CA2088043A1

CA2088043A1 - Structural system using light weight metal members

Info

Publication number: CA2088043A1
Application number: CA 2088043
Authority: CA
Inventors: James W. Strutt; William Dawson
Original assignee: Individual
Current assignee: Individual
Priority date: 1993-01-25
Filing date: 1993-01-25
Publication date: 1994-07-26

Abstract

ABSTRACT OF THE DISCLOSURE
Disclosed is a structural system comprising wall panels upon which floor and ceiling panels are supported. The various panels are composed of light-gauge metal structural studs and tracks. The studs and tracks are mechanically connected using a clinching machine for joining metal studs and tracks ranging in thickness from 16 to 20 gauge. The metal is preferably galvanized steel. The panels, as well as roof trusses, can be made in a plant where the panels can be surfaced or clad with insulation and specified finishes. The structural capacity of the panels is independent of any diaphram strength contributed by the cladding.
Field erection of the panels to form a building may be carried out without resort to cranes due to the light weight nature of the panels and using unskilled labour. Field connections may be made using sheet metal screws or by clinching. The on-site joining of one panel to another uses a mating of stud to track in a parallel configuration in which the stud is nested in the track along the joint between panels. This provides a tight, structural continuity between panels. The use of a clinching machine in the manufacture of the panels to provide a mechanical joint equivalent in strength to a welded joint eliminates the need for worker protection from toxic fumes generated by welding galvanized metal, requires less extensive quality control and eliminates spot painting of welds for rust protection.

Description

2 0 ~ f 3 BACKGROUND OF THE INVENTION
Field of the Invention The present invention relates to a structural system employing light-gauge metal structural stud members and track members to form load-bearing and non-load-bearing wall panels, floor, ceiling, and roof panels and roof trusses with most connections mechanically made by clinching the metal at interfaces between members. A side member of a panel snugly receives a side member of an adjacent panel in nesting engagement to thereby form -~
a ~oint between the panels.
DESCRIPTION OF THE PRIOR ART
It is known to use light-gauge metal studs and tracks in buildings, but such buildings have generally been "stick-built";
that is not panelized and fabricated with either welded joints or mechanical joints using rivets or screws.
The common use of light-gauge galvanized non-load-bearing metal studs and tracks is for interior non-loading-bearing partitions and non-load-bearing curtain wall structural backing for cladding in concrete or structural steel buildings. In both uses, either screws or hand crimping is used for the mechanical ;
connections which are non-structural. The manual crimping tool used can only be applied to very light-gauge metal, i.e. thinner than 20 gauge.
SU~HARY OF THE INVENTION
A structural system is provided using light-gauge metal ~preferably galvanized steel) studs and tracks to form panels for 2 ~ 4 3 exterior load-bearing and non-load-bearing walls, interior load-bearing and non-load-bearing walls and partitions, floor and ceiling structural components, and structural roof panels for certain architectural designs. Structural roof trusses are also fabricated using light-gauge metal studs and tracks. These structural components are light enough to be carried and placed in ` the building structure by a 4 man crew.
Except for corner wall panels, all panels are fabricated with one longitudinal side member comprised of a light-gauge metal stud (male side) and the other longitudinal side member comprised of a light-gauge metal track (female side). The track is cold rolled with a bend of 90 to facilitate easy mating of opposing male and female sides of two adjacent panels. The female panel side member is fabricated with a 90 bent portion at each end of the track, equal in length to the depth of the selected track (nominally 33mm, for example). This permits a mechanical connection from the longitudinal 90 track side member to two 91 track header members into which the structural studs are placed.
` The 91 track is manufactured as a "deep track~, i.e. the sides are 50mm instead of the 33mm for the standard track. Intermediate ;
studs are snapped in place at, for example, 305 or 610mm on centers to complete the assembly of structural components. All track and stud members are mechanically ioined by a plurality of clinches. Preferably, the thickness of the clinch is one half the thickness of the combined thickness of the two connected pieces.
The weakness of the clinch is in peeling or pull out and therefore all connection designs are based on taking advantage of the high ~ 2~.~3~43 shear strength of the clinch. The ratio of peeling resistance to shear strength is roughly 1 to 5.
Corner wall panels have a special detail to provide structural stud/track mating of the panels similar to intermediate panels. One corner panel has an overlapping extension piece equal to the width of the adjoining panel and contains special angle brackets to provide the corner with longitudinal continuity between panels. The angle brackets are specially configured to rely on the shear strength of the clinch, not its peel strength.
The wall panels are generally dimensioned to fit a design module of predetermined size such as 1220mm or 1224 mm.
All wall components, including doors and windows, are treated as panels. This requires the addition of stud and track pieces to the door and window frames to provide the same interface detail as provided between other panels. A typical window configuration is comprised of a header panel, a window panel and a sill panel.
In order to provide structural continuity between wall panels, the floor and ceiling panels start at the building corner as a half panel (relative to the width of the first corner panel), or as a panel 1 1/2 times as wide as interior panels, so that subsequent floor and ceiling panels always span a joint between two wall panels. The field connection of the walls to the floor and ceiling panels thus ensures both continuity between one wall panel and another and between one floor or ceiling panel and another. This continuity is provided by a light-gauge metal angle with an upstanding leg, mechanically attached (clinched) to the bottom surface of the ceiling panel and to the top and bottom ~ 20~S~43 surfaces of the floor panel at a set back dlstance equal to the thickness of the exterior wall panel structure for substantially the full length of the exterior perimeter interface between the exterior wall panels and the ceiling and floor panels.
This same continuity is provided by a light-gauge metal angle with an upstanding leg mechanically attached (clinched) to the bottom surface of the ceiling panel and top and bottom surfaces of the floor panels at a set back distance equal to half the thickness of the interior load-bearing partition panel structure for substantially the full length of the perimeter interface between the interior load-bearing partition and the ceiling and floor panels.
Designated wall, floor, ceiling and load-bearing partitions are designed as shear panels. The shear strength of the panel is determined by dimension, gauge and location of cross bracing (strapping) and strength and number of mechanical connections (clinches) for attachment to the structural panels.
Roof trusses are also manufactured with light-gauge metal studs and tracks mechanically connected with clinches. These trusses are light weight and can be designed and built for spans exceeding those deemed practical for timber.
Structural design requires the use of a variety of stud, track and strapping gauges, dimensions and profiles. Gauges, dimensions and profiles, as well as stud spacing within the various panel configurations determines the ability to withstand the different deslgn loadings required for 1 or multi-storey units.

