Timber Frame Buildings

This invention relates to timber frame buildings and other forms of construction applications and in particular, but not exclusively, to components for use in the construction of such buildings. The invention is especially suitable for timber frame buildings constructed using the system employing a ring beam structure as described in our co-pending International patent application No. PCT/GB2006/001308.

Background of invention

In general 90mm/140mm depth walls in a timber frame structure have multiple 600mm vertical grids of storey height support components, in a complex and bespoke framework with a structural sheet fixed to one side and lintel sections built-in above window/doorways, supported by shorter vertical components. The off-site produced versions are isolated from end use and alterations, if required, can create problems. The off-site produced versions usually have need for a mechanical lifting process due to their heavier construction. The on-site (stick built) versions generally lengthen the build programme compared to the off-site versions and require knowledgeable carpenters and more organisation on site.

There would be a great benefit to the industry if a method of timber frame construction could be mass produced where all modular sections were identical in length and width, standardising all incorporated component lengths. Reducing the types of modular sections required and providing them in a one man handling form, again would benefit the industry through improved production volumes, transportation and on-site assembly.

It is well known when forming flooring platforms in for example, a timber frame structure, to use either off-site pre-fabricated joists/floor cassettes, or multiples of loose joists and floor boards formed into a joist/floor cassettes in-situ on-site. In the off-site version, fabricated joists/floor cassettes arrive on-site and are lifted up into position by, for example, a crane. Unfortunately, the width of floor cassettes is limited to the width of loads that can be transported. In the on-site version, loose joists are assembled together by hand to a layout drawing in-situ on-site, usually working at least one storey from the ground, with a soft landing/safety barrier system in position to prevent accidents/fatalities from falling. The ends of the joists are generally fixed to a rim board and supported by the wall section below or to joists hangers fixed to a rim board/trimmer. Additional components in the form of loose timbers equal to joist depth, infill between joists, above the wall section below and are positioned to aid/support the soleplate/wall section above. A requirement for insulation is also usually required in this region. The variations in non-end grain supporting components in this region may have a detrimental effect on the structures movement in terms of shrinkage - a timber length shrinks a small fraction in comparison to its depth. Floor boards are added in the standard manner to complete the flooring platform.

There would be a benefit to the construction industry if a method could be found of reducing/ simplifying the infilling components between all types of joists and providing more end grain support in the region.

Framed structures, such as a ring beam structure are an ideal solution to supporting flooring platforms during and after a lifting operation but its manufacture and design is generally isolated from the joists/floor cassettes production and design. There may be a cost/material/design cutting benefit if the two independent processes could be connected

together on-site into one unit without duplicating components and their function.

Summary

According to one aspect of the present invention, there is provided a framed module, wherein, positioned horizontally, it generally forms the predominant modular section of a modular frame encasing a framed joist structure (forming a modular framed joist structure) .

The joist structure may be assembled on/off site from either off site formed joist/floor cassettes or packs of loose joists and floor boards, and enclosed on/off site by a plurality of framed modules formed on/off site, completing the modular framed joist structure.

The completed modular framed joist structure can be assembled and releasably connected at ground level to further modular framed structures to form a ring beam structure incorporating floor and roof stages as described in our afore-mentioned International patent application.

Preferably, means is provided to lift such structure, by means of cut away slots positioned below reinforced rim/trimmer board within the framed module for attachment of lifting straps, chains, cables or the like. In this way, separate lifting bars with lifting eyes as described in our afore- mentioned International patent application may not be required.

Preferably, the modular frame comprises a plurality of framed modules arranged horizontally to form the perimeter of the framed joist structure according to the desired shape of the building, for example rectangular.

Preferably, the same framed module positioned vertically, forms the predominant modular section of a structural wall, supporting and extending a modular framed joist structure.

When constructing the building the same basic framed modules, with additional functioning components attached may be used to form the structural walls of the building. The framed modules may be arranged vertically to extend, for example, in a two storey building between the soleplate and the floor stage and between the floor stage and the roof stage.

Where an aperture is provided in the wall, for example for a window or door, the framed modules may be cut to length and arranged vertically or horizontally. Thus, framed modules can be cut to the required size during manufacture for assembly on-site. In this way manufacture is simplified as many structural sections of a supporting structural frame can be designed, produced and assembled from the same basic framed module.

