GB2480994A - Timber I-beams and panels in attic roof structures - Google Patents

Abstract

An I-beam 1 comprises timber, grooved flanges 1a and composite wood board 1b. A rafter assembly comprises two I-beams and an OSB board 3. Insulation boards 5 may be inserted above the OSB board. Further panels 12 may comprise flange members (21a,b, fig 24) and a web board 20. The I-beams and panels may be constructed from timber. In use, the beams and panels are used to construct attic rooms in roof constructions.

Description

Attic Roof Structures This invention relates to an attic room in roof system and linking components, the contents of which are incorporated herein by reference. This application describes with reference to the accompanying drawings a wall, floor and roof system utilising a build up of i-beam wall panels, joist and rafter members and their additional linking /panelised components for use in wall, roof and floor structures.

This application applies in particular, but not exclusively to -beamed panelised floors, walls and raftered roof structures on masonry or timberframe construction and in particular but not exclusively to Attic room in roof assemblies either assembled in the factory for onsite installation, or assembled in-situ onsite.

Background

There are two main ways to construct Timberframe in the UK. One version is a Factory Assembled Timberframe Wall Elevation, where bespoke framed elevations are assemble in one or two parts depending on length of wall and then transported to site for installing and the other is Stick Built Timberframe, where the wall elevation is framed /formed in position on-site.

Factory assembled timber wall, elevations are becoming more popular in the UK, but like all wall constructions are constantly changing to meet new stringent building regulations on thermal, acoustic and air tightness values as well as safety issues and risk assessments.

Factory open /closed panel, floor /wall /roof elevation' s, require heavy lifting apparatus in their manufacture and installation (crane on-site) as well as specifically placed integrated lifting straps.

Factory open panelled, timberframe wall elevations, generally fill up a vehicle quickly due to their open panel design (a lot of empty space) and assortment of panel elevation length and shapes, often resulting in multiple deliveries in order to complete a number of structures, adding to the carbon footprint of the buildings, Factory assembled timberframe wall elevations, tend to have a costly sheet nailing mechanism which requires a lot of room and maintenance.

Factory assembled, timberframe external inner leaf wall elevations, often include both a breather membrane and a stud position tape application over the sheathing board, which generally covers the whole of the external side of the assembled frame. The tape, which is generally a thin plastic type material is applied over the membrane and corresponds with all stud members, to allow for example, bricklayers to identify each stud member's position through the membrane and sheathing board for fixing brick ties into studs.

Factory assembled timberframe wall, elevations shy away from installing rigid insulation within the frame because of wastage and the incalculable number of sizes required to optimising yield from a standard 2400mm x 1200mm board.

On-site, Stick Built type Timberframe, wall assembly is popular around the world, less in the UK.

They are generally sower to erect on site, but are more adaptable to the building's actual measurements. Construction design details still need to specified, especial'y line loads and window doorway heads.

SUMMARY

At least one embodiment of the present invention aims to provide standard factory produced I-beams along with additional panelised connecting components, capable of providing the building industry with: * An -beamed floor construction with an integrated fall arrest board system, which is also capable of forming a structural diaphragm * An I-beamed adjustable main wall system, which utilises spaced apart I-beams in a vertical position with their web members in line with the run of the wall they form * A secondary wall system assembly, which reinforces flinks together the spaced apart vertical I-beams of the main wall system, utilising a standard set of horizontal and vertical service panels, which includes an integrated grid of horizontal and vertical fixing grounds and continuous soUd perimeter fixing grounds at top and bottom of wall * An I-beamed raftered roof system with a integrated fall arrest board system which also performs as a structural diaphragm wall * An I-beamed rafter assembly with an integrated and independently supported gable ladder system * An I-beamed raftered roof assembly which provides /seats within the profile of the I-beamed rafters, standard sets of factory cut rigid insulation utUising the fall arrest boards as a template.

Proposed Factory Assembly Solutions It is also an intention to split the supply destination of packs of I-beam wall panels and Bridging panels, The I-beam wall panels may go to a timberframe wall elevation assembly factory, with the Bridging panels directed straight to site, providing the factories with a timberframe assembly process of: * A partially sheathed wall assembly without a sheet nailing operation * A external inner leaf which removes the need /requirement to apply stud identification tapes over the breather membrane * A one man handling, build up of sets of standard width I-beam wall elevations, including standard sets of pre-cut insulation sizes, for forming bespoke wall elevation assembly for onsite In the drawings: Fig 1-shows a view of an i-beam section 1 with a plumb cut at each end. The -beam is an engineered timber component made with three of the following elements: timber grooved flanges, composite wood board web and glue. These three elements are formed into a I shaped profiled length. The I-beam is widely used as a joist, rafter or stud structural member within the Building industry. The profile in Fig 1 is a typical rafter profile, without a birdsmouth cutaway section Fig 2 -shows a view of the I-beam 1 in fig 1 from above Fig 3-shows an end view of an I-beam section 1 of figs 1,2. The three element shown form an I shaped profile, ranging in depth from approx 150mm /600mm.

