US3609936A - Method for constructing low cost housing units - Google Patents

Abstract

A METHOD OF CONSTRUCTION FOR LOW COST HOUSING UNITS IN WHICH A PLURALITY OF PREASSEMBLED TRANSVERSE POST AND BEAM FRAME UNITS ARE ERECTED ON A FOUNDATION TO PROVIDE THE SUPPORT FOR A COMPLETE HOUSING MODULE. THE FRAME UNITS ARE SPACED TO FACILITATE THE USE OF COMMERCIALLY AVAILABLE SIZES OF PRE-CUT PANELS TO FORM INTERIOR AND EXTERIOR WALLS.

Description

METHOD FOR GONSTRUCTING LOW COST HOUSING UNITS Filed Feb. 20. 1970 J. J. TOSCANO Oct. 5, 1971 4 Sheets-Sheet l WWW/V7/////q m n m m0 N A m 0 T IU. H P E s O J BY 2 g Q J imam-1Y5 Oct. 5, 1971 J TQSCANQ 3,609,93

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mvmwnn JOSEPH J. TOSCANO ()RNEYS United States Patent 3,609,936 METHOD FOR CONSTRUCTING LOW COST HOUSING UNITS Joseph J. Toscano, 510 B 52 Bypass W., West Lafayette, Ind. 47906 Filed Feb. 20, 1970, Ser. No. 13,059 Int. Cl. E04h 1/04 US. Cl. 52741 Claims ABSTRACT OF THE DISCLOSURE A method of construction for low cost housing units in which a plurality of preassembled transverse post and beam frame units are erected on a foundation to provide the support for a complete housing module. The frame units are spaced to facilitate the use of commercially available sizes of pre-cut panels to form interior and exterior walls.

BACKGROUND OF THE INVENTION This invention relates to improvements in construction techniques for low cost housing units and more particularly, it concerns a modular post and beam construction particularly suitable for use in wood frame structures, it being contemplated that various features of the invention may be adaptable to construction employing materials other than wood, such as for example prestressed concrete.

Currently there is an acute need throughout the urban and suburban areas of the United States for housing which is low in cost, comfortable and aesthetically appealing to meet both the economic and social requirements of the times. Although various types of building designs and many diverse techniques for their construction have been devised, few if any are acceptable both from the standpoint of cost and aesthetic appeal, the latter criterion being especially important from the standpoint of creating an adequate demand for commercial reality.

The use of traditional building materials such as wood, brick, plaster or materials similar in all physical characteristics to these building materials has been recognized by the housing industry as prerequisite to commercial success presumably because of the innate warmth and aesthetic appeal stemming from the mere fact that their use is traditional. In most areas of the country, wood frame construction remains lower in cost than brick or masonry construction as a result of both material and labor costs. The fact remains however, that even with most forms of wood frame construction presently available, a significant amount of on-the-job labor is required in relation to unit space of housing provided, thereby posing serious problems to the accomplishment of low cost construction even with wood. This latter factor is particularly prevalent in the finishing of conventional mill work and the like to render the dwelling livable in an aesthetic sense.

SUMMARY OF THE PRESENT INVENTION In accordance with the present invention, many of the problems presented by the conventional frame construction techniques are solved by the employment of a cubic building module erected by arranging a series of substantially identical post and beam frame units in aligned spaced relation, the frame units constituting the sole structural support for fioors, walls and roofing. [Each of the frames includes an assembly of a lower sill, at least two posts having their bases fixed at the ends of the sill, a cap secured between the upper ends of the posts and at least one intermediate joist extending between and supported from the posts, the precise number of joists in each frame depending on the number of stories contemplated for the See building to be constructed. The frames preferably are preassembled either near the building site or at a remote factory and during construction are placed on a foundation in parallel spaced relation by using spacing members extending between the aligned posts of adjacent frames at the levels of respective sills, joists and caps. By selecting an appropriate spacing between respective frames, com mercially available panels may be used to close walls, both interiorly and externally. Floors are formed by using planking extending between the sills and joists of the frame members placed on the foundation.

Preferably the sills, joists and caps used in the construction technique according to this invention are readily available 6" by 8" beams whereas all posts employed are 6" by 6 in cross-sectional dimension. It will be appreciated, however, that the precise dimensioning of the lumber will vary depending on the size of unit to be constructed in order to develop adequate structural strength. Also, the use of lumber having at least one common dimension, such as the example given, facilitates the use of a common clip for connecting the structural members of each frame.