2~3S~ 3 The wide range of light gauge metal structural attributes requlred for any specific environment necessitates the use of a mechanical jointing process that can handle a variety of gauge interfaces ranging from 20 to 16 and access to difflcult joint configurations. A manufacturer of clinching machines has designed a tool to meet these performance specifications.
A machine has also been designed for the use of field personnel to mechanically connect the building panel configurations on site. Whereas the plant hand operated clinching head weighs approximately 23kg. the field unit weighs only 5kg.
The field connection process has also been designed for replacement of clinched joints with sheet metal screws. This is recognized as an alternative option where sophisticated toolings would not be available.
According to a broad aspect of the invention there is provided, for use in a structural system for buildings, a panel comprising first and second light gauge metal side members and first and second light gauge metal transverse end members, said side members each having first and second ends joined by clinches to said first and second end members, said first side member comprlslng a base and two sldes, said sides spaced apart a distance such as to snugly recelve a second side member of an adjacent panel in nesting engagement to thereby form a joint between sald panel and said adjacent panel.
According to another broad aspect of the invention there is provided ln a structural system for buildings comprising a plurality of walls and at least one floor and ceiling, the ~ 2~30l~3 improvement wherein said walls and said at least one floor and ceiling are formed of a plurality of interconnected panels, each of said panels comprising light gauge metal longitudlnal members and light gauge transverse end members, said longitudinal members being clinched to said end members, at least one longitudinal member of each panel being engageable in nesting relationship with a longitudinal member of an adjacent panel.
BRIEF DESCRIPTION OF THE DRA~INGS
Figure 1 shows an assembly of typical exterior and ;~
interior load-bearing wall panels; floor panels and ceiling panels; and a roof truss, for application to a variety of - -residential, institutional and commercial buildings. These components are constructed from standard "off-the-shelf" light-gauge galvanized metal profiles and gauges sized to meet the structural requirements of the specific environmental context of the building, e.g. earthquake loading of 8 on the Richter scale and hurricane resistance of 200km. per hour for structures up to 5 storie~
Figure 2 shows an exterior load-bearing wall panel according to the invention;
Figures 2A and 2D show a longitudinal track (female) side member of an exterior load bearing wall panel showing clinched connections to the top and bottom deep-track header members, respectively, of a load-bearing wall panel;
Figures 2B and 2E show connection details of a longitudinal internal structural stud to the top and bottom deep track header members, respectively, of a load-bearing wall panel;
''- .: ", Figures 2C and 2F show a longitudinal stud (male) side member of an exterior load-bearing wall panel showing clinched connections to the top and bottom deep-track header members, respectively, of a load-bearing wall panel; ::
Figures 2G and 2H show a typical wall panel to wall panel interface showing male/female connection;
Flgure 3 shows an exterior load bearing corner wall panel with corner extension;
Figure 3A shows part of a longitudinal track and stud extension configuration illustrating special brackets to provide continuity with an adjoining corner panel;
Figure 3B is a top view of the longitudinal track and stud extension conflguration and part of an ad;oining corner panel, illustrating the functioning of the special brackets;
Figure 4 shows an exterior load bearing corner wall panel without corner extension;
Figures 4A and 4B show details of the Eigure 4 structure;
Figure 4C shows part of a track member cut and bent at the end to facilitate forming a connection to the end of a transverse track member;
Figure 5 illustrates an exterior load bearing window header wall panel;
Figure 5A illustrates the connection of a track to the bottom of the window header wall panel;
Figure 6 shows an exterior load-bearing window sill wall panel;

