Building with composite foam and concrete walls having an internal continuous load path

Abstract

A composite wall includes a foam layer and a concrete layer. The wall includes at least one wall continuous load path structure within the concrete layer and extending from a bottom edge to a proximate a top edge of the wall. The at least one continuous wall load path includes a bottom bracket configured to be secured to a mount in a foundation, a lifting member proximate a top surface of the wall, wherein the concrete layer includes a cavity that exposes an aperture in the lift mechanism, such that the lifting member can be engaged to tilt the wall into an upright position, and a joining member configured to connect the bottom bracket to the lifting member.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application is based on and claims the benefit of U.S. provisional patent application Serial No. 63 / 764,250, filed February 27, 2025, the content of which is hereby incorporated by reference in its entirety.BACKGROUND

[0002] The present disclosure relates a building with composite foam and concrete walls. More particularly, the present disclosure relates to a building with composite foam and concrete walls with internal continuous load paths within a concrete layer of the composite walls and optionally a load path over an outer surface of a roof deck.

[0003] A typical wall includes a bottom plate or foundation sill that is attached to a foundation, typically a concrete slab or footer. Bottom ends of spaced apart vertical studs are secured to the bottom plate and top ends of the spaced apart vertical studs are secured to a top plate. A height of the wall is essentially defined by the length of the vertical studs. The wall provides structural support for the building as well as the support for the outer wall material, such as wood panels and siding, and also the interior wall material, such as sheet rock. Insulation is typically placed between the studs when the stud wall is raised into place and the outer wall material is secured to the stud wall.

[0004] Construction of the wood stud wall is very labor intensive and can take a considerable amount of time to construct. The studs must be cut to a precise length and secured to the bottom and top plates, typically with nails. In the event windows and / or doors are to be placed into the wall, then the studs must be cut to accommodate the required space for the window and / or door and the space must be reinforced with a lintel, which also must be constructed by the construction workers.

[0005] Once the wood stud wall is formed, it is raised and secured to the foundation, typically with bolts that are set into the concrete foundation and through bores in the bottom plate, where the bores in the bottom plate are positioned about the bolts. Washers are positioned on the bolts and nuts threadably engage each bolt to frictionally secure the bottom plate to the foundation. Once the stud wall is raised, an outer wall is secured to the studs typically with nails and then siding is secured to the outer wall.

[0006] In spite of the labor-intensive construction, wood stud wall constructed houses are susceptible to damage or destruction by violent weather such as straight-line winds, hurricanes and tornados, as well as seismic events. As such, there is a need for a building or structure that is constructed to withstand damaging weather and seismic events that can be efficiently constructed while minimizing the need for wood, or other renewable materials. Structures utilizing concrete and foam wall panels can be quickly constructed relative to wood stud wall constructed structure, while having internal continuous load path(s) and optionally a load path over the roof deck that aid in preventing damage from weather and seismic events while providing excellent energy efficiency in both hot and cold weather.

[0007] Also, structures with concrete exteriors are resistant to damage from fires relative to structures with wood exteriors. As such, there is a need for structures that are fire resistant, do not promote fires and are capable of withstanding wildfires.SUMMARY

[0008] One aspect of the present disclosure includes a composite foam and concrete wall having a foam layer and a concrete layer. The wall includes at least one continuous wall load path structure within the concrete layer and extending from a bottom edge to a proximate a top edge of the wall. The at least one continuous wall load path includes a bottom bracket configured to be secured to a mount in a foundation, a lifting member proximate a top surface of the wall, wherein the concrete layer includes a cavity that exposes an aperture in the lift mechanism, such that the lifting member can be engaged to tilt the wall into an upright position, and a joining member configured to connect the bottom bracket to the lifting member.

[0009] Another aspect of the present disclosure includes a building having a foundation having a plurality of spaced apart anchor bolts extending therefrom and a plurality of walls secured to the foundation. Each of the plurality of walls includes a foam layer and a concrete layer and a plurality of continuous wall load path structures within the concrete layer. Each continuous wall load path structure extends from a bottom edge to a proximate a top edge of the wall, wherein each of the plurality continuous load path structures includes a bottom bracket configured to be secured to one of the anchor bolts in a foundation, a lifting member proximate a top surface of the wall, wherein the concrete layer includes a cavity that exposes an aperture in the lift mechanism, such that the lifting member can be engaged to tilt the wall into an upright position. The continuous load path structure includes a joining member configured to connect the bottom bracket to the lifting member, and a roof joining mechanism configured to extend through the aperture in the lifting member and extend above a top edge of the wall. The building includes a roof supported by the plurality of walls. The roof includes a first portion with a first pitch, and a second portion with a second pitch that leads to a roof peak, wherein the second pitch is steeper than the first pitch and wherein the roof joining mechanism is configured to be secured to at least one roof member below the first portion.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 is a cutaway view of a building having a composite foam and concrete wall with a continuous wall load path structure.

[0011] FIG. 2 is a view of a building with a plurality of continuous wall load path structures.

[0012] FIG. 3 is a view of a composite wall with a plurality of continuous wall load path structures.

[0013] FIG. 4 is a sectional view taken along section line 4—4 in FIG. 3.

[0014] FIG. 5 is a sectional view taken along section line 5—5 in FIG. 3.

[0015] FIG. 6 is a view of a bottom bracket of a continuous wall load path structure.

[0016] FIG. 7 is a view of a joining member of the continuous wall load path structure

[0017] FIG. 8 is a view of a lifting member of the continuous load path structure.

[0018] FIG. 9 is a view of a J-shaped bolt that is placed into the concrete slab for securing the continuous wall load path structure.

[0019] FIG. 10 is a view of an expansion anchor this is placed into the concrete slab for securing the continuous wall load path structure.

[0020] FIG. 11 is view of a rigid member of the continuous wall load path structure.

[0021] FIG. 12 is a view of a removable mold for engaging the lifting member as concrete is placed on the foam layer.

[0022] FIG. 13 is a top view of a lifting member within the concrete layer of the composite wall.

[0023] FIG. 14 is a view of a continuous roof load path connected to a continuous wall load path on a structure.

[0024] FIG. 15 is a view of another continuous roof load path connected to a continuous wall load path on a structure.

[0025] FIG. 16 is a view of a structure with a continuous wall load path.

[0026] FIG. 17 is another view of a structure with another continuous wall load path.

[0027] FIG. 18 is a top view of a side to side roof spacing support for supporting a roof deck over a membrane.

[0028] FIG. 19 is an end view of the side to side roof spacing support.

[0029] FIG. 20 is a side view of the side to side roof spacing support.

[0030] FIG. 21 is a plan view of a prefabricated side to side roof spacing support.

[0031] FIG. 22 is an end view of the prefabricated side to side roof spacing support.

[0032] FIG. 23 is a view of the prefabricated side to side roof spacing support in a coil.

[0033] FIG. 24 is an illustration of wind flow over the contour of the roof of the building.

[0034] FIG. 25 is a sectional view of a plurality of wind deflectors.DETAILED DESCRIPTION

[0035] The present disclosure relates to a building having a continuous load path structure. The continuous load path structure can include at least one continuous wall load path structure and optionally at least one continuous roof load path structure that is connected to the at least one continuous wall load path structure. The building is typically constructed with composite walls constructed of concrete and foam layers, where the concrete layer retains the at least one continuous wall load path structure that spans a height of the wall.

[0036] The composite wall is constructed of concrete and foam layers where the continuous wall load path is located within the concrete layer. Once the concrete is cured, the wall is then tilted onto a foundation and retained in a substantially vertical position. With the wall in a substantially vertical position, a bottom end of the at least one continuous wall load path structure is secured to an anchor within the foundation and a top end of the continuous wall load path is secured to a roof member, such that the wall continuous load path structure is located along a height of the wall and couples the foundation to the roof member.

[0037] A continuous load path, such as a continuous wall load path structure and / or a roof load path structure, is an engineering term describing how wind and seismic loads are transferred both horizontally and vertically through structures. A properly designed and installed continuous load path provides structural integrity to buildings during high wind and seismic events. A structure with a continuous load path substantially resists all loads acting on a building, including both vertical and horizontal loads. Vertical loads include downward gravity forces, such as the weight of the building and uplift forces from wind. Horizontal, lateral loads include wind loads perpendicular to a wall, referred to as out of plane, and parallel to a wall, or alternatively as in plane or shear loads.

[0038] The continuous load path can optionally include the continuous roof load path structure attached to a roof deck that connects to the continuous wall load path structure in one wall. The continuous roof load path then spans the roof deck and attaches to another wall continuous load path in an opposite outer wall to provide structural support from two points in the foundations through the opposing walls and over the roof deck.

[0039] In another embodiment, a roof load path can be retrofitted onto an existing roof deck when the roof deck is being repaired or re-shingled. The roof load path is attached to the roof deck where an end is positioned through an opening in the roof deck so that the roof load path can be attached to one or more chords of a rafter and / or a ceiling joist such that the roof load path is secured to a building member below the roof deck. Attaching the roof load path to a member below the roof deck provides additional strength to the roof deck and aids in preventing the roof deck from lifting from the rafters.

