WO2010115070A1 - System and method for fabricating an aperture in a structure - Google Patents

System and method for fabricating an aperture in a structure Download PDF

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Publication number
WO2010115070A1
WO2010115070A1 PCT/US2010/029733 US2010029733W WO2010115070A1 WO 2010115070 A1 WO2010115070 A1 WO 2010115070A1 US 2010029733 W US2010029733 W US 2010029733W WO 2010115070 A1 WO2010115070 A1 WO 2010115070A1
Authority
WO
WIPO (PCT)
Prior art keywords
pair
buck
panels
slip
insulated concrete
Prior art date
Application number
PCT/US2010/029733
Other languages
French (fr)
Inventor
John Rizzotto
Original Assignee
Business Network Solutions U.S.A. Inc.
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
Priority claimed from US12/634,512 external-priority patent/US20100083595A1/en
Application filed by Business Network Solutions U.S.A. Inc. filed Critical Business Network Solutions U.S.A. Inc.
Publication of WO2010115070A1 publication Critical patent/WO2010115070A1/en

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Classifications

    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B1/00Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
    • E06B1/04Frames for doors, windows, or the like to be fixed in openings
    • E06B1/12Metal frames

Definitions

  • the present invention relates to steel frame buildings and more precisely to a metal member that acts as a door or window buck.
  • FIG. 1 is an exploded view showing a main column 5 used in the assembly of a steel building along with a gutter 2, a truss assembly 4 and a foundation assembly 6. Only a portion of the trass is shown in this Figure. This portion is made up of a left truss connection plate 4C, a lower chord 4A, a top member 4B of the trass assembly 4, and an attachment plate 4C.
  • an adjustable rain gutter 2 with a support arm 2A, which contains a series of evenly spaced holes 2B.
  • a structural adjustment sleeve 3 which includes a line of vertically positioned evenly spaced holes 3A.
  • the column 5 Directly beneath the structural adjustment sleeve 3 is the column 5, which contains holes at its top 5 A and holes at its bottom 5B.
  • the foundation assembly 6 Directly beneath the column 5 is the foundation assembly 6, which includes a low column 6D, a series of vertical holes 6H in the low column 6D, a horizontal plate 6B which is attached approximately midway up from the bottom of the low column and stabilizing tubes 6C which extend horizontally and are attached to the bottom of the low column.
  • the column assembly is shown completely assembled in FIG. 2. In this
  • the support arm 2A for the gutter 2 is placed into the top of the structural adjustment sleeve 3.
  • the bottom end of the structural adjustment sleeve is placed over the column 5.
  • the trass connection plate 4C is U-shaped and wraps around to enclose a portion of the structural adjustment sleeve.
  • the column 5 is hollow and is placed over the low column of the foundation assembly 6.
  • the trass assembly can be moved up or down along the structural adjustment sleeve to a desired height and then locked at that height by placing a bolt through the trass connection plate 4C into one of the holes in the structural adjustment sleeve 3 that is at a desired level.
  • a similar assembly and adjustment is carried out for the gutter.
  • the gutter arm which supports the gutter contains a series of vertical holes 2B, which can be aligned with the holes 3A in the structural adjustment sleeve. The gutter is moved up or down to a desired location and a bolt is placed through the structural adjustment sleeve holes and the holes in the support arm for the gutter to lock the gutter in a desired location.
  • the foundation assembly 6 is set in concrete before any assembly begins.
  • the plate 6B which extends out horizontally from the low column portion of the foundation assembly lies on the top of the concrete and sets the depth to which the foundation assembly is placed in the concrete. It is accurately positioned in the vertical plane to set the elevation of the main column which will rest on this plate. Of equal importance is the fact that this plate is set to lie in the horizontal plane which insures that the orthogonally positioned low column is perfectly vertical and will support the main column in a perfectly vertical position.
  • the foundation assembly is precisely located with respect to the various other main columns so that when a main column is placed over a low column of the foundation assembly, it is accurately located, enabling the components of the building to be assembled without cutting or drilling on site.
  • the precise location of the foundation assemblies is typically carried out with a laser interferometer which is vastly more accurate than the usual steel tape measure method used at most prior art construction sites.
  • a laser leveling device is used to insure that the top surface of all the foundation plates are at precisely the same elevation, often within an error allowance as small as +/-0.001 inch.
  • the present invention insures that the columns are precisely located in the both the horizontal and vertical planes, which means that they are at the correct elevation and are plumb and square.
  • the stabilizing tubes which are connected to the bottom of the foundation assemblies, are horizontally positioned rods. They anchor the foundation assemblies to the concrete footing and aid in preventing the foundation assemblies from being pulled from the concrete by uplift loads.
  • a second anchoring system which employs a "chair” to provide even greater uplift load capacity, is described later in this section.
  • the short column 6D of the foundation assembly is typically rectangular in cross section as is the main column.
  • the low column is typically made to be slightly smaller in cross sectional than the main column so that the low column fits inside the base of the main column.
  • a collar is substituted for the low column. The collar grips the main column from the outside, making it possible to use solid or closed ended columns for this type of construction.
  • each column is placed over the foundation assembly and locked into place by placing bolts through holes 5B in the main column and holes 6H in the low column portion of the foundation assembly.
  • This method of positioning the foundation assembly and the method of connection between the column and the foundation assembly provide a substantial advantage in assembly over the prior art. This method is simple and fast, while at the same time insuring the accurate location and positioning of the columns in both the horizontal and vertical planes.
  • an overhang for the roof is formed by inserting 1 inch by 3 inch steel tubing into the open ends of the trusses 460, cut to the proper pitch and adjusted to the proper length to create the desired overhang, and then connecting them together around the perimeter of the roof using a steel sub-fascia. A fascia and insulation may then be applied. This greatly improves the insulation qualities of the resulting building, reducing heating and cooling costs.
  • This application is directed to a slip-over buck fashioned from metal bent at right angles to accommodate standard window or door. This application is further directed to a method for forming an aperture in a structure using a slip- over buck and insulated concrete forms.
  • Fig. 1 is an exploded view showing a main column used in the assembly of a steel building;
  • Fig. 2 shows the column assembly completely assembled;
  • Fig. 3 is a view of a wall having a window opening
  • Fig. 4 is a perspective view of a window or door buck according one embodiment of the invention.
  • Fig. 5 is a side view of the window or door buck according to one embodiment of the invention.
  • Fig. 6 is a depiction of the window buck once it is installed
  • Fig. 7 is a cutaway view of the construction along the line 7-7;
  • Fig. 8 is a side-view of a buck for masonry applications
  • Fig. 9 is a side-view of an installed buck for masonry applications
  • Fig. 10 is a perspective view of a window or door buck according another embodiment of the invention
  • Fig. 11 is a side-view of a buck
  • Fig. 12 is a side-view of an installed buck
