WO1997008398A1

WO1997008398A1 - Static structures containing expanded polystyrene and methods for constructing same

Info

Publication number: WO1997008398A1
Application number: PCT/US1996/013295
Authority: WO
Inventors: Richard N. Boe
Original assignee: Boe Richard N
Priority date: 1995-08-22
Filing date: 1996-08-22
Publication date: 1997-03-06
Also published as: AU7008096A

Abstract

Static structures containing a foundation (1), weight-bearing walls (3), non weight-bearing walls (8), floor(s) (2), and a roof (98) are disclosed. The weight-bearing walls are attached to the foundation and are composed of a framework of elongate tubular support members (3a-3h, 4a-4f) connected to each other by fittings (15a-15h), the spaces within the framework are filled with panels (5) of expanded polystyrene (EPS) and the framework filled with the panels of EPS is covered on both sides with additional panels (6, 7) of expanded polystyrene. The floors are composed of horizontal spaced apart parallel joists (30) with panels (35) of EPS between them. Similarly, the roof is composed of spaced apart parallel joists (98) with panels (152) of EPS between the joists. The foundation can be of a poured construction or slab construction. The structure can be single or multi-story.

Description

STATIC STRUCTURES CONTAINING EXPANDED POLYSTYRENE AND METHODS FOR CONSTRUCTING SAME

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to static structures, and in particular to structures containing expanded polystyrene as both an insulative and structural material. The invention also relates to construction techniques using expanded polystyrene in the construction of dwellings and the like.

2. Description of the prior art

More than ever there is a need for low cost, highly energy efficient, safe and easily constructed and maintained housing. The rise in homelessness alone is testimony to this problem in the United States and elsewhere in the world. Even those persons able to afford a home are plagued with ever rising utility bills. Traditionally, most residential homes are constructed from weight-bearing walls comprising wood framing with, for example, fiberglass insulation for protection against thermal conduction. The interior surfaces of the walls are covered with gypsum board, paneling or the like while the exterior surfaces of the walls are generally covered with sheathing and/or siding. Floor and ceiling joists, as well as roof trusses span between the walls. Insulation is also typically placed between the ceiling joists and the floor joists. These wood-framed structures are often inefficient to heat and cool as the wooden framework in the weight-bearing walls provides thermal bridges for conducting heat between the exterior ambient atmosphere and the enclosed space. As a result, the thermal insulative properties (the R value) of traditional wood framed houses is limited. As the cost of energy necessary to provide heating and cooling increases, there is a greater need to construct

SUBSTTTUTE SHEET (RULE 26) >nstruct and are relatively ruct homes is de the lumber impacts e earth. Additionally,

houses and other structuπ are prone to rapid burning with the conseque ty. In many fires flames spread rapidly from __{& ^} uunαmg due to the airborne sparks and embers from the burning of a nearby wooden structure. Furthermore, the construction of a structure made from brick, concrete, or other alternative materials is labor intensive, time consuming and requires relatively expensive materials, thereby resulting in an expensive final product.

Expanded polystyrene is an excellent insulating material which can be made into preformed panels, but it does not have the structural strength of wood, concrete or other materials. Consequently there is a need for static structures which have the high insulating value of expanded polystyrene while maintaining high strength and rigidity. It is therefore an object of the present invention to provide buildings which can be constructed quickly and easily from prefabricated components assembled at the job site at a low cost.

It is also an object of the present invention to provide for structures which are energy efficient and have high strength and rigidity.

Another object of this invention is to allow for the construction of static structures which resist the effects of high temperatures and prevent the spread of fire from one structure to another.

Another object of the invention is to provide buildings and the like which do not deplete the supply of wood. These and other objects of this invention are obtained by providing a static structure having a structural framework which is made up of interconnected structural members containing interstices therebetween with expanded polystyrene substantially filling the interstices. The structural framework combined with the expanded polystyrene creates walls having two substantially parallel surfaces wherein at least one of the surfaces is covered with an additional layer of expanded polystyrene.

There have been a few other attempts to construct static structures containing expanded polystyrene. However, these have fallen short of the objectives expressed hereinabove. For example, U.S. 4,823,534 to

Hebinck discloses a method for constructing insulated homes made from expanded polystyrene wherein a block or blocks of expanded polystyrene are adhesively attached to a foundation and cement is poured into horizontal and vertical voids in the polystyrene. While it is contended that the cement provides support for the structure, the process is labor intensive and much of the fabrication must be performed on site. The current invention has the advantage that essentially all of the component parts may be prefabricated at an off site location and may be assembled at the job site with a minimum of specialized skill. Additionally, the '534 patent requires installation of the polystyrene blocks prior to the installation of the cement support structure. The present invention allows for walls to be easily constructed from a support framework with polystyrene panels inserted into interstices in the framework thereby saving time and labor costs. Interior and exterior panels, also made of expanded polystyrene, are then easily affixed to the framework and expanded polystyrene structure to provide markedly improved thermal insulation properties.

U. S. 4,641,468 to Slater discloses static structures made from a plurality of insulated building panels comprising a combination of a slab of foam plastic material, which may be expanded polystyrene, with tubular structural members, preferably made of steel, inset into the foam plastic slabs and bonded thereto. Interior and exterior finishes such as stucco, paint spray applications, wall board, wood or metal siding are applied directly to the foam and steel panels. However, because the tubular structural members are in direct contact with the interior and exterior finishes, the structural members provide a means for thermal conductivity not found in the present invention. Additionally, the structural members are fixedly attached directly to recesses in the slabs of plastic foam, thereby making construction of the panels complicated and with the attendant risk that the slabs may separate from the structural members after completion of the structure. In the current invention, the structural members are never directly affixed to the polystyrene slabs thereby eliminating the aforementioned drawbacks. In fact, most of the construction can be done using "off-the-shelf materials. In addition, the use of additional panels of expanded polystyrene on the inside surfaces and the outside surfaces of the weight-bearing walls results in markedly improved thermal insulation properties. Also, in the present invention, the wall structure is constructed entirely on-site as an inherent part of the construction process itself and therefore allows for more customization of the final structure, requires less specialized skill and can be completed at a lower cost. The framework of the present invention can be made stronger than the slab and tubular steel panels of the '468 patent and therefore allows for an essentially unlimited number of stories to be constructed with increased strength.

U. S. 4,628,650 to Parker discloses a structural insulated panel system including individual panels for forming the floor, walls and roof of a structure wherein the panels contain expanded polystyrene. However, this approach contains many of the same drawbacks as the Slater patent including thermal conduction and lack of structural strength and rigidity.

U. S. 2,970,676 to Maciunas discloses a framework construction useful in constructing prefabricated buildings and the like. The framework is composed of a plurality of vertical and horizontal support members (columns and beams) connected via fittings. However, each of the columns and beams are constructed of two extruded aluminum pieces bolted together. Each extruded piece has a channel shape with an integral flange extending outwardly and running centrally along the piece. The extruded pieces are relatively complex in shape and must be bolted together. This process is relatively labor intensive and therefore expensive. The instant invention obviates these shortcomings by providing a structural framework which can be constructed of easily available materials cut to size without the need to bolt together separate pieces to create each support member. Maciunas appears to be silent regarding details relating to insulation within the walls, floors or ceilings. In fact, the floors are merelv cement slabs.

SUMMARY OF THE INVENTION The present invention relates generally to a method for forming building walls, roofs, floors and complete static structures containing these walls, floors and roofs. The invention also relates to methods for connecting the aforementioned components to each other and to a foundation, as well as the resulting structure. More specifically, the building structure comprises a foundation to which is attached a framework composed of steel or other structural material. This framework further comprises interconnected support members with interstices therebetween, the interstices filled with panels of expanded polystyrene (hereinafter EPS), the framework and the EPS together defining weight-bearing walls, with both surfaces of the walls being covered with additional panels of EPS. In addition, there are unique flooring and roofing structures comprising EPS as well as with novel construction techniques.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially exploded perspective view of a two-story building constructed in accordance with the present invention with the roof omitted for clarity.