[0040] A building is illustrated in FIG. 1 at 10 that is constructed using the composite walls 12 that have a concrete layer 13 and a foam layer 11. The concrete layer 13 retains a portion of a continuous wall load path structure 14 that has a bottom bracket 16 secured to an anchor bolt 18 extending from a foundation 20. A top end 22 of the continuous wall load path structure 14 is attached to a roof member 50 with a roof joining member 130. The bottom bracket 16 is connected to a lifting member 18 with a joining member 24 and the roof joining member 130 is joined to the lifting member 18. When the bottom bracket 16 secured to the anchor bolt 18 and the top end 22 of the roof joining member 130 attached to the roof member 50, the continuous wall load path structure 14 extends along a height of the composite wall 12 from the foundation 20 to the roof member 50.

[0041] Any foundation 20 can be utilized with the disclosed building 10, provided the anchor bolts 18 are secured within the foundation and are configured to be positioned through an aperture or slot in the bottom bracket 16 of the continuous wall load path structure 14 within the concrete layer of the composite walls 12. Similarly, any configuration of the roof members 50 can be utilized, provided the roof joining member 130 is securable to the roof member 50 with a securing mechanism, including but not limited to, nails, screws and a threaded engagement of a bolt with a threaded nut.

[0042] Referring to FIGS. 1 and 2, the building 10 is illustrated with a plurality of continuous wall load path structures 14 that are spaced apart within the walls 12. The plurality of continuous wall load path structures 14 located in the concrete layer 18 of the wall 12 can optionally be joined together proximate the bottom brackets 16 with a bottom joining member 30, such as a rod extending through aligned apertures in the bottom brackets 16 of the adjacent continuous wall load path structures 14. The plurality of continuous wall load path structures 14 can optionally be joined together proximate the top end 22 of the continuous wall load path structures 14 with a top joining member 32, such as a rod extending through apertures in lifting members 18 in the adjacent continuous wall load paths structures 14. The top joining member 32 and the lifting member 18 are connected with a rigid member 19 having at least one end that engages an aperture in the lifting member 18. In one embodiment, the at least one end of the rigid member 19 has a hook configuration that is positionable in the aperture of the lifting member 18, where the hook configuration is retained to the lifting member 18. Another end of the rigid member 19 is configured be fixedly attached to the top joining member 32 or can be removably attached with another hooked end.

[0043] Referring to FIGS. 3-5, a typical wall 12 is illustrated with the foam layer 11 and the concrete layer 13 that are retained together. The continuous wall load path structures 14 and the bottom and top joining members 30 and 32 are secured into a selected positions within the concrete layer 13. Joining the plurality of continuous wall load path structures 14 together with the bottom and top joining members 30 and 32 can increase the strength of the wall 12 to further aid in resisting violent weather-related events and / or seismic events.

[0044] A typical foam layer 11 is constructed of modified expanded polystyrene because the foam has a high R value for insulation purposes. The foam layer 11 is typically treated with a pesticide such as zinc borate to prevent insect and rodent infestations. The modified expanded polystyrene foam also is a fire preventative material, as the modified foam material will not promote a fire once the source of the fire is extinguished or removed from the foam. One non-limiting foam material is sold under the INSULFOAM® trademark by the Insulfoam division of the Carlisle Construction Materials headquartered in Puyallup, WA. The INSULFOAM® foam material requires a constant ignition source to cause the material to burn. If an ignition source is removed from the material, the flame is extinguished. However, other materials of the foam panels are also contemplated and are within the scope of the present disclosure.

[0045] As illustrated, the foam layer 11 is nominally about six inches in thickness. However, a nominal thickness range of between about four and about eight inches is also contemplated. The foam layer 11 can be any desired thickness provided the panels provide the necessary insulation and structure to secure the concrete layer 13 thereto.

[0046] The foam layer 11 includes a plurality of spaced art channels 40 that are cut into the foam or formed using a plurality of adhered foam sheets to form the foam layer 11 from a bottom surface 42 to the top surface 44. In an exemplary embodiment, a depth of the plurality of channels 40 is nominally two or more inches, where the plurality of channels 40 have a dove tail cross-sectional configuration. However, the depth of the plurality of channels 40 can be any depth that aids in securing a concrete layer 13 to the foam layer 11 while not adversely affecting the structural integrity of the foam layer 11. It is understood that the thickness of the foam layer 11 can dictate the depth of the plurality of channels 40. While dove tail cross-sectional configured channels 40 are contemplated to aid in retaining the concrete layer 13 to the foam layer 11, it is understood that the plurality of channels 40 can have any suitable cross-sectional configuration, including, but not limited to, a rectangular cross-sectional configuration.

[0047] The foam layer 11 includes a top channel 46 at the top surface 44 that has a similar depth as that of the plurality of channels 40. The top channel 46 extends from a right side 48 to a left side 50. The foam layer 11 also includes a bottom channel 52 at the bottom surface 42 that has a similar depth as that of the plurality of channels 40. The bottom channel 52 extends from the right side 48 to the left side 50. It is also contemplated that a channel be formed around the entire perimeter of the foam layer 11, which when concrete is placed and cured on the foam layer 11, will sheer the entire panel to maintain the panel’s shape and integrity.

[0048] Once the foam layer 11 is constructed, a form is placed about the perimeter of the foam layer 11 wherein the difference in the height of the form relative to the height of the foam layer 11 determines the thickness of a wythe of concrete 13 and the depth of the channels 40 determine the thickness of pilasters extending from the wythe of concrete 13.

[0049] With the form in place and prior to placing the concrete into the form, the continuous wall load path structures 14 are positioned within and / or aligned with each of the plurality of spaced apart channels 40 and the bottom and top joining members 30 and 32 are placed into the top channel 46 and the bottom channel 52 and are spaced from the foam layer 11 with rebar chairs or other devices.

[0050] The components of the wall continuous load path structure 14 are described in more detail and are illustrated in FIGS. 6-12, where the components of the wall continuous load path structure are typically constructed of steel due to the strength of steel. However, other metals and / or other materials are also within the scope of the present disclosure for forming the continuous wall load path 14. Referring to FIG. 6, the bottom bracket 16 has a substantially “L” shape and includes a substantially flat connecting portion 60 that extends beyond the outer edge of the wall 12. The substantially flat connecting portion 60 includes an aperture 62, such as a circular hole or a key hole slot, that is configured to be positioned about an anchor bolt extending from a foundation, where a nut threadably engages the bolt to frictionally secure the substantially flat connecting portion 60 to the foundation. The bottom bracket 16 includes a top portion 64 that extends upwardly from the substantially flat connecting portion 60. An engaging plate 66 extends substantially perpendicular from the top portion 64 where the engaging plate 66 includes an aperture 68 that is configured to accept the joining member 30. The engaging plate 66 includes another aperture 70 that is configured to accept the bottom joining member 24.

[0051] FIG. 7 illustrates an exemplary joining member 24 that is constructed of metal rebar. The joining member 24 is illustrated in a looped configuration that is configured to engage the engaging plate 66 of the bottom bracket 16 and the lifting member 18, as illustrated in FIG. 8. While a looped configuration of the joining member 24 is illustrated, the joining member 24 could include a single rod configuration with hooked ends configured to engage the bottom bracket 16 and the lifting member18. Alternatively, the joining member 24 could included threaded ends that are positionable through the engaging plate 66 and the lift member 18 and retained with a threaded engagement with nuts. Other retaining mechanisms for the ends of the joining member 24 are also contemplated, including but not limited to, a pin engaging a bore in each end.

[0052] Referring to FIG. 8, the lifting member 18 is constructed of metal plate, such as steel plate. The lifting member 18 includes a main portion 70 having a plurality of apertures 72 and 74. The aperture 74 is configured to accept the joining member 24 that ties the lifting member 18 to the bottom bracket 16. The aperture 72 is configured to accept the top joining member 32 that ties the spaced apart lifting structures 18 together.

[0053] The lifting member 18 includes barbs 75 and 76 extending outwardly from the main portion 70. The barbs 75 and 76 increase the cross-sectional area of the lifting structure 18 proximate the bottom end, which aid in retaining the lifting member 18 within the concrete layer 13 as the lifting member 18 is engaged to upwardly tilt or raise the wall or panel 12. The lifting member 18 includes a rigid member 80 attached to an edge of the main portion 70 where the rigid member 80 is substantially orthogonal to the main portion 70, such that the rigid member 80 aids in preventing rotation of the lifting member 18 within the concrete layer 13 as the wall is tilted or raised by increasing the cross-sectional area of the lifting structure 18 in a direction perpendicular to the main portion 70.

[0054] The lifting member 18 includes an elongated slot 82 proximate a top end 84. The elongated slot 82 is configured to be exposed within the concrete layer 13 after the concrete has cured. The elongated slot 82 is configured to be engaged by cables or chains such that the lifting structure 18 can be mechanically coupled to a crane, hoist or other raising machine to raise or tilt the wall into a substantially vertical orientation. Once raised to the substantially vertical position, the cable or chain is removed such that the elongated slot 82 is exposed and a roof joining member 130, as illustrated in FIG. 11, can be secured therethrough to attach the lifting member 18 to the roof joining member 130.

