CA2326054A1 - A novel structural log member and methods for making and using the same - Google Patents
A novel structural log member and methods for making and using the same Download PDFInfo
- Publication number
- CA2326054A1 CA2326054A1 CA 2326054 CA2326054A CA2326054A1 CA 2326054 A1 CA2326054 A1 CA 2326054A1 CA 2326054 CA2326054 CA 2326054 CA 2326054 A CA2326054 A CA 2326054A CA 2326054 A1 CA2326054 A1 CA 2326054A1
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- Prior art keywords
- structural
- log
- torque
- core
- coverings
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- Abandoned
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- 238000000034 method Methods 0.000 title claims abstract description 16
- 241000238631 Hexapoda Species 0.000 claims abstract description 24
- 239000003063 flame retardant Substances 0.000 claims abstract description 21
- 238000009413 insulation Methods 0.000 claims abstract description 16
- 239000002023 wood Substances 0.000 claims abstract description 15
- 238000010276 construction Methods 0.000 claims abstract description 10
- 239000006261 foam material Substances 0.000 claims abstract description 10
- 238000004519 manufacturing process Methods 0.000 claims abstract description 6
- 239000000853 adhesive Substances 0.000 claims description 44
- 230000001070 adhesive effect Effects 0.000 claims description 44
- 238000005304 joining Methods 0.000 claims description 17
- 238000005520 cutting process Methods 0.000 claims description 15
- 239000000463 material Substances 0.000 claims description 12
- 230000003750 conditioning effect Effects 0.000 claims description 11
- 240000003021 Tsuga heterophylla Species 0.000 claims description 10
- 235000008554 Tsuga heterophylla Nutrition 0.000 claims description 10
- 238000005553 drilling Methods 0.000 claims description 7
- 229920006327 polystyrene foam Polymers 0.000 claims description 7
- 229920002635 polyurethane Polymers 0.000 claims description 7
- 239000004814 polyurethane Substances 0.000 claims description 7
- 241000218645 Cedrus Species 0.000 claims description 6
- 235000014466 Douglas bleu Nutrition 0.000 claims description 6
- 235000008331 Pinus X rigitaeda Nutrition 0.000 claims description 6
- 241000018646 Pinus brutia Species 0.000 claims description 6
- 235000011613 Pinus brutia Nutrition 0.000 claims description 6
- 235000005386 Pseudotsuga menziesii var menziesii Nutrition 0.000 claims description 6
- 238000009429 electrical wiring Methods 0.000 claims description 6
- 230000007613 environmental effect Effects 0.000 claims description 6
- 239000004794 expanded polystyrene Substances 0.000 claims description 6
- 239000006260 foam Substances 0.000 claims description 5
- 238000009966 trimming Methods 0.000 claims description 5
- 230000008602 contraction Effects 0.000 claims description 4
- 230000009970 fire resistant effect Effects 0.000 claims description 4
- 239000000126 substance Substances 0.000 claims description 4
- 230000000295 complement effect Effects 0.000 claims description 3
- 150000001875 compounds Chemical class 0.000 claims description 3
- 230000000855 fungicidal effect Effects 0.000 claims description 3
- 239000000417 fungicide Substances 0.000 claims description 3
- 239000002917 insecticide Substances 0.000 claims description 3
- 238000002372 labelling Methods 0.000 claims description 3
- 238000004806 packaging method and process Methods 0.000 claims description 3
- 230000000149 penetrating effect Effects 0.000 claims description 3
- 230000001932 seasonal effect Effects 0.000 claims description 3
- 238000009987 spinning Methods 0.000 claims description 3
- 230000007547 defect Effects 0.000 claims description 2
- 239000002648 laminated material Substances 0.000 claims description 2
- 241000218683 Pseudotsuga Species 0.000 claims 2
- 241000269627 Amphiuma means Species 0.000 claims 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 claims 1
- 238000004026 adhesive bonding Methods 0.000 claims 1
- 239000000077 insect repellent Substances 0.000 claims 1
- 231100000053 low toxicity Toxicity 0.000 claims 1
- 231100000252 nontoxic Toxicity 0.000 claims 1
- 230000003000 nontoxic effect Effects 0.000 claims 1
- 239000011162 core material Substances 0.000 description 39
- 240000001416 Pseudotsuga menziesii Species 0.000 description 4
- 239000004035 construction material Substances 0.000 description 3
- 239000000654 additive Substances 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- 210000004712 air sac Anatomy 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 231100001225 mammalian toxicity Toxicity 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229920002522 Wood fibre Polymers 0.000 description 1
- 239000004411 aluminium Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000000843 anti-fungal effect Effects 0.000 description 1
- 238000009435 building construction Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 241000894007 species Species 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
- E04B2/70—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of wood
- E04B2/701—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of wood with integrated supporting and obturation function
- E04B2/702—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of wood with integrated supporting and obturation function with longitudinal horizontal elements
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Building Environments (AREA)
Abstract
A novel structural log member and method for making and using the same includes a core and an outer covering. In a preferred embodiment of the invention, the core comprises insulating foam material sandwiched between two panels of oriented strand board providing structural strength, fire retardant, insect retardant and thermal insulating qualities to the structural log member. The insulation "R" value of the member is adjusted by varying the thickness of the foam material. Attached to the outer surfaces of the core are coverings made from wood milled into various profiles and given a desired texture. To construct a wall the structural log members are stacked together.
A key and notch arrangement fabricated into the respective tops and bottoms of each structural member is used to join the stacked members. A method of manufacturing the structural log includes applying a set amount of torque to tensioning bolts embedded in the structural member to secure the coverings to the core. A method of construction using the structural member includes applying a further amount of torque to the embedded tensioning bolts to secure the structural members in a stacked relationship.
Another embodiment of the invention includes at least one notch along the top and bottom of the core of the structural member so that when the structural members are stacked weatherproof utility conduits are formed.
A key and notch arrangement fabricated into the respective tops and bottoms of each structural member is used to join the stacked members. A method of manufacturing the structural log includes applying a set amount of torque to tensioning bolts embedded in the structural member to secure the coverings to the core. A method of construction using the structural member includes applying a further amount of torque to the embedded tensioning bolts to secure the structural members in a stacked relationship.
Another embodiment of the invention includes at least one notch along the top and bottom of the core of the structural member so that when the structural members are stacked weatherproof utility conduits are formed.
Description
A NOVEL STRUCTURAL LOG MEMBER
AND METHODS FOR MAKING AND USING THE SAME
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Patent Application Serial No. 60/154,516, filed November 10, 1999, the entire scope and content of which is hereby incorporated herein by reference.
FIELD OF THE INVENTION
My invention relates to building construction elements and more particularly to a novel structural log member and methods for making and using the same.
BACKGROUND
Log buildings are very common as recreational habitats. However, log buildings constructed from whole logs suffer from a variety of disadvantages such as poor thermal insulating performance, difficulty of assembly, flammability and limited durability.
Additionally, the increasingly scarcity of suitable raw materials often makes the construction of a whole log building of sufficient size to comfortably shelter a family expensive and ecologically unsustainable. Additionally, conventional log structures are not well adapted to withstand seismic loads.
Information relevant to attempts to address these problems can be found in U.S.
Patents Nos. 4,344,263, 4,433,519, 5,271,878, 5,577,357 4,305,238, 4,344,263 and 3,992,838. However, each of these references suffers from one or more of the following disadvantages: inefficient use of a scarce natural resource; bulkiness; heavy reliance on expensive artificial construction materials; fabrication and assembly complexity; and, an unappealing artificial appearance.
AND METHODS FOR MAKING AND USING THE SAME
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Patent Application Serial No. 60/154,516, filed November 10, 1999, the entire scope and content of which is hereby incorporated herein by reference.
FIELD OF THE INVENTION
My invention relates to building construction elements and more particularly to a novel structural log member and methods for making and using the same.
BACKGROUND
Log buildings are very common as recreational habitats. However, log buildings constructed from whole logs suffer from a variety of disadvantages such as poor thermal insulating performance, difficulty of assembly, flammability and limited durability.
Additionally, the increasingly scarcity of suitable raw materials often makes the construction of a whole log building of sufficient size to comfortably shelter a family expensive and ecologically unsustainable. Additionally, conventional log structures are not well adapted to withstand seismic loads.
Information relevant to attempts to address these problems can be found in U.S.
Patents Nos. 4,344,263, 4,433,519, 5,271,878, 5,577,357 4,305,238, 4,344,263 and 3,992,838. However, each of these references suffers from one or more of the following disadvantages: inefficient use of a scarce natural resource; bulkiness; heavy reliance on expensive artificial construction materials; fabrication and assembly complexity; and, an unappealing artificial appearance.
For the foregoing reasons there is need for a novel structural log member that makes efficient use of natural materials and possesses superior structural strength, durability, thermal insulation and can be inexpensively and easily manufactured and assembled.
SUMMARY
My invention is directed to a novel structural log member that satisfies these needs. A structural log member having the features of my invention comprises a core.
One of the purposes of the core is to bear the compressive and tensile loads developed by structural dead and live loads. Another purpose of the core is to provide thermal insulation, fire retardant and insect resistant properties to the structural member. Yet another purpose of the core is to reduce the amount of wood fibre needed to construct a structure, reduce the weight of construction material, reduce the shipping and assembly costs of the construction material, reduce settling of the structure and stabilize the 1 S structure in varying climatic conditions.
The core has a predetermined cross-sectional shape and is made from an inner laminate sandwiched between two outer laminates. The inner laminate may be manufactured from rigid foam material such as polystyrene foam and provides thermal insulating, fire and insect retardant properties. The inner laminate has a top surface, a bottom surface and two opposing sides. Preferably the inner laminate is between 3 and 10 inches thick to achieve the desired thermal insulating "R" value. To achieve the desired insect and fire resistant qualities of my invention, the inner laminate includes a suitable chemical additive. Preferably the foam is an insect resistant Type 1 polystyrene foam meeting ASTM C578 standards. One example of such a material is Perform GuardTM
manufactured by AFM Corporation.