2 ~ 3 Figure 7 shows an exterior load bearing wlndow panel, lncludlng a special lateral filler extension configuration which is used for a window of less than the standard panel width;
Figure 8 shows an exterior load-bearing door panel;
Figure 9 shows part of a corner floor panel, including perimeter angles for securing the heads of the bearing walls below and the sills of the bearing walls above;
Figure 10 shows part of an interior floor panel including a longitudinal track forming a female side of the panel, a plurality of internal structural studs (joists), an exterior stud forming a male side of the panel, and perimeter angles for securing the heads of supporting bearing walls below and the sills -of bearing walls above the floor;
Figure 11 shows a corner ceiling panel with a longitudinal exterior track and stud side member having clinched connections to panel header tracks, perimeter angles for securing the heads of bearing walls below the ceiling and cross bracing for resisting horizontal shear;
Figure 12 shows part of an interior ceiling panel.and an interface detail of the ceiling panel and an exterior load bearing wall panel;
Figure 13 shows an interior load bearing wall panel.
Note that the structure is similar to an exterior load-bearing wall panel; only the cladding (not shown) would be different.
Also shown is an interface detail of butting ceiling panels and an interior load bearing wall panel. Note that the same interface would apply to butting floor panels having a continuing load-2~3~3 ~ ~

bearing wall above;
Figure 14 illustrates a typical roof truss;
Figure 14a shows a typical connection at the intersection of multiple members at the truss peak;
~ 'igure 14b shows a typical connection of 2 stud truss members clinched to the base track chord of the truss;
Figure 14c shows a typical connection of a truss top and bottom chords screwed together with sheet metal screws;
Figure 15 is a schematic drawing of a clinching machine used to connect the structural members of the building system; and Figure 15a is a schematic sketch for illustrating the clinching process and indicates the adjoining materials before and after clinching.
DETAILED DESCRIPTION OF THE PREFERRED EHBODIHENTS
Before discussing the drawings in detail, it is noted that they are not drawn to scale and, to better illustrate important features, their correct relative proportions may not be shown. Clinches, if referenced, are all referenced with the number 500. In some drawings the clinches are simply shown as dots, while in others they are shown as small circles or ovals.
Similar or identical components are generally referenced with a -~
two-part number comprising a common first part and a unique second part. For example, two studs referenced 200-m and 200-n, respectively, would be of identical type but located differently in a panel member or located in different panel members. ;`~
Figure l shows a typical arrangement of building ~--components according to the invention identified as load-bearing ;~

2 ~ 3 exterior wall panels (10 to 16); floor panels ~20 & 21); ceiling panels (30 & 31); load-bearing interior wall panels ~40); roof truss (50).
Figure 3 shows a corner wall panel with extension, generally indicated at 10. The female side cap of panel 10 is a standard track 102-1 clinched 500 to top and bottom deep track panel headers 100-1 and 100-2. In connection with the present invention, the term "standard track" means a track with two sides formed at about 91 with respect to its base, i.e. bent slightly towards each other. See also Figure 3A which, on an enlarged scale, more clearly shows the connection of track 102-1 to the top deep track panel header 100-1. Although not shown in Figure 3, Figures 3A and 3B show a restraining angle 300, forming one leg of a corner "female" connection for an adjoining panel clinched 500 to the standard track 102-1 in a configuration which stresses the clinches 500 in shear only. A second restraining angle, 301, forming the other leg of the corner "female" connection for an adjoining panel 11, Figure 3B, is clinched 500 to a standard stud 200-1 in a configuration which stresses the clinches 500 in shear only. During field assembly, restraining angle 301 can be secured to the track 102-2 of corner panel 11 by sheet metal screws as -~
indicated at 501. All three of the standard studs 200-1 to 200-3 are clinched to the top and bottom deep track panel headers 100-1 and 100-2. Cross bracing 302 is clinched to the studs 200-1 to 200-3 to provide shear strength to the panel 10 and eliminate any dependency for shear strength on the subsequent application of wall sheeting. The ends of cross braces 302 could alternatively be connected to header tracks 100-1 and 100-2; in fact that is preferred.