[0055] Referring to FIG. 11, the roof joining member is illustrated at 130. The roof joining member 130 includes a first metal rod portion 132 that includes a hooked configuration 134 at one end that is configured to engage the lifting member 18 and a threaded portion 133 at another end thereof. A roof attaching portion 136 includes a plate 137 with a plurality of apertures 138 that that are configured to receive nails, screws and / or bolts that are secured to the roof members with nuts. The roof attaching portion 136 includes a second rod portion 135 attached to the plate and having a threaded end portion 139. A turnbuckle 141 threadably attached the threaded end portions 133 and 139 of the first and second rod portions 132 and 135. In an embodiment a hole is cut into the roof deck to access the turnbuckle 141 so the that the turnbuckle 141 can be manipulated to place the roof joining member 130 into tension with the lifting device 18 which will aid in retaining the rafters to the walls. While a turnbuckle is disclosed and illustrated, other fastening devices are withing the scope of the present application, including a clamp, a camming mechanism, a dual slot fastener and / or other pressure sensitive fasteners.

[0056] Referring to FIG. 9, a J shaped bolt 119 is illustrated. The J shaped bolt 119 includes a hooked shaped end 121 that is positioned within a slab of cement prior to the cement curing such that a threaded end 122 extends above the slab and the aperture in the base member such that a nut can secure the base member to the bolt.

[0057] Referring to FIG. 10, an expansion anchor bolt is illustrated at 123. The expansion anchor bolt 123 includes a bottom portion 1130 that is positioned into a concrete layer prior to curing so that a threaded end 127 extends from the slab. The based member can then be secured to the expansion anchor bolt 123 to secure the wall to the foundation. In other embodiments, a bore can be drilled into the concrete slab that allows a concrete screw to be positioned through the aperture of the base portion and retain the base portion to the foundation. An exemplary concrete screw is provided under the TITEN ® registered trademark by Simpson Sttrong-Tie Company, Inc.

[0058] To retain the continuous load path structures within the concrete layer, chairs or spacers are placed in the channels of the foam layer 11 and the lifting structure 18, the bottom bracket 16 and the joining member 24 are retained together and rest on the chairs such that the components of the continuous load path are spaced from the foam layer 11. The bottom and top joining members 30 and 32 are optionally positioned through the bottom bracket 16 and the lifting structure 18, respectively, where the bottom and top joining members 30 and 32 are also spaced from the foam layer 11. The J-shaped bolt 119 and / or the expansion bolt 123 can be located prior to placing the concrete or after the concrete has been placed and prior to curing.

[0059] A form is placed about the perimeter of the foam layer 11, and prior to placing the concrete on the foam layer 11, a removable mold 100, as illustrated in FIG. 11, is positioned about the top end 84 of the lifting structure. The removable mold 100 includes a slot 102 that is positioned about the top end 84 of the lifting structure 18 and covers the elongated slot 82.

[0060] The concrete is then placed on the foam layer 11 and extends to an upper surface of the form, wherein the concrete is screeded to have a substantially smooth and even surface. The concrete covers the internal wall continuous load path structure 14, and once the concrete is cured, some or all of the form can be removed. The mold 100, being constructed of a low surface energy material is removed from the concrete layer 13, which provides a cavity about the top end 82 of the lifting structure 18 and exposes the elongated slot 82, as illustrated in FIG. 12.

[0061] Once the wall 12 is tilted and secured to the foundation 20, the bottom bracket 16 is secured to a bolt extending from the foundation 20. Once the roof is secured to the wall 12, a hook portion 134 of the mechanism 130, as illustrated in FIG. 10, is positioned through the elongated slot 82 in the lifting member 18 and a roof joining portion 136 that extends from the hook portion 110 is secured to the roof member(s) 50 using attaching members secured through one or more apertures 136 to create a continuous load path from the foundation 20 to the roof members 50. This process is utilized to create any number of continuous load paths in one or more walls 12 of the structure 10, to aid in resisting loads, wind events and seismic events.

[0062] The rigid member 19, as illustrated in FIG. 9 can also be used to couple the lifting member 18 to the roof members 50. The hook portion 120 is positioned through the elongated slot 82 in the lifting member 18 and the threaded portion 122 is positioned through a bracket attached to the roof members 50 such that a nut can be used to secure the rigid member 19 to the roof members 50.

[0063] Referring to FIG. 14, in some embodiments, a top portion of the roof joining portion 136 of the mechanism 130 extends through a slot 152 in a roof deck 150 having a length that runs substantially parallel to a rafter beam. A roof continuous load path 160, such as a metal strap, is attached to the roof deck 150 above a rafter such that the metal strap 160 is joined to the rafter. The strap 160 extends over the roof deck 150 from at least one wall to an opposing wall 12, and is secured to opposing portions of the brackets of opposing wall continuous load paths such that the load path extends from a first location on the foundation, through a first wall, over the roof deck, through an opposing second wall (not shown) and is then secured to a second location on the foundation. The portions of the brackets 136 are typically folded over the metal strap 160 and secured with a retaining mechanism 162, such as but not limited to, a screw or a nail.

[0064] Referring to FIG. 15, in other embodiments, a roof continuous load path 170 includes a spacer 172 with an interior channel 173 that is secured to a membrane 150. The spacer 172 has opposing walls 174, 176 and a top connecting member 178 that forms the interior channel 173. The roof continuous load path 170 spans the membrane from at least proximate the first wall 12 to an opposing second wall (not shown) where the spacer 172 is attached to the roof joining member 136 of the mechanism 130 of the continuous wall load path 14 that extends through a slot in the membrane 170 and is positioned onto the membrane 170. The attachment of the roof continuous load path 170 to the opposing wall continuous load paths 14 provides support from two locations on the foundation and over the roof deck 170.

[0065] A roof deck (not shown) is attached to the spaced apart channels. A roofing material, such as shingles or other roofing materials, is then attached to the roof deck. The space between the first and second roof decks allows for ventilation therebetween.

[0066] Referring to FIG. 16, a continuous roof load path is illustrated at 180. The continuous roof load path 180 is retrofitted onto a roof deck 182 that is being reshingled or repaired. The roof continuous load path 180 is constructed of a metal strip that is attached to the roof deck 182 with a plurality of connectors 184, such as nails or screws. The continuous load path spans from one edge of the roof deck to an opposing edge of the roof deck 182. The roof deck 182 includes slots 186 through which a connecting member 188 is positioned. An end portion 190 of the connecting member 188 is positioned onto the roof deck 182 and connected to the continuous roof load path 180 with a connecting member 192, such as a nail screw.

[0067] Another portion 194 of the connecting member 190 is positioned below the roof deck 182 and is attached to one or more roof chords 196 and 198 with connecting members, such as nails or screws. The connecting member 190 can optionally include a horizontal portion 200 that is attached to a roof beam 202. Connecting the connecting member 188 to the roof chords 196 and 198 and optionally the roof beam 202 and to the continuous load path 180 increases the strength of the roof and will aid in prevent the roof deck 182 from lifting from the rafters.

[0068] FIG. 17 illustrates another continuous roof load path at 220 that is retrofitted onto a membrane 222 that is being reshingled or repaired. However, instead of using the metal strip as illustrated in FIGS. 14 and 16, the spacer 172 as illustrated in FIG. 15 is utilized. The spacer 172 is connected to the roof chords 196 and 198 and the roof beam 200 with the connecting member 188 as described with respect to FIG. 17 to provide additional strength to aid in preventing the roof deck 222 from lifting from the rafters.

[0069] The structures in FIGS. 14 and 16 typically have roof deck adjacent a membrane 150 and 182, also referred to as direct to deck. The structures in FIGS. 15 and 17 are intended to have 182 and 222 are intended to have deck spaced from the membrane by a distance of a height of the spacers 172. In some embodiments it is useful to have the deck spaced from the membrane, which provides advantages including ventilation between the membrane and deck, preventing the membrane from heating in the event the upper deck encounters excessive heat, such as by a fire and increased strength of the structure.

[0070] Referring to FIGS. 14-19, a side to side roof spacing support is illustrated at 200. In the embodiments of FIGS. 14 and 16, the side to side roof spacing support 200 is positioned over the straps 160 and 180, respectively from one side of the roof to another side of the roof. In the embodiment of FIGS. 15 and 17, portions of the side to side roof support 200 are retained between the spacers 172. The cooperation between the spacers 172 and the side to side roof support portions 200 provide a grid onto which the second roof is supported.

[0071] Referring to FIGS. 18-20, the side to side roof support 200 has a first attaching flange 202 that is separated from a second attaching flange 204 with a substantially vertical web 206. The first and second attaching flanges 202 and 204 include a plurality of spaced apart apertures 203 and 205, respectively, that are used to secure the side to side roof support to the deck and the membrane with attaching members, such as but not limited to, nails and screws.

[0072] The first and second attaching flanges 202 and 204 extend from the substantially vertical web 206 in opposition directions. The configuration of the side to side roof support 200, is not direction dependent or reversible and can be used in any configuration to secure the second, top deck to the first, lower deck.

[0073] The substantially vertical web 206 includes a plurality of apertures 208 that allow air to flow from the eave of the roof to the peak of the roof, which allows for ventilation that can result in cooling or heating depending upon the ambient temperature. If the substantially vertical web 206 were solid from end to end, each side to side roof support would prevent air from passing from the eave to the peak.

[0074] In some embodiments the plurality of apertures 208 have a triangular configuration. In other embodiments, the plurality of apertures 208 can have circular, oval or other polygonal configurations or combinations of circular, oval and / or polygonal configurations. Whatever the configuration of the plurality of apertures 208, the substantially vertical web is required to have sufficient structural integrity to support the second roof deck while being able to withstand wind-loadings within a locality’s building code.