The outer laminates are constructed from an engineered material such as oriented strand board. Oriented strand board is preferred over natural milled lumber because of its superior and uniform structural strength and stability. This reduces size of the expansion/contraction gap required around windows and doors thereby increasing the thermal efficiency of the structure. The use of an engineered material such as oriented strand board permits the attachment of household fixtures such as shelves directly to the structure eliminating the need for an additional interior wall. Preferably the oriented strand board conforms to United States Department of Commerce Standard PS2-92.
The strand board has thickness of at least 11/16 inches. The outer laminates carry the dead and live structural loads. The outer and inner laminates are bonded to each other using bonding means such as a polyurethane compound adhesive.
My invention further comprises at least one wooden outer covering attached to at least one of the outer laminates of the core. The outer covering is preferably kiln dried to a moisture content of approximately 16%. The outer covering acts as the visible surface of the structural member and provides additional thermal insulation, structural strength and aesthetic appeal to the structure. The outer coverings are made from natural log facings milled to various profiles. Typically these profiles comprise one of the following shapes: D-log, New England, New England/D-log or round. In my invention the natural log facings are manufactured from a wood belonging to the following group of woods:
western hemlock, Douglas fir, pine or cedar. However, preferably the wood coverings are manufactured from western hemlock because of its attractive appearance and its superior ability to accept stains, adhesives, finishes, insects repellants and anti-fungal compounds. As well, western hemlock is a common and fast growing species and supply is usually plentiful. The natural log facing can be further milled to produce a hand-hewn appearance. To provide the desired insect and fire retardant qualities to the structural log, the natural log facings are treated with a very low mammalian toxicity combination insecticide, fungicide and fire retardant.
A further innovative feature of my invention is the manner in which a utilities conduit is formed when the logs are stacked together during wall construction.
The top and bottom surfaces of the core contain at least one notch running along their entire lengths. Thus, when a first lower and second upper structural member are stacked together the upper notch of the first lower structural member combines in a complementary manner with the lower notch of the second upper structural member forming a weather-proof conduit within the structural member suitable for carrying electrical wiring and other utilities.
SUMMARY
My invention is directed to a novel structural log member that satisfies these needs. A structural log member having the features of my invention comprises a core.
One of the purposes of the core is to bear the compressive and tensile loads developed by structural dead and live loads. Another purpose of the core is to provide thermal insulation, fire retardant and insect resistant properties to the structural member. Yet another purpose of the core is to reduce the amount of wood fibre needed to construct a structure, reduce the weight of construction material, reduce the shipping and assembly costs of the construction material, reduce settling of the structure and stabilize the 1 S structure in varying climatic conditions.
The core has a predetermined cross-sectional shape and is made from an inner laminate sandwiched between two outer laminates. The inner laminate may be manufactured from rigid foam material such as polystyrene foam and provides thermal insulating, fire and insect retardant properties. The inner laminate has a top surface, a bottom surface and two opposing sides. Preferably the inner laminate is between 3 and 10 inches thick to achieve the desired thermal insulating "R" value. To achieve the desired insect and fire resistant qualities of my invention, the inner laminate includes a suitable chemical additive. Preferably the foam is an insect resistant Type 1 polystyrene foam meeting ASTM C578 standards. One example of such a material is Perform GuardTM
manufactured by AFM Corporation.
The outer laminates are constructed from an engineered material such as oriented strand board. Oriented strand board is preferred over natural milled lumber because of its superior and uniform structural strength and stability. This reduces size of the expansion/contraction gap required around windows and doors thereby increasing the thermal efficiency of the structure. The use of an engineered material such as oriented strand board permits the attachment of household fixtures such as shelves directly to the structure eliminating the need for an additional interior wall. Preferably the oriented strand board conforms to United States Department of Commerce Standard PS2-92.
The strand board has thickness of at least 11/16 inches. The outer laminates carry the dead and live structural loads. The outer and inner laminates are bonded to each other using bonding means such as a polyurethane compound adhesive.
My invention further comprises at least one wooden outer covering attached to at least one of the outer laminates of the core. The outer covering is preferably kiln dried to a moisture content of approximately 16%. The outer covering acts as the visible surface of the structural member and provides additional thermal insulation, structural strength and aesthetic appeal to the structure. The outer coverings are made from natural log facings milled to various profiles. Typically these profiles comprise one of the following shapes: D-log, New England, New England/D-log or round. In my invention the natural log facings are manufactured from a wood belonging to the following group of woods:
western hemlock, Douglas fir, pine or cedar. However, preferably the wood coverings are manufactured from western hemlock because of its attractive appearance and its superior ability to accept stains, adhesives, finishes, insects repellants and anti-fungal compounds. As well, western hemlock is a common and fast growing species and supply is usually plentiful. The natural log facing can be further milled to produce a hand-hewn appearance. To provide the desired insect and fire retardant qualities to the structural log, the natural log facings are treated with a very low mammalian toxicity combination insecticide, fungicide and fire retardant.
A further innovative feature of my invention is the manner in which a utilities conduit is formed when the logs are stacked together during wall construction.
The top and bottom surfaces of the core contain at least one notch running along their entire lengths. Thus, when a first lower and second upper structural member are stacked together the upper notch of the first lower structural member combines in a complementary manner with the lower notch of the second upper structural member forming a weather-proof conduit within the structural member suitable for carrying electrical wiring and other utilities.
Another novel feature of my invention is the manner in which the individual logs can be stacked together in a stable manner to form a wall. This is accomplished by a key and slot arrangement. A rectangular key is located on the top of the structural member and a rectangular slot located in the bottom of the structural member.
The key and slot are formed in each structural log during its construction by longitudinally aligning the outer coverings on either side of the core in a parallel and vertically offset manner. The top end of the core protrudes above the coverings a predetermined distance creating the rectangular key. The bottom edges of the coverings protrude below the bottom edge of the core the same predetermined distance forming a rectangular slot in the bottom of the structural member. When stacking the logs together to form a wall, the slots of the upper course of logs fit firmly into the keys of the bottom course of logs.
Yet another innovative feature of my invention is the manner in which the stacked logs are secured together. This is accomplished by providing a securing means that comprises a plurality of horizontal holes that penetrate the structural log at pre-determined positions along its length. Into each of the holes is inserted a torque bolt. The bolt is in contact with the natural log covers on each side of the core. When the bolt is tensioned the covers will move closer together. This results in a gripping action being applied to the sides of the rectangular key. This has the effect of increasing the strength of the wall structure. The torque bolt is of a sufficient size to withstand the torque to be applied and resist the expansion and contraction caused by seasonal variations in temperature. A
washer is placed beneath the head of the torque bolt to protect the wood from damage. A
T-nut placed within the bolthole for receiving threads of the torque bolt. The T-nut has spiked flanges for biting into the wood to prevent it from spinning as torque is applied to the bolt. The torque bolt and T-nut are threaded together thereby joining the coverings together in a cooperative relationship.
In one embodiment of my invention the torque bolt is between 5.5 and 7 inches in length and 3/8 inches in diameter of the NC series. The bolthole is placed in a predetermined position located substantially at the centre line of the covering. This corresponds to a location that is below the centre line of the core. During wall construction, when one structural member has been joined in a stacked relationship with another and torque is applied to the bolt, the slot in the bottom of an upper structural My structural log member can be manufactured by following these steps:
1. Fabricating a core for bearing structural compressive and tensile loads, the core having desired thermal insulation, fire retardant and insect resistant properties by:
a. Selecting an inner laminate of a material such as expanded polystyrene foam having the desired thermal insulation, insect resistant and fire resistant qualities;
b. Cutting and profiling the inner laminate to the desired dimensions and profiles;
c. Selecting at least two outer laminates of a material such as an oriented strand board having the desired compressive and tensile strength, fire retardant and insect resistant qualities;
d. Cutting and profiling the outer laminates to the desired dimensions and profiles; and, e. Joining the outer laminates to each side of the inner laminate by:
i. Placing an adhesive such as a polyurethane adhesive suitable for structural wood applications on the opposing sides of the inner laminate;
ii. Fixing the outer laminates to the inner laminate so that the adhesive is compressed between them;
iii. Compressing the joined outer laminates and inner laminate together using compression means to strengthen the adhesion between them;
and, iv. Curing the joined inner and outer laminates for a pre-determined period of time to ensure a solid adhesive bond.
2. Fabricating at least one covering for fixing to the core, the covering having desired aesthetic features, by:
a. Selecting a natural log billet made from a wood selected from a group of kiln dried woods comprising: western hemlock, Douglas fir, pine or cedar;
b. Profiling the log billet into a profile selected from a group of profiles comprising: D-log, New England, New England/D-log or round;
c. Adding aesthetic qualities to the wooden covering by creating a hand-hewn appearance;
d. Adding fire retardant and insect resistant qualities to the wooden covering through chemical treatment; and, e. Pre-conditioning the covering prior to assembly of the structural member by:
i. Placing the profiled and chemically treated covings in a pre-conditioning kiln;
ii. Setting the environmental conditions of the pre-conditioning kiln to a predetermined temperature of at least 65F and a predetermined humidity of between 20% and 90%; and, iii. Leaving the outer coverings in the pre-conditioning kiln for a period of time necessary to pre-heat the coverings to a temperature of at least 60F.
3. Joining at least one covering to at least one face of the core to form the structural member by:
a. Moving the core and coverings to an assembly area having a predetermined temperature of approximately 65F and a predetermined humidity of between 20% and 95%;
b. Applying an adhesive such as a polyurethane adhesive to the side of the core;
g c. Joining the at least one covering to the core in a pre-determined position thus forming the key in the top of the structural member and the slot in the bottom of the structural member;
d. Fixing the cover to the core by stapling or nailing;
e. Placing a plurality of removable spacing members in the slot in the bottom of the structural member prior to the compressing step to prevent crushing the inner core material and permit a greater compressive force to be applied to the structural member;
f. Compressing the structural member laterally using compressing means such as an air bladder to strengthen the adhesion between the covering and the core;
g. Clamping the structural member in a clamp to prevent deformation during curing by:
i. Placing the structural member in a plurality of clamping jigs adapted to conform to the profile of the structural member;
ii. Applying uniform pressure along the entire length of the log by compression means such as an air bladder; and, iii. Holding the structural member within the clamping jigs for a predetermined period of time.
h. Placing the clamped structural member in a curing chamber to allow the adhesive to form a strong bond for a predetermined period of time of at least 24 hours at a predetermined temperature of at least 65F and at a predetermined humidity of between 20% and 95%.