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Figure 3B is an exploded plan view showing connections of panel 10 to an adjacent corner panel 11. The arrows show forces tending to separate the panels and it can be seen that only shear forces act on the clinches 500 of restraining angles 300 and 301.
The "male" side cap of panel 10 is a standard stud 200-3 clinched to the top and bottom deep track panel headers 100-1 and 100-2, in the same manner as best seen in Figures 2C, 2F and 2G.
Referring to Figure 2G, it can be seen that the deep track panel header 100-4 is set back from the edge of the flanges 999 of stud 200-6 at the "male" side of a panel to allow for nesting in the "female" side of an adjoining panel comprised, in part, of track 101-2 and header 100-4. The stud 200-6 may have a depth X1 of 42 mm. The set back X2 of track 100-4 may be 15 mm, in which case dimenslon X3 is 27mm. The depth X4 of track 101-2 may be 33 mm.
When the two panels of Figure 2G are brought together as shown in Figure 2H, the total depth XS of the nested members 200-6 and 101- ~ ; ~
2 is 60mm. ~-Figure 4 illu~trates a wall corner panel 11 which does not have an extension like that of panel 10. The "female" side cap of panel 11 i5 a non-standard track 101-1 Isides bent at 90 vs. 91 of standard track) cllnched as indicated by "dots" 500 to ; -~-top and bottom deep track panel headers 100-3 and 100-4. See also Figure 4A which better illustrates the connection of track 101-1 to header 100-3. In Flgure 4A it can be seen that the sides of track 101-1 are cut near the top end of the track and the end portion of the track is bent 90. See also Figure 4C. The end : :- ,.
: ~, :,.

~ 2~ ~Q~3 portion of track 101-1 is inserted into the end of track 100-3 and clinched to the sides of track 100-3. Cross bracing 302 is clinched to stud 200-4 and either to deep tracks 100-3 and 100-4 or, as shown, to non-standard track 101-1 and standard track 102-2 to provide shear strength to panel 11 and eliminate any dependency for shear strength on the subsequent application of wall sheeting.
The stud 200-4 is clinched to the top and botto~ panel headers in the manner shown in Figures 2B and 2E for stud 200-5. The butting "male~ end cap of panel 11 is a standard track 102-2 clinched to top and bottom deep track panel headers 100-3 and 100-4; the connection to the top header 100-3 is clearly shown in Figure 4B.
Figure 2 shows an intermediate wall panel 12 according to the invention. The "female" side cap of panel 12 is a non-standard track 101-2 cut and bent at 90 at both ends to form the connections and is clinched to the top and bottom deep track panel headers 100-4 and 100-5. Connections of this type are more clearly shown in Figures 2A and 2D. For example, in Figure 2D, it can be seen that track 101-2 is bent at a right angle at line 106 with end portion 108 secured to deep track 100-5 by clinches 500.
Standard intermediate stud 200-5 is secured by clinches 500 to the top and bottom deep track panel headers 100-4 and 100-5 aæ best ~;~f~
seen in Figures 2B and 2E. The "male" side of panel 12 is a standard stud 200-6 attached by clinches 500 to top and bottom deep track panel headers 100-4 and 100-5, as best seen in Figures 2C and 2F. Note the set-back of the top and bottom deep track panel headers 100-4 and 100-5 from the edges of the flanges 993 of ;~
stud 200-6 to allow for the nesting with the "female~ side of an 2 0 ~

adjoining panel. The "male/female" nestlng of adjoinlng panels has been explained above in connection with Figures 2G and 2H.
The nesting of a stud such as 200-6 in a non-standard track such as 101-2 provides a positive vertical joint between adjacent wall panels. Therefore, without further attachments, differential movement between panels is eliminated along with subsequent cracking of plaster or drywall interior finishes. The joint also serves as a sealed joint to prevent air and water infiltration when properly clad with exterior insulation and fasade treatment.
Figure 5 shows a window or door header wall panel 13 according to the invention. The "female" side cap of panel 13 is a non-standard track 101-3, cut and bent at 90 at both ends to form connections to top deep track panel header 100-6 and bottom ;
standard track 102-3. An intermediate stud 200-7 is attached by clinches 500 to the top deep track 100-6 and bottom standard track 102-3. The "male" side cap of panel 13 ls a standard stud 200-8 which, like the intermediate stud 200-7, is attached by clinches 500 to top deep track 100-6 and bottom standard track 102-3. Note the set-back of top deep track 100-6 and bottom standard track 102-3 from the edges of the flanges of right end stud 200-8 to -~
- allow of the nesting of an adjolning panel, as already discussed above. A non-standard track 101-4 is attached by cllnches 500 (Figure 5A) to the bottom deep track header 102-3 to form a female member for nesting horizontally wlth a window or door panel. ;~
Figure 6 shows a window sill wall panel according to the invention, generally indicated at 15. The "female" side cap of panel 15 is a non-standard track 101-6, cut and bent at 90 at _.~ 2Q~L/j~
:

both ends to form connections by clinches 500 to bottom deep track panel header 100-8 and to top standard track 102-4. Studs 200-13 and 200-14 are attached by clinches 500 to bottom deep track panel header 100-8 and to top standard track 102-4. The standard stud 200-14 is the "male" side cap of panel 15. Note the set-back of the top and bottom headers 102-4 and 100-8 from edges of the flanges of the end stud 200-14 to allow for nesting of an adjoining panel. A non-standard track 101-7 is attached by clinches, not shown, to top standard track header 102-4 to form a ;-female member for nesting horizontally with the window panel 14, discussed below in connection with Figure 7.
Figure 7 shows a window panel, generally indicated at -~
14. Studs 200-9 and 200-10 are attached with wood or sheet-metal -~-screws, not shown, to the top and bottom, respectively, of window frame 600. A stud 200-11 is attached to the ~male~ (right) side of window frame 600. A non-standard track 101-5 is attached with --wood or sheet-metal screws, not shown, to the "female~ side of window frame 600. If the window frame 600 is less than the width of a nominal planning module (1220mm), then a filler piece ls attached to the "male" side of window frame 600. As shown in Figure 7, the filler piece consists of an additional stud, 200-12, connected by means of light-gauge metal plates 303 which are ;~
clinched to the additional stud 200-12 and to the stud 200-11 ;~
attached to the window frame.
Figure 8 shows a door panel according to the invention, generally indicated at 16. A stud 200-15 is attached with wood or sheet-metal screws, not shown, to the top of door frame 700 and 2~,3~3 -side-llght frame 701. Another stud 200-16, is attached with wood or sheet-metal screws, not shown, to the male" (right) side-light 701. A track 101-8 is attached with wood or sheet-metal screws, not shown, to the "female" side of door frame 700. The door frame 700 would usually be purchased with a side-light 701 to bring the door panel 16 to the same width as the nominal planning module;
otherwise a filler piece is added similar to that of Figure 7.
Figure 9 shows a portion of a corner floor shear panel according to the invention, generally indicated at 20. The "male"
10 edge of the floor panel 20 (stud 201-1) as well as the intermediate stud (joist) 201-2 are attached by clinches 500 to floor panel header standard ~racks. The panel headers, of which ;~
only 103-1 is shown, are set-back from the edge of the flanges of stud 201-1 to allow for the nesting of an adjoining floor panel.
Positionlng and restraining angles 304 on the top and bottom faces - of floor panel 20 are located to position and connect exterior and interior load-bearing wall panels and are clinched longitudinally along and across the floor studs (joists) 201-1 and 201-2. The longitudinal exterior edge cap of panel 20 is a standard track ; ~ ~-20 103-2 clinched to the standard track panel headers such as 103-1.
Cross bracing can be added to create a diaphragm resistance in the event the floor topping material, e.g. concrete or plywood, is inadequate for the design loads, in a manner similar to that to be explained ln connection with Figure 11.
Figure 10 shows part of an interior floor shear panel according to the invention, generally indicated at 21. The "male"
edge of the floor panel, stud Ijoist) 201-3, as well as the .
`

2~,~g~l1 3 intermediate floor studs (joists) 201-g, 201-5, are clinched (500) to the floor panel header tracks such as 103-3. Note the set-back of the panel header 103-3 from the edge of the flanges of outer stud 201-3 to allow for the nestlng of an adjoining panel.
Positioning and restraining angles 304 on the top and bottom faces of panel 21 are located to position and connect exterior and interior load-bearing wall panels and are clinched to the floor studs (~oists) 201-3,-4 and -5. The "female" edge cap of panel 21 is a non-standard track (joist) 104-1 cut and bent at 90 at both ends to form connections by clinching to the panel headers, such as 103-3. Cross bracing can be added if the flooring material is inadequate for the design loads, in a manner æimilar to that to be discussed in connection with Figure 11.
Figure 11 shows a corner ceiling shear panel, generally indicated at 30. The ~male" edge of panel 30 is a stud ~joist) 201-6, the ends of which are clinched to header tracks 103-4 and 103-5. An intermediate stud (joist) 201-7 is also clinched to the headers 103-4 and 103-5. The header tracks 103-4 and 103-5 are ;-set-back from the edge of the flanges of stud 201-6 to allow for ;;~
the nesting of an adjoining panel. Positioning and restraining angles 304 on the bottom face of the ceiling panel 30 are located to position and connect exterior and interior load-bearing wall :: ~ .: .:
panels. Two restraining angles 304 are clinched across the ~ -ceiling studs (~olsts) 201-6 and 201-7, while another is clinched along stud (joist) 201-7. The longitudinal exterior edge cap of the panel is a standard track 103-6 clinched to the standard track .- . ~
panel headers 103-4 and 103-5. Cros~ bracing 302 is clinched to . . :