It is therefore a principal object of the present invention to provide a low cost, yet attractive housing unit as well as a unique method for its construction. Other objects of the present invention includes the reduction to a minimum of on-the-job time required in cutting or otherwise shaping of members used in construction; a facility for the use of commercially available cut panels for walls, ceilings and like; the provision of a modulate building unit which may be assembled with other similar modules to provide a housing structure of substantial capacity; the provision of a unique connecting clip for post and beam type construction techniques; and the provision of a housing unit which facilitates the erection of an aesthetically appealing dwelling. Still other objects of the invention will become apparent from the detailed description of a preferred embodiment to follow below taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a fragmentary perspective view illustrating the exterior appearance of a housing module formed in accordance with the present invention incorporated as a unit in a larger structure shown partly in phantom lines;

FIG. 2 is a plan view or layout of the first floor of one design of a building module in accordance with the present invention;

FIG. 3 is a fragmentary cross-section taken on line 3-3 of FIG. 2;

FIG. 4 is a floor plan or layout of the second story of the building shown in FIG. 1;

FIG. 5 is an enlarged fragmentary cross-section taken on line 55 of FIG. 4;

FIG. 6 is a fragmentary perspective view, partially cut away illustrating the framing technique in accordance with the present invention;

FIG. 7 is an end view illustrating the preferred form of connector used in accordance with the present invention;

FIG. 8 is a side view of the connector shown in FIG. 7; and

FIG. 9 is a perspective view of the connector illustrated in FIGS. 7 and 8 of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT As shown in FIGS. 1-4 of the drawings, the housing unit module of this invention is designated generally by the reference number 10 and is characteristically cubic in general exterior configuration. Although in FIG. 1, only one module is shown in solid lines, a plurality of such modules, each constituting a family housing unit, may be arranged much in the manner of conventional townhouses where the modules are offset or staggered depending on the plot of ground on which they are placed. Although the number of floors, as Well as the layout of each floor may vary without departing significantly from the basic module 10, a two-story structure supported on a foundation 12 is used in the embodiment shown. The

plans for the first floor 14 and second floor 16, in accordance with the particular embodiment illustrated, are shown respectively in FIGS. 2 and 4 of the drawings. Also, it will be noted that the first and second floors 14 and 16 are interconnected by a stairwell 18. Apart from the location and size of the stairwell 18, as will become more apparent from the description to follow below, any arrangement of rooms may be provided on the respective first and second floors. All interior walls such as the partitions 20 in FIG. 2 and the interior partitions 22 in FIG. 4 are non-load bearing and hence can be relocated to suit the desired size and number of rooms for the intended use of the dwelling unit module 10.

The structural support or framing for the dwelling unit 10 may be most clearly understood by reference to FIG. 6 in conjunction with FIGS. 2-4 of the drawing. As shown in FIG. 6, the dwelling unit 10 includes a series of transversely disposed frame units 24, 25, 26, 27, 28, 29, 30 and 31 to be supported directly on the foundation 12 in equally spaced increments along with the length of the foundation. Although the precise organization of structural members in each of the frames 24-31 may differ slightly depending on the location of a particular frame Within the building module, each is formed of pre-cut structural members including basically a lower sill 32, a pair of end posts 34 having their lower ends fixed to the sills 32, an intermediate joist 36 supported at its ends from the posts 34 and a cap 38 supported on the upper ends of the post 34. To accommodate the stairwell 18, the joists 36 in the frames 27 and 28 are cut short and supported by short posts 40 as shown in FIG. 6. Also, a short interior post 42 may be employed in the frame 26 to provide additional support for the upper end of the stairs in the stairwell 18 and an appropriate header (not shown) may be used to frame out the stairwell 18. In the end frames 24 and 31, auxiliary short posts 44 and 46 are employed principally to carry the aesthetic post and beam design throughout the ends of the housing module 10. Although the posts 44 and 46 add a measure of structural integrity to the framework of the module, they are not essential and hence can be removed to facilitate doorways and the like as shown for example at 47 in FIG. 2 of the drawing.

In the erection of the module on the foundation 12, each of the frames 2431 are first assembled by using the connectors 48 shown in FIGS. 7-9 of the drawings. The connectors are of L-shaped configuration to define a vertical leg 50 connected to a horizontal leg 52 by spot welds 54 through overlapping tabs 56 and 58 formed as extensions of the side flanges 59 of the channel shaped cross section of each leg 50 and 52. The securement of the two channel shaped leg portions is augmented by a seam Weld at the juncture 60 of the bases or webs 61 in each leg portion. The dimension of the clips is selected to conform precisely with the exterior of the post and beam members used in the frames 24-31. As above mentioned all post members in the unit are conventional 6 inch by 6 inch hemlock or fir posts whereas all beam members are of similar construction lumber 6 inches by 8 inches in cross sectional dimension. Thus to secure the caps 38 to the upper ends of the posts 34, the clips 48 are inserted at the inside juncture of these members, as shown in FIGS. 7-9, and secured in place by nails 62 extending through appropriately located holes formed in the flanges and webs of the clip. In this manner, the individual members of the frame will be secured firmly one to the other in a manner apparent by reference to the drawing. Also it is contemplated that the other members of each frame may be connected in similar fashion by use of the clips 48 in the manner described above. 5