4. Finishing the formed structural member by the steps o~
a. Squaring the ends of the structural member;
b. Cutting the structural member into desired lengths;
c. Notching the structural member for utility connections;
d. Angle cutting the ends of the structural member as required;
e. Cutting splice joints into the structural member for horizontal attachment as required;
f. Drilling a plurality of vertical holes in pre-determined locations through the inner laminate of the core member the holes adapted to each receive a vertical hold-down bolt;
g. Drilling a plurality of horizontal and countersunk holes in pre-determined locations through the structural member, the holes adapted to each receive a torque bolt, washer, nut assembly and plug;
h. Inserting a torque bolt, washer and nut assembly into the horizontal holes and threading the nut onto the threads of the torque bolt so that the coverings are connected by the torque bolt;
i. Applying approximately 2 foot pounds of torque to the torque bolt;
j. Labelling each structural member each label identifying a pre-determined location in a finished structure; and, k. Packaging the structural members for deliver to the assembly site.
My structural log member can be used to make a wall structure by following these steps:
1. Creating a suitable wall foundation having a bottom sill plate, and a plurality of vertical hold-down bolts located at pre-determined intervals along the foundation, the vertical hold-down bolts adapted to receive the structural members through the respective vertical holes drilled therein;
2. Applying a construction adhesive to the bottom sill plate and setting a first row of structural log members on the sill plate such that the vertical holes in the structural log members are placed over the vertical hold-down bolts on the foundation and the bottom sill plate on the foundation is inserted into the bottom slot of the first row of structural members;
3. Applying an adhesive such as a polyurethane adhesive to the top key of the first row of structural members;
4. Setting a second row of structural members on the first row such that the top keys of the first row of structural members are inserted into the bottom slots of the second row of structural members and the adhesive is compressed between the upper surface of the key and lower surface of the slot;
The key and slot are formed in each structural log during its construction by longitudinally aligning the outer coverings on either side of the core in a parallel and vertically offset manner. The top end of the core protrudes above the coverings a predetermined distance creating the rectangular key. The bottom edges of the coverings protrude below the bottom edge of the core the same predetermined distance forming a rectangular slot in the bottom of the structural member. When stacking the logs together to form a wall, the slots of the upper course of logs fit firmly into the keys of the bottom course of logs.
Yet another innovative feature of my invention is the manner in which the stacked logs are secured together. This is accomplished by providing a securing means that comprises a plurality of horizontal holes that penetrate the structural log at pre-determined positions along its length. Into each of the holes is inserted a torque bolt. The bolt is in contact with the natural log covers on each side of the core. When the bolt is tensioned the covers will move closer together. This results in a gripping action being applied to the sides of the rectangular key. This has the effect of increasing the strength of the wall structure. The torque bolt is of a sufficient size to withstand the torque to be applied and resist the expansion and contraction caused by seasonal variations in temperature. A
washer is placed beneath the head of the torque bolt to protect the wood from damage. A
T-nut placed within the bolthole for receiving threads of the torque bolt. The T-nut has spiked flanges for biting into the wood to prevent it from spinning as torque is applied to the bolt. The torque bolt and T-nut are threaded together thereby joining the coverings together in a cooperative relationship.
In one embodiment of my invention the torque bolt is between 5.5 and 7 inches in length and 3/8 inches in diameter of the NC series. The bolthole is placed in a predetermined position located substantially at the centre line of the covering. This corresponds to a location that is below the centre line of the core. During wall construction, when one structural member has been joined in a stacked relationship with another and torque is applied to the bolt, the slot in the bottom of an upper structural My structural log member can be manufactured by following these steps:
1. Fabricating a core for bearing structural compressive and tensile loads, the core having desired thermal insulation, fire retardant and insect resistant properties by:
a. Selecting an inner laminate of a material such as expanded polystyrene foam having the desired thermal insulation, insect resistant and fire resistant qualities;
b. Cutting and profiling the inner laminate to the desired dimensions and profiles;
c. Selecting at least two outer laminates of a material such as an oriented strand board having the desired compressive and tensile strength, fire retardant and insect resistant qualities;
d. Cutting and profiling the outer laminates to the desired dimensions and profiles; and, e. Joining the outer laminates to each side of the inner laminate by:
i. Placing an adhesive such as a polyurethane adhesive suitable for structural wood applications on the opposing sides of the inner laminate;
ii. Fixing the outer laminates to the inner laminate so that the adhesive is compressed between them;
iii. Compressing the joined outer laminates and inner laminate together using compression means to strengthen the adhesion between them;
and, iv. Curing the joined inner and outer laminates for a pre-determined period of time to ensure a solid adhesive bond.
2. Fabricating at least one covering for fixing to the core, the covering having desired aesthetic features, by:
a. Selecting a natural log billet made from a wood selected from a group of kiln dried woods comprising: western hemlock, Douglas fir, pine or cedar;
b. Profiling the log billet into a profile selected from a group of profiles comprising: D-log, New England, New England/D-log or round;
c. Adding aesthetic qualities to the wooden covering by creating a hand-hewn appearance;
d. Adding fire retardant and insect resistant qualities to the wooden covering through chemical treatment; and, e. Pre-conditioning the covering prior to assembly of the structural member by:
i. Placing the profiled and chemically treated covings in a pre-conditioning kiln;
ii. Setting the environmental conditions of the pre-conditioning kiln to a predetermined temperature of at least 65F and a predetermined humidity of between 20% and 90%; and, iii. Leaving the outer coverings in the pre-conditioning kiln for a period of time necessary to pre-heat the coverings to a temperature of at least 60F.
3. Joining at least one covering to at least one face of the core to form the structural member by:
a. Moving the core and coverings to an assembly area having a predetermined temperature of approximately 65F and a predetermined humidity of between 20% and 95%;
b. Applying an adhesive such as a polyurethane adhesive to the side of the core;
g c. Joining the at least one covering to the core in a pre-determined position thus forming the key in the top of the structural member and the slot in the bottom of the structural member;
d. Fixing the cover to the core by stapling or nailing;
e. Placing a plurality of removable spacing members in the slot in the bottom of the structural member prior to the compressing step to prevent crushing the inner core material and permit a greater compressive force to be applied to the structural member;
f. Compressing the structural member laterally using compressing means such as an air bladder to strengthen the adhesion between the covering and the core;
g. Clamping the structural member in a clamp to prevent deformation during curing by:
i. Placing the structural member in a plurality of clamping jigs adapted to conform to the profile of the structural member;
ii. Applying uniform pressure along the entire length of the log by compression means such as an air bladder; and, iii. Holding the structural member within the clamping jigs for a predetermined period of time.
h. Placing the clamped structural member in a curing chamber to allow the adhesive to form a strong bond for a predetermined period of time of at least 24 hours at a predetermined temperature of at least 65F and at a predetermined humidity of between 20% and 95%.
4. Finishing the formed structural member by the steps o~
a. Squaring the ends of the structural member;
b. Cutting the structural member into desired lengths;
c. Notching the structural member for utility connections;
d. Angle cutting the ends of the structural member as required;
e. Cutting splice joints into the structural member for horizontal attachment as required;
f. Drilling a plurality of vertical holes in pre-determined locations through the inner laminate of the core member the holes adapted to each receive a vertical hold-down bolt;
g. Drilling a plurality of horizontal and countersunk holes in pre-determined locations through the structural member, the holes adapted to each receive a torque bolt, washer, nut assembly and plug;
h. Inserting a torque bolt, washer and nut assembly into the horizontal holes and threading the nut onto the threads of the torque bolt so that the coverings are connected by the torque bolt;
i. Applying approximately 2 foot pounds of torque to the torque bolt;
j. Labelling each structural member each label identifying a pre-determined location in a finished structure; and, k. Packaging the structural members for deliver to the assembly site.
My structural log member can be used to make a wall structure by following these steps:
1. Creating a suitable wall foundation having a bottom sill plate, and a plurality of vertical hold-down bolts located at pre-determined intervals along the foundation, the vertical hold-down bolts adapted to receive the structural members through the respective vertical holes drilled therein;
2. Applying a construction adhesive to the bottom sill plate and setting a first row of structural log members on the sill plate such that the vertical holes in the structural log members are placed over the vertical hold-down bolts on the foundation and the bottom sill plate on the foundation is inserted into the bottom slot of the first row of structural members;
3. Applying an adhesive such as a polyurethane adhesive to the top key of the first row of structural members;
4. Setting a second row of structural members on the first row such that the top keys of the first row of structural members are inserted into the bottom slots of the second row of structural members and the adhesive is compressed between the upper surface of the key and lower surface of the slot;
5. Repeating steps 3 and 4 until three rows are in place;
6. Apply a predetermined amount of torque to the vertical hold down bolts;
7. Applying approximately 5 foot-pounds of torque to the horizontal torque-bolts;
8. Placing electrical wiring and other desired utilities in the utility notches at 5 predetermined levels in the wall;
9. Repeating steps 3 to 8 until the desired wall height is achieved;
10. Applying a pre-determined amount of torque to the vertical-hold down bolt;
once the desired wall height is reached and, 11. Allowing the adhesive to cure for a predetermined period of time.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects and advantages of the present invention will become better understood with regard to the following description, appended claims and accompanying drawings where:
Fig. 1 shows a partially disassembled view of one embodiment of my invention.
Fig. 2 shows another embodiment of my invention.
Fig. 3 shows details of the utility conduits in yet another embodiment of my invention.
Fig. 4 shows further details of the utility conduits in still another embodiment of my invention.
Fig. 5 shows the various shapes of the outer covering in other embodiments of my invention.
Fig. 6 shows the slot and key arrangement in another embodiment of my invention.
Fig. 7 shows further details of the slot and key arrangement in still another embodiment of my invention.