[0075] Referring to FIGS. 21 and 22, a side to side roofing support 250 can be prefabricated with flexible horizontal bands 252, sometimes referred to as battens, and rigid spacers 254, sometimes referred to as counterbattens, attached to the horizontal bands 252. The rigid spacers 254 can be configured as illustrated in FIGS. 18-20 or can have a “C” shaped cross-section with holes in the vertical web.

[0076] The rigid spacers 254 are attached to the flexible bands 252 at selected distance such that the rigid spacers 254 are spaced a similar distance to the spacing of the rafters of the structure such that the rigid spacers 254 can be secured to the rafters. The flexible bands 252 can be metal, a plastic material and / or a combination of metal and plastic. The flexible bands 252 have ends that extend beyond the outer vertical spacers 254 such that sections of the prefabricated roofing support can be aligned and secured together by overlapping or abutting the flexible bands 252 of adjacent panels such that the rigid vertical spacers 254 align with the rafters of the structure. The aligned or overlapped flexible bands 252 are secured together and to the membrane so that the adjacent prefabricated side to side roofing support 250 uniformly spaced.

[0077] The side to side roofing support 250 can be rolled into a coil 260 as illustrated in FIG. 23 which allows for compact shipping. Additionally, the side to side roofing support 250 can be lifted to the roof membrane in a coil and unrolled on the membrane which can speed up the installation process which reduces labor costs and provide better uniformity and strength after installation.

[0078] Prior to installing the side to side roofing support 250, ends of the side to side roofing support 250 need to be installed at the edges of the membrane where the flexible bands 252 are cut proximate a first vertical spacer 254 such that the ends of the flexible bands 252 are not visible below the rigid spacer 254. The side to side roofing support 250 is then uncoiled and the flexible horizontal bands 252 are secured to the membrane and the rigid spacers 254 are secured to the rafters through the membrane. If a coil 260 is longer than required for a particular installation the flexible horizontal bands 252 can be cut and the remaining portion of the coil can be utilized in another location.

[0079] Once the side to side roofing support 250 is attached to the membrane a roof deck is attached to the vertical rigid spacers 252 such that a gap exists between the membrane and the deck. The gap allows for air to circulate and keep the membrane cool.

[0080] The support 250 can also be used on interior walls of the building to provide different surface finishes. In some embodiments, the support 250 is uncoiled and secured to a wall. Drywall is then attached to the rigid spacers 254 such a ledge is formed. The rigid spacers 254 can be sized to create a desired depth for the ledge. In some embodiments, utilizing the support 250 is more efficient that creating the ledge utilizing wooden or metal studs.

[0081] Referring back to FIG. 24 and 25, a roof 130 has a lower portion 132 having an eave extending outwardly beyond the walls 12 and an upper portion 134 extending from the lower portion 132 to a peak 136. The slope of the lower portion 134 is shallower than the slope of the upper portion which can be advantageous in high wind situations. The wind first engages the shallower slope of the lower portion 132 which directs the wind upwardly along the steeper slope of the upper portion 134. The wind traveling upwardly along the slope of the roof line acts as a buffer and prevents straight line winds from engage the roof. But rather, the upwardly directed wind along the roof line further directs the straight-line winds upward and over the peak 136 of the building 10, which aids in protecting the roof from damaging winds.

[0082] Referring to FIGS. 21 and 22, in some embodiments, a wind deflector 150 is secured to the foundation 20 and a bottom portion of a wall 152. The wind deflector 150 has a foam interior 154 that has a substantially triangular cross-section. When sides 156 and 158 at secured to the foundation 20 and the wall 152, an angled surface 160 slopes upwardly toward the wall 152. The angled surface 160 and the ends of the wind deflector 150 are covered with a fire resistant layer 162 to maintain the fire-resistant nature of the structure 10, including but not limited to stucco. In some embodiments the concrete layer 162 formed using a concrete material on a roll that is sold under the CONCRETE CANVAS ® trademark that is owned by Concrete Canvas USA, Inc. located in Houston Texas. The layer 162 can also be painted to match the colors of the house

[0083] The wind deflector 150 is angled upward at an angle Ɵ that ranges from about 2° to about45° from horizontal and more typically that ranges from about 2° to about 30° from horizontal. The wind deflector engages the wind prior to engaging the house, such that the wind travels upwardly along the wall 152 and aids in preventing the wind from harming the structure which aids in preventing stowaways in the wind such as embers and / or hard objects from contacting the walls or roof.

[0084] Additional benefits of the wind deflector 150 when placed against the wall 152 and the foundation 20 include providing energy efficiency to the building. The wind deflector 150 also aids in preventing frost from damaging the foundation 20 and the wall 152. The wind deflector 150 also aids in directing run off water from the foundation 20 while also being able control soil erosion proximate the foundation 20.

[0085] Because the wind deflector 150 controls water runoff and erosion, the need for gutters can be eliminated. Gutters can fill with debris that can be a fuel if the structure is engulfed with fire. Additionally, the cost to install and maintain the gutter can be eliminated

[0086] Another wind deflector 170 is attached to the eave 172 of extending from the wall 152 and is similar formed as the wind deflector 150. The wind deflector 170 includes a foam interior 174 that has sides 176 and 178 that are configured to be secured to the eave 172 and the wall 152. An angled surface 180 extends downwardly from the outer edge of the eave 172 to the wall 152 at an angle µ that ranges from about 2° to about 25° from horizontal. The angled surface 180 and the ends of the foam interior 174 are covered with a concrete layer 182 and such as, but not limited to a layer formed from the CONCRETE CANVAS ® material. Other non-flammable materials of construction can be used to cover the foam interior, including but not limited to stucco.

[0087] The angled surface 180 causes wind to deflect upwardly and away from the eave 172 or downwardly and away from the eave 172. The movement of the wind from the eave 172 prevents pressure from building under the eave 172 such that damage during a wind event does is minimized or eliminated due the pressure on the eave 172 lifting the roof from the walls. The wind deflector 170 can be constructed with openings that align with openings in the soffits in the eave 172 to provide ventilation. In some embodiments the openings in the wind deflector 170 can be equipped with a fire-resistant cover so that the openings can be closed in the event of predicted weather event.

[0088] As illustrated, the wind deflectors 150 and 170 are located on a plurality of walls and eaves. However, the wind deflectors 150 and 150 can be located around the perimeter of the structure and the entire roof line.

[0089] As illustrated, the wind deflectors 150 and 170 are used with a concrete and foam construction for a building. However, the wind deflectors 150 and 170 can be utilized with a structure of any construction includes a wood frame house.

[0090] Applicant is attaching US Patent No. 10,577,798 as appendix A, which provides details on the internal structure of the walls, the construction of the walls and the mold used to form the composite walls, among other features

[0091] Although the subject matter has been described in language specific to structural features and / or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above as has been determined by the courts. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.

Examples

Embodiment Construction

[0035]The present disclosure relates to a building having a continuous load path structure. The continuous load path structure can include at least one continuous wall load path structure and optionally at least one continuous roof load path structure that is connected to the at least one continuous wall load path structure. The building is typically constructed with composite walls constructed of concrete and foam layers, where the concrete layer retains the at least one continuous wall load path structure that spans a height of the wall.

[0036]The composite wall is constructed of concrete and foam layers where the continuous wall load path is located within the concrete layer. Once the concrete is cured, the wall is then tilted onto a foundation and retained in a substantially vertical position. With the wall in a substantially vertical position, a bottom end of the at least one continuous wall load path structure is secured to an anchor within the foundation and a top end of the c...

CROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application is based on and claims the benefit of U.S. provisional patent application Serial No. 63 / 764,250, filed February 27, 2025, the content of which is hereby incorporated by reference in its entirety.BACKGROUND

[0002] The present disclosure relates a building with composite foam and concrete walls. More particularly, the present disclosure relates to a building with composite foam and concrete walls with internal continuous load paths within a concrete layer of the composite walls and optionally a load path over an outer surface of a roof deck.

[0003] A typical wall includes a bottom plate or foundation sill that is attached to a foundation, typically a concrete slab or footer. Bottom ends of spaced apart vertical studs are secured to the bottom plate and top ends of the spaced apart vertical studs are secured to a top plate. A height of the wall is essentially defined by the length of the vertical studs. The wall provides structural support for the building as well as the support for the outer wall material, such as wood panels and siding, and also the interior wall material, such as sheet rock. Insulation is typically placed between the studs when the stud wall is raised into place and the outer wall material is secured to the stud wall.

[0004] Construction of the wood stud wall is very labor intensive and can take a considerable amount of time to construct. The studs must be cut to a precise length and secured to the bottom and top plates, typically with nails. In the event windows and / or doors are to be placed into the wall, then the studs must be cut to accommodate the required space for the window and / or door and the space must be reinforced with a lintel, which also must be constructed by the construction workers.

[0005] Once the wood stud wall is formed, it is raised and secured to the foundation, typically with bolts that are set into the concrete foundation and through bores in the bottom plate, where the bores in the bottom plate are positioned about the bolts. Washers are positioned on the bolts and nuts threadably engage each bolt to frictionally secure the bottom plate to the foundation. Once the stud wall is raised, an outer wall is secured to the studs typically with nails and then siding is secured to the outer wall.