In at least one embodiment, the modular framed joist structure (formed from joists attached to rim board/trimmer example) is formed from two framed elements. The first element is a plurality of framed modules arranged horizontally to the perimeter of the framed joist structure, its lower region incorporating additional vertical support components and extends below joist level, forming the upper region of the connecting wall supporting structure below, and its upper internal region has a rebated profile in this example, to receive the second element, a full length/ width rim boarded joist/floor cassette which is fixed to the rebated profile in the first element, allowing two independent processes to connect together into one structural element forming the modular framed joist structure.

Other profiles for receiving the rim/trimmer board are shown of alternative framed modules attached in the accompanying drawings, including a version where the upper and lower regions are reversed and shows joists built-in and supported on top of rim/trimmer board.

As a result all modular framed joist structure can remove the need to infill between joists at their perimeter to support vertical loads of structures above - independent of joists ends and predominantly using end grain components - and provides insulation within the modular frames built-in recesses on the proposed external side. The modular frames predominant end grain formation also provides a more stable, uniform structure, minimising shrinkage/expansion and isolated regions of either. Deeper sectioned spans of the modular frames also help support the structure from impact forces and simplify the design of the structure to comply with load requirements.

The deeper section of the now horizontally reinforced modular frame of the modular framed joist structure can also help to disperse loading points from above throughout the modular frame thereby removing the requirement for loading points to be reinforced directly below in the supporting wall structure through each storey down to the ground floor. The deeper section of the horizontally reinforced modular frame can also provide additional structural support for wall sections above and below as well as over openings in, for example, a timber frame structure from all loading points, by spreading the loading zone throughout it length.

The deeper sectioned horizontally reinforced modular frame gives additional support to attached internal load bearing horizontally formed heads of the internal load bearing walls which, in turn, provides additional support to joist/floor section during the lifting stages.

In at least one embodiment, a deeper sectioned horizontal formed modular frame is employed along gable walls, compared to the horizontally formed modular frame supporting roof structure. The deeper section extends upwards into the roof space to support fire check plaster boarded gable walls formed in either horizontal/vertical framed modules or spandrel frame (formed on site) construction. The deeper section along the gable walls supports a room in the roof wall independently, or, if a trussed roof is incorporated, is reinforced by fixing to lower regions of trusses with the external upper ends of the deeper sections matching the pitch of the roof.

According to another aspect of the invention, there is provide a modular framed structure comprising at least two modular framed structures releasably connected together wherein a lifting point is built-in into a framed module.

The lifting point preferably comprises a slot in the framed module. Preferably, a number of cut away slots are provided at set distances around the modular frame for the attachment of lifting straps, chains, cables or the like to lift modular framed structures. Where the modular framed structure comprises a plurality of modular framed structures according to the preceding aspect of the invention releasably connected together, the slots may be formed in the perimeter modular frame.

According to yet another aspect of the present invention, there is provided a framed module for use in a modular framed structure for floor and/or roof stages of a building and in a wall structure connecting to floor and/or roof stages wherein the framed modules are generally only cut to length on/off site in constructing the whole structural supporting frame.

According to yet another aspect of the invention all supporting storey height wall sections are formed from two sectors, an upper and a lower, each formed from the same basic framed module. The lower sector is generally in-filled with a plurality of vertically arranged frame modules, their height linked to the distance between bottom of sole plate and underside of lintel/top of window/doorways. The upper sector of the supporting storey height wall is in-filled with a modular frame which spans all window/doorways and supports all floor /roof sections.

According to yet another aspect of the present invention, there is provided a modular framed structure for use in a ring beam structure for floor and/or roof stages of a building and in a wall structure connecting to floor and/or roof stages.

According to a still further aspect of the present invention, there is provided a framed structure wherein a complete/partial joist cassette with a rim board located in a generally horizontally formed modular frame.

The joist cassette and modular frame may be formed on/off site and may be assembled on/off site to form the completed framed structure. The completed framed structure may be assembled and releasably connected at ground floor to further framed structure to form a ring beam structure incorporating floor and roof stages as described in our afore-mentioned International patent application.