Fig.8 shows the manner in which the slots and keys fit together in yet another embodiment of my invention.
Fig. 9 shows details of the torque boltholes in an embodiment of my invention.
Fig. 10 shows further details of the torque bolt assembly in still another embodiment of my invention.
Fig. 11 shows further details of the location of the bolthole in one embodiment of my invention.
Fig. 12 shows a method for manufacturing the structural member in another embodiment of my invention.
Fig. 13 shows the clamp details in one embodiment of my invention.
Fig. 14 shows one embodiment of my invention mounted on a foundation.
Fig. 15 shows a method for using one embodiment of my invention in constructing wall units.
Fig. 16 shows a method for splicing two structural members together in one embodiment of my invention.
Fig 17 shows details how two walls assembled from structural inventions are joined in another embodiment of my invention.
DETAILED DESCRIPTION
As shown in Fig. 1, a preferred embodiment of my invention (100) comprises a rectangular core (110) for bearing compressive and tensile loads and providing thermal insulation, fire retardant and insect resistant properties to the structural member ( 100).
The core comprises at least one inner laminate (120) having a top surface (122), a bottom surface (124), and a first (126) and second (128) opposed sides. The inner laminate (120) provides thermal insulation, fire retardant properties and insect resistant properties to the core ( 110). At least one outer laminate ( 130) is bonded to each of the first ( 126) and second (128) opposed sides ofthe inner laminate (120). The outer laminates (130) provide compressive and tensile strength to the core (110). The outer laminates (130) are preferably fabricated from oriented strand board having a predetermined thickness suitable for resisting live and dead structural loads. The thickness of the outer laminate is at least 11/16 inches.
Still referring to Figure 1, at least one covering (140) is fastened by fastening means to the outer laminates (130) of the core (110). The fastening means may be a suitable polyurethane adhesive ( 141 ) or metal staples ( 142) or a combination of both.
Preferably galvanized aluminium staples are used. The covering (140) provides additional thermal insulation, structural strength and aesthetic appeal to the structural member ( 100). The core ( I 10) and the coverings ( 140) together create the structural member (100). The inner laminate (120) of the core (110) is preferably made from a material such as rigid expanded polystyrene foam material having the desired thermal insulation, insect resistant and fire retardant characteristics. The foam preferably has a density of at least 1 pound per square foot. To suit climatic conditions the thickness of the foam varies and may be varied from 3 inches to 10 inches. The foam is preferably chemically treated or provided with a suitable additive to provide the desired insect resistant and fire retardant properties.
In a preferred embodiment of my invention as shown in Figure 2 the top (122) and bottom ( 124) surfaces of the inner laminate ( 120) contain at least one notch ( 123 & 125 top and bottom respectively) running along their entire lengths. The notches are of a sufficient size to accept such utilities as electrical wiring.
1 S As shown in Fig. 3 when a first lower ( 100) and second upper ( 101 ) structural members are stacked together the upper notch ( 123) of the first lower structural member (100) combines in a complementary manner with the lower notch (125) of the second upper structural member (101) forming a weather-proof utilities conduit (127) within the structural member suitable carrying electrical wiring and other utilities. The assembled conduit (127) is shown in Fig. 4. As shown in Fig. 5, access points (133) may be cut in the structural member (100) to install electrical switches, outlets (135) and other utilities-related hardware and to connect utilities such as wiring (137) to such hardware.
Referring to Fig. 6 other embodiments of my invention are shown wherein the natural coverings (140) are adopted to take various profiles such as: D-log, New England, round or New England/D-log. The natural log facings may be manufactured from a wood belonging to the following group of woods comprising: western hemlock, Douglas fir, pine or cedar. Preferably the natural log facing is manufactured from western hemlock.
The natural log facings are further milled to produce a hand-hewn appearance.
The natural log facings may be treated with a very low mammalian toxicity combination insecticide, fungicide and fire retardant.
once the desired wall height is reached and, 11. Allowing the adhesive to cure for a predetermined period of time.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects and advantages of the present invention will become better understood with regard to the following description, appended claims and accompanying drawings where:
Fig. 1 shows a partially disassembled view of one embodiment of my invention.
Fig. 2 shows another embodiment of my invention.
Fig. 3 shows details of the utility conduits in yet another embodiment of my invention.
Fig. 4 shows further details of the utility conduits in still another embodiment of my invention.
Fig. 5 shows the various shapes of the outer covering in other embodiments of my invention.
Fig. 6 shows the slot and key arrangement in another embodiment of my invention.
Fig. 7 shows further details of the slot and key arrangement in still another embodiment of my invention.
Fig.8 shows the manner in which the slots and keys fit together in yet another embodiment of my invention.
Fig. 9 shows details of the torque boltholes in an embodiment of my invention.
Fig. 10 shows further details of the torque bolt assembly in still another embodiment of my invention.
Fig. 11 shows further details of the location of the bolthole in one embodiment of my invention.
Fig. 12 shows a method for manufacturing the structural member in another embodiment of my invention.
Fig. 13 shows the clamp details in one embodiment of my invention.
Fig. 14 shows one embodiment of my invention mounted on a foundation.
Fig. 15 shows a method for using one embodiment of my invention in constructing wall units.
Fig. 16 shows a method for splicing two structural members together in one embodiment of my invention.
Fig 17 shows details how two walls assembled from structural inventions are joined in another embodiment of my invention.
DETAILED DESCRIPTION
As shown in Fig. 1, a preferred embodiment of my invention (100) comprises a rectangular core (110) for bearing compressive and tensile loads and providing thermal insulation, fire retardant and insect resistant properties to the structural member ( 100).
The core comprises at least one inner laminate (120) having a top surface (122), a bottom surface (124), and a first (126) and second (128) opposed sides. The inner laminate (120) provides thermal insulation, fire retardant properties and insect resistant properties to the core ( 110). At least one outer laminate ( 130) is bonded to each of the first ( 126) and second (128) opposed sides ofthe inner laminate (120). The outer laminates (130) provide compressive and tensile strength to the core (110). The outer laminates (130) are preferably fabricated from oriented strand board having a predetermined thickness suitable for resisting live and dead structural loads. The thickness of the outer laminate is at least 11/16 inches.
Still referring to Figure 1, at least one covering (140) is fastened by fastening means to the outer laminates (130) of the core (110). The fastening means may be a suitable polyurethane adhesive ( 141 ) or metal staples ( 142) or a combination of both.
Preferably galvanized aluminium staples are used. The covering (140) provides additional thermal insulation, structural strength and aesthetic appeal to the structural member ( 100). The core ( I 10) and the coverings ( 140) together create the structural member (100). The inner laminate (120) of the core (110) is preferably made from a material such as rigid expanded polystyrene foam material having the desired thermal insulation, insect resistant and fire retardant characteristics. The foam preferably has a density of at least 1 pound per square foot. To suit climatic conditions the thickness of the foam varies and may be varied from 3 inches to 10 inches. The foam is preferably chemically treated or provided with a suitable additive to provide the desired insect resistant and fire retardant properties.
In a preferred embodiment of my invention as shown in Figure 2 the top (122) and bottom ( 124) surfaces of the inner laminate ( 120) contain at least one notch ( 123 & 125 top and bottom respectively) running along their entire lengths. The notches are of a sufficient size to accept such utilities as electrical wiring.
1 S As shown in Fig. 3 when a first lower ( 100) and second upper ( 101 ) structural members are stacked together the upper notch ( 123) of the first lower structural member (100) combines in a complementary manner with the lower notch (125) of the second upper structural member (101) forming a weather-proof utilities conduit (127) within the structural member suitable carrying electrical wiring and other utilities. The assembled conduit (127) is shown in Fig. 4. As shown in Fig. 5, access points (133) may be cut in the structural member (100) to install electrical switches, outlets (135) and other utilities-related hardware and to connect utilities such as wiring (137) to such hardware.
Referring to Fig. 6 other embodiments of my invention are shown wherein the natural coverings (140) are adopted to take various profiles such as: D-log, New England, round or New England/D-log. The natural log facings may be manufactured from a wood belonging to the following group of woods comprising: western hemlock, Douglas fir, pine or cedar. Preferably the natural log facing is manufactured from western hemlock.
The natural log facings are further milled to produce a hand-hewn appearance.
The natural log facings may be treated with a very low mammalian toxicity combination insecticide, fungicide and fire retardant.
Referring to Fig. 7 a preferred embodiment of my invention includes means to join the structural logs in a stacked relationship. The joining means comprises a rectangular key (201 - shown as a cross-hatched area) located on the top of the structural member (100 & 101) and a rectangular slot (202 - shown as a cross hatched area) located in the bottom of the structural members ( 100 & 1 O 1 ).
Referring to Fig. 8 the key (201 - shown as a cross-hatched area) is formed by longitudinally aligning the coverings ( 140) on either side of the core ( 110) in a vertical off set manner wherein the top end of the core (710) protrudes above the top (712) of the coverings ( 140) a predetermined distance (720) thus creating the rectangular key (201 ) and wherein the bottom edges (730) of the coverings (140) protrude below the bottom edge (711 ) of the core ( 110) a distance equal to the distance at (720) forming a rectangular slot (202 - shown as a cross-hatched area) in the bottom of the structural member ( 100) having dimensions and shape substantially the same as the key (201 ).
Referring to Fig. 9, a top structural member (100) is shown joined in a stacked relationship with a bottom structural member (101) wherein key (201) of bottom structural member ( 1 O 1 ) is inserted into slot (202) of the upper structural member ( 100) so that the top surface (710) of the core ( 110) of bottom structural member ( 1 O 1 ) abuts tightly against the top surface (711 ) of the core ( 110) of the top structural member ( 100).
Referring to Figure 10 the structural log ( 100) of a preferred embodiment of my invention also has a securing means for securing a plurality of stacked structural members together in a stable, cooperating relationship providing superior resistance to seismic loads. The securing means comprises a plurality of horizontal holes (900) penetrating the structural member ( 100) at pre-determined positions. Each of the holes (900) is adapted for receiving a torque bolt (910). Preferably there are at least two horizontal holes penetrating the structural member located a distance of at least 12 inches from each end of the structural member.