[0006] In spite of the labor-intensive construction, wood stud wall constructed houses are susceptible to damage or destruction by violent weather such as straight-line winds, hurricanes and tornados, as well as seismic events. As such, there is a need for a building or structure that is constructed to withstand damaging weather and seismic events that can be efficiently constructed while minimizing the need for wood, or other renewable materials. Structures utilizing concrete and foam wall panels can be quickly constructed relative to wood stud wall constructed structure, while having internal continuous load path(s) and optionally a load path over the roof deck that aid in preventing damage from weather and seismic events while providing excellent energy efficiency in both hot and cold weather.

[0007] Also, structures with concrete exteriors are resistant to damage from fires relative to structures with wood exteriors. As such, there is a need for structures that are fire resistant, do not promote fires and are capable of withstanding wildfires.SUMMARY

[0008] One aspect of the present disclosure includes a composite foam and concrete wall having a foam layer and a concrete layer. The wall includes at least one continuous wall load path structure within the concrete layer and extending from a bottom edge to a proximate a top edge of the wall. The at least one continuous wall load path includes a bottom bracket configured to be secured to a mount in a foundation, a lifting member proximate a top surface of the wall, wherein the concrete layer includes a cavity that exposes an aperture in the lift mechanism, such that the lifting member can be engaged to tilt the wall into an upright position, and a joining member configured to connect the bottom bracket to the lifting member.

[0009] Another aspect of the present disclosure includes a building having a foundation having a plurality of spaced apart anchor bolts extending therefrom and a plurality of walls secured to the foundation. Each of the plurality of walls includes a foam layer and a concrete layer and a plurality of continuous wall load path structures within the concrete layer. Each continuous wall load path structure extends from a bottom edge to a proximate a top edge of the wall, wherein each of the plurality continuous load path structures includes a bottom bracket configured to be secured to one of the anchor bolts in a foundation, a lifting member proximate a top surface of the wall, wherein the concrete layer includes a cavity that exposes an aperture in the lift mechanism, such that the lifting member can be engaged to tilt the wall into an upright position. The continuous load path structure includes a joining member configured to connect the bottom bracket to the lifting member, and a roof joining mechanism configured to extend through the aperture in the lifting member and extend above a top edge of the wall. The building includes a roof supported by the plurality of walls. The roof includes a first portion with a first pitch, and a second portion with a second pitch that leads to a roof peak, wherein the second pitch is steeper than the first pitch and wherein the roof joining mechanism is configured to be secured to at least one roof member below the first portion.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 is a cutaway view of a building having a composite foam and concrete wall with a continuous wall load path structure.

[0011] FIG. 2 is a view of a building with a plurality of continuous wall load path structures.

[0012] FIG. 3 is a view of a composite wall with a plurality of continuous wall load path structures.

[0013] FIG. 4 is a sectional view taken along section line 4—4 in FIG. 3.

[0014] FIG. 5 is a sectional view taken along section line 5—5 in FIG. 3.

[0015] FIG. 6 is a view of a bottom bracket of a continuous wall load path structure.

[0016] FIG. 7 is a view of a joining member of the continuous wall load path structure

[0017] FIG. 8 is a view of a lifting member of the continuous load path structure.

[0018] FIG. 9 is a view of a J-shaped bolt that is placed into the concrete slab for securing the continuous wall load path structure.

[0019] FIG. 10 is a view of an expansion anchor this is placed into the concrete slab for securing the continuous wall load path structure.

[0020] FIG. 11 is view of a rigid member of the continuous wall load path structure.

[0021] FIG. 12 is a view of a removable mold for engaging the lifting member as concrete is placed on the foam layer.

[0022] FIG. 13 is a top view of a lifting member within the concrete layer of the composite wall.

[0023] FIG. 14 is a view of a continuous roof load path connected to a continuous wall load path on a structure.

[0024] FIG. 15 is a view of another continuous roof load path connected to a continuous wall load path on a structure.

[0025] FIG. 16 is a view of a structure with a continuous wall load path.

[0026] FIG. 17 is another view of a structure with another continuous wall load path.

[0027] FIG. 18 is a top view of a side to side roof spacing support for supporting a roof deck over a membrane.

[0028] FIG. 19 is an end view of the side to side roof spacing support.

[0029] FIG. 20 is a side view of the side to side roof spacing support.

[0030] FIG. 21 is a plan view of a prefabricated side to side roof spacing support.

[0031] FIG. 22 is an end view of the prefabricated side to side roof spacing support.

[0032] FIG. 23 is a view of the prefabricated side to side roof spacing support in a coil.

[0033] FIG. 24 is an illustration of wind flow over the contour of the roof of the building.

[0034] FIG. 25 is a sectional view of a plurality of wind deflectors.DETAILED DESCRIPTION

[0035] The present disclosure relates to a building having a continuous load path structure. The continuous load path structure can include at least one continuous wall load path structure and optionally at least one continuous roof load path structure that is connected to the at least one continuous wall load path structure. The building is typically constructed with composite walls constructed of concrete and foam layers, where the concrete layer retains the at least one continuous wall load path structure that spans a height of the wall.

[0036] The composite wall is constructed of concrete and foam layers where the continuous wall load path is located within the concrete layer. Once the concrete is cured, the wall is then tilted onto a foundation and retained in a substantially vertical position. With the wall in a substantially vertical position, a bottom end of the at least one continuous wall load path structure is secured to an anchor within the foundation and a top end of the continuous wall load path is secured to a roof member, such that the wall continuous load path structure is located along a height of the wall and couples the foundation to the roof member.

[0037] A continuous load path, such as a continuous wall load path structure and / or a roof load path structure, is an engineering term describing how wind and seismic loads are transferred both horizontally and vertically through structures. A properly designed and installed continuous load path provides structural integrity to buildings during high wind and seismic events. A structure with a continuous load path substantially resists all loads acting on a building, including both vertical and horizontal loads. Vertical loads include downward gravity forces, such as the weight of the building and uplift forces from wind. Horizontal, lateral loads include wind loads perpendicular to a wall, referred to as out of plane, and parallel to a wall, or alternatively as in plane or shear loads.

[0038] The continuous load path can optionally include the continuous roof load path structure attached to a roof deck that connects to the continuous wall load path structure in one wall. The continuous roof load path then spans the roof deck and attaches to another wall continuous load path in an opposite outer wall to provide structural support from two points in the foundations through the opposing walls and over the roof deck.

[0039] In another embodiment, a roof load path can be retrofitted onto an existing roof deck when the roof deck is being repaired or re-shingled. The roof load path is attached to the roof deck where an end is positioned through an opening in the roof deck so that the roof load path can be attached to one or more chords of a rafter and / or a ceiling joist such that the roof load path is secured to a building member below the roof deck. Attaching the roof load path to a member below the roof deck provides additional strength to the roof deck and aids in preventing the roof deck from lifting from the rafters.

[0040] A building is illustrated in FIG. 1 at 10 that is constructed using the composite walls 12 that have a concrete layer 13 and a foam layer 11. The concrete layer 13 retains a portion of a continuous wall load path structure 14 that has a bottom bracket 16 secured to an anchor bolt 18 extending from a foundation 20. A top end 22 of the continuous wall load path structure 14 is attached to a roof member 50 with a roof joining member 130. The bottom bracket 16 is connected to a lifting member 18 with a joining member 24 and the roof joining member 130 is joined to the lifting member 18. When the bottom bracket 16 secured to the anchor bolt 18 and the top end 22 of the roof joining member 130 attached to the roof member 50, the continuous wall load path structure 14 extends along a height of the composite wall 12 from the foundation 20 to the roof member 50.

[0041] Any foundation 20 can be utilized with the disclosed building 10, provided the anchor bolts 18 are secured within the foundation and are configured to be positioned through an aperture or slot in the bottom bracket 16 of the continuous wall load path structure 14 within the concrete layer of the composite walls 12. Similarly, any configuration of the roof members 50 can be utilized, provided the roof joining member 130 is securable to the roof member 50 with a securing mechanism, including but not limited to, nails, screws and a threaded engagement of a bolt with a threaded nut.

[0042] Referring to FIGS. 1 and 2, the building 10 is illustrated with a plurality of continuous wall load path structures 14 that are spaced apart within the walls 12. The plurality of continuous wall load path structures 14 located in the concrete layer 18 of the wall 12 can optionally be joined together proximate the bottom brackets 16 with a bottom joining member 30, such as a rod extending through aligned apertures in the bottom brackets 16 of the adjacent continuous wall load path structures 14. The plurality of continuous wall load path structures 14 can optionally be joined together proximate the top end 22 of the continuous wall load path structures 14 with a top joining member 32, such as a rod extending through apertures in lifting members 18 in the adjacent continuous wall load paths structures 14. The top joining member 32 and the lifting member 18 are connected with a rigid member 19 having at least one end that engages an aperture in the lifting member 18. In one embodiment, the at least one end of the rigid member 19 has a hook configuration that is positionable in the aperture of the lifting member 18, where the hook configuration is retained to the lifting member 18. Another end of the rigid member 19 is configured be fixedly attached to the top joining member 32 or can be removably attached with another hooked end.

[0043] Referring to FIGS. 3-5, a typical wall 12 is illustrated with the foam layer 11 and the concrete layer 13 that are retained together. The continuous wall load path structures 14 and the bottom and top joining members 30 and 32 are secured into a selected positions within the concrete layer 13. Joining the plurality of continuous wall load path structures 14 together with the bottom and top joining members 30 and 32 can increase the strength of the wall 12 to further aid in resisting violent weather-related events and / or seismic events.