Preferably, means is provided to lift such structure, by way of cut away slots in the modular frame for attachment of lifting straps. In this way, separate lifting bars with lifting eyes as described in our afore- mentioned International patent application may not be required.

Preferably, the modular frame comprises a plurality of panels arranged horizontally to form the perimeter of the framed joist structure according to the desired shape of the building, for example rectangular.

According to a still further aspect of the present invention, there is provided a modular panel for use in a ring beam structure for floor and/or roof stages of a building and in a wall structure connecting to floor and/or roof stages.

The modular panels preferably comprise a number of vertically oriented timber components extending lengthways of the proposed external side of the beam and fixed to a member of structural sheet material, with a parallel horizontal timber plate fixed at its bottom end.

A number of upper and lower parallel horizontal timber rails are preferably spaces apart and fixed to the proposed internal side of the structural sheet material, the length of the beam.

The framed module preferably comprises a panel member of structural sheet material with a number of vertical oriented timber components extending lengthways and fixed to one side, with a parallel horizontal timber plate fixed at its bottom end. A number of upper and lower horizontal timber rails are preferably spaced apart and fixed between vertical timber components and to structural sheet material.

When forming a modular frame to support for example a floor stage, additional components in the form of partial length vertically oriented timber components may be fixed to the opposite side of the structural sheet material, through to and inline with the vertical timber components on the opposite side of the framed module as described above . The upper and lower rails are re-positioned to the opposite side of the structural sheet material as described above.

Several framed modules can form a frame around the perimeter of a structure, by connecting end to end through the vertical timber components with an additional parallel horizontal timber rail spanning/fixed on top.

A full/partial length rim/trimmer board of, for example glulam beam, to which a number of joist hangers corresponding to a joist layout are attached may be positioned on top of the partial length vertical fixing/supporting components and fixed to the structural sheet material and through into the vertical oriented timber components on the opposite side. Joists may be attached to the joist hangers in standard manner and flooring added to the joists to complete a modular framed joist structure.

Cut away slots, at set distances may be machined out of the structural framed module below the rim/trimmer board for the routing of a lifting sling to lift the modular framed joist structure, or an alternative lifting operation may incorporate attaching some form of metal hardware to the rim board, to attach hook and chains of crane.

To support and extend the modular framed joist structure, we propose rotating the generally described horizontal framed modules through 90 degrees transforming it now into a vertical framed module, where all horizontal components become vertical/post components and all vertical components become horizontal rail components and the horizontal bottom and top edges become vertical side edges and the vertical ends become horizontal bottom and top ends.

To form a supporting wall section, the vertically framed module is attached to additional framed modules through vertical timber components to the sole-plate at their lower end and to the lower plate of the modular frame at their upper end at a later stage.

Storey height vertically timber components may be fastened to a combination of the proposed internal face components from the sole

plate, to the post in the framed module and to the lower plate and rim board in the modular frame above, tying them all together.

Services may be routed freely within the edges of the vertically framed modules on either side of the sheet material and through to adjacent framed modules through the screw/nail free zones. Insulation may be fixed to the external side of the framed modules enveloping the structure.

In at least one embodiment, a structural frame construction is provided wherein all sections of the structure use the same base framed module in either a horizontal or vertical position. For example horizontally positioned framed modules in the floor and roof stages support joist and roof sections as outlined above and could be useful in a number of non standard openings/spaces needing to be in-filled, for example under windows, along gable or at end of wall runs, where it would be easier to install a cut to length horizontally framed module rather than cutting down a vertical framed module length and making good its end. Equally it would be easier to infill a long span of supporting wall section with a number of vertically positioned framed modules where suitable.

In at least one embodiment, a structural frame construction is provided wherein a framed module in either its horizontal/vertical position allows insulation/services to be positioned either side of its sheet material/panel within the external edge regions of its upper and lower plate/post components.

In at least one embodiment, a system of structural frame construction is provided wherein all structural sheet components of the framed module are glued to a groove in the side of adjacent posts/plates components removing the need for mechanical fixings during its production and allowing insulation/services to be positioned either side of the sheet material within the plane of the outside edge region of its adjacent posts/plates.