FIG. 2 is a front elevational view of three of the foundation plate assemblies used to attach the wall framework to the foundation segments including the rods connecting the foundation plate assemblies to each other.

FIG. 3 is a front elevational view of a foundation plate assembly.

FIG. 4 is a side elevational view of the foundation plate assembly of FIG 3.

FIG. 5 is a top view of the foundation plate assembly of FIG 3.

FIG. 6 is a perspective view of foundation plate assemblies attached to a slab foundation.

FIG. 7 is a fragmentary partially exploded view of a foundation plate assembly and the slab to which it is attached.

FIG. 8 is a perspective partially exploded view showing foundation segments, joists and EPS sheets used to construct the first floor.

FIG. 9 is the same view of FIG. 8 with I-beams being used instead of joists.

FIG. 10 is an enlarged perspective partially exploded view showing the attachment of joists to the foundation segments using joist hangers.

FIG. 11 is a front elevational view of a framework for a weight- bearing wall as well as a foundation segment, first floor joists, foundation plate assemblies, and second floor joists and joist hangers.

FIG. 12 is a front view of a stud used in the framework for a weight-bearing wall.

FIG. 13 is a side view of the stud of FIG. 12. FIG. 14 is a top view of the stud of FIG. 12.

FIG. 15 is a top view of a multi-level cross fitting.

FIG. 16 is a side elevational view of the multi-level cross fitting of FIG. 15.

FIG. 17 is a front elevational view of the multi-level cross fitting of FIG. 15.

FIG. 18 is a side elevational view of multi-level corner fitting (15e).

FIG. 19 is a top view of the multi-level corner fitting of FIG. 18.

FIG. 20 is a front elevational view of the multi-level corner fitting of FIG. 18. FIG. 21 is a front view of a header.

FIG. 22 is a side view of the header of FIG. 21.

FIG. 23 is a top view of the header of FIG. 21.

FIG. 24 is a front elevational view of a combination header and joist hanger. FIG. 25 is a top view of the combination header and joist hanger of

FIG. 24.

FIG. 26 is a side view of the combination header and joist hanger of FIG. 24. FIG. 27 is a top view of a single-level "T" fitting.

FIG. 28 is a front view of the single-level "T" fitting of FIG. 27.

FIG. 29 is a side view of the single-level "T" fitting of FIG. 27.

FIG. 30 is a top view of a single-level "L" fitting. FIG. 31 is a side view of the single-level "L" fitting of FIG. 30.

FIG. 32 is a perspective partially exploded view of the building of the invention showing the roofing structure including truss joists, panels of EPS and a ridge board.

FIG. 33 is a side elevational view of the roofing structure of the invention featuring truss joists, truss joist fittings, and a ridge board.

FIG. 34 is a magnified side elevational view of a portion of the roofing structure of FIG. 33 showing a truss joist, part of the framework for a weight-bearing wall, and the truss joist fitting used to attach the truss joist to the framework. FIG. 35 is a side view of the swivel member used in cooperation with the truss joist bracket to attach the truss joist to the framework.

FIG. 36 is a front view which shows the relationship between the swivel member of FIG. 35 and the truss joist bracket with which it cooperates. FIG. 37 is a side view of a truss joist bracket.

FIG. 38 is a top view of a truss joist fitting holder.

FIG. 39 is top view of a "T" fitting truss joist fitting holder.

FIG. 40 is a side view of the "T" fitting truss joist fitting holder of FIG. 39. FIG. 41 is a perspective view of an "L" fitting truss joist fitting holder.

FIG. 42 is a side view of the "L" fitting truss joist fitting holder of FIG. 41. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Product:

A building incorporating various features of the present invention is illustrated in FIG. 1. As in all of the accompanying drawings, the numeral relating to an element denotes the element itself, while the letter following the numeral relates to the relative location of such an element. For example, (3a) would identify the element (3) located in the a position. An element labeled merely (3) would refer to the element (3) without regard to its relative position. This figure depicts a building containing two stories. However, according to the methods described herein the building may contain more or less than two stories. The building contains a poured concrete foundation which is divided into foundation segments (la,lb), each segment (la,lb) including a footing portion (V) and a wall portion (1"), which supports a first floor (2), a framework for a weight-bearing wall composed of lower vertical support members (3a-3d) connected to the top of foundation segment (la), upper vertical support members (3e-3h) connected to the upper ends of lower vertical support members (3a-3d), horizontal support members (4a-4f), and connecting members (15a-15h), also referred to as fittings, which connect the vertical support members (3a-3h) to the horizontal support members (4a-4f) and to each other. FIG. 1 also shows an EPS panel (5) ready for insertion into the spaces (interstices) between the members of the framework, an EPS panel (6) ready for attachment to the exterior surface of a weight-bearing wall formed by the framework and the first EPS panel (5), an EPS panel (7) ready for attachment to the interior surface of the weight-bearing wall and a roofing structure to be described later. As will be pointed out later, a slab foundation could be used and the first floor would not be necessary. FIG. 1 also shows an interior (non weight-bearing) wall (8) constructed of EPS. The framework is attached to the foundation segment (la) by means of a series of mounting members (lla-lld). In this example there are four such mounting members but that number is purely exemplary. Naturally, greater or fewer than this number may be used. The mounting members are components of a series of foundation plate assemblies (9) as shown most clearly in FIGS. 2, 3, 4 and 5. The foundation plate assemblies include foundation plates (10), mounting members (11) affixed to foundation plates (10), and posts (12) attached to the foundation plates and embedded in the foundation segment. As best illustrated in FIGS. 2, 3, 4, and 5, each foundation plate (10) preferably consists of a planar steel plate, square or rectangular in shape, with an upper surface and a lower surface. The mounting member (11) would typically be attached to the upper surface of the foundation plate (10) normal to the plane of the plate and near one corner thereof. The mounting member (11) may be affixed to the foundation plate (10) by welding or the like. As shown in FIGS. 3, 4, and 5, the mounting member (11) is preferably tubular in shape with a square cross-section, about 3"X3", and one foot high. The posts (12) are attached to the lower side of the foundation plates (10) by means of welding or such. In this case there are two posts (12) per foundation plate (10). This is best seen in FIGS. 3 and 5. Typically, the posts would be attached normal to the plate along a line midway between opposite edges of the foundation plate as can be seen in FIGS. 3, 4 and 5. The posts (12) may conveniently have holes (13) drilled through them for attachment to adjacent foundation plate assemblies (9) using rods (14). In FIGS. 2, 3 and 4 each post contains four such holes (13a-13d) arranged one above the other with each hole facing the same direction, that is to say that the axes of the holes are parallel to each other. As seen in FIG. 2, rods (14) connect adjacent foundation plate assemblies (9a-9c). The uppermost two rods (14a and 14b) attach to the posts (12b) of a foundation plate assembly (9b) via the uppermost holes (13a' and 13b') in the posts (12b) and also attach to the posts of a first adjacent foundation plate assembly (9a) via the uppermost holes (13a" and 13b") in the posts (12a) of the first adjacent foundation plate assembly (9a). The posts (12b) of the foundation plate assembly (9b) are also connected to the posts (9c) of a second adjacent foundation plate assembly (9c) by means of rods (14c and 14d). The second adjacent foundation plate is located in a direction opposite (180° from) the direction of the first adjacent foundation plate (9a) relative to the foundation plate assembly (9b). Rods (14c and 14d) are attached to the posts (12b) of the foundation plate assembly (9b) via the two lowermost holes (13c' and 13d') and are attached to the posts (12c) of the second adjacent foundation plate assembly (9c) via the two lowermost holes in the posts (13c"' and 13d'") of the second adjacent foundation plate assembly (9c). This is done in alternating fashion such that each foundation plate assembly, except each foundation plate assembly at the end of a foundation segment, is attached to adjacent foundation plate assemblies by two rods in one direction and two rods in the opposite direction. In this way the foundation plate assemblies (9), and consequently the mounting members (11) form rows. The rods may be threaded to allow attachment using locking nuts (not shown). Additionally, the holes (13) in the posts (12) of one foundation plate assembly are preferably arranged coaxially with the holes in the posts of the adjacent foundation plate assembly thereby allowing the rods (14) to easily penetrate the corresponding holes (13) in each post (12) of each foundation plate

11

SUBSTTTUTE SHEET (RULE 26) assembly (9).