  • Fig. 13 is a perspective view of a window or door buck according another embodiment of the invention.
  • Figs. 14a - 14e are each a side view of an embodiment of the buck
  • Figs. 15a - 15d are each a side view of an embodiment of the buck;
  • Fig. 16 is a load analysis for the buck;
  • Fig. 17 is a load analysis for the buck.
  • Fig. 18 illustrates a side view of a buck in accordance with another exemplary embodiment.
  • Figure 19 illustrates a flowchart for a method for installing an adjustable window buck in accordance with another exemplary embodiment.
  • Figure 3 depicts a wall constructed using the described window buck.
  • the wall consists of a header 20 and footer 22. Header 20 and footer 22 have a track in which studs 24 are mounted. Additionally, as shown, at the end of each wall is column 28. Steel construction, wood frame construction, masonry construction and the like could all be used with the disclosed buck. In a preferred embodiment, wall panels 26 are used to finalize the construction of the wall. As shown, a window opening is framed using building elements 32. These elements 32 create a rough opening for a window. Once the rough opening is framed, window bucks 34, according to the present invention, are installed.
  • the window bucks 34 are installed around the rough opening before a window is installed in the opening.
  • the window bucks 34 provide the final size for the window.
  • the bucks 34 are used as door bucks, the door is framed and then bucks 34 are used to provide the final sizing.
  • the doors are installed in a manner similar to the windows as detailed herein.
  • two opposing bucks are squared and secured to the structure match a window frame.
  • the pair of bucks is the top and bottom buck.
  • the other two bucks i.e., the side bucks, are then place in the rough opening.
  • the window frame is then attached to the bucks and the side bucks are secured to the structure. It should be noted that only one buck has to be secured to the structure before the window frame is attached to the buck.
  • Buck 34 is preferably made from 20 gauge steel. Alternatively, aluminum, other gauge steels, composite material, vinyl, plastic, PVC, or other material can be used. In a preferred embodiment, the metal is prepared so that it does not corrode.
  • the buck 34 has a first wall 40 extending in a first direction. This first wall 40 has holes 38 that are used to mount the buck to the face of the rough framing. In one embodiment, the holes 38 used for attaching the buck to the studs 24 are substantially slots so that if any additional shimming is required, the buck 34 can be properly placed.
  • the buck 34 has a second wall extending substantially perpendicular from one end of the first wall 40.
  • this wall extends for approximately 4-1/2 inches.
  • a third wall 44 extends substantially perpendicular to the second wall 42, and parallel to the first wall.
  • a fourth wall 46 extends substantially perpendicular to the third wall extends away from the second and third walls.
  • the width of the third and fourth walls is substantially 3 A of an inch.
  • fourth wall 46 includes mounting holes 36 used to mount the buck in the framed window opening.
  • the general shape of the buck 34 is shown in Figure 5.
  • the disclosed buck 34 is adapted to attach to the sides of a framing member as shown by the dashed line in Figure 5.
  • first wall 40 is substantially at 90° to the second wall 42 and that the third wall 44 is substantially parallel to first wall 40.
  • the fourth wall 46 is substantially parallel to the second wall 42.
  • the buck 34 is manufactured using an 8 3 A" flat strip of 20 gauge metal.
  • Figure 6 depicts a window buck 34 as it would appear on the inside of a window opening.
  • the window buck 34 is attached to a stud 24 using screws or nails 50, 51.
  • the attaching means are rivets, nuts and bolts, screws, nails, welds, epoxies, or the like.
  • attaching means 50, 51 are #8 wafer head screws.
  • Wall panel 26 is drywall.
  • Connector 54 is any structurally acceptable connector, manufacturing recommended connector, or those used for attachment means 50 and 51.
  • connector 54 is recommended by the manufacturer of the window being used.
  • Figure 7 depicts the cutaway view along line 7-7 in Figure 1.
  • the buck 34 is attached to sill 32 using connectors 50 and 51.
  • connector 54 affixes window frame 52 to buck 34.
  • connector 54 penetrates sill 32.
  • a nut holds connector 54 in place.
  • FIG 8 is another embodiment of the disclosed door and window buck.
  • the buck 80 shown in Figure 8 is preferably used for masonry applications and fits standard masonry openings. It should be noted that the buck can be reversed during installation to change the depth of the reveal. In this embodiment, both mounting tabs of the buck are mounted to the outside of the wall.
  • FIG 9 shows the buck 80 installed in an opening.
  • the buck 80 is secured to the masonry structure 82 (not shown) using the fixing means 84.
  • the buck is fixed using screws, nails, anchors, and the like.
  • the window is then affixed to the raised portion 86 of the buck 80.
  • the aperture is a rough opening formed in the concrete structure.
  • the disclosed buck is used as a form for the concrete, slipped over the structure around the four sides of the opening.
  • at least the top and bottom bucks are secured to the structure creating a rough opening sized to match the window.
  • a first side buck is affixed to the structure.
  • the window frame is then installed in the opening and secured to the three bucks already secured to the structure.
  • the window frame is then secured to the fourth unsecured buck.
  • the unsecured buck is secured to the window, it is then secured to the structure. In this manner, a zero tolerance assembly is created eliminating air and water infiltration.
  • this buck or slip over flashing effectively eliminates water and air infiltration, the feeding source for mold.
  • Figure 10 depicts a perspective view of another embodiment of the buck.
  • FIG 11 depicts another embodiment of the invention.
  • the buck 100 shown in Figure 11, is preferably used for wood frame construction.
  • the buck shown in Figure 11 eliminates the need for a nail fin on a standard window.
  • raised portion 110 is offset to accommodate window frames without a nail fin.
  • window manufacturers need not create a separate window frame for wood frame construction.
  • FIG 12 shows the buck 100 installed in an opening.
  • the buck 100 is secured to the masonry structure 102 (not shown) using the fixing means 104.
  • the buck is fixed using screws, nails, anchors, and the like.
  • the window is then affixed to the raised portion 110 of the buck 100.
  • Figure 14 depicts various window bucks for wood, steel, and masonry construction.
  • Figure 15 depicts various door bucks for wood, steel, and masonry construction.
  • the disclosed bucks can be formed using a standard break, roll forming, extrusions, and the like.
  • the disclosed buck can also be used with glass block doors, sliding doors, windows, and the like.
  • the four pieces of the buck are placed in the aperture of the structure. At least a first one of the bucks is leveled, squared, and affixed to the structure. Next, the window frame is affixed to the first buck secured to the structure. Next, the remaining bucks are affixed to the window frame then to the structure. It should be noted that using this method, as well as the method discussed above, zero tolerance between the window frame and structure is achieved, thereby eliminating air and water filtration. Additionally, using the described buck, installation is fast and precise allowing builders and installers to accelerate job completion.
  • the disclosed buck provides an increased allowable load over prior art bucks.
  • a load analysis for two embodiments of the disclosed buck is shown in Figs. 16 and 17.
  • any of the pockets created between the buck and the structure are filled with an insulating material to improve the installation capacity of the building.