[0044] A typical foam layer 11 is constructed of modified expanded polystyrene because the foam has a high R value for insulation purposes. The foam layer 11 is typically treated with a pesticide such as zinc borate to prevent insect and rodent infestations. The modified expanded polystyrene foam also is a fire preventative material, as the modified foam material will not promote a fire once the source of the fire is extinguished or removed from the foam. One non-limiting foam material is sold under the INSULFOAM® trademark by the Insulfoam division of the Carlisle Construction Materials headquartered in Puyallup, WA. The INSULFOAM® foam material requires a constant ignition source to cause the material to burn. If an ignition source is removed from the material, the flame is extinguished. However, other materials of the foam panels are also contemplated and are within the scope of the present disclosure.

[0045] As illustrated, the foam layer 11 is nominally about six inches in thickness. However, a nominal thickness range of between about four and about eight inches is also contemplated. The foam layer 11 can be any desired thickness provided the panels provide the necessary insulation and structure to secure the concrete layer 13 thereto.

[0046] The foam layer 11 includes a plurality of spaced art channels 40 that are cut into the foam or formed using a plurality of adhered foam sheets to form the foam layer 11 from a bottom surface 42 to the top surface 44. In an exemplary embodiment, a depth of the plurality of channels 40 is nominally two or more inches, where the plurality of channels 40 have a dove tail cross-sectional configuration. However, the depth of the plurality of channels 40 can be any depth that aids in securing a concrete layer 13 to the foam layer 11 while not adversely affecting the structural integrity of the foam layer 11. It is understood that the thickness of the foam layer 11 can dictate the depth of the plurality of channels 40. While dove tail cross-sectional configured channels 40 are contemplated to aid in retaining the concrete layer 13 to the foam layer 11, it is understood that the plurality of channels 40 can have any suitable cross-sectional configuration, including, but not limited to, a rectangular cross-sectional configuration.

[0047] The foam layer 11 includes a top channel 46 at the top surface 44 that has a similar depth as that of the plurality of channels 40. The top channel 46 extends from a right side 48 to a left side 50. The foam layer 11 also includes a bottom channel 52 at the bottom surface 42 that has a similar depth as that of the plurality of channels 40. The bottom channel 52 extends from the right side 48 to the left side 50. It is also contemplated that a channel be formed around the entire perimeter of the foam layer 11, which when concrete is placed and cured on the foam layer 11, will sheer the entire panel to maintain the panel’s shape and integrity.

[0048] Once the foam layer 11 is constructed, a form is placed about the perimeter of the foam layer 11 wherein the difference in the height of the form relative to the height of the foam layer 11 determines the thickness of a wythe of concrete 13 and the depth of the channels 40 determine the thickness of pilasters extending from the wythe of concrete 13.

[0049] With the form in place and prior to placing the concrete into the form, the continuous wall load path structures 14 are positioned within and / or aligned with each of the plurality of spaced apart channels 40 and the bottom and top joining members 30 and 32 are placed into the top channel 46 and the bottom channel 52 and are spaced from the foam layer 11 with rebar chairs or other devices.

[0050] The components of the wall continuous load path structure 14 are described in more detail and are illustrated in FIGS. 6-12, where the components of the wall continuous load path structure are typically constructed of steel due to the strength of steel. However, other metals and / or other materials are also within the scope of the present disclosure for forming the continuous wall load path 14. Referring to FIG. 6, the bottom bracket 16 has a substantially “L” shape and includes a substantially flat connecting portion 60 that extends beyond the outer edge of the wall 12. The substantially flat connecting portion 60 includes an aperture 62, such as a circular hole or a key hole slot, that is configured to be positioned about an anchor bolt extending from a foundation, where a nut threadably engages the bolt to frictionally secure the substantially flat connecting portion 60 to the foundation. The bottom bracket 16 includes a top portion 64 that extends upwardly from the substantially flat connecting portion 60. An engaging plate 66 extends substantially perpendicular from the top portion 64 where the engaging plate 66 includes an aperture 68 that is configured to accept the joining member 30. The engaging plate 66 includes another aperture 70 that is configured to accept the bottom joining member 24.

[0051] FIG. 7 illustrates an exemplary joining member 24 that is constructed of metal rebar. The joining member 24 is illustrated in a looped configuration that is configured to engage the engaging plate 66 of the bottom bracket 16 and the lifting member 18, as illustrated in FIG. 8. While a looped configuration of the joining member 24 is illustrated, the joining member 24 could include a single rod configuration with hooked ends configured to engage the bottom bracket 16 and the lifting member18. Alternatively, the joining member 24 could included threaded ends that are positionable through the engaging plate 66 and the lift member 18 and retained with a threaded engagement with nuts. Other retaining mechanisms for the ends of the joining member 24 are also contemplated, including but not limited to, a pin engaging a bore in each end.

[0052] Referring to FIG. 8, the lifting member 18 is constructed of metal plate, such as steel plate. The lifting member 18 includes a main portion 70 having a plurality of apertures 72 and 74. The aperture 74 is configured to accept the joining member 24 that ties the lifting member 18 to the bottom bracket 16. The aperture 72 is configured to accept the top joining member 32 that ties the spaced apart lifting structures 18 together.

[0053] The lifting member 18 includes barbs 75 and 76 extending outwardly from the main portion 70. The barbs 75 and 76 increase the cross-sectional area of the lifting structure 18 proximate the bottom end, which aid in retaining the lifting member 18 within the concrete layer 13 as the lifting member 18 is engaged to upwardly tilt or raise the wall or panel 12. The lifting member 18 includes a rigid member 80 attached to an edge of the main portion 70 where the rigid member 80 is substantially orthogonal to the main portion 70, such that the rigid member 80 aids in preventing rotation of the lifting member 18 within the concrete layer 13 as the wall is tilted or raised by increasing the cross-sectional area of the lifting structure 18 in a direction perpendicular to the main portion 70.

[0054] The lifting member 18 includes an elongated slot 82 proximate a top end 84. The elongated slot 82 is configured to be exposed within the concrete layer 13 after the concrete has cured. The elongated slot 82 is configured to be engaged by cables or chains such that the lifting structure 18 can be mechanically coupled to a crane, hoist or other raising machine to raise or tilt the wall into a substantially vertical orientation. Once raised to the substantially vertical position, the cable or chain is removed such that the elongated slot 82 is exposed and a roof joining member 130, as illustrated in FIG. 11, can be secured therethrough to attach the lifting member 18 to the roof joining member 130.

[0055] Referring to FIG. 11, the roof joining member is illustrated at 130. The roof joining member 130 includes a first metal rod portion 132 that includes a hooked configuration 134 at one end that is configured to engage the lifting member 18 and a threaded portion 133 at another end thereof. A roof attaching portion 136 includes a plate 137 with a plurality of apertures 138 that that are configured to receive nails, screws and / or bolts that are secured to the roof members with nuts. The roof attaching portion 136 includes a second rod portion 135 attached to the plate and having a threaded end portion 139. A turnbuckle 141 threadably attached the threaded end portions 133 and 139 of the first and second rod portions 132 and 135. In an embodiment a hole is cut into the roof deck to access the turnbuckle 141 so the that the turnbuckle 141 can be manipulated to place the roof joining member 130 into tension with the lifting device 18 which will aid in retaining the rafters to the walls. While a turnbuckle is disclosed and illustrated, other fastening devices are withing the scope of the present application, including a clamp, a camming mechanism, a dual slot fastener and / or other pressure sensitive fasteners.

[0056] Referring to FIG. 9, a J shaped bolt 119 is illustrated. The J shaped bolt 119 includes a hooked shaped end 121 that is positioned within a slab of cement prior to the cement curing such that a threaded end 122 extends above the slab and the aperture in the base member such that a nut can secure the base member to the bolt.

[0057] Referring to FIG. 10, an expansion anchor bolt is illustrated at 123. The expansion anchor bolt 123 includes a bottom portion 1130 that is positioned into a concrete layer prior to curing so that a threaded end 127 extends from the slab. The based member can then be secured to the expansion anchor bolt 123 to secure the wall to the foundation. In other embodiments, a bore can be drilled into the concrete slab that allows a concrete screw to be positioned through the aperture of the base portion and retain the base portion to the foundation. An exemplary concrete screw is provided under the TITEN ® registered trademark by Simpson Sttrong-Tie Company, Inc.

[0058] To retain the continuous load path structures within the concrete layer, chairs or spacers are placed in the channels of the foam layer 11 and the lifting structure 18, the bottom bracket 16 and the joining member 24 are retained together and rest on the chairs such that the components of the continuous load path are spaced from the foam layer 11. The bottom and top joining members 30 and 32 are optionally positioned through the bottom bracket 16 and the lifting structure 18, respectively, where the bottom and top joining members 30 and 32 are also spaced from the foam layer 11. The J-shaped bolt 119 and / or the expansion bolt 123 can be located prior to placing the concrete or after the concrete has been placed and prior to curing.

[0059] A form is placed about the perimeter of the foam layer 11, and prior to placing the concrete on the foam layer 11, a removable mold 100, as illustrated in FIG. 11, is positioned about the top end 84 of the lifting structure. The removable mold 100 includes a slot 102 that is positioned about the top end 84 of the lifting structure 18 and covers the elongated slot 82.

