US3715836A - Method of building construction - Google Patents

Abstract

A WALL-CARRYING BASE PLATE IS MOUNTED ON A POURED, STILL PLASTIC CEMENTITIOUS FOUNDATION BY RESTING GAUGING MEANS INTEGRAL WITH ONE EDGE OF THE BASE PLATE ON A FORM MEMBER TO DETERMINE THE ELEVATION OF THE BASE PLATE. A DEPENDING FLANGE ON THE BASE PLATE IS ENGAGED AGAINST AN INNER SIDE OF THE FORM TO DETERMINE THE LONGITUDINAL PLACEMENT OF THE BASE PLATE. THE BASE PLATE IS THEN SUPPORTED BY THE FORM UNTIL THE FOUNDATION MATERIAL HAS SET. FLANGE MEANS ON THE BASE PLATE ARE EMBEDDED IN THE FOUNDATION MATERIAL WHILE STILL PLASTIC TO ANCHOR THE PLATE TO THE FOUNDATION. AFTER THE FOUNDATION MATERIAL HAS SET STUDS MAY ANCHORED ON THE BASE PLATE AND SIDING CONNECTED TO THE GAUGING MEANS AS A STARTER AND SECURED TO THE STUDS. DOOR FARMING IS ADAPTED TO BE ASSOCIATED WITH THE BASE PLATE, AS WELL AS THRESHOLD STRUCTURE.

Description

Feb. 13, 1973 D. G. MONROE 3,715,836

METHOD OF BUILDING CONSTRUCTION Original Filed Jan. 9. 1970 3 Sheets-Sheet 1 Feb. ,1973 D. G. MONROE METHOD OF BUILDING CONSTRUCTION 3 Sheets-Sneet 2 Original Filed Jan. 9. 1970 Feb. 13, 1973 DQG. MONROE 3,715,836

METHOD OF BUILDING CONSTRUCTION Original Filed Jan. 9. 1970 s Shets-Sneet s 3,715,836 METHOD OF BUILDING CONS'IRUC'I 10N Donald G. Monroe, Prospect Heights, Ill., asslgnor to Active Garage Builders Inc., Chicago, ll]. Original application Jan. 9, 1970, Ser. No. 1,721. Divided and this application Aug. 19, 1971, Ser. No. 173,082 Int. Cl. 1304b 1/40 US. Cl. 52-741 14 Claims ABSTRACT OF THE DISCLUSURE A wall-carrying base plate is mounted on a poured, still plastic cementitious foundation by resting gauging means integral with one edge of the base plate on a form member to determine the elevation of the base plate. A depending flange on the base plate is engaged against an inner side of the form to determine the longitudinal placement of the base plate. The base plate is then supported by the form until the foundation material has set. Flange means on the base plate are embedded in the foundation material while still plastic to anchor the plate to the foundation. After the foundation material has set studs may be anchored on the base plate and siding connected to the gauging means as a starter and secured to the studs. Door framing is adapted to be associated with the base plate, as well as threshold structure.

This application is a division of my pending application Ser. No. 1,721, filed Jan. 9, 1970, and now Pat. No. 3,636,673.

This invention relates to a method of building construction, and is more particularly concerned with the mounting of base structures especially adaptable for wooden frame buildings.

A principal problem in wooden frame building construction is in the base or starter structure on which the lower ends of the studs rest and to which they are secured. This has generally heretofore consisted in laying on and sometimes bolting to the foundation a timber such as a two-by-four and nailing the lower ends of the studs thereto as by diagonally driven nails. Such a base structure is ditficult to arrange square according to plan, is highly susceptible to deterioration due to moisture, especially where relatively close to grade as in garages and similar utility buildings. Lack of squareness and practical difficulties in attaining true elevation or flatness in poured concrete foundations and slabs increase the difficulty in attaining any substantial degree of accuracy in the stud base structure. Variations from true elevation result in gaps between the foundation surface and the stud base members with all the resulting disadvantages of lack of weather tightness, insect and small creature entries, sagging tendencies, and the like. Considerable skill has been demanded and often time-consuming and expensive expedients have been employed to overcome these deficiencies as well as others, involved in the conventional wooden timber stud base structures.

Another problem has been that of starting the siding at the base ends of the studs, and attempting to compensate for and close the gaps between the base timber and the foundation. Where gypsum wallboard is employed as the rough siding an especial problem in respect to moisture-induced deterioration along the lower edge is prevalent.