  • the slip-over flashing for use as a door or window buck described herein comprises a first pair of walls substantially parallel to one another which are used to affix the buck to the structure. At the top end of these two walls there is at least one wall perpendicular to the sidewalls. A second pair of walls substantially parallel to one another and parallel to the first two walls rise above the perpendicular wall. These second two power walls are joined at their tops with a perpendicular wall. This perpendicular wall is used as the window frame mount.
  • the window frame mount can be positioned in various locations to accommodate various window frames and construction techniques as shown in the various environments disclosed herein. However, it should be noted that there are other potential embodiments and not all of the embodiments are disclosed herein.
  • an insulated concrete form and adjustable buck can be combined. Specifically, during construction, an adjustable buck is inserted onto the insulated concrete forms with the adjustable buck's vertical walls aligning adjacent to two pieces of insulating material. These insulating materials can preferably be 2" Styrofoam forms or any other suitable insulating material as should be appreciated by those skilled in the art.
  • the adjustable buck may be a metal sheet, such as steel, aluminum or the like. The buck is positioned accordingly as used in all other methods of construction.
  • FIG. 18 shows an adjustable buck 1800 in accordance with this embodiment.
  • adjustable buck 1800 is comprised of a first set of panels 1801a, 1801b), a second set of panels 1802a, 1802b, a first pair of mounting panels 1803a, 1803b, a second pair of mounting panels 1804a, 1804b, and a connecting panel 1805.
  • the first set of panels 1801a, 1801b each include an upper end portion and a lower end portion.
  • the second set of panels 1802a, 1802b are affixed to the respective lower end portions of the first set of panels 1801a, 1801b.
  • the connecting panel 1805 is adapted to connect the respective upper end portions of the first set of panels 1801a, 1801b.
  • the connecting panel 1805 is a perpendicular wall that is used as the frame mount. It should be understood that while the exemplary embodiment illustrates the connecting panel being connect perpendicularly to the first set of panels 1801a, 1801b, the disclosure herein is in no way intended to be limited to a perpendicular connection.
  • the first pair of mounting panels 1803a, 1803b are affixed to a lower surface of panel 1802a of the second set of panels 1802a, 1802b.
  • the second pair of mounting panels 1804a, 1804b are affixed to a lower surface of panel 1802b of the second set of panels 1802a, 1802b.
  • the second pair of mounting panels 1804a, 1804b are affixed at a substantially perpendicular angle to a lower surface of panel 1802b of the second set of panels 1802a, 1802b. Accordingly, in this embodiment, each panel of the pairs of mounting panels are positioned substantially parallel to one another.
  • both pairs of mounting panels 1803a, 1803b and 1804a, 1804b preferably extend in a direction away from the second set of panels 1802a, 1802b that is opposite (i.e., 180 degrees) from the first set of panels 1801a, 1801b.
  • the outer panel 1803a of the first pair of mounting panels is substantially shorter than the inner panel 1803b.
  • the outer panel 1804b of the second pair of mounting panels is substantially shorter than the inner panel 1804a.
  • each panel of the pair of mountings panels are substantially the same length.
  • both the first pair of mounting panels 1803a, 1803b and the second pair of mounting panels 1804a, 1804b are each adapted to be secured to respective insulated concrete forms 1806, 1807.
  • insulated concrete form 1807 is secured to the second pair of mounting panels 1804a, 1804b, and panel 1802b with screws 1808, 1809, and 1810.
  • insulated concrete form 1806 can similarly be secured to the first pair of mounting panels 1803a, 1803b and panel 1802a with screws (not shown).
  • the panels described above are affixed to one another in one embodiment, the panels are alternatively formed by bending one or more strips of metal at the appropriate locations. It its broadest sense, two or more panels are connected to each another by bending one strip of metal at the appropriate location(s).
  • the insulated concrete forms 1806, 1807 and the buck 1800 are attached to one another prior to installation in the structure, with two or more half inch #8 wafer head self drilling screws (/. e. , screws 1808, 1809 and/or 1810) used to keep the interior components ⁇ e.g., insulated concrete forms 1806, 1807) and the exterior component (e.g., the window buck 1800) as one unit.
  • two or more half inch #8 wafer head self drilling screws /. e. , screws 1808, 1809 and/or 1810 used to keep the interior components ⁇ e.g., insulated concrete forms 1806, 1807) and the exterior component (e.g., the window buck 1800) as one unit.
  • a two and a half inch #12 hex head will attach the interior and exterior components to the foam (Le., insulated concrete forms 1806, 1807) by screwing from the outside of the buck 1800 through the foam and into the interior metal so as to attach the interior and exterior components by sandwiching the two inch foam form.
  • the screws 1808, 1809 and/or 1810 can be removed so that the buck 1800 can be adjusted as required by the standard seal attachment methods.
  • the buck 1800 can be reattached to the structure with concrete screws 1808, 1809 and/or 1810, such as Tapcon® concrete screws or the like. It is noted that in alternative embodiment, different caliber of screws can be used.
  • FIG 19 illustrates a flowchart for a method for installing an adjustable window buck in accordance with an exemplary embodiment.
  • a user forms an aperture in a building.
  • the aperture is a rough opening formed in the structure and can be formed in accordance with conventional techniques.
  • the user secures a pair of insulated concrete forms 1806, 1807 to a structure where the aperture is formed.
  • the user mounts a buck 1800 onto the pair of insulated concrete forms. Specifically, both pairs of mounting panels 1803a, 1803b and 1804a, 1804b onto the respective insulated concrete forms 1806 and 1807.
  • step 1931 the user attaches the buck 1800 to insulated concrete form 1807 by screwing the second pair of mounting panels 1804a, 1804b, and panel 1802b with screws 1808, 1809, and 1810 to insulated concrete form 1807.
  • insulated concrete form 1806 can be secured to buck 1800 in a similar manner. It should be appreciated that if the insulated concrete forms 1806, 1807 and the buck 1800 are attached to one another prior to installation, steps 1911 through 1931 are not performed in the exemplary method. In such an embodiment, the combination of insulated concrete forms 1806, 1807 and the buck 1800 are installed in the aperture as a single unit.
  • step 1941 the user pours concrete into the pair of insulated concrete forms to create a concrete wall as one of skill in the art would appreciate.
  • step 1951 the user decides whether the buck 1800 needs to be adjusted based on the positioning of the buck 1800 with respect to the building structure. If adjustment is unnecessary, buck 1800 is effectively installed (i.e., the window/door frame can be installed) and the process ends at step 1971.
  • step 1961 the user adjusts the buck 1800 to the proper position.
  • buck 1800 is adjusted by unscrewing screws 1808, 1809 and/or 1810, positioning buck 1800 in the proper position, and tightening screws 1808, 1809 and/or 1810 to secure buck 1800 in the desired position.
  • the process terminates (step 1971) and the window/door frame can be installed.
  • buck 1800 can eliminate health conditions and reduce mold litigation. By creating an air tight opening, there is a reduction in loss of heating and cooling thereby saving money in energy bills. Manufacturers can make one standard window type instead of two (with and without nail fins) because all construction accepts the same window allowing the maker of windows to be more profitable. Additionally, installation is fast and precise allowing the builder/installer to accelerate job completion. This method resolves the form/buck problem which leads to blow outs. This method creates a rigid exterior Arris so that synthetic stucco will not easily crack or chip around windows or door. This method also creates a true finished interior Arris to accept drywall and corner beads.