Still referring to Figure 10, a torque bolt (910) placed into each of the holes (900) in such a way as to connect the covers ( 140) to each other for applying compressive pressure to the core (110) and to the sides (901 and 902) ofthe rectangular slot (202).
Referring to Fig. 8 the key (201 - shown as a cross-hatched area) is formed by longitudinally aligning the coverings ( 140) on either side of the core ( 110) in a vertical off set manner wherein the top end of the core (710) protrudes above the top (712) of the coverings ( 140) a predetermined distance (720) thus creating the rectangular key (201 ) and wherein the bottom edges (730) of the coverings (140) protrude below the bottom edge (711 ) of the core ( 110) a distance equal to the distance at (720) forming a rectangular slot (202 - shown as a cross-hatched area) in the bottom of the structural member ( 100) having dimensions and shape substantially the same as the key (201 ).
Referring to Fig. 9, a top structural member (100) is shown joined in a stacked relationship with a bottom structural member (101) wherein key (201) of bottom structural member ( 1 O 1 ) is inserted into slot (202) of the upper structural member ( 100) so that the top surface (710) of the core ( 110) of bottom structural member ( 1 O 1 ) abuts tightly against the top surface (711 ) of the core ( 110) of the top structural member ( 100).
Referring to Figure 10 the structural log ( 100) of a preferred embodiment of my invention also has a securing means for securing a plurality of stacked structural members together in a stable, cooperating relationship providing superior resistance to seismic loads. The securing means comprises a plurality of horizontal holes (900) penetrating the structural member ( 100) at pre-determined positions. Each of the holes (900) is adapted for receiving a torque bolt (910). Preferably there are at least two horizontal holes penetrating the structural member located a distance of at least 12 inches from each end of the structural member.
Still referring to Figure 10, a torque bolt (910) placed into each of the holes (900) in such a way as to connect the covers ( 140) to each other for applying compressive pressure to the core (110) and to the sides (901 and 902) ofthe rectangular slot (202).
The torque bolt (910) is of a sufficient size to withstand the torque to be applied and resist the expansion and contraction caused by seasonal variations in temperature.
Now referring to Figure 11, a washer (930) placed beneath the head (940) of the torque bolt (910) to protect the wood covering (140) from damage. A T-nut (950) is placed within the bolthole (900) for receiving threads (960) of the torque bolt (910). The T-nut (950) has spiked flanges (952) for biting into the wood covering to prevent it from spinning as torque is applied to the bolt. The torque bolt (910) and T-nut (950) thread together joining the coverings (140) together in a cooperative relationship.
Preferably, the torque bolt is be between 5.5 and 7 inches in length and can be 3/8 inches in diameter of the NC series. Wooden plugs (970) may be inserted into either side of the bolthole (900) to close it after the bolts have been installed and torqued.
Referring to Figure 12, the bolthole (900) is placed generally at the centre line (960) of the covering (140). Bolthole (900) is further placed in a predetermined position below the centre line (970) of the core ( 120). During assembly of the structural member, a predetermined first amount of torque is applied to the torque bolt to hold the covers to the core while the adhesive is curing. The first amount of torque is 2 foot-pounds.
During wall construction, when one structural member (100) has been joined in a stacked relationship with another member (101), a second predetermined amount torque is applied to the bolt (910). The second amount of torque is 5 foot-pounds. The second application of torque causes the sides (901 and 902) of the slot (202) in the bottom of upper structural member ( 100) to compress around the key (201 ) on the top of lower structural member ( 1 O 1 ) in a binding relationship. This has the effect of creating a secure structural connection between the two members ( 100) and ( 1 O 1 ).
Referring to Figure 13, one embodiment of my invention can be manufactured by following these steps:
1. Selecting (2) a natural log billet made from a wood selected from a group of kiln dried woods comprising: western hemlock, Douglas fir, pine or cedar;
2. Profiling (4) the log billet into a profile selected from a group of profiles comprising: D-log, New England, New England/D-Log or round;
3. Adding aesthetic qualities (6) to the wooden covering by creating a hand-hewn appearance;
4. Trimming the wooden covering to predetermined dimensions (8);
S. Adding fire retardant and insect resistant qualities (10) to the wooden covering 5 through chemical treatment;
6. conditioning ( 12) the covering prior to assembly of the structural member by:
a. Placing the profiled and chemically treated covings in a conditioning chamber ( 14);
b. Setting the environmental conditions of the conditioning chamber to a 10 temperature of at least 65F and a humidity of between 20% and 95%; and, c. leaving the outer coverings in the conditioning chamber for a period of time so that the temperature of the wood coverings reaches a minimum of 60F.
7. Selecting (16) at least two outer laminates made from a material such as 15 oriented strand board having the desired strength, fire retardant and insect resistant properties.
8. Cutting and profiling (18) the outer laminates to predetermined shapes and sizes.
9. joining the outer coverings to the outer laminates (20) by a adhesive means or staples or a combination of both;
10. selecting an inner laminate (22) of a material such as expanded polystyrene foam having the desired thermal insulation, insect resistant and fire resistant qualities;
11. cutting and profiling (24) the inner laminate to the desired dimensions and profiles;
12. Joining the outer laminates and outer coverings to each side of the inner laminate by:
a. Placing (26) an adhesive such as a polyurethane adhesive on the opposing sides of the outer laminate;
b. Joining the outer laminates to the inner laminate (28);
c. Placing a plurality of removeable resilient spacing members on the in the notch and key of the assembled structural log member to prevent crushing of the inner laminate material during initial curing and to permit a greater bonding force to be applied to the assembled structural log member (30);
Now referring to Figure 11, a washer (930) placed beneath the head (940) of the torque bolt (910) to protect the wood covering (140) from damage. A T-nut (950) is placed within the bolthole (900) for receiving threads (960) of the torque bolt (910). The T-nut (950) has spiked flanges (952) for biting into the wood covering to prevent it from spinning as torque is applied to the bolt. The torque bolt (910) and T-nut (950) thread together joining the coverings (140) together in a cooperative relationship.
Preferably, the torque bolt is be between 5.5 and 7 inches in length and can be 3/8 inches in diameter of the NC series. Wooden plugs (970) may be inserted into either side of the bolthole (900) to close it after the bolts have been installed and torqued.
Referring to Figure 12, the bolthole (900) is placed generally at the centre line (960) of the covering (140). Bolthole (900) is further placed in a predetermined position below the centre line (970) of the core ( 120). During assembly of the structural member, a predetermined first amount of torque is applied to the torque bolt to hold the covers to the core while the adhesive is curing. The first amount of torque is 2 foot-pounds.
During wall construction, when one structural member (100) has been joined in a stacked relationship with another member (101), a second predetermined amount torque is applied to the bolt (910). The second amount of torque is 5 foot-pounds. The second application of torque causes the sides (901 and 902) of the slot (202) in the bottom of upper structural member ( 100) to compress around the key (201 ) on the top of lower structural member ( 1 O 1 ) in a binding relationship. This has the effect of creating a secure structural connection between the two members ( 100) and ( 1 O 1 ).
Referring to Figure 13, one embodiment of my invention can be manufactured by following these steps:
1. Selecting (2) a natural log billet made from a wood selected from a group of kiln dried woods comprising: western hemlock, Douglas fir, pine or cedar;
2. Profiling (4) the log billet into a profile selected from a group of profiles comprising: D-log, New England, New England/D-Log or round;
3. Adding aesthetic qualities (6) to the wooden covering by creating a hand-hewn appearance;
4. Trimming the wooden covering to predetermined dimensions (8);
S. Adding fire retardant and insect resistant qualities (10) to the wooden covering 5 through chemical treatment;
6. conditioning ( 12) the covering prior to assembly of the structural member by:
a. Placing the profiled and chemically treated covings in a conditioning chamber ( 14);
b. Setting the environmental conditions of the conditioning chamber to a 10 temperature of at least 65F and a humidity of between 20% and 95%; and, c. leaving the outer coverings in the conditioning chamber for a period of time so that the temperature of the wood coverings reaches a minimum of 60F.
7. Selecting (16) at least two outer laminates made from a material such as 15 oriented strand board having the desired strength, fire retardant and insect resistant properties.
8. Cutting and profiling (18) the outer laminates to predetermined shapes and sizes.
9. joining the outer coverings to the outer laminates (20) by a adhesive means or staples or a combination of both;
10. selecting an inner laminate (22) of a material such as expanded polystyrene foam having the desired thermal insulation, insect resistant and fire resistant qualities;
11. cutting and profiling (24) the inner laminate to the desired dimensions and profiles;
12. Joining the outer laminates and outer coverings to each side of the inner laminate by:
a. Placing (26) an adhesive such as a polyurethane adhesive on the opposing sides of the outer laminate;
b. Joining the outer laminates to the inner laminate (28);
c. Placing a plurality of removeable resilient spacing members on the in the notch and key of the assembled structural log member to prevent crushing of the inner laminate material during initial curing and to permit a greater bonding force to be applied to the assembled structural log member (30);
d. Placing the assembled structural log member into a bladder clamp (32); and, e. Applying a predetermined amount of compressive force to the structural log member (34);
f. Allowing the adhesive bonds to cure for a predetermined first amount of time (36);
13. Placing (38) first amount of time cured structural member in a curing chamber to allow the adhesive to form a strong bond for a period of at least 24 hours at a temperature of 65F and at humidity between 20% and 95%.
14. Finishing (40) the formed structural member by the steps of:
a. Squaring the ends of the structural member;
b. Cutting the structural member into desired lengths;
c. Notching the structural member for utility connections;
d. Angle cutting the ends of the structural member as required;
e. Cutting splice joints into the structural member for horizontal attachment as required;
f. Drilling a plurality of vertical holes in pre-determined locations through the inner laminate of the core member the holes adapted to each receive a vertical hold-down bolt;
g. Drilling a plurality of horizontal and countersunk holes in pre-determined locations through the structural member, the holes adapted to each receive a torque bolt, washer and nut assembly;
h. Inserting a torque bolt washer and nut assembly into the horizontal holes and threading the nut onto the threads of the torque bolt so that the coverings are connected by the torque bolt (42);
i. Applying approximately 2 foot pounds of torque to the torque bolt (44);
j. Fixing a wooden plug into each of the horizontal hole openings (46);
k. Inspecting the product for defects (48); and, I. Labelling each structural log member so that each label idenfities a pre determined location of each member in a finished structure (50); and, m. Packaging the structural members for delivery to the assembly site (52).
f. Allowing the adhesive bonds to cure for a predetermined first amount of time (36);
13. Placing (38) first amount of time cured structural member in a curing chamber to allow the adhesive to form a strong bond for a period of at least 24 hours at a temperature of 65F and at humidity between 20% and 95%.