2~SQ~ ~

the studs (joists) 201-6 and 201-7 of panel 30.
Figure 12 shows one end portion of an interior ceiling shear panel according to the invention, generally indicated at 31. :
The "male" edge of the ceiling panel 31 stud (joist) 201-8 as well as the intermediate ceiling studs (joists) 201-9 and 201-10 are ~.
clinched to the header tracks, one of which is shown at 103-7 in Figure 12. The header tracks are set-back from the edges of the flanges of outer stud tjoist) 201-8 to allow for the nesting of an adjoining panel. Positioni~g and restraining angles 304 on the bottom face of the ceiling panel 31 are located to position and connect exterior and interior load-bearing wall panels, such as partially shown at 40, and are clinched to the ceiling studs (joists) 201-9 and 201-10 and to non-standard track 104-2. The "femaleH edge of the ceiling panel 31 is the non-standard track (joist) 104-2 which is cut and bent at 90 at both ends to form connections by clinching to the panel headers, such as 103-7. If necessary, cross bracing may be clinched to the stud (joist) 201-8 :~
and non-standard track 104-2 in a similar manner as shown in ~ :
Figure 11.
Figure 13 shows an interior, intermediate partition wall panel according to the invention, generally indicated at 40. The HfemaleH side cap of panel 40 is a non-standard track 101-9, cut and bent at both ends to form connectionæ by clinching to top and bottom deep track panel headers 100-9 and 100-10, in the same : .
manner as wall panel 12 shown in Figure 2. Standard studs 200-17 and 200-18 are clinched to the top and bottom deep track panel headers 100-9 and 100-10, in the same manner as shown in Figures 2 ~ 3 .

2B and 2E for an intermediate stud and Figures 2C and 2F for a "male" stud forming a side cap. Note the set-back of the top and bottom deep track panel headers 100-9 and 100-10 from the edges of ~ ;
the flanges of side cap stud 200-18 to allow for the nesting of an adjolning panel as explained above in connection with Figure 2H.
Note also in Figure 13 the interfacing of two ceiling panels 30 bearing, as indicated by a dotted llne, partially on load-bearing partition panel 40 to provide connectivity for the ceiling panels and the load-bearing partition panels through the restraining angles 302 clinched or attached with sheet metal screws. The floor and ceiling panels always rest partially on each of two load-bearing panels so as to provide connectivity between ad~oining wall panels and adjoining floor or ceiling panels.
; Figure 14 shows a roof truss in accordance with the invention, generally indicated at 50. Details are shown in Figures 14a, 14b and 14c. The truss S0 is fabricated with standard studs 202 and standard tracks 105 of gauges and dimensions to meet design loads. The clinching Dachine used in fabricating the structures according to this invention has certain limits of accessibility to connections that are not at 90 and therefore positioning and rotation of members within the truss configuration is critical. The joint at the peak of the truss -(see Figure 14a) accommodates the intersection of two or more studs 202 and track 105 upper chords by means of a light-gauge galvanized metal plate 304 on both faces of the truss, with clinches 500 to the ends of each of the intersecting members. The intersection of three studs 202 to the bottom track 104 chord of 2 0 3 ~ ¢ ~ 3 the truss is accommodated by the spacing and the orientation of the stud 202 profile for direct clinching. See Figure 14b, showing two studs 202 connected to chord 105. The intersections -: -of the top tracks 105 with the bottom chord track 105 are impossible to clinch because of design limitations of the clinching tool and therefore these connections are made by means of sheet metal screws 501 (Fig. 14c).
A cllnching machine for use in fabricating structures -according to the invention is schematically illustrated in Figures 15 and 15a. The clinch made by the machine is designed to provide the equivalent binding strength of a spot weld. The clinching process is not dependent on the skill of the operator. In designing the number of clinches per connection and the relationship between adjoining structural members, provision is made to minimize forces which might cause the members to "peel"
from each other, i.e. pull out of the clinched connection. The connections are therefore designed to utilize the maximum strength of the clinch which is in shear, although the peel strength is high. Figure 15 shows a schematic profile of the tool. Figure 15a shows the action of the three elements which form the clinch.
The Punch is actuated by hydraulic fluid with pressures exceeding 1000 psi and can be regulated by adjusting air pressure to the hydraulic cylinder to meet the requirements of joining a variety of metal thicknesses ranging from 20 to 16 gauge. Regular samples are preferably made during manufacture to ensure that the resultant thickness of the clinch is 50% of the combined thicknesses of the adjoining metals prior to clinching.

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2 ~ 3 The actual clinch is formed in less than 3 seconds and occurs in 2 stages.
1. The Punch is rectangular in plan and is so designed as to shear the metal members on two opposite short sides of the rectangle and bend the metal on the other long sides as it punches the metal on to the die button.
2. As the punch continues its downward motion, the metal is squeezed between the anvil and the punch. This squeezing action causes the metal to flow laterally thus displacing the die button which is spring loaded and therefore moves away to permit the full clinching action to take place. From this action the deformation of the 2 (or 3) layers of metal into 1 layer through lateral flow, causes the joint to resist both peeling and shear forces. Peeling ~
and shear resistance is provided by the clinch - peeling due to ~; ;
the larger diameter of the clinched metal relative to the size of the punched hole and shear by the bending of the metals on the longer sides of the punched hole.
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Claims

1. For use in a structural system for buildings, a panel comprising first and second light gauge metal side members and first and second light gauge metal transverse end members, said side members each having first and second ends joined by clinches to said first and second end members, said first side member comprising a base and two sides, said sides being spaced apart a first predetermined distance such as to snugly receive a second side member of an adjacent panel in nesting engagement to thereby form a joint between said panel and said adjacent panel.