The foundation plate assemblies (9) are typically located approximately four feet apart from each other and along an axis equidistant from the longitudinal sides of the foundation segment (1), and are configured such that vertical mounting members (lla and lid) are placed at the ends of each foundation segment (1).

In the case of a slab foundation, as shown in FIGS. 6 and 7, the foundation plate assemblies are placed around the slab (25) near the perimeter. The foundation plate assemblies for the slab (26) may differ from those of a poured foundation in that the posts (12) in FIGS. 3, 4, and 5 of the foundation plate assemblies for a poured foundation may be omitted and the foundation plate (10) for the slab may be affixed to the slab with steel bolts (27) or the like. The mounting members (11), however, are affixed to the top of the foundation plates (10) in much the same manner as with the foundation plates for a poured foundation

(refer to FIGS. 3, 4 and 5). In addition, a layer of EPS (28) is preferably positioned between the ground and the slab (25) for added insulation, pest control, and as a moisture barrier.

As made clear in FIGS. 1, 8, and 9, in the case of a poured foundation, a first floor is supported by joists (30) spanning the distance between a first foundation segment (la) and a second foundation segment (lb). The second foundation segment (lb) is parallel to and spaced a distance from the first foundation segment (la). A particularly convenient way of attaching the joists (30) to the foundation is to form ledges (31) on the interior walls of the foundation segments (la and lb) as shown in FIGS. 1 and 8. The joists (30) may then be set upon the ledges (31) and affixed to the foundation segment (1) using standard methods in the industry such as brackets etc. The joists (30) are

12

SUBSTTTUTE SHEET (RULE 26) generally horizontal, parallel to one another and separated by a distance to be determined by building plans using as considerations load bearing requirements, expense, and other factors. Typically, the joists will be separated from each other by about two feet. One preferred joist is the Residential TJI^®/25 joist manufactured by Truss Joist Co. of Valdosta, Georgia USA. The spaces (32) between the joists (30) are filled with sheets of EPS (35) as best shown in FIG. 8 thereby increasing the strength of the floor, as well as providing fire protection and soundproofing. Typically, the sheets of EPS (35) will be 9"X22" and will vary in length depending on building plans. I-beams (33) may also be used to support the first floor. As shown in FIG. 9, the I-beams (33) may be set directly into the foundation segments (la and lb). FIG. 10 illustrates another preferred means of attaching the first floor joists (30) to the poured foundation by the use of joist hangers (40) attached to the foundation and the joists. No matter how the floor joists (30 or 33) are affixed to the foundation segments (1), sheets of EPS (35) are contained within the spaces (32) between the floor joists. The floor joists (30) may be covered with plywood or other conventional subflooring, (42) in FIG. 1. The subflooring is covered with any conventional flooring material. In the case of a slab foundation the installation of the first floor joists is omitted because the slab itself will constitute the first floor.

Details of the framework will now be discussed. As best shown in FIGS. 1 and 11, a vertical support member (3) (also referred to as a stud) is attached to each mounting member (11). As shown in FIGS. 1, 7 and 11, the foundation plate assemblies (9) are positioned such that there is a mounting member (lla, lid) located at the end of each foundation segment (1). In this embodiment that would be at the corners of the building. In FIG. 11 the posts (12) are omitted for clarity. A stud (3)

13

SUBSTTTUTE SHEET (RULE 26) fits over each mounting member (11) and is rigidly affixed thereto. Each stud (3) is similar in cross section to each mounting member (lϊ) and sized to fit over the mounting member (11) in close relationship. This can best be seen in FIGS. 11 and 14. Referring now to FIGS. 12, 13, and 14 the stud (3) is typically square in cross section, 8 feet in length and is shown with bolt holes (45) proximate one end of the stud (3) to facilitate attachment to the mounting members (11).

In the case of a multiple-story dwelling, cross-fittings (15) attach to the upper end of each stud (3) for affixing a second floor and additional framework members. At all but the corner studs (3a, 3d), cross-fittings (15f, 15g) are used. These are shown in FIGS. 1, and 11. Slightly modified cross fittings (corner fittings) (15e, 15h) are used at the corner studs (3a, 3d). These are also shown in FIGS. 1 and 11. A multi-level cross-fitting (15f) is more closely illustrated in FIGS. 15, 16, and 17. Obviously, multi-level cross fitting (15f) is identical in structure to multi¬ level cross fitting (15g). Each cross fitting (15f, 15g) comprises a central body portion (50) with two horizontal tubular arms (52) and two vertical tubular arms (51) extending therefrom, the vertical arms (51) being rectangular in cross-section and dimensioned to fit closely within the studs (3b, 3c), in similar fashion to the attachment of the lower ends of the studs (3) to the vertical mounting members (11). In the embodiment of FIGS. 15, 16 and 17, the central body portion (50) is depicted as a short length of tubular material with a square cross section and having interior and exterior dimensions similar to those of the vertical studs (3). The tubular arms (51, 52) are coplanar and mutually peφendicular with each other. Additionally, arms (51) are coaxial with each other and arms (52) are coaxial with each other. Conveniently, the arms may be established in the aforementioned relationship with each other by the

14

SUBSTTTUTE SHEET (RULE 26) following means. A tubular member (55), which will comprise the vertical arms of the cross fitting (15f), of dimensions in cross-section equal to those of the vertical mounting members (11) is passed through the central body portion (50) such that the arms (51) protruding from the central body portion (50) are approximately of equal lengths on each side of the body portion (50). Two horizontal arms (52), coaxial with each other and of the same dimensions as the protruding arms (51) are attached normal to two opposite sides of the central body portion (50) as shown to establish the coplanar and peφendicular relationship of the four arms. The vertical tubular member (55) and the two horizontal arms (52) may be attached to the central body (50) by welding or other suitable means. In this way four square-in-cross-section arms extend from the central body portion and form a cross. Other methods of manufacturing known in the art may be employed to construct the fittings, such as casting the entire fitting as a unit, or welding each horizontal arm (52) and each vertical arm (51) to the central body portion (50).

One of the vertical arms (51) of the cross-fittings (15f, 15g) is inserted vertically downward into the stud (3) such that the two horizontal arms (52) extend horizontally in the direction of adjacent studs and one vertical arm (51) extends vertically upwards.

At the corner studs (3a, 3d), modified cross-fittings know as multi¬ level corner fittings (15e, 15h) are used instead of the previously described cross fittings (15f, 15g). The location and basic structure of the corner fittings (15e, 15h) are shown in FIGS. 1 and 11. A corner fitting (15e) is more closely depicted in FIGS. 18, 19, and 20. It is constructed in similar fashion to the cross-fittings (15f, 15g), but the horizontal arms (60) are attached normal to adjacent sides of the central body portion (50) rather than to opposite sides so that the horizontal arms (60) form a ninety degree angle as viewed from above.

One vertical arm (51) of each corner fitting (15e, 15h) is inserted into the top of each corner stud (3a, 3d) such that each horizontal arm on each corner fitting points toward an adjacent horizontal arm belonging to a cross-fitting attached to a stud on an adjacent wall. Bolt holes (62) may be provided on the vertical arms (51) of the corner fittings (15e, 15h) and the cross-fittings (15f, 15g) to facilitate installation. These bolt holes (62) may conveniently line up in registry with holes (45) in the studs (3) as shown in FIG. 12.