According to the present invention, the foregoing and other disadvantages, shortcomings, defects, inefficiencies and problems are overcome by the provision of a new and improved method of constructing building structure,

United States Patent 3,715,836 Patented Feb. 13, 1973 having particular regard to an especially advantageous wall-supporting base plate and related structures.

An important object of the present invention is to provide a new and improved method of and means for providing a square, level stud base.

Another object of the invention is to provide a new and improved method of mounting a wall-supporting base plate on a freshly poured, still plastic cementitious foundation.

A further object of the invention is to provide a new and improved method of constructing buildings of the vehicle garage type.

Other objects, features and advantages of the invention will be readily apparent from the following description of certain preferred embodiments thereof, taken in conjunction with the accompanying drawings, although variations and modifications may be effected without departing from the spirit and scope of the novel concepts of the disclosure, and in which:

FIG. 1 is a fragmentary perspective view of one corner of a concrete floor and foundation slab according to the invention and showing various details of combination stud and wallboard base structure and threshold structures embodying features of the invention;

FIG. 2 is a perspective inside corner view of the same structure as shown in FIG. 1 but with studs, rough siding wallboard and door framing in place;

FIG. 3 is an enlarged fragmentary vertical sectional detail view taken substantially along the line IIIIII of FIG. 2, showing a step in the method of mounting the base plate;

FIG. 4 is a fragmentary detail view taken at the base of the vehicle entrance door frame shown in FIG. 2;

FIG. 5 is a fragmental isometric detail view looking generally rearwardly, in a position adjacent to the threshold shown in FIG. 1;

FIG. 6 is an enlarged fragmentary elevational view taken substantially on the plane of line VI-VI of FIG. 3; and

FIG. 7 is a fragmentary sectional detail view taken substantially along the line VHVII of FIG. 6.

By way of example, the method according to this invention will be described in connection with the construction of a utility building structure such as a garage, although it will be readily apparent that various features of the invention are applicable to other types of buildings, and more particularly wooden frame buildings wherein the framing comprises wooden studs and siding. In the illustrated example, a foundation 10 (FIG. 1) is desirably of poured concrete, monolithic throughout the outline of the intended building and for which it will serve as the load bearing support, and monolithic with a floor slab 11 within the foundation. By preference, the foundation 10 extends to a suitable height above ground level or grade 12 to provide a protective curb or dike against ingress of drainage and also to rise above the general floor level of the floor slab 11 which is thus sunk below the top of the foundation but is desirably above the level of the grade 12, though not as high as the foundation, but sufiiciently so that while the floor surface of the slab 11 slopes from the rear downwardly toward the front of the building outline to promote good drainage, its front edge 13 will be close to grade but will be elevated to a limited extent to prevent blowing in of rain, snow or loose material when the garage door, not shown, is closed down thereagainst. Forwardly from the front edge 13 of the floor slab a driveway or ramp 14 may be provided.

On the foundation 10 are mounted means for anchoring the superstructure of the building, and comprising longitudinally on and along each extent of the foundation a combination stud and wallboard base plate 15. In an eflicient, low cost, sturdy, highly advantageous form, the base plate may be constructed as an aluminum extrusion, although as will be evident it could be made as a rolled section from any suitable material. Synthetic materials may be employed for the plate structure, but aluminum has, currently, advantages both as to availability, low cost, ease of manufacture by extrusion process, ready workability, light weight, corrosion resistance, and the like.