Fig 4-shows a view of a spacer /bracing /supporting board 3. The board 3 is for example an 11mm type 3 -OSB board 1200mm long and 5 90mm wide Fig 5-shows a view of a spacer/bracing/supporting board 3. The board 3 is for example an 11mm OSB board 1200 long Fig 6 -shows an end view of the board 2 in figs 4 and 5. The board 3 is for example an 11mm OSB board 590mm wide Fig 7-shows a view of an anti-slip /seat cut component 4. The example shown is a 63mm x 38mm CLS timber rail 1200mm long with a seat cut in its lower region.

Fig 8-shows an exploded view of the lower region of fig 7. The example shown is a 63mm x 38mm CLS timber rail 1200mm long with a seat cut in its lower region forming a tight seat joint on top of a wall-plate type member Fig 9 -shows a side view of component 4 fixed to the underside of the lower flange la of rafters 1 with a seat cut in its lower region forming a tight seat joint even on top of a variable wall-plate member, replacing the inconsistent birdsmouth joints of tradition roof construction. Also shown is the rafter 1 extending down past the wall-plate to form eaves detail. The ends of rafters 1 can now be profiled to required eaves detail.

Fig 9a page 9 -shows an alternative lower eaves region detail, incorporating wall panels 12b, an I-beam floor structure50 consisting of I-beam joists 51, floor board 52, spacer /fall arrest boards 3. The floor structure50 is set in from the wall /head-plate 14b to allow rafters 1 now with an adapted lower region to extend down over the wall-plate 14b and match a typical attic truss eaves detail regards facia depth and soffit length.

The adapted rafters 1 which have a section of their lower flangela and webib removed in it's lower region, are supported on a Glulam beam /beam lOb which now spans from gable /spandrel to gable /spandrel and is located with its bottom face marginally(approx 50mm) above the floor 52 of floor structure50, and set in approximately 600mm from the floor structures edge (depenthng on pitch of roof). The Glulam beam lOb now takes the loading points from the front elevation to the gable /side wall elevation.

On town houses with short front elevations (our main target market for the room in roof structure) which are filled mainly with window doorways, (popular in the UK) there may be thermal /span table /construction advantages to transferring the loads from the front elevation, to the side gable /walls, (generally wall only) removing the loading on upper front elevation lintel sections as well as reducing their cold bridging elements, improving thermal values.

The Glulam beam /beam lOb is restrained by bracing members lOc, for example, diagonal timber blocks lOc as shown or diagonal /1 shaped metal braces (not shown). The blocksiOc are fixed to beam lOb and the floor structureSO at set distances along the beams lOb length. The anti slip components 4 are now fixed to the underside of rafter 1 with their seat joint on top of the Glulam beam fbeam lob. An alternative bracing member, designed either solid /diagonally or L shaped, outlined in fig 37 may extends over /under and down /up both sides of the beam lOb and fix down to the floor structure 50 as well as forming a seat joint /attaching to bottom flange of raftersl, replacing anti slip component 4. The spacer /bracing /fall arrest boards 3 are now positioned to act as a restraint board connecting the wall /head-plate 14b to the upper, lower flangela of rafters Fig 10-shows a view of a collar 6. The collar example shown is an 11mm OSB board approximately 1200mm long x 600mm high. The cutaway section lOa is designed to receive a Perlin member, if applicable. The collar 6 also has two anti-slip components 4 attached with their seat cut at the collar 6 lower region. The components 4 are positioned a distance equal to the depth of rafter 1 bottom flange, down and along the collars diagonal length for fixing to the underside of rafter 1 when forming a rafter assembly.

Fig 11 -shows an end view of collar 6 in fig 10. The example shown is an 11mm OSB board, 600mm high Fig 12 -shows two i-beam raftersi aid flat on a floor structure (not shown) and joined by attaching /fixing collar 6 to the lower flange member la of the two adjoining /apposing rafters 1 upper region, both through the collar board and anti-slip component 4, forming a rafter assembly Fig 13 -shows a view of two number of raised rafter assemblies joined together by bracing /spacer /faIl arrest boards 3 which are spaced apart and fixed to the upper face of the lower flange la of each adjacent raftersl.Fig 13 shows the rafter assembly's lower regions extending past/over wall plate member 13. The rafter ends are profiled at a later stage to receive a facia/soffit board.