Once the individual frames 24-31 have been assembled using the clips 48, the framework for the module 10 is erected by placing an end frame, for example the frame 24, at its proper location on the foundation 12. Each successive frame is then similarly placed on the foundation with the space between frames being determined by spacers 64, 66 and 68 extending between the end posts 34 of adjacent frames at the levels respectively of the sills 32, joists 36 and caps 38. The spacers 64, 66 and 68 are, in the embodiment shown, formed from conventional 2 inch by 4 inch lumber assembled to provide a box-like configuration as shown in FIG. 6 of the drawings. Because of the reduced lateral dimension of the spacers 46, they will be recessed slightly from the exterior and interior faces of the posts 34 to facilitate placement of wall panels between the posts and flush therewith in a manner to be described below. Also it will be appreciated that the spacers may be secured in place by conventional nailing techniques.

After all of the frames 24-31 have been erected to the configuration illustrated in FIG. 6 of the drawings flooring 69 is laid in a direction perpendicular to the direction of the sills 32 and joists 36. As shown in FIG. 6, the flooring for both the first floor and the second floor is 2 inch fir or pine plan'king which may be finished directly to achieve the desired aesthetic appearance and also lend structural integrity of the framing structure. A roof structure 70 of plywood panels 72 covered by asphalt 74 or other suitable compositions and an aggregate such as gravel is applied over the caps 38. Once the flooring planks 69 are in place interior portions such as the walls 20 and 22 may be installed using conventional techniques. g E

As shown in FIG. 5 of the drawings, the exterior walls of the dwelling unit are formed by panels 76 selected to achieve the desired aesthetic appearance of the building. Because of the uniformity of spacing between the frames 24-31, the panels 76 may be pre-cut and preferably 4 feet by 8 feet in size to enable adaptability of the most prevalent size plywood panels. The panels 76 are merely secured in place at their tops and bottoms by nailing directly to the spacers 64, 66 or 68 and along their sides by cleats (not shown) nailed to the posts 34. Appropriate facing trim 78 may be fixed over the ends of the paneling 76 to achieve the appearance of the building shown in FIG. 1 of the drawings.

The interior Wall surfaces for the building unit may include panels 80 of gypsum board, plywood or the like affixed in a manner similar to the exterior panels 76 as shown in FIG. 5 of the drawings. The panels 80 may extend between the posts 34 to achieve an open beam appearance or they may be secured over the interior faces of the posts to provide a continuous wall surface if desired. Also as shown in FIG. 5, the ceilings for the rooms on the respective first and second floors may also be finished to achieve an open beam appearance. Insulation 82 is provided between the interior and exterior wall panels to provide protection against temperature extremes and as well as a sound barrier.

Thus it will be appreciated that by this invention, an improved low-cost housing unit and method for its construction is provided by which the above-mentioned objectives are completely fulfilled. Also, it will be appreciated that variations may be made in a disclosed embodiment without departing from the true spirit and scope of this invention. Accordingly, it is expressly intended that the foregoing description is illustrative of a preferred embodiment, not limiting, and that the true spirit and scope of the present invention be determined by reference to the appended claims.

I claim:

1. The method of constructing a building comprising the steps of: assembling a plurality of frames each having a sill, at least two vertical posts having the bases thereof fixed at opposite ends of said sill, a cap supported on the upper ends of said posts and at least one joist supported by said posts and extending in parallel spaced relation between said sill and said cap, placing said frames on a foundation in parallel spaced relation so that the posts on the ends of said sills in the respective frames are aligned, fixing the spaced relationship of said frames by securing horizontal spacing members between the aligned posts of adjacent frames at the levels of said sills, joists and caps respectively, placing flooring planks on said sills and said joists between said spaced frame, and placing roofing on said caps.

2. The method recited in claim 1 including assembling said frames using pre-cut construction lumber to form said sills, posts, joists and caps, said lumber having one common dimension to provide substantially flush surfaces on opposite sides of each frame.

3. The method recited in claim 2 wherein said sills, joists and caps are formed from lumber having a cross section on the order of six inches by eight inches and wherein said posts are formed from lumber having cross sectional dimensions on the order of six inches by six inches.

4. The method recited in claim 2 including the step of connecting the members of each frame by inserting an L-shaped clip of channel section at the juncture of the respective members in each frame and nailing said clip to said members.

5. The method recited in claim 1 including the step of installing pre-cut wall panels between the posts of adjacent frames.

References Cited UNITED STATES PATENTS 2,480,330 8/1949 Kump 52-745 3,008,195 11/1961 Coffey 52-650 3,393,483 7/1968 Waillon 52-74 3,461,633 8/1969 Ziegelman 52-79 JOHN E. MURTAGH, Primary Examiner U.S. Cl. X.R. 52-236, 650

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