereto; and 5. means for lowering said ceiling unit onto the tops of said wall frameworks; d. means for securing service fixtures to said wall frameworks outside said interior wall covering; and e. means for securing external covering to said dwelling.
2. means for turning over said floor joist framework; and
2. means for interfastening said ceiling joist framework;
2. The assembly line of claim 1 including a track and means for moving said dwelling along said track from said floor assembly region past said ceiling assembly region and toward a finishing region.
2. means for interfastening said supported stud framework;
2. means for interfastening said ceiling joist framework;
2. means for interfastening said supported stud framework;
2. means for fastening a subfloor to the top of said floor joist framework to form a floor unit; b. a wall assembly region including:
3. means for covering said ceiling joist framework with interior ceiling material to form a ceiling unit;
3. means for fastening interior wall covering on said supported framework; and
3. means for fastening interior wall covering on said supported framework; and
3. The assembly line of claim 1 including means at said floor assembly region for securing service fixtures to said floor joist framework before inversion thereof.
3. means for covering said ceiling joist framework with interior ceiling material to form a ceiling unit;
3. means for fastening a subfloor to the top of said turned over floor joist framework to form a floor unit for said dwelling; b. a wall assembly region including:
4. means for turning over said ceiling jig with said covered ceiling unit secured thereto; and
4. The assembly line of claim 1 including means at said ceiling assembly region for securing service fixtures to said ceiling joist framework before covering said ceiling joist framework with said interior ceiling material.
4. means for erecting said covered wall framework on said floor unit; c. a ceiling assembly region above said line including;
4. means for erecting said covered wall framework on said floor unit; c. a ceiling assembly region including:
4. means for inverting said ceiling unit; and
5. means for positioning said ceiling unit on the tops of said wall frameworks; d. means for securing service fixtures to said wall frameworks outside said interior wall covering; and e. means for securing external covering to said wall frameworks.
5. The assembly line of claim 1 wherein said wall jig includes a gantry walkway arranged behind said sloped surface and near the top of said sloped surface to support a workman in a comfortable position for fastening the upper portions of said stud framework.
5. means for lowering said ceiling unit onto the tops of said wall frameworks; d. means for securing service fixtures to said wall frameworks outside said interior wall covering; and e. means for securing external covering to said dwelling.
6. The assembly line of claim 5 wherein a pair of said wall jig support surfaces are arranged on opposite sides of said gantry walkway.
7. The assembly line of claim 1 wherein said ceiling jig comprises two opposed jig surfaces arranged on a rotatable body, means for rotating said body about a horizontal axis to turn either of said jig surfaces uppermost, and means for latching said body in positions orienting either of said jig surfaces uppermost.
8. The assembly line of claim 1 including windlass strap means arranged on said ceiling jig for fastening to said ceiling to lower said ceiling from the bottom of said ceiling jig.