Referring to FIG. 1, the horizontal arms (52) of the cross-fittings (15f, 15g) and the horizontal arms (60) of the corner fittings (15e, 15h) are connected to each other by means of horizontal support members known as headers (4). Headers (4a, 4c) span the distance between the horizontal arms (52) of the cross fittings (15f, 15g) and the horizontal arms (60) of the corner fittings (15e, 15h), while header (4b) spans the distance between the horizontal arms (52) of adjacent cross-fittings (15f, 15g). The headers (4) are constructed as shown in FIGS. 21, 22, and 23. The headers (4) comprise an elongate member, "U" shaped in cross- section, with the corners of the "U" being squared-off. The dimensions of the three sides of the "U" are similar to the dimensions of the four sides of the square seen in the cross-section of the studs (3), and the headers (4) are preferably approximately four feet in length. Put another way, the headers match the cross-sectional dimensions of the studs (3) with one side removed. Therefore, the headers (4) will fit closely over the horizontal arms (52) of the cross-fittings (15f, 15g) and the horizontal arms (52) of the corner fittings (15e, 15h) which are of outer dimensions matching those of the vertical mounting members (11). The headers (4)

16

SUBSTTTUTE SHEET (RULE 26) may be conveniently attached to the cross-fittings (15f, 15g) and to the corner fittings (15e, 15h) by means of bolts (not shown) passing through holes (65) in the headers (4) placed in registry with holes (61) in the horizontal arms (52) of the cross fittings (15f, 15g) and the holes (61) in the horizontal arms (60) of the corner fittings (15e, 15h). In this way an entire framework can be established from which to support a second floor. Note that at each corner-fitting and at each cross-fitting there remains an unused vertical arm (51). These will be used to support second story studs and will be dealt with later. A second floor is attached to the headers (4) using joist hangers

(40) as depicted in FIG. 10. or any other method of attachment known in the industry. Alternatively, a combination header and joist hanger (70) shown in FIGS. 24, 25 and 26 may be used to support the second floor joists. The combination header and joist hanger (70) is constructed similarly to the header (4) depicted in FIGS. 21, 22 and 23. However, one vertical side (72) of the header (4) is extended to accommodate the vertical height of the joist. The combination header and joist hanger (70) is also provided with a horizontal ledge (74) upon which the edge of the joist will lie. The joist may then be affixed to the combination header and joist hanger by means of brackets or the like. As in the embodiment using the headers (4), the combination header and joist hanger (70) will span the distance between the horizontal arms (52) of the cross fittings (15f, 15g) and the horizontal arms (60) of the corner fittings (15e, 15h). The combination header and joist hangers (70) may be attached to the horizontal arms (52 and 60) via means similar to those used to attach the headers (4). In similar fashion to the first floor joists, the spaces between the second floor joists are filled with panels of EPS.

Second story studs (3e, 3f, 3g, 3h) are affixed to the remaining

17

SUBSTTTUTE SHEET (RULE 26) unused vertical arms (51) extendmg from the corner fittings (15e, 15h) and the cross-fittings (15f, 15g). Holes (62) in the vertical arms (51) of the cross-fittings (15f, 15g) and holes (62) in the vertical arms (51) of the corner fittings (15e, 15h) may be placed in registry with the holes (45) in the ends of the second story studs (3e-3h) to facilitate connection between the vertical arms (51) and the second story studs (3e-3h) using bolts, screws, rivets etc. (not shown). Once the appropriate number of floors have been built using the framework and joist system, a ceiling and roof is affixed to the uppermost end of the uppermost stud. In the embodiment of FIGS. 1 and 11, it would be after installation of the second floor. There are attached to the upper ends of the studs (3e-3h) ceiling fittings (15a-15d) which allow for attachment of a ceiling and roof. At all but the corner studs (3e, 3h), "T" type fittings (15b, 15c) shown in Figs. 1 and 11, attach to the upper end of the hollow studs (3f, 3g). The fittings (15b, 15c) are dimensioned to fit inside the studs (3f, 3g) in the same way as the fittings (15e-15h) for the second floor are dimensioned to fit inside the studs (3a-3d). "T" fitting (15b) and T" fitting (15c) are structurally identical. As shown more closely in FIGS. 27, 28, and 29, each "T" fitting comprises a central body portion (80), and connected thereto are two horizontal arms (82) and one vertical arm (84). The arms are arranged such that the two horizontal arms (82) are coaxial with each other and the vertical arm (84) is peφendicular to the other two. In the embodiment of FIGS. 27, 28, and 29, the central body portion (80) is depicted as a short length of horizontal hollow tubular structural material, square in cross section. Through the tube passes another square-in-cross-section tube (86) dimensioned to fit closely within the body portion (80) but long enough that two equal sized arms (82) protrude from the central body portion (80). The two protruding arms (82) will constitute the horizontal arms of the "T" fittings (15b, 15c). A vertical arm (84) is then affixed, via welding or the like, normal to a side of the central body portion in order to establish the proper peφendicularity between the three arms. The vertical arm (84) is dimensioned to fit closely within the vertical studs (3f, 3g) and is square in cross section. The vertical arms (84) of the "T" fittings may be equipped with bolt holes (85) for attachment to the studs in similar fashion to the second floor cross fittings (15f, 15g) and the second floor corner fittings (15e, 15h). The fittings are attached to the upper ends of the vertical studs (3f,

3g) and are configured such that the horizontal arms (82) of one fitting (15b) are along the same axis as the horizontal arms (82) of an adjacent fitting (15c) although a substantial distance will exist between them. At the corner studs (3e, 3h) modified fittings (15a, 15d) ("L" fittings) are affixed to the upper ends of the vertical studs (3e, 3h) and are slightly different in configuration. As shown in FIGS. 30 and 31, the "L" fitting contains a central body portion (80), similar to that of the " fitting, but affixed to the central body portion (80) are three depending arms; one vertical arm (90), and two horizontal arms (92). The horizontal arms (92) are coplanar but arranged at a ninety-degree angle in relation to each other in order to allow connection between the fittings on one wall and the fittings on an abutting wall. The vertical arm (90) is inserted into the top of corner stud (3e) such that the horizontal arms (92) of the "L" fitting (15a) are configured to be coaxial with the horizontal arms (82) belonging to the T fittings on abutting walls. The vertical arms (90) of the "L" fittings (15a, 15d) may be equipped with bolt holes (94) for attachment to the corner studs (3e, 3h) in the same fashion as the other fittings. Abutting weight-bearing walls, not shown

19

SUBSTTTUTE SHEET (RULE 26) completely in FIG. 1, are similar in structure to the weight-bearing wall depicted in FIGS. 1 and 11. The abutting walls may be attached to a foundation segment similar to the foundation segment (la) of the wall depicted in FIGS. 1 and 11 although the ledge (31) may be omitted. The foundation segment of each wall is preferably continuous with the foundation segment of an abutting wall as is typical in the industry for building wood-framed houses and the like.

Ceiling headers (4d-4f) span the distance between the "L" and "T" fittings. The headers (4d-4f) are constructed as are the second story headers shown in FIGS. 21, 22 and 23 or, alternatively, they are constructed as are the combination header and joist hangers of the embodiment shown in FIGS. 24, 25 and 26. The headers may be conveniently attached to the "T" fittings (15b, 15c) and "L" fittings (15a, 15d) by the use of bolts fitting through holes (65) in the headers (4d-4f) placed in registry with holes (96) in the horizontal arms (92) of the "L" fittings (15a, 15d) and with the holes (96) in the horizontal arms of the " fittings (15b, 15c) (See FIGS. 27-31). Similarly, the studs (3) may be affixed to the vertical arms of the fittings (15) and to the vertical mounting members (11) of the foundation plate assemblies (9) by bolts passing through holes (45) in the studs (3) and matching holes in the vertical arms of the fittings (15) or the mounting members (11.) This framework structure is exemplary, and other frame structures, such as those forming geodesic domes, may be used instead. The ceiling headers (4d-4f) support ceiling joists which may be identical to the joists used for the first and/or second floors. The ceiling joists span the distance between opposite walls of the framework in much the same way as the floor joists, and may be attached to the ceiling headers (4d-4f) in the same fashion the second floor joists are attached to the second floor headers (4a-4c). In similar fashion to the floor joists, the spaces between the ceiling joists may be filled with panels of EPS. In a preferred embodiment, the ceiling is vaulted. In the case of a vaulted ceiling, the ceiling joists are omitted and the roof is attached to the ceiling headers (4d-4f).

