Field of the Invention
[0001] This invention relates to a structural wall framework, to a method of forming the
framework and to a bracing unit for use in the framework.
Background of the Invention
[0002] Prefabricated wall frameworks for buildings such as houses are made by advancing
a top plate and bottom plate past a fastening station. Studs are located between the
plates and are fixed in place by a nailing or pressing machine or the like.
[0003] As is well known, studs are arranged at predetermined spacings such as about 450
to 600 mm in order support loads which the framework will be subjected to when installed
in a building. The studs are also required at these spacings to support plasterboard
which will form the internal wall surface of the building.
[0004] In order to ensure that the framework has the required structural integrity, the
framework is braced by bracing. The bracing can take a number of forms, including
angle brace, plywood brace and wooden brace. Generally the angle brace and wood brace
needs to be cut into the framework, thereby reducing its strength, as the framework
is being prefabricated, and this greatly increases the time taken to form the framework
and also the complexity of the manufacturing process. Plywood braces are usually only
suitable for external walls or where brick veneer cladding is used.
[0005] Modern building designs and, in particular, domestic dwellings generally include
large window spaces. The incorporation of large window spaces in the framework limits
the amount of bracing which can be used, and therefore the raking strength of the
framework. The raking strength of the framework is the ability of the framework to
restrain horizontal shear forces which apply a load which tends to flatten the framework
generally in the plane of the framework. The effectiveness of the common forms of
wall bracing diminishes significantly as the length of the braced section of the wall
frame diminishes.
Summary of the Invention
[0006] Among the objects of a first aspect of the invention is to provide a structural wall
framework which can provide for large window spacings, yet still have sufficient raking
strength to support required loads.
[0007] This aspect of the invention may be said to reside in a structural wall framework
comprising a top plate, a bottom plate, and a plurality of studs extending between
the top plate and the bottom plate. The studs have a first face and a second opposite
face which are parallel to the plane of the wall framework. Side faces join the first
and second faces. At least one bracing unit is connected to the top plate and bottom
plate, and comprised of at least two of said studs and separate bracing elements interconnecting
the studs. Each of the separate elements are connected to the first or second faces
of the at least two studs. The bracing elements extend substantially all of the way
from the top plate to the bottom plate.
[0008] By providing the plurality of bracing elements which are connected to the studs and
extend between the top plate and bottom plate, the framework is provided with the
required raking strength in a smaller space than with conventional angle brace and
wooden brace. This allows large window spaces to be formed in the framework whilst
at the same time providing the required raking strength.
[0009] The use of a prefabricated bracing unit reduces the complexity of manufacture of
the framework because studs together with suitable bracing can be concurrently provided
in the framework. Thus, it is not necessary to perform a separate step of cutting
in angle brace or wood brace into the framework. Thus, both the time taken to produce
the framework and the complexity of the manufacturing process can be reduced.
[0010] A further aspect of the invention may be said to reside in a bracing unit for a structural
wall framework. The bracing unit comprises at least two spaced apart studs, each having
a first face and a second face which are parallel. Side faces join the first and second
faces. The studs have first and second ends. A plurality of separate bracing elements
are connected to the first face or second face of the studs and extend substantially
all the way from the first end to the second end of the studs.
[0011] A further aspect of the invention relates to a method of forming a structural wall
framework. This aspect of the invention comprises providing a top plate and a bottom
plate, and locating at least one prefabricated bracing unit between the top plate
and the bottom plate. The bracing unit comprises at least two studs each having ends,
the studs having a first face and a second face which are parallel to a plane of the
wall framework and side faces joining the first and second faces, and a plurality
of separate bracing elements extending substantially all of the way from one end of
the bracing unit to the other end of the bracing unit. The bracing unit is connected
to the top plate and bottom plate.
[0012] Thus, according to this aspect of the invention, both bracing and studs are incorporated
into the framework in a single operation, thereby decreasing the amount of work which
is required to form the framework, and also simplifying the manufacturing process.
[0013] Other objects and features of the present invention will be in part apparent and
in part pointed out hereinafter.