9. A dwelling assembly method comprising: a. interfastening a floor joist framework in upside down position; b. turning over said floor joist framework; c. fastening a subfloor to the top of said turned-over floor joist framework to form a floor unit for said dwelling; d. moving said floor unit to a wall assembly region; e. interfastening stud frameworks for walls of said dwelling; f. fastening interior wall covering on said wall stud frameworks; g. securing said covered wall frameworks in erect positions on said floor unit; h. interfastening a ceiling joist framework supported in upside down position on the surface of a ceiling jig above the top of said dwelling; i. covering said ceiling joist framework with interior ceiling materials to form a ceiling unit; j. turning over said ceiling jig with said covered ceiling unit secured thereto; k. moving said dwelling under said ceiling jig; l. lowering said ceiling unit onto said erected wall frameworks; m. securing said ceiling unit to the top of said erected wall frameworks; n. fastening services fixtures to said wall frameworks outside said interior wall covering; and o. securing external covering to said dwelling.
10. The method of claim 9 including securing service fixtures to said floor joist framework before turning over said floor joist framework.
11. The method of claim 9 including securing service fixtures to said ceiling joist framework before covering said ceiling framework.
12. The method of claim 9 including gluing said interior wall covering to said wall stud framework.
13. The method of claim 9 including: a. laying a pair of parallel rails to extend from the peak to the lower edge of the roof of said dwelling along the respective side edges of said roof, said rails having corresponDing sets of positioners parallel with said peak and spaced apart by the width of the shingle rows for said roof; b. arranging a crosspiece successively between said positioners; c. butting a row of shingles against said crosspiece in each position of said crosspiece; and d. securing each row of said shingles in place on said roof.
14. The method of claim 9 including securing lifting hardware to said floor joist framework and lifting said dwelling from overhead by said hardware for positioning said dwelling.
15. The method of claim 9 including positioning said dwelling on a relatively light-construction trailer for transport to a site, and fastening said floor joist framework of said dwelling to said trailer at a plurality of points to strengthen said trailer.
16. The method of claim 15 including turning a plurality of lag screws through the frame of said trailer into the bottom of said floor joist framework to fasten said dwelling to said trailer.
17. The method of claim 12 including using nails holding cleats against the interior surface of said wall covering and passing removably through said wall covering and into said framework to hold said wall covering in place until said glue sets.
18. A dwelling factory assembly line comprising: a. a floor assembly region including:
19. A dwelling assembly method comprising: a. interfastening a floor joist framework; b. fastening a sub floor to the top of said floor joist framework to form a floor unit; c. moving said floor unit to a wall assembly region; d. interfastening stud frameworks for walls of said dwelling; e. fastening interior wall covering on said wall stud frameworks; f. securing said covered wall frameworks in erect positions on said floor unit; g. interfastening a ceiling joist framework supported in inverted position on a surface of a ceiling jig; h. covering said ceiling joist framework with interior ceiling materials to form a ceiling unit; i. inverting said ceiling unit; j. positioning said ceiling unit on said erected wall frameworks; k. securing said ceiling unit to the tops of said erected wall frameworks; l. fastening service fixtures to said wall frameworks outside said interior wall covering; and m. securing external covering to said wall frameworks.
20. The dwelling assembly method of claim 9 including arranging said floor joist framework upside down on a plane surface for said interfastening so said subfloor lies substantially in a plane on said right side up floor joist framework.
US760103A 1968-09-16 1968-09-16 Dwelling assembly line and method Expired - Lifetime US3574920A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US76010368A 1968-09-16 1968-09-16