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  • Engineering & Computer Science (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Door And Window Frames Mounted To Openings (AREA)

Abstract

A slip-over buck fashioned from metal bent at right angles to accommodate standard window or door. Preferably, the slip-over buck has a first pair of panels that each have upper and lower end portions and are substantially parallel to one another. Moreover, a connecting panel is provided and is adapted to connect the respective upper end portions of the first pair of panels to one another. This connecting panel is used as the frame mount. In addition, a second pair of panels is connected substantially perpendicularly to the respective lower end portions of the first pair of panels and two pairs of mounting panels are connected to the second pair of panels, respectively.

Description

SYSTEM AND METHOD FOR FABRICATING AN APERTURE IN A STRUCTURE
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. Patent Application Serial No. 12/634,512 entitled SYSTEM FOR FABRICATING AN
APERTURE IN A STRUCTURE, filed December 9, 2009, which is a continuation of U.S. Patent Application Serial No. 11/320,806, entitled
SYSTEM AND METHOD FOR FABRICATING AN APERTURE IN A
STRUCTURE, filed December 30, 2005, which claims the benefit of U.S. Provisional Application Serial No. 60/640,224 filed January 3, 2005, the contents of each of which are incorporated by reference herein. The application also claims the benefit of U.S. Provisional Application Serial No. 61/166,118, filed April 2, 2009, the contents of which is incorporated by reference herein.
FIELD OF THE INVENTION The present invention relates to steel frame buildings and more precisely to a metal member that acts as a door or window buck.
BACKGROUND OF THE INVENTION
Steel framing is used for rapid, low-cost building assembly. While it is known to construct steel frame buildings where the frame connects between the foundation and roof beams, there is no convenient mechanism for creating door and window bucks. U.S. Patent Publication No. US 2002/0148188, incorporated herein by reference, discloses a system for assembling a steel frame building.
FIG. 1 is an exploded view showing a main column 5 used in the assembly of a steel building along with a gutter 2, a truss assembly 4 and a foundation assembly 6. Only a portion of the trass is shown in this Figure. This portion is made up of a left truss connection plate 4C, a lower chord 4A, a top member 4B of the trass assembly 4, and an attachment plate 4C. At the top of this drawing is an adjustable rain gutter 2 with a support arm 2A, which contains a series of evenly spaced holes 2B. Directly beneath the support arm 2A, is a structural adjustment sleeve 3 which includes a line of vertically positioned evenly spaced holes 3A.
Directly beneath the structural adjustment sleeve 3 is the column 5, which contains holes at its top 5 A and holes at its bottom 5B. Directly beneath the column 5 is the foundation assembly 6, which includes a low column 6D, a series of vertical holes 6H in the low column 6D, a horizontal plate 6B which is attached approximately midway up from the bottom of the low column and stabilizing tubes 6C which extend horizontally and are attached to the bottom of the low column. The column assembly is shown completely assembled in FIG. 2. In this
Figure, the support arm 2A for the gutter 2 is placed into the top of the structural adjustment sleeve 3. The bottom end of the structural adjustment sleeve is placed over the column 5. The trass connection plate 4C is U-shaped and wraps around to enclose a portion of the structural adjustment sleeve. The column 5 is hollow and is placed over the low column of the foundation assembly 6.
All the components shown in FIGS. 1 and 2 are bolted together. There is no need to weld any component, facilitating assembly on the job site. In addition, where height adjustment is required, it is provided by series of vertical holes. For example, the trass assembly can be moved up or down along the structural adjustment sleeve to a desired height and then locked at that height by placing a bolt through the trass connection plate 4C into one of the holes in the structural adjustment sleeve 3 that is at a desired level. A similar assembly and adjustment is carried out for the gutter. The gutter arm which supports the gutter contains a series of vertical holes 2B, which can be aligned with the holes 3A in the structural adjustment sleeve. The gutter is moved up or down to a desired location and a bolt is placed through the structural adjustment sleeve holes and the holes in the support arm for the gutter to lock the gutter in a desired location.
The foundation assembly 6 is set in concrete before any assembly begins. The plate 6B, which extends out horizontally from the low column portion of the foundation assembly lies on the top of the concrete and sets the depth to which the foundation assembly is placed in the concrete. It is accurately positioned in the vertical plane to set the elevation of the main column which will rest on this plate. Of equal importance is the fact that this plate is set to lie in the horizontal plane which insures that the orthogonally positioned low column is perfectly vertical and will support the main column in a perfectly vertical position. The foundation assembly is precisely located with respect to the various other main columns so that when a main column is placed over a low column of the foundation assembly, it is accurately located, enabling the components of the building to be assembled without cutting or drilling on site.
The precise location of the foundation assemblies is typically carried out with a laser interferometer which is vastly more accurate than the usual steel tape measure method used at most prior art construction sites. In addition, a laser leveling device is used to insure that the top surface of all the foundation plates are at precisely the same elevation, often within an error allowance as small as +/-0.001 inch. The present invention insures that the columns are precisely located in the both the horizontal and vertical planes, which means that they are at the correct elevation and are plumb and square.
The stabilizing tubes, which are connected to the bottom of the foundation assemblies, are horizontally positioned rods. They anchor the foundation assemblies to the concrete footing and aid in preventing the foundation assemblies from being pulled from the concrete by uplift loads. A second anchoring system, which employs a "chair" to provide even greater uplift load capacity, is described later in this section.
The short column 6D of the foundation assembly is typically rectangular in cross section as is the main column. Where the main column is hollow, the low column is typically made to be slightly smaller in cross sectional than the main column so that the low column fits inside the base of the main column. Where the main column is solid, a collar is substituted for the low column. The collar grips the main column from the outside, making it possible to use solid or closed ended columns for this type of construction.