Brief Description of the Drawings
[0014] Preferred embodiments of the invention will be described, by way of example, with
reference to the accompanying drawings, in which:
Figure 1 is a view of a bracing unit according to one embodiment of the invention;
Figure 2 is a view of a bracing unit according to a second embodiment of the invention;
Figure 3 is a view of a bracing element according to the preferred embodiment of the
invention;
Figure 4 is a view of a structural wall framework according to one embodiment of the
invention;
Figure 5 is a detailed view showing connection of a bracing unit to a bottom plate
of the framework; and
Figure 6 is a view along the line V-V of Figure 5.
[0015] Corresponding reference characters indicate corresponding parts throughout the views
of the drawings.
Detailed Description of the Preferred Embodiments
[0016] Figure 1 shows a bracing unit 10 according to one 30 embodiment of the invention.
The bracing unit 10 comprises spaced apart studs 12 and 14 which have free ends 13
and which are connected together by a bracing system 15 which comprises discrete bracing
elements 16 and 17.
[0017] In the preferred embodiment of the invention, the elements 16 comprise metal braces
sold under the name P0SI-STRUT manufactured by MiTek. The bracing element 17 comprises
one half of a bracing element 16. As is shown in Figure 3 the bracing element 16 has
a weakening 32 formed by partially cutting or scoring the element 16 so the element
16 can be easily broken in half to form the two elements 17. The bracing elements
16 and 17 are provided with punched teeth 31 (see Figure 3) at end plate regions 18
which penetrate into the studs 12 and 14 to thereby fix the bracing elements 16 and
17 to the studs 12 and 14 to form the bracing unit 10.
[0018] The bracing elements which are connected to the studs may comprise only bracing elements
16, only bracing elements 17, or as is shown in the drawings, a combination of the
elements 16 and 17. By using elements 16 and 17 it is more easy to provide an integral
number of bracing elements which extend all of the way from one end of the studs to
the other end of the studs with suitable small spacings between the elements to provide
as many bracing elements as is possible from the bracing elements 16 and 17 to thereby
increase the raking strength of the framework including the bracing unit.
[0019] In other embodiments, bracing elements of a different type to those formed by or
of the POSI-STRUT braces referred to above could be used. These include thin strips
of metal, wooden elements such as rectangular cross-section boards. Furthermore, the
shape of the elements may be different to those referred to above. Still further,
the elements need not extend between the studs at acute angles (about 45 degrees as
in the preferred embodiment), but could extend at other angles including perpendicular
(i.e., horizontally) to the studs.
[0020] The vertical height of the units 10 depend on the size of the wall frame which is
being made, and the height of the units 10 may be anywhere between, for example, 2100
mm to 2700 mm. The studs 12 and 14 may be spaced apart by a distance between 300 and
400 mm for example. The bracing elements 16 and 17 extend substantially the full length
of the studs 12 and 14 between free ends 13 of the studs so that when the unit 10
is arranged vertically, the bracing elements 16 and 17 extend all the way from an
upper end of the bracing unit 10 to a lower end of the bracing unit 10. The elements
16 and 17 are spaced apart, as is required to enable a number of the bracing units
16 or 17 to be so located.
[0021] The formation of the bracing system 15 from the discrete bracing elements 16 or 17
accommodates a greater variation in height of the frame unit by simply increasing
the size of the gaps between elements 16, 17 as is needed to ensure that an integral
number of the units are provided to extend between the top end and lower end of the
bracing unit 10.
[0022] A nogging 19 may be provided between the studs 12 and 14 as is shown.
[0023] Figure 2 shows a second embodiment in which a bracing unit 20 is comprised of three
studs 22, 24 and 26. As in the previous embodiment, a bracing system 25 is provided
which extends from the upper end of the bracing unit 20 to the bottom end of the bracing
unit 20. The bracing system 25 comprises two sets 25' and 25" of discrete bracing
elements 16 and 17 which are the same as those described with reference to Figure
1. Once again, the bracing elements 16 and 17 are spaced apart to extend all of the
way between the free ends 13 of the studs 22, 24 and 26.
[0024] As in the earlier embodiment, noggings 19 may be provided between adjacent studs
22, 24 and 26.
[0025] In other embodiments, the bracing unit may include four or more studs with appropriate
numbers of bracing sets interconnecting the adjacent studs.
[0026] It should also be understood in other embodiments the bracing elements may have a
different configuration to those shown in the drawings. Whilst in the embodiment of
Figure 2 the two sets of bracing elements are horizontally aligned, the horizontal
configuration is optional and the two sets of bracing elements could be staggered
with respect to one another.