Fig 14-shows an exploded end view of assembled components in fig 13 including insulation 5.

The example -shown, shows two adjacent raftersl of approximately 300mm deep, joined by 11mm OSB board 3, which is fixed to the top of the upper face of each raftersl lower flange. The 590mm wide board 3 spaces the rafters to form a standard width seating aperture for the insertion of standard width insulation blocks of 590mm. The -beam raftersl end profile is ideal for sliding the spacer boards 3 into place as well as housing blocks of insulation, the web member depth also reduce cold bridging by an average 60% to less than 5%, improving thermal value results.

Fig 15 -shows an example of an adapted end /gable rafter 1 preparing for a gable adder assembly. The rafter 1 has a predetermined set of spaced apart apertures 7c within it's upper web region lb. the apertures 7c are machined slightly bigger than the noggins 7 which are inserted later. The web member lb is ideally suited to receive the spaced apart apertures 7c without being detrimental to rafter 1 structural performance.

Fig 16-shows noggins 7 of for example 45mm x 100mm section inserted into apertures 7c in end /gable rafterl fig 15 and supported by soldiers 7b of for example 45mm x 100mm section.

The support soldiers 7b are positioned between the rafters 1 bottom flange la and the underside of the noggins 7, to form a support function.

Fig 17 Full Description -shows the end / gable rafterl with gable rail 7a of for example 150mm x 45mm section attached. The rail 7a is attached to the noggins members 7 (not seen) which are supported by soldiers 7b (shown) Fig 18 -shows gable ladder assembly, prior to external gable wall /spandrel construction. The drawing shows a length of noggin components 7 of for example, 1200mm inserted through aperture7c, within end /gable rafter 1.The noggin 7 extends /supported by the upper flange of the adjacent rafter 1 on one side and extend over gable fspandrel wall (not shown) the other, to receve gable rails 7a. Further noggin7 support is provided by soldiers 7b which are positioned between the end rafters, bottom flange la and the underside of noggin 7, to form a self supporting gable ladder fabrication.

Fig 21 -shows the position of the spacer /bracing /support /fall arrest board 3 when incorporated within a joist /floor structure 50. The drawing shows for example two number of joists joined together /spaced apart by boards 3 which is for example an 11mm OSB board, 590mm wide. The boards 3 are spaced apart along the run of joist and fixed /rest on to the upper face of the lower flange 51a of each adjacent joist 51.The boards 3 may include a aperture to route services.The boards 3 can also act as support if required for a fibre type sound insulation, an integrated bracing and fall arrest system and a fixing surface for cables, pipe-work etc. Fig 22 -shows a view of an i-beam type wall panel 12.This multifunctional wall panel, can be incorporated in a singular or multiple leaf wall construction, including external inner leaf, separating, internal load-bearing and partition walls. Each panel 12 has a structural board/web 20, which extends! bonds into an offset groove within a flange member 21 on each vertical edge, providing a specific recess depth on each side/face. Crucially the web members within each panel 12 are aligned along the same plane/run of wall elevation to which they form.

Wall Panel 12 is a one man handling panel operation which combined with a number of additional panels 12 generally spaced apart, forms any wall elevation length. Generally installed onsite or in the factory the panels 12, in conjunction with a combination of Breather membrane, Vapour Control Layer, nsulatiori and Bridging /Service panels whose description and assembly are described in Fig's 30-31-32-33-34 and 35 provides a wall panelised assembly capable of adapting to any sole-plate length discrepancy's by adjusting spaces between panels. t also provides a wall assembly easily adapted to last minute changes and incorporates standard dimensions of push fit /secure rigid insulation predominately throughout the wall elevations.

The board/web 20 may also extend past each flange member 21 at their lower and upper region, overlapping the edge of a secondary /sole Jhead-plate /guide rail 14c and provides the means to secure the panel 12 by fixing through the web 20 into the sole /head-plate /guide rail 14c with mechanical fixings.

There is also a provision for a double leaf inner wall fig 25 formed from the same i-beam panel 12 incorporated in the singular inner wall applications figs 23/24.The double leaf version is generally utilized in external walls requiring greater U/values and improved racking /loading performances. Multiple leaf wall assembly includes layers of identical depth insulation in sets of standard widths and depths. The reversal of one leaf profile in relation to its adjacent leaf is a key feature to this achievement. The double leaf i-beam wall fig 25 is connected at its upper and lower region to an extended sole/head -plate 14b /c whose depth is set to the depth of both leafs Fig 23-illustrates each panel 12 has a structural board/web 20, which extends / bonds into an offset grove within a flange member 21 on each vertical edge, providing a specific recess depth on each side/face. The off set groove can be machined into each flange or formed by utilising standard -bearns with an additional plant on timbers 21a, matching width and length of flange to one or both sides, the thickness of plant on depending on recess required for insulation, for

example.