14. Finishing (40) the formed structural member by the steps of:
a. Squaring the ends of the structural member;
b. Cutting the structural member into desired lengths;
c. Notching the structural member for utility connections;
d. Angle cutting the ends of the structural member as required;
e. Cutting splice joints into the structural member for horizontal attachment as required;
f. Drilling a plurality of vertical holes in pre-determined locations through the inner laminate of the core member the holes adapted to each receive a vertical hold-down bolt;
g. Drilling a plurality of horizontal and countersunk holes in pre-determined locations through the structural member, the holes adapted to each receive a torque bolt, washer and nut assembly;
h. Inserting a torque bolt washer and nut assembly into the horizontal holes and threading the nut onto the threads of the torque bolt so that the coverings are connected by the torque bolt (42);
i. Applying approximately 2 foot pounds of torque to the torque bolt (44);
j. Fixing a wooden plug into each of the horizontal hole openings (46);
k. Inspecting the product for defects (48); and, I. Labelling each structural log member so that each label idenfities a pre determined location of each member in a finished structure (50); and, m. Packaging the structural members for delivery to the assembly site (52).
Referring to Fig. 14, additional details of the bladder clamp and resilient inserts are shown. The assembled structural member comprising an inner laminate (120), two outer laminates (130) and the outer coverings (140) is placed inside the bladder clamp jig (600). Resilient inserts (601 ) are placed on top of the assembled structural log member (100) so that the shoulders (602) of the inserts abut against the inside surfaces of the inner laminates ( 130). The shoulders resist compressive loads placed on the inner laminate (120) of the assembled structural log member (100) preventing the inner laminate (120) from being crushed or otherwise deformed during curing. Resilient inserts (601 ) are also placed into the slots (202) of the assembled structural member so that the shoulders of the inserts also abut against the inside surfaces of the inner laminates (130).
The bladder (605) is inflated with air and pushes against the assembled structural log member ensuring a strong adhesive bond is formed during the initial curing period.
Referring to Fig. 15, a preferred embodiment of my invention can be used to make a wall by following these steps:
Creating a suitable wall foundation ( 1 S 1 ) having a bottom sill plate (152), and a plurality of vertical hold-down bolts (153) at pre-determined intervals along the foundation, the vertical hold-down bolts adapted to receive the structural members through the respective vertical holes drilled therein (154);
2. Applying a suitable construction adhesive to the bottom sill plate;
3. Setting a first row of structural members (100) on the sill plate (152) such that the vertical holes (154) in the structural members are placed over the vertical hold-down bolts (153) and the bottom sill plate (152) foundation is inserted into the bottom slot (202) of the first row of structural members (100);
4. Applying an adhesive to the top key (201) of the first row of structural members ( 100);
5. Setting a second row of structural members ( 102) on the first row ( 100) such that the top keys (201) of the first row of structural members are inserted into the bottom slots (202) of the second row of structural members and the adhesive is compressed between the upper surface of the key and lower surface of the slot;
The bladder (605) is inflated with air and pushes against the assembled structural log member ensuring a strong adhesive bond is formed during the initial curing period.
Referring to Fig. 15, a preferred embodiment of my invention can be used to make a wall by following these steps:
Creating a suitable wall foundation ( 1 S 1 ) having a bottom sill plate (152), and a plurality of vertical hold-down bolts (153) at pre-determined intervals along the foundation, the vertical hold-down bolts adapted to receive the structural members through the respective vertical holes drilled therein (154);
2. Applying a suitable construction adhesive to the bottom sill plate;
3. Setting a first row of structural members (100) on the sill plate (152) such that the vertical holes (154) in the structural members are placed over the vertical hold-down bolts (153) and the bottom sill plate (152) foundation is inserted into the bottom slot (202) of the first row of structural members (100);
4. Applying an adhesive to the top key (201) of the first row of structural members ( 100);
5. Setting a second row of structural members ( 102) on the first row ( 100) such that the top keys (201) of the first row of structural members are inserted into the bottom slots (202) of the second row of structural members and the adhesive is compressed between the upper surface of the key and lower surface of the slot;
6. applying an adhesive to the top key (201 ) of the second row of structural members ( 102);
7. setting a third row of structural members (103) on top of the second row (102);
8. Placing electrical wiring and other utilities in the notches (123) in the keys of the structural members at pre-determined levels in the wall;
9. placing a removeable washer and nut assembly (158) over the vertical hold down bolt and applying a predetermined amount of torque to the nut to compress the first three layers of structural members and then removing said washer and nut assembly;
10. applying approximately 5 foot pounds of torque to each of the bolts (900) in all of the structural members;
11. repeating steps 3 to 9 until a desired wall height is reached, and, 12. Allowing the adhesive to cure for a suitable period of time.
As shown in Figure 16, my invention further includes splicing means to splice two structural members (161 and 162) together in a linear relationship. The splicing means comprises a substantially rectangular splice (163) made from piece of oriented strand board cut to predetermined dimensions. An adhesive (164) is placed over the joint between two structural members. The splice is placed over the adhesive in an overlapping relationship between the two structural members. The splice is then fixed to the joined structural members using fixing means (165) comprising one of staples or nails.
As shown in Figure 17, my invention further includes a means to finish the corners of a structure assembled using structural logs. When building a structure, two walls (171 and 172) will meet at right angles. To secure the walls at the corner joints metal angles (173) are placed in the corner and secured by securing means (174). A
wooden plug (175) is inserted into the corner joint and fixed thereto by fixing means (176). Trimming (177) is then fixed in place along the outside ends of each wall. The trimming comprises grooves (178) adapted to receiving a half round corner member (179). The half round corner member is placed into the groves of the trimming and fixed thereto using fixing means. The fixing means may be one of or a combination of staples, nails or adhesive.
7. setting a third row of structural members (103) on top of the second row (102);
8. Placing electrical wiring and other utilities in the notches (123) in the keys of the structural members at pre-determined levels in the wall;
9. placing a removeable washer and nut assembly (158) over the vertical hold down bolt and applying a predetermined amount of torque to the nut to compress the first three layers of structural members and then removing said washer and nut assembly;
10. applying approximately 5 foot pounds of torque to each of the bolts (900) in all of the structural members;
11. repeating steps 3 to 9 until a desired wall height is reached, and, 12. Allowing the adhesive to cure for a suitable period of time.
As shown in Figure 16, my invention further includes splicing means to splice two structural members (161 and 162) together in a linear relationship. The splicing means comprises a substantially rectangular splice (163) made from piece of oriented strand board cut to predetermined dimensions. An adhesive (164) is placed over the joint between two structural members. The splice is placed over the adhesive in an overlapping relationship between the two structural members. The splice is then fixed to the joined structural members using fixing means (165) comprising one of staples or nails.
As shown in Figure 17, my invention further includes a means to finish the corners of a structure assembled using structural logs. When building a structure, two walls (171 and 172) will meet at right angles. To secure the walls at the corner joints metal angles (173) are placed in the corner and secured by securing means (174). A
wooden plug (175) is inserted into the corner joint and fixed thereto by fixing means (176). Trimming (177) is then fixed in place along the outside ends of each wall. The trimming comprises grooves (178) adapted to receiving a half round corner member (179). The half round corner member is placed into the groves of the trimming and fixed thereto using fixing means. The fixing means may be one of or a combination of staples, nails or adhesive.
Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible.
Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein.
Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein.
Claims (34)
1. A novel structural log member suitable for constructing walls, the structural member comprising:
a. a core having a predetermined cross-sectional shape further comprising:
i. at least one inner laminate consisting of a top surface, a bottom surface, and first and second opposed sides wherein the inner laminate is adapted for providing thermal insulation, fire retardant properties and insect resistant properties to the core; and, ii. at least one outer laminate bonded by bonding means to each of the first and second opposed sides of the inner laminate wherein the outer laminate is adapted for providing compressive and tensile strength to the core;
b. at least one covering adapted for providing additional thermal insulation, structural strength, insect resistant, fire retardant and aesthetic characteristics to the structural member wherein each covering is fixed by fixing means to at least one outer laminate of the core such that the combination of the core and the outer covering forms the structural member;
c. means for joining a plurality of structural members in a stacked relationship to define a wall; and, d. means for permanently securing a plurality of stacked structural members to each other in a wall to provide structural strength to the wall.
a. a core having a predetermined cross-sectional shape further comprising:
i. at least one inner laminate consisting of a top surface, a bottom surface, and first and second opposed sides wherein the inner laminate is adapted for providing thermal insulation, fire retardant properties and insect resistant properties to the core; and, ii. at least one outer laminate bonded by bonding means to each of the first and second opposed sides of the inner laminate wherein the outer laminate is adapted for providing compressive and tensile strength to the core;
b. at least one covering adapted for providing additional thermal insulation, structural strength, insect resistant, fire retardant and aesthetic characteristics to the structural member wherein each covering is fixed by fixing means to at least one outer laminate of the core such that the combination of the core and the outer covering forms the structural member;
c. means for joining a plurality of structural members in a stacked relationship to define a wall; and, d. means for permanently securing a plurality of stacked structural members to each other in a wall to provide structural strength to the wall.
2. The novel structural log member of claim 1 further comprising:
a. means for joining structural members in a linear relationship; and, b. means for joining walls assembled from structural members.
a. means for joining structural members in a linear relationship; and, b. means for joining walls assembled from structural members.