According to another aspect of the present invention, there is provided a modular frame structure having a perimeter frame comprising a plurality of framed modules arranged to extend horizontally, the perimeter frame incorporating a support structure for a floor or roof stage, wherein the perimeter frame is deeper than the support structure . and extends below the support structure into a wall zone for attaching a wall structure.

Preferably, the perimeter frame provides a continuous ring beam such that by extending the perimeter frame into the wall zone below the support structure, the perimeter frame spans openings in the wall structure for doors and windows and can be used in place of separate lintels over openings for door and windows, thereby avoiding the need to employ separate lintels in the building process. Moreover, the connection to the wall structure results in a construction that is better able to withstand racking forces.

The invention will now be described in more detail by way of example only with reference to the accompanying drawings wherein like reference numerals are used throughout to indicate similar parts

Brief description of the drawings

Fig 1 shows a section of a framed module

Fig 2 shows a front elevation of the framed module

Fig 3 shows a plan of the framed module

Fig 4 shows a section of a modular framed joist structure section with a section of the joist/floor cassette attached in its upper region and its lower region extending below joist/floor cassette level

Fig 5 shows a section of a modular framed joist structure with its upper region extending up into the roof line along gable, with a spandrel frame with two layers of plaster board providing a fire check on top and to one side with the lower edge of the deeper framed modules in line with a lower edge of the less deep framed modules supporting roof structure

Fig 6 shows the roof/load bearing head component

Fig 7 shows a framed module in its horizontal position on a gable.

Fig 8 shows a cut out section within the framed modules for the attachment of lifting straps for the lifting process

Figs 9a, 9b show an alternative framed module with posts to support the floor joist structure and

Figs 10a, 10b show a framed module with no fixing posts/rails, with its sheet/panel edges into a groove in an adjacent post/plate

Detailed description of the exemplary embodiments

Figures 1 to 3 show a basic framed module 1 that preferably comprises the same design employed for either vertical or horizontal arranged modular sections in a timber frame structure. This basic design is adapted with additional components attached to form all framed modules in turn and all sections of the structural supporting timber frame in this invention. The basic framed module 1 comprises a number of vertically oriented timber components 3 extending lengthways of one side of the framed module 1 and fixed to a panel member of structural sheet material Ia with a parallel horizontal timber plate fixed at its bottom end 4. A parallel horizontal timber plate 5 (not shown in Figs 1 ,2,3) is attached at its upper end in a later stage. A number of upper and lower parallel

horizontal timber rails 2 are spaced apart and fixed to the upper and lower ends of the structural sheet material Ia along the length of the framed module 1.

Referring now to Figure 4, there is shown a floor stage comprising a framed floor support structure having a perimeter frame of rectangular shape into which slot one or more joist cassettes. It will be understood that the perimeter frame may be of any shape depending on the design of the building being constructed.

The perimeter frame is constructed from a plurality of framed modules 1 arranged to extend horizontally with the timber component 4 at the lower edge. The joist cassette comprises a plurality of joists 7, for example, TJI joists, attached to rim boards 6 by means of joist hangers 9. Floor boards (not shown) can then be fixed to the joists 7. The sheet members Ia are deeper than the joist cassette and extend below the joist cassette in the installed position.

The floor stage is generally spaced above ground floor level and is supported by a ground floor wall structure comprising a plurality of framed modules 1 arranged to extend vertically between and connect at opposite ends to the sole plate and depending portion of the horizontal framed modules 1 of the perimeter frame of the modular framed joist structure.

Where openings are provided in the wall structure for windows, doors or the like, the framed modules 1 can be cut to length during manufacture and assembled vertically or horizontally as desired. The ground floor wall structure may have additional reinforcement/support provided by storey height fixing posts 10 which extend between the sole plate (not shown) and the floor stage. The fixing posts 10 are attached to the sole plate and the timber components 4/panel Ic of the perimeter framed

modules and to the rim boards 6 of the joist structure by suitable fixings 8 such as nails.

A timber component 5 similar to the timber component 4 is secured to the upper edge of the perimeter frame of the modular framed joist structure for securing a first floor wall structure (Figure 5) .

Referring now to Figure 5, there is shown a roof stage comprising a framed roof support structure having a perimeter frame of rectangular shape matching the shape of the perimeter frame of the floor stage.