[0060] The concrete is then placed on the foam layer 11 and extends to an upper surface of the form, wherein the concrete is screeded to have a substantially smooth and even surface. The concrete covers the internal wall continuous load path structure 14, and once the concrete is cured, some or all of the form can be removed. The mold 100, being constructed of a low surface energy material is removed from the concrete layer 13, which provides a cavity about the top end 82 of the lifting structure 18 and exposes the elongated slot 82, as illustrated in FIG. 12.

[0061] Once the wall 12 is tilted and secured to the foundation 20, the bottom bracket 16 is secured to a bolt extending from the foundation 20. Once the roof is secured to the wall 12, a hook portion 134 of the mechanism 130, as illustrated in FIG. 10, is positioned through the elongated slot 82 in the lifting member 18 and a roof joining portion 136 that extends from the hook portion 110 is secured to the roof member(s) 50 using attaching members secured through one or more apertures 136 to create a continuous load path from the foundation 20 to the roof members 50. This process is utilized to create any number of continuous load paths in one or more walls 12 of the structure 10, to aid in resisting loads, wind events and seismic events.

[0062] The rigid member 19, as illustrated in FIG. 9 can also be used to couple the lifting member 18 to the roof members 50. The hook portion 120 is positioned through the elongated slot 82 in the lifting member 18 and the threaded portion 122 is positioned through a bracket attached to the roof members 50 such that a nut can be used to secure the rigid member 19 to the roof members 50.

[0063] Referring to FIG. 14, in some embodiments, a top portion of the roof joining portion 136 of the mechanism 130 extends through a slot 152 in a roof deck 150 having a length that runs substantially parallel to a rafter beam. A roof continuous load path 160, such as a metal strap, is attached to the roof deck 150 above a rafter such that the metal strap 160 is joined to the rafter. The strap 160 extends over the roof deck 150 from at least one wall to an opposing wall 12, and is secured to opposing portions of the brackets of opposing wall continuous load paths such that the load path extends from a first location on the foundation, through a first wall, over the roof deck, through an opposing second wall (not shown) and is then secured to a second location on the foundation. The portions of the brackets 136 are typically folded over the metal strap 160 and secured with a retaining mechanism 162, such as but not limited to, a screw or a nail.

[0064] Referring to FIG. 15, in other embodiments, a roof continuous load path 170 includes a spacer 172 with an interior channel 173 that is secured to a membrane 150. The spacer 172 has opposing walls 174, 176 and a top connecting member 178 that forms the interior channel 173. The roof continuous load path 170 spans the membrane from at least proximate the first wall 12 to an opposing second wall (not shown) where the spacer 172 is attached to the roof joining member 136 of the mechanism 130 of the continuous wall load path 14 that extends through a slot in the membrane 170 and is positioned onto the membrane 170. The attachment of the roof continuous load path 170 to the opposing wall continuous load paths 14 provides support from two locations on the foundation and over the roof deck 170.

[0065] A roof deck (not shown) is attached to the spaced apart channels. A roofing material, such as shingles or other roofing materials, is then attached to the roof deck. The space between the first and second roof decks allows for ventilation therebetween.

[0066] Referring to FIG. 16, a continuous roof load path is illustrated at 180. The continuous roof load path 180 is retrofitted onto a roof deck 182 that is being reshingled or repaired. The roof continuous load path 180 is constructed of a metal strip that is attached to the roof deck 182 with a plurality of connectors 184, such as nails or screws. The continuous load path spans from one edge of the roof deck to an opposing edge of the roof deck 182. The roof deck 182 includes slots 186 through which a connecting member 188 is positioned. An end portion 190 of the connecting member 188 is positioned onto the roof deck 182 and connected to the continuous roof load path 180 with a connecting member 192, such as a nail screw.

[0067] Another portion 194 of the connecting member 190 is positioned below the roof deck 182 and is attached to one or more roof chords 196 and 198 with connecting members, such as nails or screws. The connecting member 190 can optionally include a horizontal portion 200 that is attached to a roof beam 202. Connecting the connecting member 188 to the roof chords 196 and 198 and optionally the roof beam 202 and to the continuous load path 180 increases the strength of the roof and will aid in prevent the roof deck 182 from lifting from the rafters.

[0068] FIG. 17 illustrates another continuous roof load path at 220 that is retrofitted onto a membrane 222 that is being reshingled or repaired. However, instead of using the metal strip as illustrated in FIGS. 14 and 16, the spacer 172 as illustrated in FIG. 15 is utilized. The spacer 172 is connected to the roof chords 196 and 198 and the roof beam 200 with the connecting member 188 as described with respect to FIG. 17 to provide additional strength to aid in preventing the roof deck 222 from lifting from the rafters.

[0069] The structures in FIGS. 14 and 16 typically have roof deck adjacent a membrane 150 and 182, also referred to as direct to deck. The structures in FIGS. 15 and 17 are intended to have 182 and 222 are intended to have deck spaced from the membrane by a distance of a height of the spacers 172. In some embodiments it is useful to have the deck spaced from the membrane, which provides advantages including ventilation between the membrane and deck, preventing the membrane from heating in the event the upper deck encounters excessive heat, such as by a fire and increased strength of the structure.

[0070] Referring to FIGS. 14-19, a side to side roof spacing support is illustrated at 200. In the embodiments of FIGS. 14 and 16, the side to side roof spacing support 200 is positioned over the straps 160 and 180, respectively from one side of the roof to another side of the roof. In the embodiment of FIGS. 15 and 17, portions of the side to side roof support 200 are retained between the spacers 172. The cooperation between the spacers 172 and the side to side roof support portions 200 provide a grid onto which the second roof is supported.

[0071] Referring to FIGS. 18-20, the side to side roof support 200 has a first attaching flange 202 that is separated from a second attaching flange 204 with a substantially vertical web 206. The first and second attaching flanges 202 and 204 include a plurality of spaced apart apertures 203 and 205, respectively, that are used to secure the side to side roof support to the deck and the membrane with attaching members, such as but not limited to, nails and screws.

[0072] The first and second attaching flanges 202 and 204 extend from the substantially vertical web 206 in opposition directions. The configuration of the side to side roof support 200, is not direction dependent or reversible and can be used in any configuration to secure the second, top deck to the first, lower deck.

[0073] The substantially vertical web 206 includes a plurality of apertures 208 that allow air to flow from the eave of the roof to the peak of the roof, which allows for ventilation that can result in cooling or heating depending upon the ambient temperature. If the substantially vertical web 206 were solid from end to end, each side to side roof support would prevent air from passing from the eave to the peak.

[0074] In some embodiments the plurality of apertures 208 have a triangular configuration. In other embodiments, the plurality of apertures 208 can have circular, oval or other polygonal configurations or combinations of circular, oval and / or polygonal configurations. Whatever the configuration of the plurality of apertures 208, the substantially vertical web is required to have sufficient structural integrity to support the second roof deck while being able to withstand wind-loadings within a locality’s building code.

[0075] Referring to FIGS. 21 and 22, a side to side roofing support 250 can be prefabricated with flexible horizontal bands 252, sometimes referred to as battens, and rigid spacers 254, sometimes referred to as counterbattens, attached to the horizontal bands 252. The rigid spacers 254 can be configured as illustrated in FIGS. 18-20 or can have a “C” shaped cross-section with holes in the vertical web.

[0076] The rigid spacers 254 are attached to the flexible bands 252 at selected distance such that the rigid spacers 254 are spaced a similar distance to the spacing of the rafters of the structure such that the rigid spacers 254 can be secured to the rafters. The flexible bands 252 can be metal, a plastic material and / or a combination of metal and plastic. The flexible bands 252 have ends that extend beyond the outer vertical spacers 254 such that sections of the prefabricated roofing support can be aligned and secured together by overlapping or abutting the flexible bands 252 of adjacent panels such that the rigid vertical spacers 254 align with the rafters of the structure. The aligned or overlapped flexible bands 252 are secured together and to the membrane so that the adjacent prefabricated side to side roofing support 250 uniformly spaced.

[0077] The side to side roofing support 250 can be rolled into a coil 260 as illustrated in FIG. 23 which allows for compact shipping. Additionally, the side to side roofing support 250 can be lifted to the roof membrane in a coil and unrolled on the membrane which can speed up the installation process which reduces labor costs and provide better uniformity and strength after installation.

[0078] Prior to installing the side to side roofing support 250, ends of the side to side roofing support 250 need to be installed at the edges of the membrane where the flexible bands 252 are cut proximate a first vertical spacer 254 such that the ends of the flexible bands 252 are not visible below the rigid spacer 254. The side to side roofing support 250 is then uncoiled and the flexible horizontal bands 252 are secured to the membrane and the rigid spacers 254 are secured to the rafters through the membrane. If a coil 260 is longer than required for a particular installation the flexible horizontal bands 252 can be cut and the remaining portion of the coil can be utilized in another location.

[0079] Once the side to side roofing support 250 is attached to the membrane a roof deck is attached to the vertical rigid spacers 252 such that a gap exists between the membrane and the deck. The gap allows for air to circulate and keep the membrane cool.

[0080] The support 250 can also be used on interior walls of the building to provide different surface finishes. In some embodiments, the support 250 is uncoiled and secured to a wall. Drywall is then attached to the rigid spacers 254 such a ledge is formed. The rigid spacers 254 can be sized to create a desired depth for the ledge. In some embodiments, utilizing the support 250 is more efficient that creating the ledge utilizing wooden or metal studs.