If preferred, the appropriate length of sections of the plate 15 may be anchored to the selected lengths of the foundation after the foundation has been poured and the concrete cured. A preferred and advantageous structure of the plate has it equipped with means for anchoring it in the foundation while the concrete is still plastic so that when the concrete has set and cured the plate is permanently anchored thereto and provides a thorough weather seal across the top of the foundation. To this end, the plate is provided with integral depending anchor flange means arranged to be embedded in the foundation and comprising at least an inner edge longitudinal depending anchor flange 17 and an outer edge depending longitudinal anchor flange 18 (FIG. 3). To facilitate extrusion of the section, the flanges 17 and 18 are desirably continuous and of uniform dimensions throughout. A thoroughly interlocked relationship of the flanges 17 and 18 with the concrete of the foundation is assured by the provision along the lower edges of the flanges of laterally turned or extending anchoring beads 19 serving as anchor lug terminals and desirably located on the inner sides of the respective flanges to leave the outer sides thereof plain. Additional anchorage is desirably provided by means of a longitudinal spear headed depending anchoring flange 20 intermediate the flanges 17 and 18 and which be narrower, as shown. Through this arrangement, the plate 15 is adapted to be applied to the plastic concrete of the foundation immediately after the foundation has been poured within a concrete form, by pressing and working the flanges 17, 18 and 20 down into the concrete until the underside of the plate 15 is in firm contact with the concrete. In effecting this, one of the depending edge flanges, herein the flange 18, is desirably located at the outer face and to become the upper portion of the outer face of the foundation. Thereby, the flange 18 serves as a gauge for accurate longitudinal placement of the base plate, by sliding the flange 18 downwardly along the inner side of a removable concrete, or so-called cement, form 21 of any preferred type which serves to form the outer side of the foundation and also provides a screed to determine the height of the foundation. Further, finishing of the top of the foundation is avoided by applying the plate 15 thereto and using the screed 21 to gauge the height accurately. For this purpose, the plate is desirably provided with a gauging flange 22 extending downwardly and outwardly obliquely from an upward extension 23 from the flange 18. By having the top of the screed 21 level, resting of the edge of the gauging flange 22 thereon, with the flange 18 square against the vertical inner surface of the screed perfectly locates the plate 15 horizontally. Because of its flange reinforced construction, the plate 15 will retain its substantially warp-free, rigid square alignment, resisting distortion and remaining true while being pressed and worked into position in the foundation concrete. After the concrete has set and the screed form 21 has been removed, the outer face of the flange 18 serves as the upper portion of the outer face of the foundation 10, and the flange 22 is face to overhang the outer side of the foundation as part of a weather seal provided by it and the flange extension as well as the flange 18.

At the inner side of the foundation 10, the flange 17 may be flush with the inner side of the foundation similarly as the flange 18 is flush with the outer side, but in a preferred form, the flange 17 is completely embedded in the concrete and the foundation is provided with a fillet 24 of preferably ogee form sloping downwardly from about the level of the plate 15 to the floor surface of the floor slab 11. Through this arrangement, the fillet 24 provides an inside curb for the floor to drain away from the foundation and by avoiding sharp corners makes the curb area easy to clean. It also provides a protective buffer for the lower portion of the building structure. By having the ends of the respective base plate sections cut square, they will when joined in right angular abutment, as seen in FIGS. 1 and 5, assure that the base outline for the building will be square.

In constructing the building superstructure, studs 25 (FIGS. 2 and 3) such as two-by-four timbers, are erected by resting their lower ends on the base plate 15. Means for properly orienting the lower ends of the studs comprise a channel arrangement on the upper face of the plate arranged to receive the studs with their major transverse dimension extending across and normal to the length of the plate. For this purpose, the plate is provided with an upwardly projecting flange 27 as an extension of and in a plane with the flange 17 and coextensive therewith along the inner edge of the base plate. In order to enable the flange 27 to be secured to the base end portion of the stud 25 as by means of nails 28, the flange 27 extends to a height sufficient to provide for a pair of vertically spaced nailing grooves 29 in an upper portion thereof sufliicently spaced from one another and above the plate 15 to enable reception of the securing nails 28 without splitting the wood of the stud where the nails are relatively offset not only with respect to one another but also with respect to the width of the stud, substantially as shown in FIGS. 6 and 7. Not only do the nailing grooves 29 provide guide marks on the flange 27 to show Where the nails should be driven, but they provide thin areas in the flange to facilitate driving the nails therethrough and avoiding any need for prepunching the flange to receive the nails. To reinforce the flange 27 it is desirably provided with a thickened upper edge 36 which is desirably formed with an inwardly projecting claw tip 31 therealong adapted to bite into the confronting surface of the stud 25 to enhance the stud anchorage. Placement of the stud base and assisting in retaining it in place to be nailed is a back up channel flange 33 rising from the plate 15 in coextensive spaced parallel relation to the flange 27 and confronting the edge of the stud opposite to that which is in nailing confrontation to the flange 27. For this purpose the flange 33 need be only a fraction as high as the flange 27, such for example as on the order of about one-third as high, but high enough to back up the stud effectively while the anchoring nails 28 are being driven.