Fig 24-shows a mechanical fixed together version of panel 12 figs 21 /23 The mechanically fixed together panel 12a is arranged to the same profile as panel 12 by having a two part flange / stud members 21a /21b and a web board 20a which extends the full width of the panel in between each set of flange/suds t2la /2 lb. The panel 12a is assembled in the same way as the panel assembly process described for spandrel / walls figs 25/27.

Fig 25 -shows a view from above of an exploded section of the panel assembly shown in fig 25 without a head plate for clarity Fig 27-shows a view from above of a double leaf spandrel wall with spaced apart panels 1 Fig 28 -shows a view of horizontal bridging /service panel 13 Fig 29-shows an exploded view of panel 13 Fig 30-shows horizontal bridging /service panels 13 binding panels 13a in fig 27 to a sole-plate 14 in its lower region and a head -plate 14b in its upper region Fig 31 -shows a view of vertical bridging jservice panel 13a Fig 32 -shows a view of panel 13a from above Fig 33 -shows vertical bridging /service panels 13a spanning between horizontal bridging jservice panels 13 and over spaces between panels 12 of fig 32 Fig 34-shows a lintel section supported by hangers attached to single leaf spandrel fwall assembly Fig 35 -shows an end view of panel 12a which is an alternative i-beam panel to panel 12 shown in Figs 22/23 Fig 35 -shows an end view of panel 12b which is an alternative I-beam panel adaption to panel 12 shown in Figs 22/23 This multifunctional wall panel, can also be incorporated in a singular or multiple leaf storey height wall construction, including external inner leaf, separating, internal load-bearing and partition walls onsite or in the factory.

Each panel 12b has a structural board/web 20, which extends / bonds into a central groove within each flange member 21b, and two plant-on members 21 c and 21d, which match the width and also length in the case of 21c of flanges 21b to one or both sides of panel 12b. The length of plant on 21d is generally equal to depth of panel 12b plus depth of sole-head-plate members, this addition feature provides a lower and upper region location function as well as additional holding down Jconnection strength.

By altering the depth of plant on 21c Id, the depth of recess can be adjusted, in turn also the depth of wall, allowing the sole /head-plate to remain a standard width, for example 100mm.

The example of 100mm wide sole /head-plate provides an opportunity to construct /align wall supporting elements directly off a traditional brick and block designed, over-site of: 100mm block inner leaf -80/100mm cavity and 102mm brick work outer skin. The 80/100mm cavity can now be reduced automatically to a 50mm open cavity by the additional 30/50mm plant on components 21d attached to panel 12b. This method of construction will allow timber wall construction to UK's Code for Sustainable Homes level 5 on over-sites designed for block work inner leafs.

The small I-beam panels 12b are assembled with each web member 20 aligned /arranged /spaced along the same plane/run of wall elevation to which they are forming. Wall Panel 12b is a one man handling wall panel operation which combined with a number of additional panels 12b generally spaced apart forms any wall elevation length. The panels 12b, in conjunction with a combination of breather membrane, vapour control layer, Insulation and bridging /service panels, whose description and assembly are described in Fig's 30 -31-32-33-34 and 35 provides a wall panelised assembly capable of adapting to any sole-plate length discrepancy's by adjusting spaces between panels 12b. It also provides a wall assembly easily adapted to last minute changes and incorporates standard dimensions of push fit /secure rigid insulation predominately throughout the wall elevations.

Fig 36-shows panel 12b from above and incorporating in its construction a structural board/web 20, which extends / bonds into a central groove within each flange member 21b, and four plant-on members, two of 21c and two of 21d, whose depth is adjustable to provide depth of recess required. The panel assembly 12b can be assembled with or without any plant on members 21c /d.

Fig 37 shows an alternative bracing member, designed either solid fdiagonally or L shaped, may extends over /under and down /up both sides of the beamlOb and fix down to the floor structure 50 as well as forming a seat joint /attaching to bottom flange of raftersi, replacing anti slipcomponent4 Genera' Joist /Aoor Assemb'y on Site Begin floor structure 50 by positioning /spanning two joists 51. Utilise alternating spaced apart spacer boards3 in between and fixed on top of said joists 51 lower flanges 51a, Continue adding a combination of joists5l and perimeter spacer boards3 to complete joist layout. Lay first row of floor boards, working from scaffold, position /lay additional spacer boards 52 before 2nd row of flooring is installed. Repeat process until floor structure 50 is complete. The spaces between each spacer board 3 along /between each set of joist Slis not expected to be greater than 300mm if the boards are utilised has a fall through arrest system Genera' Wa Assemb'y Begin by fixing a sole-plate 14 down to wall length required, with window positions marked and doorways positions cut out. Place and fix on sole-plate, pre-assembled lower window sets (panelised sections below window).