[0027] The embodiment of Figure 2 provides a stronger wall frame than the embodiment of
Figure 1. Although the effective length L of the bracing unit of Figure 2 is double
the length L of the bracing unit of Figure 1 the configuration of Figure 2 gives more
than double the strength. Thus, the embodiment of Figure 2 provides more than double
the raking strength compared to the embodiment of Figure 1 while still using relatively
small components which are also used in the embodiment of Figure 1.
[0028] The embodiments of Figures 1 and 2 greatly increase the horizontal raking load a
wall frame using the bracing units can take, compared to an equivalent width of a
braced framework according to conventional bracing techniques. Typically, conventional
systems for bracing adjacent studs have a single brace extending between a top of
one stud to a bottom of the adjacent stud. When studs must be spaced relatively closer
together, the brace tends to become more nearly vertical. That leaves the brace practically
ineffective in resisting the horizontal loads. This is not the case in the present
invention which features multiple unit braces which remain more nearly horizontal.
[0029] Typically the load which the bracing unit of Figure 2 can take is in the order of
2.7 kN and the length L of the bracing unit is in the order of 750 mm. This compares
to a conventional braced wall frame using angle iron or timber bracing which would
require bracing of a length of in order of 1800 mm in order to provide the same capacity.
Thus, in this embodiment of the invention, the load capacity is provided by a greatly
reduced length L compared to conventional systems, thereby increasing the amount of
space which is available for a window without sacrificing raking strength.
[0030] Figure 4 is a view of a framework 50 according to one embodiment of the invention.
The framework 50 has a top plate 51 and a bottom plate 52. For illustrative purposes,
the bracing unit 10 described with reference to Figure 1 is located at one end of
the framework 50 and the bracing unit 20 described with reference to Figure 2 is located
at the other end. However, it should be understood that the wall framework may include
only bracing units according to the embodiment of Figure 1, or only bracing units
according to the embodiment of Figure 2, or some other combination of those two types
of bracing units. A window space 30 is defined between the bracing units 10 and 20
and the top plate 51 and bottom plate 52. The framework 50 is formed by locating the
bracing unit 10 between the plates 52. and 52 so the free ends 13 of the studs abut
respective plates 51 and 52 and securing the framework 10 to the plates 51 and 52
by fasteners, as will be described with reference to Figures 5 and 6. Similarly, the
bracing unit 20 is located at the other end of the plates 51 and 52 and secured in
place.
[0031] The bottom plate 52 may be provided with tie down connectors 60 to facilitate connection
of the framework to a floor frame or concrete slab of a building.
[0032] In the preferred embodiment of the invention, the bracing elements formed from the
POSI-STRUT braces are thin and are connected on a first face 21 of the studs 12 so
that the opposite second face 23 of the studs are left completely free, thereby providing
a surface for location of plasterboard which is not interfered with by bracing or
the like. The first face 21 and second face 23 of the studs are joined by side faces
27. The first face 21 of the studs is the side of the studs which is intent to be
outermost when the framework is installed in a building. Thus, the bracing on first
face 21 of the studs is substantially flush with the studs and is easily accommodated
within the brick cavity of an exterior building wall.
[0033] The framework of the present invention therefore particularly lends itself to exterior
walls of a building in which window spaces are required. However, the framework could
be used as an internal wall of a building if required.
[0034] The framework shown in Figure 4 may also include individual studs 29 which are connected
to the top plates 51 and 52 in the usual manner. Typically, a number of such conventional
studs 29 are connected in the normal manufacturing technique by advancing the top
plate 51 and bottom plate 52 past a securing station and locating the stud or studs
29 in place, and then securing them to the top plate 51 and bottom plate 52.
[0035] After the standalone studs 29 have been connected in place, the bracing units 10
and 20 can be lifted into position and then secured to the top plate 51 and bottom
plate 52.
[0036] Figures 5 and 6 show one method of connecting the studs of 35 the bracing units 10
and 20 to the top plate 51 and bottom plate 52. The stand alone studs 29 can be connected
in the same manner.
[0037] As is shown in Figures 5 and 6, the studs 12 and 14 are connected to bottom plate
52 by a generally U-shaped strap 90 which has an arm 91 and opposite arm 92 and a
base 93. The arms 91 and 92 may be provided with punched teeth for penetrating the
stud 12 and bottom plate 52, or may be provided with holes so that the arms 91 and
92 can be nailed to the stud 12 such as by nails 33.