In the assembly of the trusses and hollow columns, each column is placed over the foundation assembly and locked into place by placing bolts through holes 5B in the main column and holes 6H in the low column portion of the foundation assembly. This method of positioning the foundation assembly and the method of connection between the column and the foundation assembly provide a substantial advantage in assembly over the prior art. This method is simple and fast, while at the same time insuring the accurate location and positioning of the columns in both the horizontal and vertical planes.
The rest of the building may then be finished as desired by the builder. For example, in a preferred embodiment, an overhang for the roof is formed by inserting 1 inch by 3 inch steel tubing into the open ends of the trusses 460, cut to the proper pitch and adjusted to the proper length to create the desired overhang, and then connecting them together around the perimeter of the roof using a steel sub-fascia. A fascia and insulation may then be applied. This greatly improves the insulation qualities of the resulting building, reducing heating and cooling costs. It is important to remember that houses constructed with steel frames can still contain fair amounts of wood: floors, roof panels, joists, stairs, carpet anchors, decorative pillars, lanai pillars, eaves, railings, window frames, doors, and door jambs. In the prior art, pressure treated lumber is used to frame the window and door openings. Window or door bucks are typically wooden frames that provide the rough opening and structure into which doors or windows are installed. Conventional houses built of lumber or steel use the same dimensional lumber for these openings as is used in the rest of the wall. Bucks may be made of 3/4" plywood, and may vary from 12" in width (thus being half the thickness of a 24" wall) up to the entire thickness of the wall. Bucks are often constructed to be less than the thickness of the wall.
However, lumber is not as durable as steel and greatly reduces the insulating properties of the building. What is needed is a door and window buck.that maximizes the steel construction structure. Furthermore, building construction using wooden framing is susceptible to blow outs, and air and water infiltration which can lead to mold. What is needed is a buck and a building method that prevents blow outs. Additionally, the structure with the buck or incorporating the building method must be air and water tight to prevent mold buildups.
SUMMARY OF THE INVENTION
This application is directed to a slip-over buck fashioned from metal bent at right angles to accommodate standard window or door. This application is further directed to a method for forming an aperture in a structure using a slip- over buck and insulated concrete forms.
BRIEF DESCRIPTION OF THE FIGURES
Fig. 1 is an exploded view showing a main column used in the assembly of a steel building; Fig. 2 shows the column assembly completely assembled;
Fig. 3 is a view of a wall having a window opening;
Fig. 4 is a perspective view of a window or door buck according one embodiment of the invention;
Fig. 5 is a side view of the window or door buck according to one embodiment of the invention;
Fig. 6 is a depiction of the window buck once it is installed;
Fig. 7 is a cutaway view of the construction along the line 7-7;
Fig. 8 is a side-view of a buck for masonry applications;
Fig. 9 is a side-view of an installed buck for masonry applications; Fig. 10 is a perspective view of a window or door buck according another embodiment of the invention;
Fig. 11 is a side-view of a buck;
Fig. 12 is a side-view of an installed buck;
Fig. 13 is a perspective view of a window or door buck according another embodiment of the invention;
Figs. 14a - 14e are each a side view of an embodiment of the buck;
Figs. 15a - 15d are each a side view of an embodiment of the buck; Fig. 16 is a load analysis for the buck;
Fig. 17 is a load analysis for the buck; and
Fig. 18 illustrates a side view of a buck in accordance with another exemplary embodiment. Figure 19 illustrates a flowchart for a method for installing an adjustable window buck in accordance with another exemplary embodiment.
DETAILED DESCRIPTION OF THE INVENTION
Figure 3 depicts a wall constructed using the described window buck.
As shown, the wall consists of a header 20 and footer 22. Header 20 and footer 22 have a track in which studs 24 are mounted. Additionally, as shown, at the end of each wall is column 28. Steel construction, wood frame construction, masonry construction and the like could all be used with the disclosed buck. In a preferred embodiment, wall panels 26 are used to finalize the construction of the wall. As shown, a window opening is framed using building elements 32. These elements 32 create a rough opening for a window. Once the rough opening is framed, window bucks 34, according to the present invention, are installed.
The window bucks 34 are installed around the rough opening before a window is installed in the opening. The window bucks 34 provide the final size for the window. Likewise, when the bucks 34 are used as door bucks, the door is framed and then bucks 34 are used to provide the final sizing. The doors are installed in a manner similar to the windows as detailed herein.
In one embodiment, two opposing bucks are squared and secured to the structure match a window frame. Preferably, the pair of bucks is the top and bottom buck. The other two bucks, i.e., the side bucks, are then place in the rough opening. The window frame is then attached to the bucks and the side bucks are secured to the structure. It should be noted that only one buck has to be secured to the structure before the window frame is attached to the buck.
A perspective view of window buck 34 is shown in Figure 4. Buck 34 is preferably made from 20 gauge steel. Alternatively, aluminum, other gauge steels, composite material, vinyl, plastic, PVC, or other material can be used. In a preferred embodiment, the metal is prepared so that it does not corrode. The buck 34 has a first wall 40 extending in a first direction. This first wall 40 has holes 38 that are used to mount the buck to the face of the rough framing. In one embodiment, the holes 38 used for attaching the buck to the studs 24 are substantially slots so that if any additional shimming is required, the buck 34 can be properly placed. The buck 34 has a second wall extending substantially perpendicular from one end of the first wall 40. In a preferred embodiment, this wall extends for approximately 4-1/2 inches. At the far end of the second wall is a third wall 44 extends substantially perpendicular to the second wall 42, and parallel to the first wall. Finally, a fourth wall 46 extends substantially perpendicular to the third wall extends away from the second and third walls. The width of the third and fourth walls is substantially 3A of an inch. It should be noted that fourth wall 46 includes mounting holes 36 used to mount the buck in the framed window opening. The general shape of the buck 34 is shown in Figure 5. The disclosed buck 34 is adapted to attach to the sides of a framing member as shown by the dashed line in Figure 5. It should be noted that the first wall 40 is substantially at 90° to the second wall 42 and that the third wall 44 is substantially parallel to first wall 40. Likewise, the fourth wall 46 is substantially parallel to the second wall 42. In a preferred embodiment, the buck 34 is manufactured using an 83A" flat strip of 20 gauge metal. Figure 6 depicts a window buck 34 as it would appear on the inside of a window opening. As shown, the window buck 34 is attached to a stud 24 using screws or nails 50, 51. In another embodiment, the attaching means are rivets, nuts and bolts, screws, nails, welds, epoxies, or the like. In a preferred embodiment, attaching means 50, 51 are #8 wafer head screws. Wall panel 26 is drywall. Once the buck 34 is fixed to the window opening, window sash 52 is affixed to the buck 34 using connecting means 54. Connector 54 is any structurally acceptable connector, manufacturing recommended connector, or those used for attachment means 50 and 51. Preferably, connector 54 is recommended by the manufacturer of the window being used.