Starting from each end of window sections and edge of doorways, install /fix storey height beam panels 12b (each web member 20 aligned along the same plane/run of sole-plate /wall elevation. Fit lintel section, for example panel 12b positioned horizontally, above window and doorways (window and doorway sets are now formed). nfill remaining wall area between window/door sets, with a combination of pre-cut insulation spacer blocks 12e and panels 12b, generally starting with an insulation block 12e, adding head-plate 14a when appropriate.

(Wall Panel 12b is a one man handling wall panel build up operation which combined with a number of additional panels 12b, generally spaced apart forms any wail elevation length in-situ).

nfill remaining layers of insulation blocks, where required fend of wall runs may see the insulation block ripped down in final space). Fit a Vapour Control Layer to the inside face.

Position and fix horizontal bridging /service panels 13 to upper and lower regions of the internal face, bridging /connecting panels 12b /sole /head-plates. Fit and fix vertical bridging /service panels 13a between horizontal service panels and over insulation spacer blocks 13e. Complete internal face with vertical rails around window /doorway and end of wall run. Fit Breather Membrane to external face.

The panels 12b, in conjunction with a combination of breather membrane, vapour control layer, insulation and bridging /service panels, provides a wall panelised assembly capable of adapting to any sole-plate length discrepancy's by adjusting spaces between panels 12b.

t also provides a wall assembly easily adapted to last minute changes and incorporates standard dimensions of factory cut push fit /secure rigid insulation predominately throughout the wall elevations.

Genera' Roof Assemby The roof structure may be constructed in various methods, with the placement of two /three /four specified Glulam beams spanning /supported from gable to gable. The Glulam beam lOb is located marginally above floor 52 of floor structure 50, to dimension set in drawing, for example 600mm from front and back edges of floor structure 50.The Glulam beam lOb is restrained by bracing block lob, which is fixed to the Glulam and the outer floor structure 50 at set distances along the beams lOb length.

The Glulam beam lOb is then marked out to drawing roof layout, Two number of opposing I-beam raftersi are laid flat on the floor structure and joined by attaching collar 6 to their upper region, lower flange, forming a rafter assembly. This operation is repeated until required rafter assemblies are assembled.

A rafter assembly is raised and installed vertically at an end of the building, The rafter assembly's lower region extends past/over Glulam beam/head-plate members, for profile at a later stage to receive a facia/soffit board.

A spacer board is fixed to each upper region of the lower flange of the installed I-beam rafter, at their lower regions. A second rafter assembly is raised and connected/braced via the spacer boards opposite unfixed edge, which lips/fixes onto the upper region of the lower flange of the second rafter assembly. Additional boards are spaced along/between and fixed to the upper region of the lower flanges of each rafter member, the boards provide set spacing's and support for insulation, which when fitted also acts as a protective layer, preventing roof operatives falling through the structure.

The third and fourth remaining rafter assembly's are grouped vertically together at the opposite end of the building. The fourth rafter assembly's lower region is fixed in its position on top of Glulam beam lob. The third rafter assembly slides along, if applicable an installed Perlin 1O,a distance set by its spacer boards, which are attached spaced and fixed in the manner described earlier. The remaining space between the two sets of rafter assembly's are in filled with a combination of i-beams raftersi, spacer boards3, collar boards6, anti-slip components 4, whose seat cut angle is set to pitch of roof.

Alternatively the perlin 10 can be omitted and two additional upper Glulam beams lOb can be installed, supported off gable walls and positioned under seat cuts of anti-slip components 4 within collars 6 and then in-filled with a number of rafter assemblies.

Standard sets of insulation, sized to match spacer board can be inserted between the raftersi upper and lower flange members la, seating on top of spacer boards 3.

nsuathig Between Beam Wafi, F'oor and Roof Eevatons

Background

The process of installing rigid insulation boards from below the rafter line and within the rafter zone is generally an intricate process in terms of securing and accurately sizeing the insulation boards. When fitting the insulation from below the rafter line has on attic truss assemblies for example, there is a vast amount of obstructing bracing to contend with, coupled to variable truss spacing's (a tolerance of + or -5mm is more than except able in the industry) which now requires specific cut to size insulation widths in between each section of trusses, if accurate fitting insulation to reduce cold bridging and improve air tightness /thermal values is the goal.

if installing the insulation from above the rafter line is the goal, as for example on a traditional cut rafter, room in roof, there is an increase in the risk of falling through the structure as well as the quandary of securing the insulation boards from blowing away> or dropping through rafter zone.