2. A panel as claimed in claim 1, comprising at least one additional member disposed between said side members and joined by clinches to said first and second end members.

3. A panel as claimed in claim 2 wherein said second side member has a base and two sides extending outwardly with respect to said panel, said sides of said second side member being spaced apart a second predetermined distance less than said first predetermined distance and having outer edges, said first and second end members being set back from said outer edges, whereby said second side member can be partially nested in a first side member of an adjacent panel.

4. A panel as claimed in claim 3 wherein said end members each have a base and two sides and first and second end portions of said first side member extend at substantially 90° from the base of said first side member and are disposed between the two sides of the first and second end members, respectively.

5. For use in a structural system for buildings, a corner wall panel comprising a plurality of light gauge metal longitudinal members and light gauge metal top and bottom members, each of said longitudinal members having first and second ends joined by clinches to said top and bottom members, first and second adjacent longitudinal members on a first side of said panel each having an angle bracket attached to it for securing one side member of a second corner wall panel extending at right angles to said first-mentioned corner wall panel.

6. A panel as claimed in claim 5 wherein a third one of said plurality of longitudinal members forms a second side of said panel, said third longitudinal member having a base and two sides extending outwardly with respect to said panel, said sides of said third longitudinal member having outer edges, said top and bottom members being set back from said outer edges, whereby said third longitudinal member can be partially nested in a first side member of an adjacent wall panel.

7. A panel as claimed in claim 6 and further comprising cross bracing clinched to and extending between diagonally opposed corner regions of said panel.

8. For use in a structural system for buildings, a window header panel comprising a plurality of light gauge metal upright members and light gauge metal top and bottom members, each of said upright members having first and second ends joined by clinches to said top and bottom members, one of said upright members forming a first side of said panel and comprising a track having a base and two sides, said sides being spaced apart a distance such as to snugly receive a second side member of an adjacent wall panel to thereby form a joint between said header panel and said adjacent wall panel.

9. A window header panel as claimed in claim 8 wherein a second one of said upright members forms a second side of said panel, said second upright member comprising a stud having a base and two sides, said sides extending outwardly with respect to said panel, said sides of said stud having outer edges, said top and bottom members being set back from said outer edges, whereby said second stud can be partially nested in a first side member of an adjacent panel.

10. A window header panel as claimed in claim 9 and further comprising a track member clinched to said bottom member, said track member having a base and two downwardly depending sides spaced apart a distance such as to snugly receive a top member of a window panel in nesting engagement to thereby form a joint between said window header panel and said window panel.

11. For use in a structural system for buildings, a window sill panel comprising a plurality of light gauge metal upright members and light gauge metal top and bottom members, each of said upright members having first and second ends joined by clinches to said top and bottom members, one of said upright members forming a first side of said panel and comprising a track having base and two sides, said sides being spaced apart a distance such as to snugly receive a second side member of an adjacent wall panel to thereby form a joint between said sill panel and said adjacent wall panel.

12. A window sill panel as claimed in claim 11 wherein a second one of said upright members forms a second side of said panel, said second upright member comprising a stud having a base and two sides, said sides extending outwardly with respect to said panel, said sides of said stud having outer edges, said top and bottom members being set back from said outer edges, whereby said stud can be partially nested in a first side member of an adjacent panel.

13. A window sill panel as claimed in claim 12 and further comprising a track member clinched to said top member, said track member having a base and two upwardly extending sides spaced apart a distance such as to snugly receive a bottom member of a window panel in nesting engagement to thereby form a joint between said sill panel and said window panel.

14. For use in a structural system for buildings, a window panel comprising a window frame having a top, a bottom and two sides to each of which is secured a light gauge metal member having a base and two sides, the member secured to said top being engageable in nesting relationship with a bottom member of a header panel, the member on said bottom being engageable in nesting relationship with a top member of a sill panel, and the members secured to said sides being engageable in nesting relationship with side members of adjacent wall panels.

15. A window panel as claimed in claim 14 and further comprising a filler piece attached to a member on one of said sides, said filler piece comprising a further light gauge metal member connected by light-gauge metal plates clinched to said further member and to said member on said one of said sides.

16. For use in a structural system for buildings, a door panel comprising a door frame having a top, a bottom and two side frame members, a light gauge metal member having a base and two sides being secured to each of said base and said two side frame members, the light gauge metal member secured to said top being engageable in nesting relationship with a bottom light gauge metal member of a header panel and the light gauge metal members secured to said side frame members being engageable in nesting relationship with light gauge metal side members of adjacent wall panels.