Figure 7 depicts the cutaway view along line 7-7 in Figure 1. As shown, the buck 34 is attached to sill 32 using connectors 50 and 51. Additionally, connector 54 affixes window frame 52 to buck 34. In a preferred embodiment, connector 54 penetrates sill 32. Alternatively, a nut holds connector 54 in place.
Figure 8 is another embodiment of the disclosed door and window buck. The buck 80 shown in Figure 8 is preferably used for masonry applications and fits standard masonry openings. It should be noted that the buck can be reversed during installation to change the depth of the reveal. In this embodiment, both mounting tabs of the buck are mounted to the outside of the wall.
Figure 9 shows the buck 80 installed in an opening. As shown, the buck 80 is secured to the masonry structure 82 (not shown) using the fixing means 84. The buck is fixed using screws, nails, anchors, and the like. The window is then affixed to the raised portion 86 of the buck 80.
In operation, the aperture is a rough opening formed in the concrete structure. The disclosed buck is used as a form for the concrete, slipped over the structure around the four sides of the opening. In a preferred environment, at least the top and bottom bucks are secured to the structure creating a rough opening sized to match the window. Next, a first side buck is affixed to the structure. The window frame is then installed in the opening and secured to the three bucks already secured to the structure. The window frame is then secured to the fourth unsecured buck. After the unsecured buck is secured to the window, it is then secured to the structure. In this manner, a zero tolerance assembly is created eliminating air and water infiltration. Thus, this buck or slip over flashing, effectively eliminates water and air infiltration, the feeding source for mold.
Figure 10 depicts a perspective view of another embodiment of the buck.
Figure 11 depicts another embodiment of the invention. The buck 100, shown in Figure 11, is preferably used for wood frame construction. The buck shown in Figure 11 eliminates the need for a nail fin on a standard window. As shown, raised portion 110 is offset to accommodate window frames without a nail fin. Thus, window manufacturers need not create a separate window frame for wood frame construction.
Figure 12 shows the buck 100 installed in an opening. As shown, the buck 100 is secured to the masonry structure 102 (not shown) using the fixing means 104. The buck is fixed using screws, nails, anchors, and the like. The window is then affixed to the raised portion 110 of the buck 100.
Figure 14 depicts various window bucks for wood, steel, and masonry construction. Figure 15 depicts various door bucks for wood, steel, and masonry construction. The disclosed bucks can be formed using a standard break, roll forming, extrusions, and the like. Likewise, while described for use in wood, masonry, and steel construction with standard frame windows, the disclosed buck can also be used with glass block doors, sliding doors, windows, and the like.
It should be noted that in one embodiment, the four pieces of the buck are placed in the aperture of the structure. At least a first one of the bucks is leveled, squared, and affixed to the structure. Next, the window frame is affixed to the first buck secured to the structure. Next, the remaining bucks are affixed to the window frame then to the structure. It should be noted that using this method, as well as the method discussed above, zero tolerance between the window frame and structure is achieved, thereby eliminating air and water filtration. Additionally, using the described buck, installation is fast and precise allowing builders and installers to accelerate job completion.
The disclosed buck provides an increased allowable load over prior art bucks. A load analysis for two embodiments of the disclosed buck is shown in Figs. 16 and 17. In one embodiment, any of the pockets created between the buck and the structure are filled with an insulating material to improve the installation capacity of the building.
The slip-over flashing for use as a door or window buck described herein comprises a first pair of walls substantially parallel to one another which are used to affix the buck to the structure. At the top end of these two walls there is at least one wall perpendicular to the sidewalls. A second pair of walls substantially parallel to one another and parallel to the first two walls rise above the perpendicular wall. These second two power walls are joined at their tops with a perpendicular wall. This perpendicular wall is used as the window frame mount. The window frame mount can be positioned in various locations to accommodate various window frames and construction techniques as shown in the various environments disclosed herein. However, it should be noted that there are other potential embodiments and not all of the embodiments are disclosed herein.
In another embodiment, an insulated concrete form and adjustable buck can be combined. Specifically, during construction, an adjustable buck is inserted onto the insulated concrete forms with the adjustable buck's vertical walls aligning adjacent to two pieces of insulating material. These insulating materials can preferably be 2" Styrofoam forms or any other suitable insulating material as should be appreciated by those skilled in the art. In one aspect of this embodiment, the adjustable buck may be a metal sheet, such as steel, aluminum or the like. The buck is positioned accordingly as used in all other methods of construction.
Figure 18 shows an adjustable buck 1800 in accordance with this embodiment. As shown, adjustable buck 1800 is comprised of a first set of panels 1801a, 1801b), a second set of panels 1802a, 1802b, a first pair of mounting panels 1803a, 1803b, a second pair of mounting panels 1804a, 1804b, and a connecting panel 1805. The first set of panels 1801a, 1801b each include an upper end portion and a lower end portion. In the exemplary embodiment, the second set of panels 1802a, 1802b are affixed to the respective lower end portions of the first set of panels 1801a, 1801b. Moreover, the connecting panel 1805 is adapted to connect the respective upper end portions of the first set of panels 1801a, 1801b. Preferably, the connecting panel 1805 is a perpendicular wall that is used as the frame mount. It should be understood that while the exemplary embodiment illustrates the connecting panel being connect perpendicularly to the first set of panels 1801a, 1801b, the disclosure herein is in no way intended to be limited to a perpendicular connection.