NSULATON SUMMARY

This invention provides a hinged performing insulation board for installation between two adjacent I-beams arranged into wall, floor or raftered elevations. The hinged operating rigid insulation board has a saw cut running approximately down the middle of the boards length, the saw cut depth is set to depth of board, less its lower foil face, which allows the board to hinge apart and be inserted past the upper flanges of each adjoining I-beamed floor or rafter members and down to fseated on top of the fall arrest boards, which are fixed to the I-beams upper region, lower flange members.

When the hinged insulation board, is positioned against each adjacent web member and fall arrest board below, the board is then pressed down from its middle upper region, springing the board back into its original shape, nestling into /within the I-beam and secured by the upper flanges, side web members and fall arrest board below.

INSULATION DESCRft'TION Room in Roofs assemblies utilising i-beam raftersi and spacer boards3 have the benefit of utilising their upper flower flangesla to support /secure a foil faced rigid insulation board 5, within the rafter zone, with further support provided by the spacer /fall arrest boards3. If the rigid insulation5, installation is to be a separate operation (preferred) from the I-beam roof construction, then a process for inserting the rigid insulation board5 is required. The obvious solution is to feed the boards5 into the rafter zone in the rafter lower region, but this would require a clear /unobstructed feeding zone, which is not always serviceable. Another solution is to provide a method of installation which provides an easy insulation infill application from above the rafter line by utilising a foil faced rigid insulation board5 with a saw cut5b running approximately down the middle of the boards length, the saw depth set to depth of board, less lower foil face5a, allowing the board to hinge apart, then positioned within rafter zone and then spring back into shape within the said rafter zone, between adjacent I-beam rafter rnembersl, In the drawings: Fig 1 page 11-shows an end view of two I-beam raftersl, a spacer board3 and the rigid insulation5 in its hinged position.

Fig 2 page 11 -shows the insulation5 shown in fig 1 sprung back into shape within the rafter zone of fig 1 Aternatve Boar and Root Assemb'y tar Room n Roof Construction This invention adds to the disclosures of the attic room in roof system and linking components described above, the contents of which are incorporated herein by reference. This application describes with reference to the accompanying drawings further functions to the Attic roof structures floor and roof sections.

This invention applies in particular, but not exclusively to I profiled beam rafters and joist, for example I-beams along with linking components described above, which together forms a panelised Attic room in roof structure, either assembled in the factory for building site installation, or assembled as individual components in-situ on building sites.

Further Roof Assembly Background

A number of Attic roof designs are installed throughout the building industry, of which there are a number of design examples particularly widespread in the UK. One design in particular has a short eaves overhang and its rafters lower edge seated on a wall-plate which corresponds closely too the underside of the floor joists. If standard ceiling/window heights are to be maintained this detail creates in general, a horizontal soffit line from the lower level of the facia board to top of window.

This conventional eaves detail design favours the Attic truss assemblies because they provide this eaves profile feature within their assembly, which makes them the most prominent form of this type of construction and generally rules out a combined, but independently installed floor and roof assembly, where the floor board is installed as a structural diaphragm on joists and rafters are supported off Perlins and seated on a wall-plate positioned generally level with top of joists, creating a much wider overhang detail to match horizontal soffit line described above.

Attic truss supply and assemblies are well known in the industry and generally have the following recognised Advantages and Disadvantages.

Attic Truss Disadvantages: * Expensive add on cost * Requires a large amount of factory space to fabricate * Awkward to transport and have road haulage height restrictions * Awkward to unload and store on site, requires a scaffold cradle * Needs a crane during installation * Craned operation requires the services of a banksman and slinger during installation * Crane operation restricted by wind speed * Crane operation blocks off access, generally obstructing other site operations * Tolerances in assembly and obstructing bracing make it awkward, time consuming and expensive to insulate accurately * Awkward to secure insulation and make air tight * Assembly has around 15% cold bridge elements, reducing thermal values * Requires a separate fall arrest system * Room in roof habitual space restricted by intermediate struts near eaves region * Spanning restrictions * Gable ladders require gable wall support before making roof watertight * On terrace type constructions, truss assembly cannot be completed until gable waits are built (masonry) * Requires solid bridging /herringbone strutting in floor zone * Requires secondary top hat assembly on taller roof structures * Awkward to brace temporary or permanently * In-situ need for profiling solid timber end of trusses for facia /soffit are strenuous to shape by hand saw and dangerous by power saws because of position of saw action Attic Truss Advantages: * No RSJ fPerlin members in habitual room in roof zone * Assembly available prior to gable wall construction (detached only) * Initial speed of assembly * No ridge member * Rafter and floor zone combined in one operation, apart from trimming of joist and rafters around stairwells, Dormers, chimneys, skylights, gable adders, solid bridging /herringbone strutting and floor board installation * Roof assembly structural calculations and drawings performed in one operation There are many variations of combined, but independently installed Floor and Roof Assemblies, on the market. They all, in general have the following Advantages and Disadvantages.