The roof is also constructed of a series of joists (98) as best seen in FIGS. 32 and 33. These joists (98), known as truss joists, are attached to the ceiling headers (4d-4f) by means of special truss joist fittings (100) shown best in FIGS. 33 and 34. The fittings are made up of two major components; swivel members (102) and truss joist brackets (108). These are shown in detail in FIGS. 35, 36 and 37. The bracket (108) is generally U-shaped in cross-section with squared-off corners and projects longitudinally for a distance of about one foot and is dimensioned such that when the open side is up, the joist (98) may fit within its confines. The side walls (110) of the bracket (108) are conveniently equipped with holes (112) for attachment of the truss joist (98) to the bracket using bolts and nuts (not shown). On the underside of the bracket, located near one end thereof, and midway between the longitudinal edges of the bracket is a lug (114) containing a hole (116) therein. This lug (114) is designed to cooperate in moveable fashion with the swivel member (102). The swivel member (102) comprises a swivel head (104), with a threaded shank (105) depending therefrom. The swivel head (104) may be constructed of steel or the like and is essentially a trough, U-shaped in cross section with squared-off corners, and contains side walls (106) which appear as semicircles in side view, as seen in FIGS. 35 and 36. The swivel head (104) is dimensioned to allow the lug (114) of the truss joist bracket (108) to fit within the trough of the swivel head (104) and bolt holes (107) are provided in the sidewalls (106) of the swivel head

21

SUBSTTTUTE SHEET (RULE 26) (102) to facilitate attachment between the lug (114) of the truss joist bracket (108) and the swivel head (104) using bolts (not shown) passing through the holes (107) in the sidewalls (106) of the swivel head (104) placed in registry with the holes (116) of the lug (114) of the truss joist bracket (108). This is best seen in FIG. 36. It is important to note that the bottom of the lug (114) does not reach the bottom of the trough of the swivel head (104) when the truss joist bracket (108) is secured in place. In operation, the truss joist bracket (108) is therefore free to be adjusted around the axis of the bolt. In this way, the angle of the truss joist (98) which is connected to the truss joist bracket (108) may be adjusted with respect to the plane of the ceiling.

FIGS. 33 and 34 illustrate the positioning of the truss joist fittings (100) relative to the wall framework and the roof truss joists (98). The truss joist fittings (100) are affixed to the uppermost headers (4d-4f) in FIGS. 1 and 11) via the threaded shank (105) of the roof joist swivel members (102), preferably every two feet. In a preferred embodiment, the truss joist fittings (100) are attached to the headers (4d-4f) by means of truss joist fitting holders (120 in FIG.38) placed between the headers (4d-4f) and the truss joist fittings (100). The truss joist fitting holder (120) comprises a plate (121) constructed of steel or the like whose width is approximately that of the corresponding header (4d-4f). The truss joist fitting (100) may be secured to the truss joist fitting holder (120) by means of the threaded shank (105) of the truss joist fitting swivel member (102) by inserting the shank (105) through the hole (123) in the truss joist fitting holder (120) and bolting it in place. The truss joist fitting holder (120) may simply be bolted to the top of the header where it is desired to place a truss joist fitting (100) using bolt holes (122) placed in registry with holes drilled in the headers (4d-4f). The truss joist fitting

22

SUBSTTTUTE SHEET (RULE 26) holders (120) provide additional structural support and facilitate installation of the truss joist fittings (100). At the locations of the "T" fittings (15b and 15c in Figs. 1 and 11) and "L" fittings (15a and 15d) modified truss joist fitting holders are placed. The "T" fitting truss joist fitting holder (130) is illustrated in FIGS. 39 and 40 while the "L" fitting truss joist fitting holder (140) is illustrated in FIGS. 41 and 42. The T fitting truss joist fitting holder (130) is similar to the truss joist fitting holder (120) except that a square-in-cross section tubular member (132) is connected to the plate (134). The tubular member (132) is affixed normal to the plate (134) by means of welding or the like in such a way that the tubular member can be inserted into a square hole cut into the top of the T fittings (15b, 15c). In this way the plates (134) extend along the top of the headers (4d-4f) and are flush therewith, and may be attached to the headers (4d-4f) using bolts fitting through holes (136) in the plate (134) and fitting through matching holes drilled into the top of the headers (4d-4f). The tubular member (132) provides additional stability at the locations of the T fittings. The "L" fitting truss joist fitting holders (140) are slightly different in configuration to accommodate the corner location of the "L" fittings. The plate (142) is shaped as a symmetrical "L" containing a 90 degree angle between the legs (142a and 142b) of the plate (142). The legs (142a, 142b) of the plate (142) are dimensioned to approximate the width of the headers to which they will attach. A square-in-cross-section tubular member (144) is affixed normal to the plate (142) at its corner via welding or the like such that the tubular member (144) will fit into a square hole cut into the top of the "L" fittings (15a, 15d) and the legs (142a, 142b) will overlie the top of the headers associated with adjacent walls. As with the other truss joist fitting holders, the plate (142) of the "L" fitting truss joist fitting

23

SUBSTTTUTE SHEET (RULE 26) holder (140) is equipped with bolt holes (145) for securing the plate to the tops of the headers. Additionally, the "L" fitting truss joist fitting holder contains a hole (146) in the corner of the plate (142), midway between the edges for attachment of the threaded shank (105) of the truss joist fitting swivel member (102) to the "L" fitting truss joist fitting holder.

Referring to FIGS. 32, 33 and 34 the truss joists (98) for a gable- type roof are attached to the truss joist brackets (108) of the truss joist fittings (100) in parallel spaced apart relation, peφendicular to the uppermost headers (4d-4f) and extend upwardly from the plane of the ceiling. Similarly, truss joists (98) extend from the opposite wall of the structure and meet the first set of truss joists at a ridge board (150) somewhere between the opposite walls, where they are secured. The spaces between the truss joists (98) are filled with sheets of EPS (152 in FIG. 32) as described previously with respect to the floor and ceiling joists to increase the structural strength of the roof system, and to provide insulation and a sound barrier. This is shown in FIGS. 32 and 33 in relation to a gable-type roof, wherein the roof trusses (98) slope upwardly from the plane of the ceiling, although other roofing styles are possible using the same or similar structural components. The roof trusses (98) are then covered with plywood sheathing or the like (154) and the sheathing (154) is further covered with traditional roofing materials such as shingles, tile, galvanized or pre-painted steel or the like. A moisture-proof material such as foil is desirably placed between the EPS (152) of the roof and the sheathing material (154). If ceiling joists are used, there will be created an attic between the ceiling joists and the roof.

In the case of a single-story dwelling, the "L" fittings (15a, 15d) and

24

SUBSTTTUTE SHEET (RULE 26) the "T" fittings (15b, 15c) would be positioned atop the first set of studs (3a-3d) and the roof would be positioned the same as in a multi-story dwelling atop the "L" fittings (15a, 15d), the "T" fittings (15b, 15c) and the headers (4d-4f) associated with the "L" and " fittings using the truss joist fittings and truss joist fitting holders previously described in relation to a multi-story dwelling.