[0038] The other ends of the studs 12 and 14 are connected to the top plate 51 (not shown
in Figures 5 and 6) in the same manner.
[0039] Thus, the studs 12 and 14 are connected to the plates 51 and 52 in the same manner
as individual studs would have been connected in the conventional manufacturing method.
However, in this embodiment of the invention, bracing is concurrently incorporated
into the framework when the studs 12 and 14 are secured to the plates 51 and 52. Thus,
in the preferred embodiment of the invention the bracing elements 16 and 17 are connected
to the studs 12 and 14, and 22, 24 and 26 before the bracing units 10 and 20 are attached
to the top plate 51 and bottom plate 52. Therefore the bracing is provided at the
same time as those studs. However, in other embodiments the bracing elements 16 and
17 could be attached on site after the studs 12 and 14, and 22, 24 and 26 are connected
to the top plates 51 and 52.
[0040] In the preferred embodiment shown in Figures 1 and 2 the ends of the studs 12 and
14, 22, 24 and 26 connect directly to the top plate 51 and bottom plate 52. However,
in other embodiments cross members (not shown) may be provided at the ends 13 of the
studs and the cross members may connect to the top plate 51 and bottom plate 52.
[0041] In the claims which follow and in the preceding description of the invention, except
where the context requires otherwise due to express language or necessary implication,
the word "comprise", or variations such as "comprises" or "comprising", is used in
an inclusive sense, i.e. to specify the presence of the stated features but not to
preclude the presence or addition of further features in various embodiments of the
invention.
[0042] Since modifications within the spirit and scope of the invention may readily be effected
by persons skilled within the art, it is to be understood that this invention is not
limited to the particular embodiment described by way of example hereinabove.
1. A bracing unit for a structural wall framework, the bracing unit comprising:
at least two spaced apart studs, each having a first face and a second face which
are parallel, side faces joining the first and second faces, and the studs having
a first end and a second end; and
a plurality of separate bracing elements connected to the first face or second face
of the studs and extending substantially all the way from the first end to the second
end of the studs.
2. The bracing unit of Claim 1 wherein the unit comprises two studs and the said bracing
elements.
3. The bracing unit of Claim 1 wherein the bracing unit comprises three studs comprised
of a first outer stud, an intermediate stud, and a second outer stud, and a first
set of said separate bracing elements connected to the first stud and the intermediate
stud, and a second set of said separate bracing elements connected to the intermediate
stud and the second stud.
4. The bracing unit of anyone of Claims 1 to 3 wherein the bracing unit includes at least
one flogging located between adjacent said studs of the bracing unit.
5. The bracing unit of any one of Claims 1 to 4 wherein the bracing elements have punched
teeth for connecting the bracing elements to the respective studs.
6. The bracing unit of any one of Claims 1 to 5 wherein the separate bracing elements
are all connected to the first face of the studs.
7. The bracing unit of any one of Claims 1 to 6 wherein the separate bracing elements
are spaced apart from one another so that a predetermined number of the bracing elements
extend between the first end and second opposite end of the studs.
8. A method of forming a structural wall framework, comprising:
providing a top plate and a bottom plate;
locating at least one prefabricated bracing unit between the top plate and the bottom
plate, the bracing unit comprising at least two studs each having ends, the studs
having a first face and a second face which are parallel to a plane of the wall framework,
and side faces joining the first and second faces, and a plurality of separate bracing
elements extending substantially all of the way from one end of the bracing unit to
the other end of the bracing unit; and
connecting the bracing unit to the top plate and bottom plate.
9. The method of Claim 8 wherein the prefabricated bracing unit comprises two said studs
and the said bracing elements.
10. The method of Claim 8 wherein the prefabricated bracing unit comprises three studs
and two sets of separate bracing elements, a first of the two sets of bracing elements
extending between a first outer stud of the three studs and an intermediate stud of
the three studs, and the second set of bracing elements extending between the said
intermediate stud and a second outer stud of the three studs.
11. The method of any one of Claims 8 to 10 wherein the bracing elements have a plurality
of punched teeth for connecting the bracing elements to the studs.
12. The method of any one of Claims 8 to 11 wherein the prefabricated bracing unit also
includes at least one nogging extending between adjacent studs.