Publications (1)

Publication Number Publication Date
US3574920A true US3574920A (en) 1971-04-13

Family

ID=25058100

Family Applications (1)

Application Number Title Priority Date Filing Date
US760103A Expired - Lifetime US3574920A (en) 1968-09-16 1968-09-16 Dwelling assembly line and method

Country Status (2)

Country Link
US (1) US3574920A (en)
GB (1) GB1250682A (en)

Cited By (24)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3699628A (en) * 1971-04-05 1972-10-24 Behring Corp Vertical assembly apparatus
US3763547A (en) * 1971-01-26 1973-10-09 Stacor Corp Automatic fastening machine
US3768140A (en) * 1972-01-03 1973-10-30 R Whitney Machine for and method of changing wooden framing members into preformed and bound units
US3777357A (en) * 1972-06-29 1973-12-11 R Whitney Machine and method for simultaneously forming a plurality of building sections
US3805365A (en) * 1972-12-13 1974-04-23 Ashby H Method and apparatus for constructing house structures to be transported and installed at remote locations
US3958320A (en) * 1972-09-19 1976-05-25 Lely Cornelis V D Methods for the manufacture of prefabricated building sections or room units and factories for the implementation of such methods
US3962773A (en) * 1972-09-19 1976-06-15 Lely Cornelis V D Methods for the manufacture of prefabricated building sections or room units and factories for the implementation of such methods
US3968558A (en) * 1973-12-14 1976-07-13 Nissan Motor Co., Ltd. Apparatus for and method of automatically assembling an automobile body structure
US3994060A (en) * 1971-10-01 1976-11-30 Lely Cornelis V D Methods and production lines for the manufacture of prefabricated buildings
US4175313A (en) * 1978-04-20 1979-11-27 Neumann Paul G Method and apparatus for manufacturing door frames
US4450617A (en) * 1981-05-14 1984-05-29 The Dillon Company System for and assembly of a prefabricated home module
US6067699A (en) * 1995-04-19 2000-05-30 Jeld-Wen, Inc. Method for assembling a multi-panel door
US20040187291A1 (en) * 2003-03-31 2004-09-30 Richard Syrek Method for changing fixtures used to position a plurality of different workpieces on an assembly line
WO2005001213A1 (en) * 2003-06-30 2005-01-06 The Mattamy Corporation Method for the manufacture of houses
US20070264110A1 (en) * 2006-05-09 2007-11-15 Rhodes Design And Development Corporation Building transport device
US20080086978A1 (en) * 2006-10-11 2008-04-17 The Mattamy Corporation Housing manufacturing system and method
US20080111327A1 (en) * 2006-11-13 2008-05-15 Rhodes Design And Development Corporation Transport device capable of adjustment to maintain load planarity
US20080164078A1 (en) * 2007-01-05 2008-07-10 Rhodes Design And Development Corporation Device and method for transporting a load
US20080184640A1 (en) * 2007-02-01 2008-08-07 James Rhodes Movable building and building foundation
US20080184659A1 (en) * 2007-02-01 2008-08-07 James Rhodes Method and apparatus for sheltered, in-place home building
US20080184630A1 (en) * 2007-02-01 2008-08-07 James Rhodes Home manufacturing facility
US20080184658A1 (en) * 2007-02-01 2008-08-07 James Rhodes Method for setting a building on a subdivision lot
US20080289287A1 (en) * 2007-05-21 2008-11-27 James Rhodes Building manufacturing facility with rotatable subassembly areas
US20090025322A1 (en) * 2007-07-26 2009-01-29 James Rhodes Method and apparatus for building homes in a factory lacking a roof or exterior wall

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3319323A (en) * 1965-06-03 1967-05-16 Kingsberry Homes Corp Jig for making and assembling separate gable sections
US3399445A (en) * 1965-10-20 1968-09-03 John R Carroll Full automatic framing machine
US3443303A (en) * 1966-12-23 1969-05-13 Kingsberry Homes Corp Process and apparatus for forming a building structure

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3319323A (en) * 1965-06-03 1967-05-16 Kingsberry Homes Corp Jig for making and assembling separate gable sections
US3399445A (en) * 1965-10-20 1968-09-03 John R Carroll Full automatic framing machine
US3443303A (en) * 1966-12-23 1969-05-13 Kingsberry Homes Corp Process and apparatus for forming a building structure