17. A door panel as claimed in claim 16 wherein said door panel includes a side-light.

18. For use in a structural system for buildings, a corner floor panel comprising first and second light gauge metal side members, first and second light gauge metal header members and an intermediate light gauge metal joist member parallel to and spaced from said first side member a predetermined distance, said side members and said intermediate joist member being clinched to said header members, said second side member having a base and two sides extending outwardly of said panel, said sides having outer edges, said header members being set back from said edges of said second side member whereby said second side member is partially engageable in nesting relationship with a side member of an adjacent floor panel, said corner floor panel further comprising a first angle member clinched to a top surface of said intermediate joist member, and a second angle member clinched to and extending between said intermediate joist member and said second side member on a top side of said panel, said first and second angle members serving to locate and secure bottom edges of wall panels.

19. A corner floor panel as claimed in claim 18 and further comprising a third angle member clinched to and extending between said intermediate joist member and said second side member on a bottom side of said panel, said third angle member serving to locate and secure a top edge of a wall panel.

20. For use in a structural system for buildings, an interior floor panel comprising first and second light gauge metal side members, a plurality of light gauge metal intermediate joist members and first and second light gauge metal header members, said side members and joist members having first and second ends joined by clinches to said first and second header members, said first side member having a base and two sides, said sides being spaced apart a first predetermined distance such as to snugly receive a second side member of an adjacent floor panel in nesting engagement to thereby form a joint between said floor panel and said adjacent floor panel.

21. An interior floor panel as claimed in claim 20 wherein said second side member comprises a joist having a base and two sides, said sides of said second side member being spaced apart a second predetermined distance less than said first predetermined distance.

22. An interior floor panel as claimed in claim 21 and further comprising first and second angle brackets on a top side of said panel adjacent said first and second headers, said angle brackets locating and securing wall panels, said angle brackets being clinched to said joist members.

23. An interior floor panel as claimed in claim 22 and further comprising third and fourth angle brackets on a bottom side of said panel adjacent said first and second headers, said third and fourth angle brackets locating and securing wall panels, said third and fourth angle brackets being clinched to said side members and joist members.

24. An interior floor panel as claimed in any one of claims 21 to 23 wherein said sides of said joist extend outwardly with respect to said panel, said sides having outer edges, said first and second header members being set back from said outer edges, whereby said joist can be partially nested in a first side member of an adjacent floor panel.

25. For use in a structural system for buildings, a corner ceiling panel comprising first and second light gauge metal side members, first and second light gauge metal header members and an intermediate light gauge metal joist member parallel to and spaced from said first side member a predetermined distance, said side members and said intermediate joist member being clinched to said header members, said second side member having a base and two sides, said sides extending outwardly of said panel, said sides having outer edges, said header members being set back from said edges of said second side member whereby said second side member is partially engageable in nesting relationship with a side member of an adjacent ceiling panel, said corner ceiling panel further comprising a first angle member clinched to a bottom surface of said intermediate joist member, and a second angle member clinched to and extending between said intermediate joist member and said second side member on a bottom side of said panel, said first and second angle members serving to locate and secure top edges of wall panels.

26. For use in a structural system for buildings, an interior ceiling panel comprising first and second light gauge metal side members, a plurality of light gauge metal intermediate joist members and first and second light gauge metal header members, said side members and joist members having first and second ends joined by clinches to said first and second header members, said first side member having a base and two sides, said sides being spaced apart a first predetermined distance such as to snugly receive a second side member of an adjacent ceiling panel in nesting engagement to thereby form a joint between said ceiling panel and said adjacent ceiling panel.

27. An interior ceiling panel as claimed in claim 26 wherein said second side member comprises a joist having a base and two sides, said sides of said joist being spaced apart a second predetermined distance less than said first predetermined distance.

28. An interior ceiling panel as claimed in claim 27 and futher comprising first and second angle brackets on a bottom side of said panel adjacent said first and second headers, said angle brackets locating and securing upper ends of wall panels, said angle brackets being clinched to said side members and joist members.

29 29. For use in a structural system for buildings, a roof truss comprising a bottom track member, first and second upper track members, and a plurality of studs, said track members and studs being of light gauge metal, said studs extending between said bottom member and said upper track members, said upper track members extending from opposite ends of said bottom track member and meeting at an apex of said truss, said upper track members being joined at said apex by metal plates clinched to said upper tracks on both faces of said truss, one of said studs having one end at said apex clinched to said plates and another end clinched to said bottom track, the remaining said studs having opposite ends clinched to said bottom track and to one or other of said upper tracks, said upper tracks being secured to said bottom track at said opposite ends by fastening means.

30. A truss as claimed in claim 29 wherein said fastening means comprises sheet-metal screws.

31. In a structural system for buildings comprising a plurality of walls and at least one floor and ceiling, the improvement wherein said walls and said at least one floor and ceiling are formed of a plurality of interconnected panels, each of said panels comprising light gauge metal longitudinal members and light gauge transverse end members, said longitudinal members being clinched to said end members, at least one longitudinal member of each panel being engageable in nesting relationship with a longitudinal member of an adjacent panel.