[0081] Referring back to FIG. 24 and 25, a roof 130 has a lower portion 132 having an eave extending outwardly beyond the walls 12 and an upper portion 134 extending from the lower portion 132 to a peak 136. The slope of the lower portion 134 is shallower than the slope of the upper portion which can be advantageous in high wind situations. The wind first engages the shallower slope of the lower portion 132 which directs the wind upwardly along the steeper slope of the upper portion 134. The wind traveling upwardly along the slope of the roof line acts as a buffer and prevents straight line winds from engage the roof. But rather, the upwardly directed wind along the roof line further directs the straight-line winds upward and over the peak 136 of the building 10, which aids in protecting the roof from damaging winds.

[0082] Referring to FIGS. 21 and 22, in some embodiments, a wind deflector 150 is secured to the foundation 20 and a bottom portion of a wall 152. The wind deflector 150 has a foam interior 154 that has a substantially triangular cross-section. When sides 156 and 158 at secured to the foundation 20 and the wall 152, an angled surface 160 slopes upwardly toward the wall 152. The angled surface 160 and the ends of the wind deflector 150 are covered with a fire resistant layer 162 to maintain the fire-resistant nature of the structure 10, including but not limited to stucco. In some embodiments the concrete layer 162 formed using a concrete material on a roll that is sold under the CONCRETE CANVAS ® trademark that is owned by Concrete Canvas USA, Inc. located in Houston Texas. The layer 162 can also be painted to match the colors of the house

[0083] The wind deflector 150 is angled upward at an angle Ɵ that ranges from about 2° to about45° from horizontal and more typically that ranges from about 2° to about 30° from horizontal. The wind deflector engages the wind prior to engaging the house, such that the wind travels upwardly along the wall 152 and aids in preventing the wind from harming the structure which aids in preventing stowaways in the wind such as embers and / or hard objects from contacting the walls or roof.

[0084] Additional benefits of the wind deflector 150 when placed against the wall 152 and the foundation 20 include providing energy efficiency to the building. The wind deflector 150 also aids in preventing frost from damaging the foundation 20 and the wall 152. The wind deflector 150 also aids in directing run off water from the foundation 20 while also being able control soil erosion proximate the foundation 20.

[0085] Because the wind deflector 150 controls water runoff and erosion, the need for gutters can be eliminated. Gutters can fill with debris that can be a fuel if the structure is engulfed with fire. Additionally, the cost to install and maintain the gutter can be eliminated

[0086] Another wind deflector 170 is attached to the eave 172 of extending from the wall 152 and is similar formed as the wind deflector 150. The wind deflector 170 includes a foam interior 174 that has sides 176 and 178 that are configured to be secured to the eave 172 and the wall 152. An angled surface 180 extends downwardly from the outer edge of the eave 172 to the wall 152 at an angle µ that ranges from about 2° to about 25° from horizontal. The angled surface 180 and the ends of the foam interior 174 are covered with a concrete layer 182 and such as, but not limited to a layer formed from the CONCRETE CANVAS ® material. Other non-flammable materials of construction can be used to cover the foam interior, including but not limited to stucco.

[0087] The angled surface 180 causes wind to deflect upwardly and away from the eave 172 or downwardly and away from the eave 172. The movement of the wind from the eave 172 prevents pressure from building under the eave 172 such that damage during a wind event does is minimized or eliminated due the pressure on the eave 172 lifting the roof from the walls. The wind deflector 170 can be constructed with openings that align with openings in the soffits in the eave 172 to provide ventilation. In some embodiments the openings in the wind deflector 170 can be equipped with a fire-resistant cover so that the openings can be closed in the event of predicted weather event.

[0088] As illustrated, the wind deflectors 150 and 170 are located on a plurality of walls and eaves. However, the wind deflectors 150 and 150 can be located around the perimeter of the structure and the entire roof line.

[0089] As illustrated, the wind deflectors 150 and 170 are used with a concrete and foam construction for a building. However, the wind deflectors 150 and 170 can be utilized with a structure of any construction includes a wood frame house.

[0090] Applicant is attaching US Patent No. 10,577,798 as appendix A, which provides details on the internal structure of the walls, the construction of the walls and the mold used to form the composite walls, among other features

[0091] Although the subject matter has been described in language specific to structural features and / or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above as has been determined by the courts. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.

Examples

Embodiment Construction

[0035]The present disclosure relates to a building having a continuous load path structure. The continuous load path structure can include at least one continuous wall load path structure and optionally at least one continuous roof load path structure that is connected to the at least one continuous wall load path structure. The building is typically constructed with composite walls constructed of concrete and foam layers, where the concrete layer retains the at least one continuous wall load path structure that spans a height of the wall.

[0036]The composite wall is constructed of concrete and foam layers where the continuous wall load path is located within the concrete layer. Once the concrete is cured, the wall is then tilted onto a foundation and retained in a substantially vertical position. With the wall in a substantially vertical position, a bottom end of the at least one continuous wall load path structure is secured to an anchor within the foundation and a top end of the c...

Claims

1. A composite foam and concrete wall comprising;a foam layer;a concrete layer; andat least one continuous wall load path structure within the concrete layer and extending from a bottom edge to a proximate a top edge of the wall, the at least one continuous load path comprising:a bottom bracket configured to be secured to a mount in a foundation;a lifting member proximate a top surface of the wall, wherein the concrete layer includes a cavity that exposes an aperture in the lift mechanism, such that the lifting member can be engaged to tilt the wall into an upright position; anda joining member configured to connect the bottom bracket to the lifting member.

2. The composite foam and concrete wall of claim 1, wherein the foam layer includes channels which are filled with concrete to form pilasters extending from the concrete layer.

3. The composite foam and concrete wall of claim 2, wherein the at least one continuous load path structure is aligned with a pilaster.

4. The composite foam and concrete wall of claim 1, wherein the bottom bracket comprises a substantially flat bottom portion located proximate a bottom edge of the concrete layer wherein a portion of the substantially flat bottom portion extends beyond an outer edge of the concrete layer, wherein the portion includes an aperture configured to accept a stud extending from a foundation.

5. The composite foam and concrete wall of claim 4, wherein the bottom bracket comprises an upper portion extending from the substantially flat bottom portion, wherein the upper portion includes an aperture configured to engage the joining member.

6. The composite foam and concrete wall of claim 1, wherein the lifting member comprises barbs proximate a lower end wherein the barbs extend in opposite directions.

7. The composite foam and concrete wall of claim 1, wherein the at least one continuous load path structure comprises a plurality of spaced apart continuous load path structures.

8. The composite foam and concrete wall of claim 7, wherein the plurality of continuous load path structures comprises a bottom joining member engaging each of the bottom brackets.

9. The composite foam and concrete wall of claim 7, wherein the plurality of continuous load path structures comprises a top joining member engaging each of the lifting members.

10. The composite foam and concrete wall of claim 1 and further comprising a top joining member configured to engage the aperture in the lifting member and to be secured to a roof member.

11. The composite foam and concrete wall of claim 10, wherein the top joining member comprises a hook portion configured to be positioned through the aperture in the lifting member and to be retained therein.

12. A building comprising:a foundation having a plurality of spaced apart anchor bolts extending therefrom;a plurality of walls secured to the foundation, each of the plurality of walls comprising:a foam layer;a concrete layer; anda plurality of continuous wall load path structures within the concrete layer, each continuous load path structure extending from a bottom edge to a proximate a top edge of the wall, wherein each of the plurality continuous wall load paths comprises:a bottom bracket configured to be secured to one of the anchor bolts in a foundation;a lifting member proximate a top surface of the wall, wherein the concrete layer includes a cavity that exposes an aperture in the lift mechanism, such that the lifting member can be engaged to tilt the wall into an upright position;a joining member configured to connect the bottom bracket to the lifting member; anda roof joining mechanism configured to extend through the aperture in the lifting member and extend above a top edge of the wall; anda roof supported by the plurality of walls, the roof comprisinga first portion with a first pitch; anda second portion with a second pitch that leads to a roof peak, wherein the second pitch is steeper than the first pitch and wherein the roof joining mechanism is configured to be secured to at least one roof member below the first portion.

13. The building of claim 12, wherein the foam layer includes channels which are filled with concrete to form pilasters extending from the concrete layer.

14. The building of claim 13, wherein each of the plurality of continuous load path structures is aligned with a pilaster.

15. The building of claim 12, wherein the bottom bracket comprises a substantially flat bottom portion located proximate a bottom edge of the concrete layer wherein a portion of the substantially flat bottom portion extends beyond an outer edge of the concrete layer, wherein the portion includes an aperture configured to accept the anchor bolt extending from a foundation.

16. The building of claim 15, wherein the bottom bracket comprises an upper portion extending from the substantially flat bottom portion, wherein the upper portion includes an aperture configured to engage the joining member.

17. The building of claim 12, wherein the plurality of continuous load path structures comprises a bottom joining member engaging each of the bottom brackets.

18. The building of claim 12, wherein the plurality of continuous load path structures comprises a top joining member engaging each of the lifting members.

19. The building of claim 12, wherein the roof joining member comprises a hook portion configured to be positioned through the aperture in the lifting member and to be retained therein.

20. The building of claim 12 and further comprising:a continuous roof load path attached to a roof deck and spanning from proximate a first edge of the roof to proximate the second end of the roof, wherein the continuous roof load path attaches to one of the continuous wall load paths in each of opposed walls of the building.

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