The perimeter frame of the framed roof support is constructed at the gable ends from framed module 1 arranged to extend horizontally with the timber component 4 at the lower edge and connected on opposite sides by narrower framed modules 11 shown in section in Figure 6.

The framed modules 11 include a reinforcing board 11a and a timber component 5 along the upper edge to provide support for roof trusses 13. The gable end framed modules 1 are deeper than truss support framed modules 11 and extend above the truss support framed modules 11 in the installed position to locate and support for example a spandrel frame 14 or further vertically framed modules 1. The gable ends may be in-filled with horizontally extending frame modules cut to size with end faces angled to match the pitch of the roof (see Figure 7) . The roof stage is spaced above the first floor stage and is supported by first floor wall structure comprising a plurality of modular panels 1 arranged to extend vertically between and connected at opposite ends to the ground floor stage and roof stage. Where openings are provided in the wall structure for windows, the panels 1 can be cut to length during manufacture and assembled vertically or horizontally as desired. The ground and first floor wall structures may be lined with plasterboard 12 which may also be provided in the roof space at the gable ends.

Referring now to Figure 8, there is shown part of the framed joist structure of the first floor stage shown in Figure 4 wherein slots 15 (one only shown) are provided in the sheet members Ia below the joists on two opposed sides of the structure. The slots 15 allow lifting straps to be secured to the modular framed joist structure for lifting the structure from ground level to first floor height during construction of the building.

Typically the first floor stage is assembled on the ground floor with the roof stage and both stages are lifted together and lowered for locating and securing the first floor stage in position on the ground floor wall structure. The roof stage is then separated from the first floor stage and the lifting straps secured to the roof stage so that it can be lifted clear off of the floor stage for assembly of the first floor wall structure allowing the roof stage to be lowered for locating and securing n position on the first floor wall structure. In another arrangement, the first floor stage and roof stage are assembled on the ground floor and are lifted and lowered into place separately when required in the construction process . In yet another arrangement the first floor stage and roof stage are assembled in situ during the construction process .

As will be appreciated, the stages form ring beams and, when employed, the temporary connection of the floor stage and roof stage forms a ring beam structure of the kind described in our afore-mentioned International patent application and can be employed in a similar manner for construction of a timber frame building. It will be understood that the ring beam structure may comprise one or more floor stages where the design of the building comprises two or more storeys .

It will also be understood that the ring beam structure incorporating floor and roof stages can be pre-fabricated at ground level and built-into the same module, load bearing and supporting wall structure to form a load bearing wall structure all from the same basic module.

It will now be apparent that the framed structures above-described are an ideal solution to supporting flooring platforms during and after a lifting operation that allow the manufacture and design to be integrated with the production and design of floor joist cassettes so that joist/floor cassettes and supporting frame can be secured together to avoid duplicating components and their function within the modular framed joist structure. Furthermore, the design of the framed modules allows a common component to be used both for the modular framed joist structure, wall structure and other areas of the building thereby simplifying manufacture by reducing the number of separate components to be designed.

The framed module 1 above-described may be adapted to form alternative frame modules with various functions,

Figures 9a, 9b show a modification to Figures 1,2,3 in which the framed module 1 further comprises additional partial length vertically oriented timber fixing/supporting components 3a positioned on the proposed internal side of the structural sheet member Ia of a horizontally positioned framed module of a modular framed joist structure and fixed to the structural sheet material Ia in its proposed lower region. Spaced apart parallel rails 2 are repositioned on the same side and fixed to the structural sheet member Ia in its upper and lower regions. This arrangement is generally for the attachment of joists (not shown) which may be attached to rim boards 6 positioned above the components 3a, 3b, 3c as shown in Figures 1 ,2,3.

Referring now to Figures 10a and 10b, an alternative framed module 1 ' is shown in which opposite side edges of the sheet member Ia are received in grooves cut in timber components 4 and secured by glue or other suitable means. The framed module 1 ' may be used in place of the framed module 1 shown in any of the structures above-described.