The weight-bearing walls of the structure comprise the aforementioned framework and three layers of EPS. As shown in FIG. 1, an insulative layer of EPS (5) fills the spaces (interstices) defined by the framework composed of the vertical studs (3) and the horizontal headers (4). The EPS insulation is preferably dimensioned to fit within the interstices of the framework. This can be accomplished by providing a rectangular sheet of EPS with shoulders (5') cut out of the upper corners of the sheet of EPS (5) to accommodate the fittings (15) and the portion of the EPS sheet (5") between the shoulders being somewhat thinned in order to fit inside the open bottom portion of the horizontal headers (4). External panels of EPS (6) and internal panels of EPS (7) are affixed to the framework and insulation structure by means of e.g. adhesives to complete the exterior (weight-bearing) wall structure. The internal panels of EPS (7) preferably contain rectangular-in-cross-section airflow cavities (7'). In the case of a vaulted ceiling, the internal EPS panels (7) and the external EPS panels (6) extend all the way up to the roof truss joists (98) and are dimensioned to fit snugly against the roof truss joists (98) and the panels of EPS (152) inserted between the roof truss joists (98). Some or all of the airflow cavities (7') may connect with the central air and heat exchange system. Interior wall (8) may be placed where desired using metal angle irons (8',8") or the like as attachment means.

The exterior surface (6') of the external panels (6) of the exterior

25

SUBSTTTUTE SHEET (RULE 26) (weight-bearing) walls may be finished with conventional housing materials such as siding, stucco, paint etc. Various fire-rated finishes can be applied to the exterior surface (7") of internal panels (7) of the exterior (weight-bearing) walls as well as to the ceiling and to the surfaces of the interior walls (8) as pre-formed sheets, stucco or paint spray applications, as well as hand brushed or trowelled finishes.

Method: Once the structural elements and their relationship to each other is understood, the method for building the structure is relatively straightforward.

The preliminary preparations for a building site are conducted in standard fashion: a location is chosen, the topsoil is removed, and the ground is terraced or leveled as needed.

In the case of a poured foundation, forms are prepared in accordance with the building plans for the construction of a concrete foundation. Generally, the forms are made of plywood or the like as is well known in the building industry. Referring to FIG. 1, the forms (not shown) are constructed such that after they are filled with poured concrete, the concrete allowed to harden, and the forms removed, there will be a foundation segment (1) on the ground wherever a weight- bearing wall is to be placed. The foundation (1) will contain a footing portion (1') and a wall portion (1"). As with a traditional poured foundation, provision may be made for access holes, vents, conduits etc. wherever needed. Once the forms are properly placed, foundation plate assemblies, (9a-9c) in Fig. 2, and connecting rods (14) are positioned within the form such that once the cement has hardened, the foundation plate assemblies, (9a-9c) will be retained within the walls (1") of the foundation segment (1) with the foundation plates (10) being essentially flush with the top of each wall (1") of each foundation segment (1). The cement is then poured inside the forms, thereby surrounding the foundation plate assemblies (9) and the connecting rods (14), and allowed to harden. In this way a foundation is constructed with foundation plate assemblies (9) firmly integrated with the walls (1") of the foundation segment (1) via the posts (12) and the rods (14) which have become embedded in the cement. The foundation plates (10) are essentially flush with the tops of the walls (1") of the foundation segments (1) and the mounting members (11) attached to the foundation plates (10) extend vertically upwards.

The joists (30) for the first floor are then attached to the interior surfaces of the walls (1") of the foundation segments (1) either via the use of joist hangers, (40) in FIG. 10, or via ledges (31) formed on the interior surfaces of the walls (1") of the foundation segments (1). These ledges, (31) in FIGS. 1 and 8, may easily be formed during construction of the foundation by shaping the forms appropriately. After installation of the floor joists (30), sheets of EPS (35) are placed between the joists (30). The floor joists are then covered with the subfloor (42).

Referring to FIGS. 6 and 7, in the case of a slab foundation, after the soil is prepared, a layer of EPS (28) is placed on the ground and a concrete and wire mesh slab (25) is constructed on top of the layer of EPS (28). Then the foundation plate assemblies for the slab (26) are affixed to the surface of the slab (25) around its perimeter using steel bolts (27) as described above. Naturally, in the case of a slab foundation the installation of the first floor joists (30) is omitted as the slab (25) itself will constitute the first floor. In this way, the mounting members

27

SUBSTTTUTE SHEET (RULE 26) (11) for the slab are positioned in much the same way as are the mounting members (11) for the poured foundation. From this point on, construction proceeds in the same way for a slab and for a poured foundation. After the mounting members (11) are affixed to the foundation via the foundation plates (10), the framework is constructed. A stud (3) is placed over each of the mounting members (11) and rigidly affixed thereto as described in the "Product" section above. Once all the first story studs (3) have been attached to the mounting members (11), the fittings (15) are attached to the tops of the studs (3) as previously described in the "Product" section.

If the structure is to contain only a single story, the fittings (15) would be of the "T" type, for example (15b) shown in FIGS. 1, 11, 27, 28, and 29, except at the corners where "L" type fittings, for example (15d) shown in FIGS. 1, 11, 30 and 31 would be used. Headers (4) are then installed as described above in the "Product" section and the roof would be added at this stage. Construction of the roof will be covered later.

If a multistory dwelling is desired, the fittings (15) attached to the tops of the first set of studs (3) would be the multi-level cross fittings, for example (15f) depicted in FIGS. 1, 11, 15, 16 and 17, except at the corners where multi-level corner fittings, for example (15e) shown in FIGS. 1, 11, 18, 19 and 20, are installed. Then the headers (4), or the combination header and joist hangers, (70) in FIGS. 24, 25 and 26, are attached to the fittings (15) in the manner described above in the "Product" section.

Joists for a second story floor may now be installed as described above using joist hangers attached to the headers (4) or, in the alternative, the combination header and joist hangers (70). The joists are

28

SUBSTTTUTE SHEET (RULE 26) attached to the joist hangers or to the combination header and joist hangers (70) and span the distance between one weight-bearing wall and the weight-bearing wall on the opposite side of the structure. Once all the second floor joists have been installed, the spaces between the joists are filled with panels of EPS in the same way as was done with the first floor in the case of a poured foundation structure. A subfloor of plywood or the like may now be attached to the tops of the joists of the second floor as was done with the first floor (of a poured foundation structure). Second story studs (3) are then attached to the thus far unused vertical arm (51) of each fitting (15) in the manner described in the "Product" section above. "T" fittings, such as (15b) are attached to the upper ends of all second story studs, for example (3f), except at the corner studs, e.g. (3e), where "L" fittings, such as (15e) shown in FIGS. 1, 11, 18, 19 and 20 are used. If more than two stories are desired, this process of installing studs (3), fittings (15), headers (4), joists (30), panels of EPS (35), and subflooring (42) is repeated until the proper number of stories has been reached. The roof is then installed.

The roof is added to the top of the framework as described above in the "Product" section. If a roof with a ceiling and attic is desired, ceiling joists are attached to the uppermost headers (4d-f) in FIG. 1, or to the combination header and joist hangers, (70) in FIGS. 24, 25 and 26, the same as with the floor joists. If a vaulted ceiling is preferred, the joist hangers are omitted and headers (4) are used. Naturally, no ceiling joists would be installed. With either a vaulted ceiling or one with an attic, the roof is installed in the same fashion.

The truss joist fittings (100) are attached to the uppermost headers (4d-4f) in FIGS. 1 and 11 or the uppermost combination header and joist

29

SUBSTTTUTE SHEET (RULE 26) hangers (70) using the truss joist fitting holders (120) in FIG. 38, the "T" fitting truss joist fitting holders (130) in FIGS. 39 and 40 and the "L" fitting truss joist fitting holders (140) in FIGS. 40 and 41. The truss joists (98) in FIGS. 32, 33 and 34 are then attached to the truss joist fittings (100) as shown in the "Product" section and positioned such that the truss joists (98) attached to opposite sides of the structure meet at the ridge board (150) as shown in FIGS. 32 and 33. The spaces between the truss joists (98) are then filled with sheets of EPS (152) as shown in FIG. 32 and the roof is finished as described in the "Products" section. Referring to FIG. 1, the weight-bearing walls of the structure are completed by inserting the insulative sheets of EPS (5) into the interstices of the framework, and affixing to the combined framework and insulation structure external panels of EPS (6) and internal panels of EPS (7) by means of adhesives or the like. Prior to the insertion of the insulative panel of EPS (5) provision can be made for electrical conduits, plumbing pipes, fixtures etc. within the framework as dictated by the building plans.