3. The novel structural log member of claim 1 wherein the inner laminate further comprises rigid expanded polystyrene foam material adapted for providing the desired thermal insulation, insect resistant and fire retardant characteristics to the core.
4. The novel structural log member of claim 3 wherein the foam material has a density of at least one pound per square foot.
5. The novel structural log member of claim 4 wherein the foam material comprises Type # 1 EPS foam.
6. The novel structural log member of claim 5 wherein the core is substantially rectangular in shape.
7. The novel structural log member of claim 6 wherein varying the thickness of the foam material varies the insulation characteristic of the core.
8. The novel structural log member of claim 7 wherein the thickness of the foam material varies from 3 to 10 inches.
9. The novel structural log member of claim 8 wherein the foam material further comprises a non-toxic insect-repellent and fire retardant.
10. The novel structural log member of claim 9 wherein the top and bottom surfaces of the inner laminate contain at least one notch running along their entire lengths so that when a first lower and second upper structural member are stacked together, the upper notch of the first lower structural member combines in a complementary manner with the lower notch of the second upper structural member to form a weatherproof conduit within the structural member suitable carrying electrical wiring and other utilities.
11. The novel structural log member of claim 6 wherein a plurality of vertical holes is drilled into the core at predetermined positions along its length.
12. The novel structural log member of claim 1 wherein the outer laminates comprise an engineered material having a predetermined thickness suitable for bearing the compressive and tensile wall loads.
13. The novel structural log member of claim 12 wherein the outer laminates comprise oriented strand board.
14. The novel structural log member of claim 13 wherein the outer laminates are at least 11/16 inches thick.
15. The novel structural log member of claim 1 wherein the bonding means comprises a urethane adhesive compound.
16. The novel structural log member of claim 1 where in the coverings are manufactured from a wood comprising one of: western hemlock, Douglas fir, pine or cedar.
17. The novel structural log member of claim 16 wherein the coverings are kiln dried to moisture content of approximately 16%.
18. The novel structural log member of claim 17 wherein the coverings are manufactured from western hemlock.
19. The novel structural log member of claim 18 wherein the outer covering is milled to one of the following shapes: D-log, New England, New England/D-log or round.
20. The novel structural log member of claim 19 wherein the outer coverings are further milled to produce a hand-hewn appearance.
21. The novel structural member of claim 20 wherein the outer coverings are treated with a low-toxicity combination insecticide, fungicide and fire retardant.
22. The novel structural log member of claim 1 wherein the joining means comprise:
a. a rectangular key located on the top of the structural log member; and, b. a corresponding rectangular slot located in the bottom of the structural log member.
whereby when a first bottom and second top structural members are stacked one on top of the other the key located on the top of the first bottom structural member is adapted to engage in a cooperative relationship with the slot located on the bottom of the second top structural member thus joining the two members together.
a. a rectangular key located on the top of the structural log member; and, b. a corresponding rectangular slot located in the bottom of the structural log member.
whereby when a first bottom and second top structural members are stacked one on top of the other the key located on the top of the first bottom structural member is adapted to engage in a cooperative relationship with the slot located on the bottom of the second top structural member thus joining the two members together.
23. The novel structural log member of claim 22 wherein the key and slot are formed in a structural member during assembly thereof by longitudinally aligning the outer coverings on either side of the core in a parallel manner and vertically off-set from the top of the core a predetermined distance such that the top edges of the coverings are located the predetermined distance below the top of the core thereby causing the top end of the core to protrude above the top end of the coverings the predetermined distance creating the key and wherein the bottom edges of the coverings protrude below the bottom edge of the core the predetermined distance thus forming a corresponding slot in the bottom of the structural member.
24 24. The novel structural log member of claim 1 wherein the securing means for securing a plurality of stacked structural members in a wall comprises:
a. a plurality of horizontal holes penetrating the structural member at pre-determined positions, each of the holes adapted to receive a torque bolt;
b. a torque bolt placed into each of the holes connecting the covers so that when torque is applied to the bolt a compressive pressure is applied to the core;
c. a washer placed beneath the head of the torque bolt to protect the structural member from damage; and, d. a T-nut placed within the bolt hole for receiving threads of the torque bolt, the T-nut having spiked flanges for biting into the structural member to prevent it from spinning as torque is applied to the bolt wherein the torque bolt and T-nut threading together join the coverings together in a cooperative relationship.
a. a plurality of horizontal holes penetrating the structural member at pre-determined positions, each of the holes adapted to receive a torque bolt;
b. a torque bolt placed into each of the holes connecting the covers so that when torque is applied to the bolt a compressive pressure is applied to the core;
c. a washer placed beneath the head of the torque bolt to protect the structural member from damage; and, d. a T-nut placed within the bolt hole for receiving threads of the torque bolt, the T-nut having spiked flanges for biting into the structural member to prevent it from spinning as torque is applied to the bolt wherein the torque bolt and T-nut threading together join the coverings together in a cooperative relationship.
25. The novel structural log member as claimed in claim 24 wherein the torque bolt is of a predetermined size adapted for withstanding the torque applied and resist the expansion and contraction caused by seasonal variations of temperature.
26. The structural member of claim 25 wherein the horizontal bolt hole is located in a predetermined position being substantially through the centre of the covering thus corresponding to a position a predetermined distance below the middle line of the core so that when torque is applied to the bolt, the inside surfaces of each of the coverings are drawn towards each other thus compressing the bottom portion of the core and causing the bottom protruding portions of the outer coverings forming the slot in the bottom of an upper structural member to grip the key on the top of a lower structural member thus creating a secure structural connection between the two members.
27. A method of fabricating a structural log member comprising the steps of a. Selecting a natural log billet made from a wood selected from a group of kiln dried woods comprising: western hemlock, Douglas fir, pine or cedar;
b. Profiling the log billet into a profile selected from a group of profiles comprising: D-log, New England, New England/D-Log or round;
c. Adding aesthetic qualities to the wooden covering by creating a hand-hewn appearance;
d. Trimming the wooden covering to predetermined dimensions;
e. Adding fire retardant and insect resistant qualities to the wooden covering through chemical treatment;
f. conditioning the covering prior to assembly of the structural member by:
i. Placing the profiled and chemically treated covings in a conditioning chamber;
ii. Setting the environmental conditions of the conditioning chamber to a temperature of at least 65F and a humidity of between 20% and 95%;
and, iii. leaving the outer coverings in the conditioning chamber for a period of time so that the temperature of the wood coverings reaches a minimum of 60F;
g. Selecting at least two outer laminates made from a material such as oriented strand board having the desired strength, fire retardant and insect resistant properties;
h. cutting and profiling the outer laminates to predetermined shapes and sizes i. joining the outer coverings to the outer laminates by a adhesive means or staples or a combination of both;
j. selecting an inner laminate of a material such as expanded polystyrene foam having the desired thermal insulation, insect resistant and fire resistant qualities;
k. cutting and profiling the inner laminate to the desired dimensions and profiles;
l. Joining the outer laminates and outer coverings to each side of the inner laminate by:
i. Placing an adhesive such as a polyurethane adhesive on the opposing sides of the inner laminate;
ii. Joining the outer laminates to the inner laminate;
iii. Placing a plurality of removable resilient spacing members on the in the notch and key of the assembled structural log member to prevent crushing of the inner laminate material during initial curing and to permit a greater bonding force to be applied to the assembled structural log member;
iv. Placing the assembled structural log member into a bladder clamp;
and, v. Applying a predetermined amount of compressive force to the structural log member;
m. Allowing the adhesive bonds to cure for a first predetermined amount of time;
n. Placing cured structural member in a curing chamber to allow the adhesive to form a strong bond for a period of at least 24 hours at a temperature of 65F
and at humidity between 20% and 95% for a second predetermined amount of time;
o. Finishing the formed structural member by the steps of:
i. Squaring the ends of the structural member;
ii. Cutting the structural member into desired lengths;
iii. Notching the structural member for utility connections;
iv. Angle cutting the ends of the structural member as required;
v. Cutting splice joints into the structural member for horizontal attachment as required;
vi. Drilling a plurality of vertical holes in pre-determined locations through the inner laminate of the core member the holes adapted to each receive a vertical hold-down bolt;
vii. Drilling a plurality of horizontal and countersunk holes in pre-determined locations through the structural member, the holes adapted to each receive a torque bolt, washer and nut assembly;
viii. Inserting a torque bolt washer and nut assembly into the horizontal holes and threading the nut onto the threads of the torque bolt so that the coverings are connected by the torque bolt;
ix. Applying approximately 2 foot pounds of torque to the torque bolt;
x. Fix a wooden plug into each of the horizontal hole openings;
xi. Inspect the product for defects;
xii. Labelling each structural log member so that each label identifies a pre-determined location of each member in a finished structure; and, xiii. Packaging the structural members for delivery to the assembly site.