In order to facilitate placement of and to at least initially support siding wallboard 34, and more particularly such walboard to serve as rough siding, the flanges 23 and 33 of the plate 15 cooperate in spaced parallel coextensive relation to provide a channel outwardly alongside the stud-receiving chanel to receive the lower edge of the wallboard 34. Further, by thus receiving the wallboard, a thorough weather seal relationship is provided across the base of the building superstructure. While the wallboard 34 may be of any desired construction, gypsum wallboard or other type of wallboard having a generally rigid, heat-insulating and preferably also fire-resistant core Within parallel covers is especially well suited for the purpose. Any preferred means for securing the wallboard 34 to the studs 25 may be employed, such as nails 35.

Over the outer side of the wallboard 34 a protective siding is desirably attached such as clapboard type panels 37 which may be metal backed by an insulating material and having along their lower edges respective hook-like flanges 38 interengageable with complementary oblique anchor flanges 39 along the upper margins of subjacent panels and which upper margins are secured to the wallboard 34 as by means of the nails 35. The first course of the siding panels 37 is secured in place by engaging its lower edge hook flange 38 with the gauging flange 22 of the base plate serving in this instance as a starter strip flange with which the hook flange 38 interengages in a manner to complete the weather seal across the base of the building superstructure.

As will be observed in FIGS. 1 and 5, at the corners of the building, the contiguous ends of the base plate members are so related that the wallboard channel of one of the members opens in alignment with the end of the members to enable full closing of the corner by engagement of the respective vertical end edge portions of the wallboards at the corners, and the outer surface siding panels 37 will be joined and corner strips applied as is customary with this type of siding.

A vehicle entrance is framed at the front edge 13 of the floor slab 11 as by having shortened lengths of the foundation and base plate assembly blunt ended at each side of the vehicle door opening for supporting and anchoring at each blunt end a vertical framing timber 40 (FIGS. 2 and 4). For this purpose, the framing timber is desirably notched out as at 41 in its lower end to seat on the adjacent end portion of the base plate to receive the anchoring nails 28 driven through the anchoring flange 27. The lower end portion of the framing timber 40 alongside the notch may then extend freely along the blunt end of the foundation and provide a door-receiving length extending to the floor.

It is generally desirable to provide an access door in addition to the vehicle entrance door, and this may be provided for by a suitable gap at the desired place in the base plate, as best seen in FIGS. 1, 2 and 5, and in that gap mounting a threshold 42 on the foundation 10 with its end in contiguity with the discontinuous ends of the base plate. In a desirable form, the threshold 42 may comprise an aluminum extrusion having a body which slopes from the inner side toward the outer side and has thereunder in order to maintain the sloping relation and to have the threshold of as thin a section as practicable, a set of parallel spaced stepped spacer ribs 43 which rest on the top of the foundation, or may be embedded in the cement thereof, if preferred. Along the outer side, the threshold 42 is desirably provided with a cap or kick plate depending skirt 44 which bears against the outer face of the foundation or may be embedded substantially flush therewith. Desirably a weather strip 45 is inserted in a groove extending longitudinally in the upper face of the threshold 42 adjacent to its inner margin. Such strip may be of vinyl or other suitable resilient material for engagement with the lower edge of a door which will be hung on a door frame 48 which will frame the door opening. The lower ends of the door frame are desirably engaged with the base plate -15 at the opposite ends of the threshold 42, with the siding board panel flanges 23 and 33 desirably suitably cut out, as shown in FIG. 5 to re ceive the lower ends of the door frame uprights which are adapted to be anchored in place by nailing the same to the anchor flange 27. At their outer edges, the door frame uprights 48 may overhang and extend downwardly along the foundation 10 alongside the threshold weather seal and kick plate 44, as shown at 49 (FIG. 2). If desired, a sidewalk 50 (FIG. 1) may be provided in alignment with the doorway opening.

From the foregoing it will be apparent that the present invention enables easy, rapid and accurate frame building construction, at least in the initial stage wherein the combination stud and wallboard base plate structure provides continuous straight lengths which are as free as may practically be obtained from sagging, bending or other warpage, are adapted to be quite accurately mounted on a freshly poured cement or concrete foundation both as to elevation and as to building perimeter or outline, and after setting of the foundation not only provide for easy and accurate erecting of the studs and wallboard, as well as siding thereon and thereto, but provide efficient weather seal across the joint between the foundation and the building. Doorway openings and framing therefor are efficiently accommodated and maintained in erected condition as facilitated by the base plate structure. An eflicient threshold structure is provided especially cooperative with respect to the base plate structure. Exceptional benefits are derived by use of the invention in the construction of utility buildings such as garages.