Furthermore, in the exemplary embodiment, the first pair of mounting panels 1803a, 1803b are affixed to a lower surface of panel 1802a of the second set of panels 1802a, 1802b. Likewise, the second pair of mounting panels 1804a, 1804b are affixed to a lower surface of panel 1802b of the second set of panels 1802a, 1802b. Preferably, the second pair of mounting panels 1804a, 1804b are affixed at a substantially perpendicular angle to a lower surface of panel 1802b of the second set of panels 1802a, 1802b. Accordingly, in this embodiment, each panel of the pairs of mounting panels are positioned substantially parallel to one another. Moreover, it should be appreciated that both pairs of mounting panels 1803a, 1803b and 1804a, 1804b preferably extend in a direction away from the second set of panels 1802a, 1802b that is opposite (i.e., 180 degrees) from the first set of panels 1801a, 1801b. As further shown in Figure 18, the outer panel 1803a of the first pair of mounting panels is substantially shorter than the inner panel 1803b. Similarly, the outer panel 1804b of the second pair of mounting panels is substantially shorter than the inner panel 1804a. However, in a further refinement of this embodiment, each panel of the pair of mountings panels are substantially the same length.
Furthermore, as illustrated in Figure 18, both the first pair of mounting panels 1803a, 1803b and the second pair of mounting panels 1804a, 1804b are each adapted to be secured to respective insulated concrete forms 1806, 1807. In one refinement of this embodiment, insulated concrete form 1807 is secured to the second pair of mounting panels 1804a, 1804b, and panel 1802b with screws 1808, 1809, and 1810. It should be understood that insulated concrete form 1806 can similarly be secured to the first pair of mounting panels 1803a, 1803b and panel 1802a with screws (not shown). Moreover, it should be appreciated that while the panels described above are affixed to one another in one embodiment, the panels are alternatively formed by bending one or more strips of metal at the appropriate locations. It its broadest sense, two or more panels are connected to each another by bending one strip of metal at the appropriate location(s).
In one embodiment of the present invention, the insulated concrete forms 1806, 1807 and the buck 1800 are attached to one another prior to installation in the structure, with two or more half inch #8 wafer head self drilling screws (/. e. , screws 1808, 1809 and/or 1810) used to keep the interior components {e.g., insulated concrete forms 1806, 1807) and the exterior component (e.g., the window buck 1800) as one unit. Once the buck 1800 is placed on the insulated concrete form, a two and a half inch #12 hex head will attach the interior and exterior components to the foam (Le., insulated concrete forms 1806, 1807) by screwing from the outside of the buck 1800 through the foam and into the interior metal so as to attach the interior and exterior components by sandwiching the two inch foam form. After the concrete pour, the screws 1808, 1809 and/or 1810 can be removed so that the buck 1800 can be adjusted as required by the standard seal attachment methods. Furthermore, the buck 1800 can be reattached to the structure with concrete screws 1808, 1809 and/or 1810, such as Tapcon® concrete screws or the like. It is noted that in alternative embodiment, different caliber of screws can be used.
Figure 19 illustrates a flowchart for a method for installing an adjustable window buck in accordance with an exemplary embodiment. Initially, in step 1901, a user forms an aperture in a building. As discussed above, the aperture is a rough opening formed in the structure and can be formed in accordance with conventional techniques. Next, at step 1911, the user secures a pair of insulated concrete forms 1806, 1807 to a structure where the aperture is formed. In step 1921, the user mounts a buck 1800 onto the pair of insulated concrete forms. Specifically, both pairs of mounting panels 1803a, 1803b and 1804a, 1804b onto the respective insulated concrete forms 1806 and 1807. In step 1931, the user attaches the buck 1800 to insulated concrete form 1807 by screwing the second pair of mounting panels 1804a, 1804b, and panel 1802b with screws 1808, 1809, and 1810 to insulated concrete form 1807. Likewise, insulated concrete form 1806 can be secured to buck 1800 in a similar manner. It should be appreciated that if the insulated concrete forms 1806, 1807 and the buck 1800 are attached to one another prior to installation, steps 1911 through 1931 are not performed in the exemplary method. In such an embodiment, the combination of insulated concrete forms 1806, 1807 and the buck 1800 are installed in the aperture as a single unit. In step 1941, the user pours concrete into the pair of insulated concrete forms to create a concrete wall as one of skill in the art would appreciate. In step 1951, the user decides whether the buck 1800 needs to be adjusted based on the positioning of the buck 1800 with respect to the building structure. If adjustment is unnecessary, buck 1800 is effectively installed (i.e., the window/door frame can be installed) and the process ends at step 1971. Alternatively, if position adjustment of buck 1800 is necessary, in step 1961 the user adjusts the buck 1800 to the proper position. Preferably, buck 1800 is adjusted by unscrewing screws 1808, 1809 and/or 1810, positioning buck 1800 in the proper position, and tightening screws 1808, 1809 and/or 1810 to secure buck 1800 in the desired position. At that point, the process terminates (step 1971) and the window/door frame can be installed.
The benefit of installing windows or doors with this method is that it eliminates air and water infiltration which is the food source for mold. Advantageously, buck 1800 can eliminate health conditions and reduce mold litigation. By creating an air tight opening, there is a reduction in loss of heating and cooling thereby saving money in energy bills. Manufacturers can make one standard window type instead of two (with and without nail fins) because all construction accepts the same window allowing the maker of windows to be more profitable. Additionally, installation is fast and precise allowing the builder/installer to accelerate job completion. This method resolves the form/buck problem which leads to blow outs. This method creates a rigid exterior Arris so that synthetic stucco will not easily crack or chip around windows or door. This method also creates a true finished interior Arris to accept drywall and corner beads.
While this invention has been described by reference to preferred embodiments, it should be understood that numerous changes could be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the disclosed embodiment, but that it have the full scope permitted by the language of the following claims.