Cited By (30)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3763547A (en) * 1971-01-26 1973-10-09 Stacor Corp Automatic fastening machine
US3699628A (en) * 1971-04-05 1972-10-24 Behring Corp Vertical assembly apparatus
US3994060A (en) * 1971-10-01 1976-11-30 Lely Cornelis V D Methods and production lines for the manufacture of prefabricated buildings
US3768140A (en) * 1972-01-03 1973-10-30 R Whitney Machine for and method of changing wooden framing members into preformed and bound units
US3777357A (en) * 1972-06-29 1973-12-11 R Whitney Machine and method for simultaneously forming a plurality of building sections
US3962773A (en) * 1972-09-19 1976-06-15 Lely Cornelis V D Methods for the manufacture of prefabricated building sections or room units and factories for the implementation of such methods
US3958320A (en) * 1972-09-19 1976-05-25 Lely Cornelis V D Methods for the manufacture of prefabricated building sections or room units and factories for the implementation of such methods
US3805365A (en) * 1972-12-13 1974-04-23 Ashby H Method and apparatus for constructing house structures to be transported and installed at remote locations
US3968558A (en) * 1973-12-14 1976-07-13 Nissan Motor Co., Ltd. Apparatus for and method of automatically assembling an automobile body structure
US4175313A (en) * 1978-04-20 1979-11-27 Neumann Paul G Method and apparatus for manufacturing door frames
US4450617A (en) * 1981-05-14 1984-05-29 The Dillon Company System for and assembly of a prefabricated home module
US6067699A (en) * 1995-04-19 2000-05-30 Jeld-Wen, Inc. Method for assembling a multi-panel door
US20040187291A1 (en) * 2003-03-31 2004-09-30 Richard Syrek Method for changing fixtures used to position a plurality of different workpieces on an assembly line
WO2005001213A1 (en) * 2003-06-30 2005-01-06 The Mattamy Corporation Method for the manufacture of houses
US20070264110A1 (en) * 2006-05-09 2007-11-15 Rhodes Design And Development Corporation Building transport device
US7452173B2 (en) 2006-05-09 2008-11-18 Custom Quality Homes, L.L.C. Building transport device
US7832087B2 (en) 2006-10-11 2010-11-16 The Mattamy Corporation Housing manufacturing system
US9957710B2 (en) 2006-10-11 2018-05-01 The Mattamy Corporation Housing manufacturing system and method
US9587395B2 (en) 2006-10-11 2017-03-07 The Mattamy Corporation Housing manufacturing system and facility
US8887399B2 (en) 2006-10-11 2014-11-18 The Mattamy Corporation Housing manufacturing system and method
US20080086978A1 (en) * 2006-10-11 2008-04-17 The Mattamy Corporation Housing manufacturing system and method
US20110016694A1 (en) * 2006-10-11 2011-01-27 The Mattamy Corporation Housing Manufacturing System and Method
US20080111327A1 (en) * 2006-11-13 2008-05-15 Rhodes Design And Development Corporation Transport device capable of adjustment to maintain load planarity
US20080164078A1 (en) * 2007-01-05 2008-07-10 Rhodes Design And Development Corporation Device and method for transporting a load
US20080184658A1 (en) * 2007-02-01 2008-08-07 James Rhodes Method for setting a building on a subdivision lot
US20080184630A1 (en) * 2007-02-01 2008-08-07 James Rhodes Home manufacturing facility
US20080184659A1 (en) * 2007-02-01 2008-08-07 James Rhodes Method and apparatus for sheltered, in-place home building
US20080184640A1 (en) * 2007-02-01 2008-08-07 James Rhodes Movable building and building foundation
US20080289287A1 (en) * 2007-05-21 2008-11-27 James Rhodes Building manufacturing facility with rotatable subassembly areas
US20090025322A1 (en) * 2007-07-26 2009-01-29 James Rhodes Method and apparatus for building homes in a factory lacking a roof or exterior wall

Also Published As

Publication number Publication date
GB1250682A (en) 1971-10-20

Similar Documents

Publication Publication Date Title
US3574920A (en) Dwelling assembly line and method
US11585082B2 (en) Automated system for robotised construction and construction method
US7467469B2 (en) Modular housing system and method of manufacture
CA2827690C (en) Homes and home construction
US9358688B2 (en) Machine for aligning items in a pattern and a method of use
US5617622A (en) Rotatable work platform with clamps for wall and truss fabrication
US20170152659A1 (en) Modular building system
US6253530B1 (en) Structural honeycomb panel building system
US2497887A (en) Paneled building construction
US4000588A (en) Space-bounding sections for forming a building or part thereof, and methods of erecting such a building
US20050210764A1 (en) Prefabricated building with self-aligning sections and method of manufacture and assembly of same
CN104060853B (en) Lightweight steel construction modularization house
CA2019924C (en) Modular log structures and methods of constructing same
CN205153114U (en) Lightweight steel structure modularized residential building
WO2019088948A2 (en) Modular ready-made structures with aluminum profile frame whose three axes immediately could be installed
US20060070328A1 (en) Apparatus, system, and method for constructing a wall using wall blocks
US3624889A (en) Mobile plant for the fabrication of structural modules
US4480420A (en) Dormer structure and method
CN113006324B (en) Sandwich plate installation method for steel structure factory building
US2762105A (en) Sectional concrete forms
CN85102678A (en) Prefabricated folding structure
EP1831475A1 (en) Method and product in the erection of a building
CN113235840A (en) Quick installation and construction method for inner-layer plate of factory building roof
EA043188B1 (en) AUTOMATED SYSTEM FOR CONSTRUCTION WORKS USING ROBOTIC TECHNOLOGIES
JP2023127656A (en) Board fixing method and board planking robot