Floor and Roof Assembly Disadvantages: * Struggles to match Attic truss eaves profile * Expensive in cassette form * Expensive add on cost * Requires a large amount of factory space to fabricate if cassettes are utilised as floor /roof structures * Requires a type of Perlin, for example Steel RSJ fGIuIam beam support * Needs a crane during installation for Perlins and cassettes * Awkward to unload and store on site, in cassette form * Craned operation requires the services of a banksman and slinger during installation * Crane operation restricted by wind speed * Crane operation blocks off access, generally obstructing other site operations

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* Tolerances in assembly make it awkward, time consuming and expensive to insulate accurately, unless in cassette form, which is still expensive * Awkward to secure insulation and make air tight, unless roof cassettes are utilised * Assembly has around 15% cold bridge elements, reducing thermal values, unless i-beam rafters are utilised in cassette form * Requires a separate fall arrest system * Gable ladders require gable wall support before making roof watertight * On terrace type constructions, rafter assemb'y cannot be completed until gable fparty fseparating walls are built up, because of Perlins * Special /throw away lifting straps required on cassette forms Floor and Roof Assembly Advantages: * Engineered joists fabrication, such as i-beams, provide silent floor * Engineered joists fabrication, such as I-beams, require no solid bridging /herringbone strutting * Engineered joists frafter fabrications, such as I-beams, provide greater span capability * Roof/Floor cassettes are fast to erect on-site * Floor software programmes available for take off applications and structural calculations It is our intention fgoal is to provide a combined, but independently installed floor and roof construction for an Attic room in roof assembly on masonry or timberframe, inline terrace town house constructions, free of all the Disadvantages listed above, whilst comparing well with the Advantage list.

Proposed Assembly Solutions It is an intention to utilise, I profiled joist and rafter members, such as I-beams as the main structural component within the floor and roof structure, This will allow us to position from the ceiling level positioned wall-plates, (bottom ofjoists)the floor structures, joist components, to allow the rafters to extend down over the wall-plate and provide a similar eaves detail to Attic truss constructions, in terms of facia and soffit positions The ceiling level wall-plates and all relevant vertical shear walls below, are tied in /restrained with a structural diaphragm, utiUsing the alternating, spaced apart, rows of linked together spacer/fall arrest /bracing boards fixed to the upper region of the lower flange member of each I-beam joist member The instaUation of the inked together diaphragm, predominately from the floor below, now automatically provides an integrated protective fall arrest system for operatives installing the floor board stage from above joist level.

The wall-plate and eaves region is further reinforced, utilising a number of specifically spaced apart, rafter connecting eaves members which have a angled cut end to match pitch of roof and a metal connector attached. The rafter connecting eaves members are fixed through boards 3 into wall-plate and generally depending on joist type (they may form a type of strong back operation through gaps on an open web type joist application) extend to the first adjacent joist to the wall-plate run. The rafter connecting members are positioned to align with the roof's rafter run /positions and at a later stage become the fixing locations for each rafter.

It is an intention to set out within the joist layout drawing, the additional positions of the floor structural diaphragm /fall arrest system, along with the rafter connecting members showing rafter run positions of roof, Further reinforcement is provided to the wall-plate, rafter junction by means of a roof line structural diaphragm, utilising the alternating, spaced apart, rows of linked together spacer /fall arrest /bracing boards fixed to the upper region of the lower flange member of each i-beam rafter member. The roof line spacer boards are fixed in their lowest region to /along a noggin member between each rafter /metal connector and on top of the wall-plate, tying in the floor and rafter line structural diaphragms.

The metal connectors are also utilised to form the rafter assembly. The connectors provide restraint fspreading action, to the apex region of the rafter assembly, which is reinforced further when coupled to a ceiling tie member.

Further restraining /strengthening operations to wall-plate region may be provided by the array of lateral /holding down straps available on the market..

These particular processes removal the need for perlin type support members and subsequently their gable wall support prior too the roof assembly, this feature is enhanced by the availability of our independent supported integrated gable ladder assembly as, allowing access from end gables throughout terraced roof structure.

ft is also our intention / goal to transfer further components more associated with the roof stage to the floor programme software takeoff list and applications, to ease /simplify the structural calculation workload of this proposed roof structure and to allow the room in roof designers along with the site carpenters to combine! prepare more for the roof construction within the floor stage.