As will be understood, several modules can form a frame around the perimeter of a structure by connecting end to end through the partial fixing components3a/vertical components 3/panels Ib ₁ Ic with an additional parallel horizontal timber plate 5 fixed on top. Cut away slots 15 machined at set distances out of the structural module above/below the rim board allow a lifting sling to be attached to lift the ring beamed structure. Alternatively, the ring beam structure may incorporate some form of metal hardware to the rim board such as a lifting eye to attach rings of a chain or hooks of a cable..

It will be apparent from the description herein that we support and extend the ring beam structure/modular framed joist structure by rotating the generally horizontal framed module 90 degrees thereby transforming it into a vertical wall section module. As a result, all of the horizontal rails of the module when used in the ring beam are converted into vertical/post components, all of the vertical components become horizontal rail components, and the horizontal bottom and top edges become vertical side edges while the vertical ends become the horizontal bottom and top ends.

To form a supporting wall section the framed module is attached to additional framed modules through vertical timber components with spaced out nail/screw free zones for services to be routed and through their full/partial rails to a sole-plate at their lower end and to the lower plate of the modular frame at their upper end at a later stage.

Storey height vertically timber components may be fastened to a combination of the proposed internal face components from the sole plate, to the post in the framed wall module and to the lower plate and rim board in the modular frame above, tying them all together.

Standard framed modules could be mass produced, to predominately form all sections of the supporting structural wall/modular frame, standardising its components and mass production to gain maximum optimisation in terms of strength and mass, balanced with cold bridging and easy handling, sustainability, transportation, build- ability, safety, speed, insulation values, waste, volumes and cost.

It will now be apparent that the framed structures above-described are an ideal solution to supporting flooring platforms during and after a lifting operation that allow the manufacture and design to be integrated with the production and design of floor joist cassettes so that joist/floor cassettes and supporting frame can be secured together to avoid duplicating components and their function within the framed joist structure. Furthermore, the design of the framed modules allows a common component to be used both for the framed joist structure, wall structure and other areas of the building thereby simplifying manufacture by reducing the number of separate components to be designed.

It will be understood from the foregoing description of the present invention that the framed modules which has two key functions. The first key function is in its horizontal orientation wherein any number of like panels are joined end to end to form a frame that encloses an off/on site prefabricated partially/complete framed rim boarded joists/floor cassette with floorboard attached, to form a framed module floor structure. Further framed structures may be added, including a half depth modular framed roof structure and the head of an internal load bearing wall structure, wherein a rim board connects and reinforces the module members. The second key function is in its vertical orientation

(but not excluding its horizontal form) where it is an infill module supporting horizontal forms of the modular framed structure.

The modular frame also has a number of secondary roles and applications :

1. it becomes a lintel section over window and doorways

2. it forms the upper region of the supporting wall (usually the section between top of window/doorways and underside of joist) .

3. it spreads loading points from above, usually removing the need to reinforce the wall section directly below.

4. in either horizontal or vertical forms, it provides all of the supporting frame structure.

5. only one module needs to be fabricated and cut to length.

6. all components, for example insulation, structural panel, rails and posts are the same size in manufacturing.

7. it supports attached gable wall section and internal load bearing heads, during lifting process.

8. The horizontal and vertical framed modules can connect together to form a deeper wall section, with improved insulation and strength.

It will also be understood that the combined modular framed floor/roof structures and load bearing supporting wall structures act in the same way as a traditional structure in that it takes dead, live and snow load from floors and roof construction, and supports its own self weight, but differs by resisting wind loads independently, allowing the completion of inner leaf of a structure, including roof and joists stages, in advance of outer leaf skin.

It will be understood that the invention is not limited to the embodiments above-described and that various modifications are possible. For example, the ring beam structure may comprise a roof stage and one or more floor stages. The framed and modular frame module may be of any suitable construction that allows the construction of the load bearing and supporting wall structure.

LIST OF PARTS

1 modular panel

Ia sheet member

Ib sheet member

Ic sheet member

2 timber component

3 timber component

3a timber component

4 timber component

4a reduced width timber component

4b rebated timber component

5 timber component

6 rim board

7 joist

8 fixing

9 hanger

10 storey height post

11 roof/load bearing head frame panel

11 a reinforcing board

12 plasterboard

13 truss

14 spandrel frame

15 slot

17 insulation