b. Profiling the log billet into a profile selected from a group of profiles comprising: D-log, New England, New England/D-Log or round;
c. Adding aesthetic qualities to the wooden covering by creating a hand-hewn appearance;
d. Trimming the wooden covering to predetermined dimensions;
e. Adding fire retardant and insect resistant qualities to the wooden covering through chemical treatment;
f. conditioning the covering prior to assembly of the structural member by:
i. Placing the profiled and chemically treated covings in a conditioning chamber;
ii. Setting the environmental conditions of the conditioning chamber to a temperature of at least 65F and a humidity of between 20% and 95%;
and, iii. leaving the outer coverings in the conditioning chamber for a period of time so that the temperature of the wood coverings reaches a minimum of 60F;
g. Selecting at least two outer laminates made from a material such as oriented strand board having the desired strength, fire retardant and insect resistant properties;
h. cutting and profiling the outer laminates to predetermined shapes and sizes i. joining the outer coverings to the outer laminates by a adhesive means or staples or a combination of both;
j. selecting an inner laminate of a material such as expanded polystyrene foam having the desired thermal insulation, insect resistant and fire resistant qualities;
k. cutting and profiling the inner laminate to the desired dimensions and profiles;
l. Joining the outer laminates and outer coverings to each side of the inner laminate by:
i. Placing an adhesive such as a polyurethane adhesive on the opposing sides of the inner laminate;
ii. Joining the outer laminates to the inner laminate;
iii. Placing a plurality of removable resilient spacing members on the in the notch and key of the assembled structural log member to prevent crushing of the inner laminate material during initial curing and to permit a greater bonding force to be applied to the assembled structural log member;
iv. Placing the assembled structural log member into a bladder clamp;
and, v. Applying a predetermined amount of compressive force to the structural log member;
m. Allowing the adhesive bonds to cure for a first predetermined amount of time;
n. Placing cured structural member in a curing chamber to allow the adhesive to form a strong bond for a period of at least 24 hours at a temperature of 65F
and at humidity between 20% and 95% for a second predetermined amount of time;
o. Finishing the formed structural member by the steps of:
i. Squaring the ends of the structural member;
ii. Cutting the structural member into desired lengths;
iii. Notching the structural member for utility connections;
iv. Angle cutting the ends of the structural member as required;
v. Cutting splice joints into the structural member for horizontal attachment as required;
vi. Drilling a plurality of vertical holes in pre-determined locations through the inner laminate of the core member the holes adapted to each receive a vertical hold-down bolt;
vii. Drilling a plurality of horizontal and countersunk holes in pre-determined locations through the structural member, the holes adapted to each receive a torque bolt, washer and nut assembly;
viii. Inserting a torque bolt washer and nut assembly into the horizontal holes and threading the nut onto the threads of the torque bolt so that the coverings are connected by the torque bolt;
ix. Applying approximately 2 foot pounds of torque to the torque bolt;
x. Fix a wooden plug into each of the horizontal hole openings;
xi. Inspect the product for defects;
xii. Labelling each structural log member so that each label identifies a pre-determined location of each member in a finished structure; and, xiii. Packaging the structural members for delivery to the assembly site.
28. A method of assembling a structural wall using a plurality of structural members comprising the steps of:
a. creating a suitable wall foundation having a sill plate, and a plurality of vertical hold-down bolts at pre-determined intervals, the vertical hold-down bolts adapted to receive the structural members through the respective vertical holes drilled therein;
b. applying a construction adhesive to the bottom sill plate and setting a first row of structural members on the sill plate such that the vertical holes in the structural members are placed over the vertical hold-down bolts on the foundation and the bottom plate on the foundation is inserted into the bottom of the first row of structural members;
c. applying an adhesive to the top key of the first row of structural members;
d. setting a second row of structural members;
e. applying an adhesive to the top key of the first row of structural members;
f. setting a second row of structural members on the first row such that the top keys of the first row of structural members are inserted into the bottom slots of the second row of structural members and the adhesive is compressed between the upper surface of the key and the lower surface of the slot;
g. repeating steps d, e, and f until three rows are in place;
h. applying a predetermined amount of torque to the vertical hold down bolts to compress the stacked structural members together;
i. applying 5 foot-pounds of torque to the horizontal torque bolts;
j. placing desired utilities in the utility conduits at predetermined levels in the wall;
k. repeating steps c to j until the desired wall height is achieved;
l. applying a predetermined amount of torque to the vertical hold down bolts; and, m. allowing the adhesive to cure for a predetermined amount of time.
a. creating a suitable wall foundation having a sill plate, and a plurality of vertical hold-down bolts at pre-determined intervals, the vertical hold-down bolts adapted to receive the structural members through the respective vertical holes drilled therein;
b. applying a construction adhesive to the bottom sill plate and setting a first row of structural members on the sill plate such that the vertical holes in the structural members are placed over the vertical hold-down bolts on the foundation and the bottom plate on the foundation is inserted into the bottom of the first row of structural members;
c. applying an adhesive to the top key of the first row of structural members;
d. setting a second row of structural members;
e. applying an adhesive to the top key of the first row of structural members;
f. setting a second row of structural members on the first row such that the top keys of the first row of structural members are inserted into the bottom slots of the second row of structural members and the adhesive is compressed between the upper surface of the key and the lower surface of the slot;
g. repeating steps d, e, and f until three rows are in place;
h. applying a predetermined amount of torque to the vertical hold down bolts to compress the stacked structural members together;
i. applying 5 foot-pounds of torque to the horizontal torque bolts;
j. placing desired utilities in the utility conduits at predetermined levels in the wall;
k. repeating steps c to j until the desired wall height is achieved;
l. applying a predetermined amount of torque to the vertical hold down bolts; and, m. allowing the adhesive to cure for a predetermined amount of time.
29. A method of assembling a plurality of structural members in a vertical relationship to create a wall the method comprising a first stage and a second stage, wherein the first stage of sub-wall assembly occurs under controlled environmental conditions during the fabrication of the structural member and the second stage occurs during the assembly of the structure on a construction site;
30. The method as claimed in claim 29 wherein the first stage comprises the steps of a. establishing desired environmental conditions at the fabrication site;
b. drilling a plurality of horizontal holes through the structural member at predetermined locations along its length;
c. inserting a torque bolt, washer and nut assembly in each of the horizontal holes and threading the nut onto the threads of the torque bolt so that the coverings are connected to each other through the torque bolt;
d. applying a first application of torque to each of the torque bolts so that the coverings are compressed against the core; and, e. curing the structural member for a suitable period of time to ensure adhesive bonding.
b. drilling a plurality of horizontal holes through the structural member at predetermined locations along its length;
c. inserting a torque bolt, washer and nut assembly in each of the horizontal holes and threading the nut onto the threads of the torque bolt so that the coverings are connected to each other through the torque bolt;
d. applying a first application of torque to each of the torque bolts so that the coverings are compressed against the core; and, e. curing the structural member for a suitable period of time to ensure adhesive bonding.
31. The method of claim 30 wherein the second stage occurs after the structural log members have been cured and comprises the steps of a. Placing a first row of structural members on a wall foundation sill plate;
b. placing an adhesive on the top surface of the key of the first row of structural;
c. placing a second row of structural members on top of the first structural unit so that the key of the bottom unit is inserted into the slot of the top unit and the adhesive is compressed between the two units;
d. placing a third row of structural members on top of the second row;
e. applying a second application of torque to the torque bolts in all of the structural members so that the coverings are compressed against the core and the sides of the slot are compressed against the key inserted therein;
f. repeating steps b, c, d and a until the desired wall height is reached;
and, g. curing the adhesive for a suitable period of time.
b. placing an adhesive on the top surface of the key of the first row of structural;
c. placing a second row of structural members on top of the first structural unit so that the key of the bottom unit is inserted into the slot of the top unit and the adhesive is compressed between the two units;
d. placing a third row of structural members on top of the second row;
e. applying a second application of torque to the torque bolts in all of the structural members so that the coverings are compressed against the core and the sides of the slot are compressed against the key inserted therein;
f. repeating steps b, c, d and a until the desired wall height is reached;
and, g. curing the adhesive for a suitable period of time.
32. The method as claimed in claim 31 wherein the environmental conditions comprise a temperature of approximately 65F and a humidity of between 20% and 95%.
33. The method as claimed in claim 32 wherein the first application of torque does not exceed 2 foot-pounds.
34. The method as claimed in claim 33wherein the second application of torque does not exceed 5 foot-pounds.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2326054 CA2326054A1 (en) | 2000-11-10 | 2000-11-10 | A novel structural log member and methods for making and using the same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2326054 CA2326054A1 (en) | 2000-11-10 | 2000-11-10 | A novel structural log member and methods for making and using the same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2326054A1 true CA2326054A1 (en) | 2002-05-10 |
Family
ID=4167678
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2326054 Abandoned CA2326054A1 (en) | 2000-11-10 | 2000-11-10 | A novel structural log member and methods for making and using the same |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2326054A1 (en) |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2007009222A1 (en) * | 2005-07-20 | 2007-01-25 | Thermo Structure Inc. | Stackable insulated unit for wall construction and method |
| WO2007069908A1 (en) * | 2005-12-14 | 2007-06-21 | Leif Melvin Nettum | Building element with insulation |
| US7823351B2 (en) | 2005-07-20 | 2010-11-02 | Thermo Structure Inc. | Stackable insulated unit for wall construction and method of fabrication thereof |
| FR2958949A1 (en) * | 2010-04-16 | 2011-10-21 | David Stanley Ludovic Bibay | Structural component for agglomerated or massive wood bearing wall in e.g. passive building, has concrete blocks and planks formed with same sections integrating insulating core installed in zigzag manner at upper and lower surfaces |
| WO2013127010A1 (en) * | 2012-03-01 | 2013-09-06 | Composante De Construction Ecolog.Ix Inc. | Engineered building block modular construction |
| CN114427267A (en) * | 2021-12-23 | 2022-05-03 | 浙江环宇建设集团有限公司 | Prefabricated outer wall of prefabricated building and wall body quick connect component thereof |
-
2000
- 2000-11-10 CA CA 2326054 patent/CA2326054A1/en not_active Abandoned
Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2007009222A1 (en) * | 2005-07-20 | 2007-01-25 | Thermo Structure Inc. | Stackable insulated unit for wall construction and method |
| US7823351B2 (en) | 2005-07-20 | 2010-11-02 | Thermo Structure Inc. | Stackable insulated unit for wall construction and method of fabrication thereof |
| WO2007069908A1 (en) * | 2005-12-14 | 2007-06-21 | Leif Melvin Nettum | Building element with insulation |
| FR2958949A1 (en) * | 2010-04-16 | 2011-10-21 | David Stanley Ludovic Bibay | Structural component for agglomerated or massive wood bearing wall in e.g. passive building, has concrete blocks and planks formed with same sections integrating insulating core installed in zigzag manner at upper and lower surfaces |
| WO2013127010A1 (en) * | 2012-03-01 | 2013-09-06 | Composante De Construction Ecolog.Ix Inc. | Engineered building block modular construction |
| CN114427267A (en) * | 2021-12-23 | 2022-05-03 | 浙江环宇建设集团有限公司 | Prefabricated outer wall of prefabricated building and wall body quick connect component thereof |
| CN114427267B (en) * | 2021-12-23 | 2023-11-28 | 浙江环宇建设集团有限公司 | Prefabricated outer wall of assembled building and wall body quick connecting component thereof |
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