Claims

CLAIMSWHAT IS CLAIMED IS:
1. A slip-over buck comprising: a first pair of panels each having a first end portion and a second end portion, the first pair of panels being substantially parallel to one another; a connecting panel adapted to connect the respective first end portions of the first pair of panels to one another; a second pair of panels connected substantially perpendicularly to the respective second end portions of the first pair of panels; a first pair of mounting panels connected to one of the second pair of panels; and a second pair of mounting panels connected to the other of the second pair of panels.
2. The slip-over buck of claim 1 , wherein each of the pair of mounting panels is configured to be mounted onto an insulated concrete form.
3. The slip-over buck of claim 1, wherein a pair of insulated concrete forms are secured to the pair of mounting panels, respectively.
4. The slip-over buck of claim 1 , wherein the mounting panels of both the first pair and the second pair of mounting panels are positioned substantially parallel to one another.
5. The slip-over buck of claim 1, wherein all of the mounting panels are substantially the same length.
6. The slip-over buck of claim 1, wherein the connecting panel is connected substantially perpendicularly to the first pair of panels.
7. The slip-over buck of claim 1, wherein the first pair of mounting panels is connected substantially perpendicularly to the respective panel of the second pair of panels.
8. The slip-over buck of claim I5 wherein the second pair of mounting panels is connected substantially perpendicularly to the respective panel of the second pair of panels.
9. The slip-over buck of claim 1, wherein the panels of the first pair of mounting panels are each connected to respective end portions of the respective panel of the second pair of panels.
10. The slip-over buck of claim 1, wherein the panels of second pair of mounting panels are each connected to respective end portions of the respective panel of the second pair of panels.
11. The slip-over buck of claim 1 , wherein the first pair of panels extends in a first direction from the second pair of panels and each of the pair of mounting panels extends in a second direction from the second pair of panels, such that the second direction is approximately 180° from the first direction.
12. A method of forming an aperture in a building, comprising: securing a pair of insulated concrete forms to a structure where an aperture is to be formed; mounting a buck onto the pair of insulated concrete forms; attaching the buck to the pair of insulated concrete forms where an aperture will be formed; and pouring concrete into the pair of insulated concrete forms to create a wall.
13. The method of claim 12, further comprising: determining if the buck needs to be adjusted; adjusting the buck to the proper position.
14. The method of claim 12, wherein the attaching step comprises screwing the buck to the pair of insulated concrete forms.
15. The method of claim 13, wherein the attaching step comprises screwing the buck to the pair of insulated concrete forms using a plurality of screws.
16. The method of claim 15, wherein adjusting step comprises: unscrewing the buck from the insulated concrete forms; adjusting the position of the buck with respect to the insulated concrete forms; and rescrewing the buck to the insulated concrete forms.
PCT/US2010/029733 2009-04-02 2010-04-02 System and method for fabricating an aperture in a structure WO2010115070A1 (en)

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
US16611809P 2009-04-02 2009-04-02
US61/166,118 2009-04-02
US12/634,512 2009-12-09
US12/634,512 US20100083595A1 (en) 2005-01-03 2009-12-09 System for fabricating an aperture in a structure
US75273810A 2010-04-01 2010-04-01
US12/752,738 2010-04-01

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2742117A (en) * 1951-07-30 1956-04-17 Andean Corp Adjustable door jamb
US3299592A (en) * 1964-06-25 1967-01-24 Angeles Metal Trim Co Building structure
US20060248823A1 (en) * 2005-05-05 2006-11-09 Bollinger Stephen R Window subassembly for use with insulated concrete forms

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2742117A (en) * 1951-07-30 1956-04-17 Andean Corp Adjustable door jamb
US3299592A (en) * 1964-06-25 1967-01-24 Angeles Metal Trim Co Building structure
US20060248823A1 (en) * 2005-05-05 2006-11-09 Bollinger Stephen R Window subassembly for use with insulated concrete forms

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