Interior (non weight-bearing) walls (8) may then be placed within the structure wherever desired using angle irons (8', 8"). The structure is completed by placing appropriate finishes on the surfaces of the load- bearing and non load-bearing walls, as well as to the roof.

Provision is, of course, made for the installation of doors, windows etc. during construction as required by the building plans, and the location and dimensions of the support elements as well as the panels of EPS may be customized for this puφose. It is to be understood that while certain forms of the present invention have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of parts described and shown.

30

SUBSTTTUTE SHEET (RULE 26)

Claims

CLAIMSI claim:

1. A wall for a static structure comprising: a foundation on or in the ground; a structural framework attached to said foundation; said structural framework containing spaces therein; said spaces containing expanded polystyrene, said framework and said expanded polystyrene in combination defining a wall having an inside surface and an outside surface; said inside surface of said wall, said outside surface of said wall, or both of said surfaces being covered with a layer of expanded polystyrene.

2. A wall for a static structure comprising: a foundation on or in the ground; a plurality of vertical support members arranged in a row and extending substantially vertically from said foundation, said vertical support members having a lower end attached to said foundation and an upper end distal from said foundation; a plurality of horizontal support members, each of said horizontal support members having an elongate body with two opposite ends, said ends being attached to adjacent vertical support members in said row such that said horizontal support members extend substantially horizontally and span the distance between said adjacent horizontal support members, said vertical support members and said horizontal support members together establishing a framework for a wall, said framework containing interstices between said horizontal support members and said vertical support members; said interstices containing expanded polystyrene, said framework

31

SUBSTTTUTE SHEET (RULE 26) and said expanded polystyrene in combination defining a wall having an inside surface and an outside surface; said inside surface of said wall having affixed thereto a first layer of expanded polystyrene and said outside surface of said wall having affixed thereto a second layer of expanded polystyrene.

3. The wall of claim 2 wherein said expanded polystyrene contained within said interstices comprises preformed panels sized to fit said interstices.

4. The wall of claim 3 wherein said first layer of expanded polystyrene, said second layer of expanded polystyrene, or both of said layers comprise one or more preformed panels of expanded polystyrene, each of said panels having a first side affixed to said wall surface and a second side opposite the side affixed to said wall surface.

5. The wall of claim 4 wherein said preformed panel(s) of expanded polystyrene affixed to said inside and said outside surfaces of said wall are affixed by means of adhesive.

6. The static structure of claim 4 wherein said second side of said preformed panel(s) of expanded polystyrene affixed to said inner surface of said wall, said second side of said preformed panel(s) affixed to said outer surface of said wall, or both, are further covered with a layer of decorative or protective material.

7. The wall of claim 4 wherein said vertical support members comprise elongate beams.

8. The wall of claim 4 wherein said elongate beams comprise hollow tubular members.

9. The wall of claim 4 wherein said horizontal support members are attached to said vertical support members by means of fittings connecting said upper ends of said vertical support members to said ends

32

SUBSTTTUTE SHEET (RULE 26) of said horizontal support members.

10. A method of constructing a wall for a static structure comprising: providing a foundation on or in the ground; attaching to said foundation a plurality of vertical support members arranged in a row and extending substantially vertically from said foundation, said vertical support members having a lower end attached to said foundation and an upper end distal from said foundation; attaching a plurality of horizontal support members to said vertical support members, each of said horizontal support members having an elongate body with two opposite ends, said ends being attached to adjacent vertical support members in said row such that each of said horizontal support members extends substantially horizontally and spans the distance between said adjacent horizontal support members, said vertical support members and said horizontal support members together establishing a framework for a wall upon said foundation, said framework containing interstices between said horizontal support members and said vertical support members; introducing expanded polystyrene into said interstices, said framework and said expanded polystyrene together defining a wall, said wall having an inside surface and an outside surface; affixing to said inside surface of said wall a first layer of expanded polystyrene and affixing to said outside surface of said wall a second layer of expanded polystyrene.

11. The method of claim 10 wherein said expanded polystyrene introduced into said interstices comprises preformed panels sized to fit said interstices.

12. The method of claim 11 wherein said first layer of expanded

33

SUBSTTTUTE SHEET (RULE 26) polystyrene, said second layer of expanded polystyrene, or both of said layers comprise one or more preformed panels of expanded polystyrene, each of said panels having a first side affixed to said wall surface and a second side opposite the side affixed to said wall surface.

13. The static structure of claim 12 wherein said preformed panel(s) of expanded polystyrene affixed to said inside and said outside surfaces of said walls are affixed by means of adhesive.

14. The method of claim 12 wherein said second side of said preformed panel(s) of expanded polystyrene affixed to said inner surface of said wall, said second side of said preformed panel(s) affixed to said outer surface of said wall, or both are further covered with a layer of decorative or protective material.

15. The method of claim 12 wherein said vertical support members comprise elongate beams.

16. The method of claim 12 wherein said elongate beams comprise hollow tubular members.

17. The method of claim 12 wherein said horizontal support members are attached to said vertical support members by means of fittings connecting said upper ends of said vertical support members to said ends of said horizontal support members.

18. A static structure comprising; a concrete slab provided on the ground or on a layer of expanded polystyrene which is provided on the ground, said slab having a planar surface facing upwards, away from the ground; a plurality of vertical support members extending substantially vertically from said slab and arranged in rows, each of said rows being located wherever a weight-bearing wall is desired, with each of said vertical support members having a lower end proximate to said slab and

34

SUBSTTTUTE SHEET (RULE 26) an upper end distal from said slab; a plurality of horizontal support members, each of said horizontal support members having an elongate body with two opposite ends, said ends being attached to adjacent vertical support members in each of said rows such that said horizontal support members extend substantially horizontally and span the distance between said adjacent horizontal support members, said vertical support members and said horizontal support members together establishing frameworks for weight-bearing walls upon said slab, each of said frameworks containing interstices between said horizontal support members and said vertical support members; said interstices containing expanded polystyrene, said framework and said expanded polystyrene in combination defining weight-bearing walls, each of said weight-bearing walls having an inside surface and an outside surface; said inside surface of each of said weight-bearing walls having affixed thereto a first layer of expanded polystyrene and said outside surface of each of said weight-bearing walls having affixed thereto a second layer of expanded polystyrene.

19. The static structure of claim 18 wherein said expanded polystyrene contained within said interstices comprises preformed panels sized to fit said interstices.

20. The static structure of claim 19 wherein said first layer of expanded polystyrene, said second layer of expanded polystyrene, or both of said layers comprise one or more preformed panels of expanded polystyrene, each of said panels of expanded polystyrene having a first side affixed to said wall surface and a second side opposite the side affixed to said wall surface.

35

SUBSTTTUTE SHEET (RULE 26)

21. The static structure of claim 20 wherein said preformed ρanel(s) of expanded polystyrene affixed to said inside and said outside surfaces of said walls are affixed by means of adhesive.

22. The static structure of claim 20 wherein said second side of said preformed panel(s) of expanded polystyrene affixed to said inner surface of said weight-bearing walls, said second side of said preformed panel(s) affixed to said outer surface of said weight-bearing walls, or both, are further covered with a layer of decorative or protective material.

23. The static structure of claim 20 wherein said vertical support members comprise elongate beams.

24. The static structure of claim 20 wherein said elongate beams comprise hollow tubular members.

25. The static structure of claim 20 wherein said horizontal support members are attached to said vertical support members by means of fittings connecting said upper ends of said vertical support members to said ends of said horizontal support members.