As will be appreciated the present invention utilises the I profile of the I-Beams to achieve the many functions described within this patent application and that any other suitably adapted profiled structural member could also be utilised In the Drawings: Fig 1 page 13-shows an afternative, room in roof, lower eaves region detail, incorporating an I-beam floor structure50 consisting of I-beam joists 51, floor board 52, spacer ffall arrest /bracing boards 3. The floor structure50 joist components are set in from the wall /head-plate 14b to allow rafters ito extend down over the wall-plate 14b and provide a similar eaves detail to Attic truss constructions, in terms of facia and soffit positions The connecting rows of the floor /rafter zone's spacer /bracing /fall arrest boards 3, now provide a triangulated structural diaphragm, which also acts as a restraint board for supporting walls below, by connecting the walls /head-plate 14b, too the floor structure 50 and roof structure at the eaves junction and roof elevation to roof elevation at the apex. A noggin component (not shown) between each rafter and on top of wall-plate 14b at the eaves junction, provides the means to complete this operation.

The angled end, rafter connecting eaves members 101 coupled to metal connectors 102 reinforces the eaves junction and provides resistance to both downward and upward forces of the raftered roof section. Connectors 102 provides a universal pitch adjusted metal connection when coupled to an angled end of the rafter connector member 101, by nailing through the connectors 102 side members into the rafters 1 Fig 2 page 13 -shows another view of the rafter connecting memberl0i with connector 102 attached prior too rafter assembly and fixed on top of spacer ffall arrest /bracing /restraint board 3, which in turn is fixed to wall-plate 14b below, which in turn has a plaster board ceiling batten 14e fixed to its inner edge. The connector 102 has extended sections to fix too wall-plate 14b below (resisting roof structure uplift) as well as above along the support rails 101 upper face (resisting roof structure down force) Fig 3 page 14-shows a view of an apex region of a rafter assembly. The rafter assembly also utilises the connectors 102 in its upper apex region to provide further restraint fspreading action, reinforced further when coupled to a ceiling tie member bid. The universal pitch connectors 102 utilise their universally pitched tangled positioned extended region to bend /connect ftie in /triangulate the structural components shown. Also shown is the spacer ffall arrest /bracing boards 3 which form a connected diaphragm along the pitch of the roof Fig 4 page 14-shows an alternative rafter support eaves member lOla utilised within the alternative eaves detail of fig 1. Rafter connecting member lOla has two angled end cuts, one to pitch of roof, the other has a reduced pitch angle to provide clearance 105 from rafter member 1 when roof is loaded, to prevent transferring load from roof to floor structure50 Fig S page 14-shows another view of rafter support eaves member lOla with metal connector 102 attached and position of a holding down strap 104 over wall-plate 14b Fig 6 page 14-shows an example of a metal holding down strap available today Genera' Joist /Roor Assemby on Site Begin floor structure 50 by positioning /spanning joists member 51 set in from both runs of wall-plate 14b as shown on joist layout drawing. Utilising a plurality of spaced apart /continuous fall arrest boards3, to tie in /fx wall-plate member 14b to upper region of lower flange 51a of adjacent joist members5l. Continue adding a combination of joists 51 and spacer/fall arrest boards 3 (alternating spaces in between joist runs) to complete joist layout and structural diaphragm. nstalI rafter support eaves members 101/lOla including metal components 102, again to joist layout drawing. Install rows of floorboards 52 to complete floor structure.

Gener& Root Assemby Begin the roof structure assembly by placing two number of opposing i-beam raftersi flat on the floor structure and join together by attaching metal connectors 102 and tie in rail lOld to their upper apex region, forming a rafter assembly, This operation is repeated until required numbers of rafter assemblies are assembled.

A rafter assembly is raised and installed vertically at an end of the building. The rafter assembly's lower region extends into the metal connectors 102 attached to the rafter support member 101 hUla at wall-plate level and is fixed and temporary braced off scaffold. The rafter 1 ends are profile in line at a later stage to receive a facia/soffit board.

A spacer /fall arrest board3 is, fixed to each upper region of the lower flange of the installed I-beam rafterl, as well as to a noggin member on top of wall-plate 14b. A second rafter assembly is raised and connected/braced via the spacer boards opposite unfixed edge, which lips/fixes onto the upper region of the lower flange of the second rafter assembly. Additional spacer flail arrest boards are spaced along/between and fixed to the upper region of the lower flanges la of each rafter memberl, the boards3 provide set spacing's and support for insulation, which when fitted also acts as a protective layer, preventing roof operatives failing through the structure.

This process is repeated until raftered roof structure s completed.

Standard sets of insulation, sized to match spacer board can be placed between the raftersl upper and lower flange members la, seating on top of spacer boards 3.