It will be understood that variations and modifications may be effected without departing from the spirit and scope of the novel concepts of this invention.

I claim as my invention:

1. A method of mounting a wall-supporting base plate on a cementitious foundation to attain accurate vertical and longitudinal placement of the base plate on the foundation while the foundation is in a plastic state, comprismg:

placing the base plate on the plastic foundation; and

resting gauging means on one edge of the base plate on a form member to determine the elevation of the base plate, and thus supporting the base plate until the foundation material has set.

2. A method according to claim 1, including engaging a depending flange on the base plate against an inner side of the form to determine the longitudinal placement of the base plate.

3. A method according to claim 2, including employing said form as a screed to determine the height of the foundation, and pressing said flange into position between the form and the foundation material.

4. A method according to claim 2, including embedding additional flange means of the base plate into the material of the foundation while said material is still in a plastic state to anchor the base plate to the foundation.

5. A method according to claim 2, including removing said form after the foundation material has set, erecting studs on said base plate, and connecting siding to said gauging means as a starter and seccuring the siding to said studs.

6. A method according to claim 5, wherein said base plate has a wallboard channel along said one edge and a stud channel between the wallboard channel and the opposite edge of the base plate, erecting the studs in the stud channel and wallboard in the wallboard channel, and securing said siding to the wallboard and the wallboard to the studs.

7. A method of building construction including:

forming a raised elongated foundation;

anchoring to the top of and longitudinally along the foundation a wall-receiving base plate having an end terminating at a doorway section of said foundation; and

mounting a threshold member on the foundation in alignment with and in endwise contiguity to said end of the base plate and placing a depending kick plate of the threshold member along an outer side of the foundation.

8. A method according to claim 7, including embedding an outer side depending flange of the base plate substantially flush with said outer side of the foundation while the foundation is still in plastic state, and embedding said kick plate panel in the still plastic outer side of the foundation substantially flush with said depending flange.

9. A method according to claim 7, comprising mounting a door frame member on and securing it to said base plate at said end of the base plate, and extending a portion of the door frame member downwardly along the foundation contiguous to the adjacent end of said kick plate panel.

10. A method of building construction including:

forming a raised foundation having an end at a doorway opening;

mounting on said foundation a base plate and anchoring the base plate to the foundation with an end of the base plate terminating at said end of the foundation; and

mounting a door frame member in upright position on and securing it to said base plate and orienting a portion of the frame member to extend downwardly along said base member and foundation end.

11. A method according to claim 10, wherein said door frame member is a wooden stud, comprising notching out said wooden stud on a lower end portion thereof to provide a downward shoulder to rest on said base plate and to provide said portion which is oriented downwardly along the ends of the base plate and the foundation,

12. A method of building construction comprising:

mounting on a raised foundation having a right angle adjoining said *base plates at said corner with the end of the wallboard channel of said second base plate clear of the stud attachment flange of the first base plate, and mounting wallboard panels in the wallboard channels of the base plates with vertical edges of the panels adjoining at said corner.

13. A method according to claim 12, comprising notching out the stud attachment flange of said first base memher to provide the clearance for said end of the wallboard channel of said second base plate.

14. A method according to claim 12, comprising mounting respective studs in contiguity on the contiguous end portions of said base plates, and attaching said wallboard panels thereto.

References Cited UNITED STATES PATENTS 3/1938 Barnett 52295 X 7/1960 Babcock 52-74 1 5/1967 LlltCh 52295 X 8/1967 Russell 5Z294 X OTHER REFERENCES Article Post Anchors, from Popular Mechanics magazine, August 1964, p. 141. 0

PRICE C. FAW, JR., Primary Examiner U .8. Cl. X.R.

UNITED STATES PATENT 1 OFFICE CERTIFICATE OF CORRECTION Patent 3.715.836 Dated February 13 1973 Inventor(s) D. G. MONROE It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column 3, line 35, for "which be" read --which may be".

Column 4, line 52, for "walboard" read wa1Ib0ard-'-;

line' '55, for -'chane1" read channel.-

Signed and sealed this 5th day of March 19711..

(SEAL) Abtest:

EDWARD -M.FLETCHER,JR. I c. MARSHALL DANN Attesting Officer Commissioner of Patents"

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