26. A method of constructing a static structure comprising: providing on the ground a slab of concrete with or without a layer of expanded polystyrene between the ground and said slab, said slab having a planar surface facing upwards, away from the ground; attaching to said slab a plurality of vertical support members extending substantially vertically from said slab and arranged in rows, each of said rows being located wherever a weight-bearing wall is desired, with each of said vertical support members having a lower end proximate to said slab and an upper end distal from said slab; attaching a plurality of horizontal support members to said vertical support members, each of said horizontal support members having an

36

SUBSTTTUTE SHEET (RULE 26) elongate body with two opposite ends, said ends being attached to adjacent vertical support members in each of said rows such that each of said horizontal support members extends substantially horizontally and spans the distance between said adjacent horizontal support members, said vertical support members and said horizontal support members together establishing frameworks for weight-bearing walls upon said slab, each of said frameworks containing interstices between said horizontal support members and said vertical support members; introducing expanded polystyrene into said interstices, said framework and said expanded polystyrene together defining weight- bearing walls, each of said weight-bearing walls having an inside surface and an outside surface; affixing to said inside surface of each of said weight-bearing walls a first layer of expanded polystyrene and affixing to said outside surface of each of said weight-bearing walls a second layer of expanded polystyrene.

27. The method of claim 26 wherein said expanded polystyrene introduced into said interstices comprises preformed panels sized to fit said interstices.

28. The method of claim 27 wherein said first layer of expanded polystyrene, said second layer of expanded polystyrene, or both of said layers comprise one or more preformed panels of expanded polystyrene, each of said panels having a first side affixed to said wall surface and a second side opposite the side affixed to said wall surface.

29. The static structure of claim 28 wherein said preformed panel(s) of expanded polystyrene affixed to said inside and said outside surfaces of said walls are affixed by means of adhesive.

30. The method of claim 28 wherein said second side of said preformed panel(s) of expanded polystyrene affixed to said inner surface

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SUBSTTTUTE SHEET (RULE 26) of said weight-bearing walls, said second side of said preformed panel(s) affixed to said outer surface of said weight-bearing walls, or both are further covered with a layer of decorative or protective material.

31. The method of claim 28 wherein said vertical support members comprise elongate beams.

32. The method of claim 28 wherein said elongate beams comprise hollow tubular members.

33. The method of claim 28 wherein said horizontal support members are attached to said vertical support members by means of fittings connecting said upper ends of said vertical support members to said ends of said horizontal support members.

34. A static structure comprising: a foundation on or in the ground; a plurality of structural frameworks attached to said foundation, each of said structural frameworks being located wherever a wall is desired, said structural frameworks containing spaces therein; said spaces containing expanded polystyrene, said framework and said expanded polystyrene in combination defining walls having an inside surface and an outside surface, said inside surface of said walls, said outside surface of said walls or both of said surfaces being covered with a layer of expanded polystyrene.

35. A static structure comprising: a foundation on or in the ground, said foundation containing a foundation segment wherever a weight-bearing wall is to be erected, a plurality of vertical support members arranged in a row on each foundation segment and extending substantially vertically from said foundation segments, said vertical support members having a lower end attached to said foundation segments and an upper end distal from said

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SUBSTTTUTE SHEET (RULE 26) foundation segments, a plurality of horizontal support members, each of said horizontal support members having an elongate body with two opposite ends, said ends being attached to adjacent vertical support members in each of said rows such that said horizontal support members extend substantially horizontally and span the distance between said adjacent horizontal support members, said vertical support members and said horizontal support members together establishing frameworks for weight-bearing walls upon said foundation segments, each of said frameworks containing interstices between said horizontal support members and said vertical support members; said interstices containing expanded polystyrene, said framework and said expanded polystyrene in combination defining weight-bearing walls having an inside surface and an outside surface, said inside surface of said weight-bearing walls having attached thereto a first layer of expanded polystyrene and said outside surface of said weight-bearing walls having attached thereto a second layer of expanded polystyrene.

36. The static structure of claim 35 wherein said expanded polystyrene contained within said interstices comprises preformed panels sized to fit said interstices.

37. The static structure of claim 36 wherein said first layer of expanded polystyrene, said second layer of expanded polystyrene, or both of said layers comprise one or more preformed panels of expanded polystyrene, each of said panels of expanded polystyrene having a first side affixed to said wall surface and a second side opposite the side affixed to said wall surface.

38. The static structure of claim 37 wherein said preformed

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SUBSTTTUTE SHEET (RULE 26) panel(s) of expanded polystyrene affixed to said inside and said outside surfaces of said walls are affixed by means of adhesive.

39. The static structure of claim 37 wherein said second side of said preformed panel(s) of expanded polystyrene affixed to said inner surface of said weight-bearing walls, said second side of said preformed panel(s) affixed to said outer surface of said weight-bearing walls, or both, are further covered with a layer of decorative or protective material.

40. The static structure of claim 37 wherein said vertical support members comprise elongate beams.

41. The static structure of claim 37 wherein said elongate beams comprise hollow tubular members.

42. The static structure of claim 37 wherein said horizontal support members are attached to said vertical support members by means of fittings connecting said upper ends of said vertical support members to said ends of said horizontal support members.

43. The static structure of claim 35 wherein each of said foundation segments comprises a footing portion below ground level and a wall portion extending vertically from said footing portion, said wall portion having a bottom integral with said footing portion and a top opposite said bottom and extending above ground level.

44. A method for constructing a static structure comprising: providing a foundation on or in the ground, said foundation containing a foundation segment wherever a weight-bearing wall is to be erected, attaching to each of said foundation segments a plurality of vertical support members extending substantially vertically from said foundation segment and arranged in a row, with each of said vertical support

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SUBSTTTUTE SHEET (RULE 26) members having a lower end proximate to said foundation segment and an upper end distal from said foundation segment; attaching a plurality of horizontal support members to said vertical support members, each of said horizontal support members having an elongate body with two opposite ends, said ends being attached to adjacent vertical support members in each of said rows such that each of said horizontal support members extends substantially horizontally and spans the distance between said adjacent horizontal support members, said vertical support members and said horizontal support members together establishing frameworks for weight-bearing walls upon said foundation segments, each of said frameworks containing interstices between said horizontal support members and said vertical support members; introducing expanded polystyrene into said interstices, said framework and said expanded polystyrene together defining weight- bearing walls, each of said weight-bearing walls having an inside surface and an outside surface; affixing to said inside surface of each of said weight-bearing walls a first layer of expanded polystyrene and affixing to said outside surface of each of said weight-bearing walls a second layer of expanded polystyrene.

45. The static structure of claim 44 wherein said expanded polystyrene contained within said interstices comprises preformed panels sized to fit said interstices.

46. The static structure of claim 45 wherein said first layer of expanded polystyrene, said second layer of expanded polystyrene, or both of said layers comprise one or more preformed panels of expanded polystyrene, each of said panels of expanded polystyrene having a first side affixed to said wall surface and a second side opposite the side

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SUBSTTTUTE SHEET (RULE 26) affixed to said wall surface.

47. The static structure of claim 46 wherein said preformed panel(s) of expanded polystyrene affixed to said inside and said outside surfaces of said walls are affixed by means of adhesive.

48. The static structure of claim 46 wherein said second side of said preformed panel(s) of expanded polystyrene affixed to said inner surface of said weight-bearing walls, said second side of said preformed panel(s) affixed to said outer surface of said weight-bearing walls, or both, are further covered with a layer of decorative or protective material.

49. The static structure of claim 46 wherein said vertical support members comprise elongate beams.

50. The static structure of claim 46 wherein said elongate beams comprise hollow tubular members.

51. The static structure of claim 46 wherein said horizontal support members are attached to said vertical support members by means of fittings connecting said upper ends of said vertical support members to said ends of said horizontal support members.

52. The static structure of claim 44 wherein each of said segments of said foundation comprises a footing portion below ground level and a wall portion extending vertically from said footing portion, said wall portion having a bottom integral with said footing portion and a top opposite said bottom and extending above ground level.

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SUBSTTTUTE SHEET (RULE 26)